Page 4 IN−1 INTRODUCTION − HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN0KN−01 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 5 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. 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 6: Identification Information
IN−3 INTRODUCTION − IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN01P−08 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label. A: Vehicle Identification Number Plate B: Certification Label B02417 ENGINE SERIAL NUMBER 1GR−FE Engine...
Page 7: Repair Instructions
IN−4 INTRODUCTION − REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO−32 GENERAL INFORMATION BASIC REPAIR HINT Prevent damage and maintain vehicle cleanliness by pro- tective covering on the fender, seat and floor. During disassembly, line up parts in the order they were removed to facilitate reassembly. Installation and removal of battery terminal: NOTICE: When connecting the negative (−) terminal make sure that...
Page 8 IN−5 INTRODUCTION − REPAIR INSTRUCTIONS Precoated parts are indicated in component illustra- tions by the ”L” symbols. 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 9 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). Release the parking brake on a level surface and shift to the N position.
Page 10 IN−7 INTRODUCTION − REPAIR INSTRUCTIONS Installation and removal of vacuum hose: Example When disconnecting vacuum hoses, use tags to identify where they should be reconnected to. After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout.
Page 11 IN−8 INTRODUCTION − REPAIR INSTRUCTIONS IN0DY−05 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION S S S S S S S S S S S S S S S S S S Front S S S S S S S S S Center of crossmember Rear S S S S S S S S S Center of rear axle housing SUPPORT POSITION Safety stand S S S S S S S S S S S S S S S S...
Page 12: For All Of Vehicles
IN0KM−01 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The TOYOTA TUNDRA is equipped with an SRS (Sup- plemental Restraint System), such as the driver airbag, front passenger airbag assembly and seat belt preten- sioner. Failure to carry out service operations in the correct se-...
Page 13 IN−10 INTRODUCTION − FOR ALL OF VEHICLES Even in case of a minor collision where the SRS does not deploy, the steering wheel pad (see page RS−24), front passenger airbag assembly (see page RS−38), side airbag assembly (see page RS−77, RS−52 or RS−67) curtain shield airbag as- sembly (see page RS−85) and seat belt pretension-...
Page 14 IN−11 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 upward may lead to a serious accident if the airbag inflates for some reason.
Page 15 IN−12 INTRODUCTION − FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY Always store a removed or new front passenger air- bag assembly with the airbag deployment side fac- ing up. Storing the airbag assembly with the airbag deploy- ment side facing down could cause a serious acci- dent if the airbag inflates.
Page 16 IN−13 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 could cause serious injury. Never disassemble the seat belt pretensioner. Never install the seat belt pretensioner in another vehicle.
Page 17 IN−14 INTRODUCTION − FOR ALL OF VEHICLES SIDE AIRBAG ASSEMBLY Always store a removed or new side airbag assem- bly with the airbag deployment side facing up. Storing the airbag assembly with the airbag deploy- ment side facing down could cause a serious acci- dent if the airbag inflates.
Page 18 IN−15 INTRODUCTION − FOR ALL OF VEHICLES CURTAIN SHIELD AIRBAG ASSEMBLY Always store a removed or new curtain shield air- bag assembly in a clear plastic bag, and keep it in a safe place. NOTICE: Protection bag is not reused. CAUTION: Never disassemble the curtain shield airbag assembly Never measure the resistance of the airbag squib...
Page 19 IN−16 INTRODUCTION − FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY If an airbag sensor assembly has been involved in a collision where its SRS has deployed, do not re- use it. The connectors to the airbag sensor assembly should be connected or disconnected with the sen- sor mounted on the floor.
Page 20 IN−17 INTRODUCTION − FOR ALL OF VEHICLES FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow 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 21: Table Of Contents
IN01T−19 GENERAL INFORMATION A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be a very intricate, requiring a high level of technical knowledge to troubleshoot. However, following the problem checking procedures of the ECU controlled system’s circuits carefully is not complex.
Page 22 IN−19 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN01U−15 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure below. Only a basic procedure is shown. Details in the Diagnostics section show the most effective methods for each circuit. Confirm troubleshooting proce- dures first for the relevant circuit before beginning troubleshooting of that circuit.
Page 23 IN−20 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS The 5 items in the table below are important points in the problem analysis. In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order to give an accurate judgement. To ascertain 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 24: Tire Pressure Warning System
SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TUNDRA fulfills various functions. The first function is the Diagnostic Trouble Code (DTC) Check. In a DTC Check, a previous malfunc- tion’s DTC can be checked by a technician during troubleshooting. (A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs.)
Page 25 IN−22 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS In the DTC Check, it is very important to determine whether the problem indicated by the DTC is: 1) still occur- ring, or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related.
Page 26 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. Directions from the flow chart will indicate how to proceed to DTC troubleshooting or to the troubleshooting of problem symptoms table.
Page 27 IN−24 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION The most difficult case in troubleshooting is when no problem symptoms occurring. In such cases, a thor- ough customer problem analysis must be carried out. Then simulate a simulation of the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be carried out.
Page 28 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 device. Check whether or not if the malfunction occurs.
Page 29 IN−26 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble area and proper inspection procedure. Engine diagnostic trouble code chart is shown below as an example. D DTC No.
Page 30 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 when, during a DTC check, a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring.
Page 31 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 of the circuit and its component parts are explained.
Page 32 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. If it is abnor- Ignition Switch LOCK (OFF) mal, use it to determine whether the problem START...
Page 33 IN−30 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05X−32 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION For troubleshooting, diagnostic trouble code (DTC) charts or problem symptom table are provided for each circuit with detailed inspection procedures in this manual.
Page 34 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 35 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: If a test terminal is pulled out more easily than others, there may be poor contact in that section.
Page 36 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 by conduct- ing a voltage check. Sensor As shown in Fig.
Page 37 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 and body ground...
Page 38: Anti−Lock Brake System
IN−35 INTRODUCTION − TERMS TERMS IN04Q−34 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti−Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System Active Control Engine Mount ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air−Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator...
Page 39 IN−36 INTRODUCTION − TERMS Direct Current Defogger Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatible Disc Electric Brake Force Distribution Electrochoromic ECAM Engine Control And Measurement System...
Page 40 IN−37 INTRODUCTION − TERMS Hatchback H−FUSE High Current Fuse High High Intensity Discharge (Head Lamp) Housing Hard Top Heated Windshield System Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Junction Block Junction Connector...
Page 41: Supplemental Restraint System
Special Service Materials Special Service Tools Standard Cold−Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer−Controlled System Timing Control Valve Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension TOYOTA Free−Tronic...
Page 42 IN−39 INTRODUCTION − TERMS Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. Traction Control System TURBO Turbocharge Three−Way Catalyst Underdrive Undersize Vacuum Control Valve VENT Ventilator Vehicle Interface Module Vehicle Identification Number...
Page 43 − TERMS IN0CI−10 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 44 IN−41 INTRODUCTION − TERMS 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 − Knock Sensor Knock Sensor Mass Airflow Air Flow Meter Manifold Absolute Pressure...
Page 45 IN−42 INTRODUCTION − TERMS 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 Airflow Air Flow Meter Voltage Regulator...
Page 46: Outside Vehicle
MA−1 MAINTENANCE − OUTSIDE VEHICLE OUTSIDE VEHICLE MA001−44 GENERAL MAINTENANCE These maintenance checks on the vehicle are performed on the owner’s responsibility. The owner may perform the maintenance or take the vehicle to a service center. Check the parts of the vehicle described below on a daily basis. In most cases, special tool are not required.
Page 47: Inside Vehicle
MA−2 MAINTENANCE − INSIDE VEHICLE INSIDE VEHICLE MA002−52 GENERAL MAINTENANCE These maintenance checks on the vehicle are performed on the owner’s responsibility. The owner may perform the maintenance or take the vehicle to a service center. Check the parts of the vehicle described below on a daily basis. In most cases, special tool are not required.
Page 48 MA−3 MAINTENANCE − INSIDE VEHICLE ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort and catching. CLUTCH PEDAL (See page CL−2) Check the pedal for smooth operation. Check that the pedal has the proper freeplay. BRAKE PEDAL (See page BR−10) Check the pedal for smooth operation.
Page 49: Under Hood
MA−4 MAINTENANCE − UNDER HOOD UNDER HOOD MA003−52 GENERAL MAINTENANCE GENERAL NOTES Maintenance requirements vary depending on the country. Check the maintenance schedule in the owner’s manual supplement. Following the maintenance schedule is mandatory. Determine the appropriate time to service the vehicle using either miles driven or time (month) elapsed, whichever reaches the specification first.
Page 50 MA−5 MAINTENANCE − ENGINE ENGINE MA004−20 INSPECTION HINT: Perform the following procedures. REPLACE TIMING CHAIN OR BELT (1GR−FE: See pages EM−32 and EM−44) (2UZ−FE: See pages EM−16 and EM−23) INSPECT VALVE CLEARANCE (1GR−FE: See page EM−4) (2UZ−FE: See page EM−4) INSPECT DRIVE BELT(S) (1GR−FE: See pages SR−3...
Page 51 MA−6 MAINTENANCE − ENGINE REPLACE SPARK PLUGS (1GR−FE: See page IG−1) (2UZ−FE: See page IG−1) INSPECT CHARCOAL CANISTER (1GR−FE: See page EC−6) (2UZ−FE: See page EC−9)
Page 52 MA−7 MAINTENANCE − BRAKE BRAKE MA014−07 INSPECTION INSPECT BRAKE LINE PIPES AND HOSES HINT: Work in a well−lighted area. Check the entire circumference and length of the brake hoses using a mirror if neccessary. Turn the front wheels fully to the right or left before beginning. Check all the brake lines and hoses for: MA0055 Damage...
Page 53 MA−8 MAINTENANCE − CHASSIS CHASSIS MA04D−04 INSPECTION INSPECT STEERING LINKAGE Check the steering wheel freeplay (see page SR−9). Check the steering linkage for looseness or damage. Check that the tie rod ends do not have excessive play. Check that the dust seals and boots are not damaged. Check that the boot clamps are not loose.
Page 54 MA−9 MAINTENANCE − CHASSIS LUBRICATE PROPELLER SHAFT AND TIGHTEN BOLTS 4WD: Lubricate the propeller shaft, referring to the lubrication chart. Before pumping in grease, wipe off any mud and dust on the grease fitting. Grease grade: Propeller shaft (Except Double−cardan joint): Lithium base chassis grease NLGI No. 2 Double−cardan joint: Molybdenum disulphide lithium base chassis grease NLGI No.
Page 55 MA−10 MAINTENANCE − BODY BODY MA04E−02 INSPECTION TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Where necessary, tighten all parts of the chassis. Front axle and suspension Drive train Rear axle and suspension Brake system Engine mounting, etc. Where necessary, tighten all parts of the body. Seat belt system Seats Doors and hood...
Page 56 PP−1 PREPARATION − MAINTENANCE MAINTENANCE PP0G5−02 EQUIPMENT Mirror Brake hose Torque wrench...
Page 57 PP−2 PREPARATION − ENGINE MECHANICAL (1GR−FE) ENGINE MECHANICAL (1GR−FE) PP445−01 SST (Special Service Tools) 09011−38121 12 mm Socket Wrench for 12 CYLINDER BLOCK Pointed Head Oil Pan Seal Cutter TIMING CHAIN 09032−00100 09201−01055 Valve Guide Bushing Remover & Re CYLINDER HEAD placer 5.5 Valve Guide Bushing Remover &...
Page 58 PP−3 PREPARATION − ENGINE MECHANICAL (1GR−FE) 09330−00021 Companion Flange Holding Tool TIMING CHAIN 09843−18030 Tacho−pulse Pickup Wire No.2 IDLE SPEED 09843−18040 Diagnosis Check Wire No.2 IGNITION TIMING Puller C Set TIMING CHAIN 09950−50013 (09951−05010) Hanger 150 TIMING CHAIN (09952−05010) Slide Arm TIMING CHAIN Center Bolt 150 TIMING CHAIN...
Page 59 PP−4 PREPARATION − ENGINE MECHANICAL (1GR−FE) (09951−07150) Handle 150 CYLINDER BLOCK CYLINDER HEAD...
Page 60 PP−5 PREPARATION − ENGINE MECHANICAL (1GR−FE) PP43S−01 RECOMMENDED TOOLS 09040−00011 Hexagon Wrench Set . Socket Hexagon Wrench 8. (09043−20080) (09043−20100) Socket Hexagon Wrench 10. (09043−30140) Straight Hexagon Wrench 14. 09042−00010 Torx Socket T30 . 09043−50100 Bi−hexagon Wrench 10 mm .
Page 61 PP−6 PREPARATION − ENGINE MECHANICAL (1GR−FE) PP43T−01 EQUIPMENT CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator with magnetic base Engine sling device Feeler gauge Heater Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Reamer Spring tester Steel square Tachometer...
Page 62 PP−7 PREPARATION − ENGINE MECHANICAL (1GR−FE) PP43U−01 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent (FIPG) Seal Packing 1282B, 08826−00100 THREE BOND 1282B or equivalent (FIPG) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent...
Page 63 PP−8 PREPARATION − ENGINE MECHANICAL (2UZ−FE) ENGINE MECHANICAL (2UZ−FE) PP431−01 SST (Special Service Tools) 09201−01055 Valve Guide Bushing Remover & Re placer 5.5 Valve Stem Oil Seal Replacer 09201−41020 09202−70020 Valve Spring Compressor Attachment (09202−00010) 09213−70011 Crankshaft Pully Holding Tool Bolt (90105−08076) (90119−08216)
Page 64 PP−9 PREPARATION − ENGINE MECHANICAL (2UZ−FE) 09843−18040 Diagnosis Check Wire No.2 09950−50013 Puller C Set (09951−05010) Hanger 150 Crankshaft pulley Crankshaft timing pulley Slide Arm Crankshaft pulley (09952−05010) Crankshaft timing pulley (09953−05010) Center Bolt 100 Crankshaft pulley Crankshaft timing pulley (09953−05020) Center Bolt 150 Crankshaft pulley...
Page 65 PP−10 PREPARATION − ENGINE MECHANICAL (2UZ−FE) (09951−07100) Handle 100 Spark plug tube Valve guide bushing Variable Pin Wrench Set 09960−10010 (09962−01000) Variable Pin Wrench Arm Assy Camshaft sub−gear Pin 4 Camshaft sub−gear (09963−00400) (09963−00500) Pin 5 Camshaft sub−gear (09963−01000) Pin 10 Camshaft sub−gear...
Page 66 PP−11 PREPARATION − ENGINE MECHANICAL (2UZ−FE) PP1BL−08 RECOMMENDED TOOLS 09040−00011 Hexagon Wrench Set . Engine Sling Device For suspension engine 09090−04020 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . Plug for vacuum hose, fuel hose etc. 09904−00010 Expander Set .
Page 67 PP−12 PREPARATION − ENGINE MECHANICAL (2UZ−FE) PP1BM−01 EQUIPMENT Caliper gauge CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune−up tester Groove cleaning tool Heater Magnetic finger Micrometer Pin hole grinder OBD II scan tool Piston ring compressor Piston ring expander Plastigage...
Page 68 PP−13 PREPARATION − ENGINE MECHANICAL (2UZ−FE) PP432−01 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent Camshaft bearing cap (FIPG) Cylinder head semi−circular plug Cylinder head cover Rear oil sear retainer Seal Packing Black or equivalent Camshaft housing plug 08826−00080 (FIPG) 08826−00100...
Page 69 PP−14 PREPARATION − EMISSION CONTROL (1GR−FE) EMISSION CONTROL (1GR−FE) PP43H−01 EQUIPMENT Vacuum gauge Pressure gauge...
Page 70 PP−15 PREPARATION − EMISSION CONTROL (2UZ−FE) EMISSION CONTROL (2UZ−FE) PP42V−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester.
Page 71 PP−16 PREPARATION − EMISSION CONTROL (2UZ−FE) PP1AK−06 EQUIPMENT MITYVAC (Hand−held vacuum pump) Pressure gauge Torque wrench Vacuum gauge Hose Clipper...
Page 72 PP−17 PREPARATION − SFI (1GR−FE) SFI (1GR−FE) PP43I−01 SST (Special Service Tools) 09268−41047 Injection Measuring Tool Set INJECTOR FUEL PUMP NO.7 Union INJECTOR (09268−41091) 09268−41140 Adapter INJECTOR Clamp INJECTOR 09268−41400 (90467−13001) Clip FUEL PUMP Hose INJECTOR (95336−08070) FUEL PUMP 09268−45014 EFI Fuel Pressure Gauge FUEL PUMP (09268−41200)
Page 73 PP−18 PREPARATION − SFI (1GR−FE) (09808−01410) Holder FUEL PUMP Claw FUEL PUMP (09808−01420) (09808−01430) Bolt FUEL PUMP Wiring ”F” EFI Inspection SFI SYSTEM 09842−30070 09842−30080 EFI Inspection Wire ”H” INJECTOR...
Page 74 PP−19 PREPARATION − SFI (1GR−FE) PP43J−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set.
Page 75 PP−20 PREPARATION − SFI (1GR−FE) PP43K−01 EQUIPMENT Graduated cylinder Transmission jack...
Page 76 PP−21 PREPARATION − SFI (2UZ−FE) SFI (2UZ−FE) PP433−01 SST (Special Service Tools) 09268−21010 Fuel Hose Puller Injection Measuring Tool Set 09268−41047 (09268−41091) NO.7 Union Adaptor (09268−41110) (09268−41300) Clamp Injection Measuring Attachment (09268−52011) 09268−45014 EFI Fuel Pressure Gauge (09268−41190) Adapter I Union (90405−06167) 09612−24014 Steering Gear Housing Overhaul...
Page 77 PP−22 PREPARATION − SFI (2UZ−FE) (09808−01410) Holder Claw (09808−01420) (09808−01430) Bolt Wiring ”F” EFI Inspection 09842−30070...
Page 78 PP−23 PREPARATION − SFI (2UZ−FE) PP0U4−05 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. TOYOTA Electrical Tester. (09082−00040) 09258−00030 Hose Plug Set . Plug for vacuum hose, fuel hose etc.
Page 79 PP−24 PREPARATION − SFI (2UZ−FE) PP0NI−02 EQUIPMENT Graduated cylinder Injector OBD II scan tool Sound scope Injector Torque wrench Vacuum gauge...
Page 80 PP−25 PREPARATION − COOLING (1GR−FE) COOLING (1GR−FE) PP435−01 EQUIPMENT Heater Radiator cap tester Slide calipers Thermometer Torque wrench...
Page 81 PP436−01 COOLANT Item Capacity Classification Engine coolant ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non−silicate, non− 11.6 liters (12.3 US qts, 10.2 lmp. qts) amine, non−nitrite, and non−borate coolant with long−life hybrid organic acid technology...
Page 82 PP−27 PREPARATION − COOLING (2UZ−FE) COOLING (2UZ−FE) PP1AQ−05 EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench...
Page 83 COOLING (2UZ−FE) PP1AR−05 COOLANT Item Capacity Classification ”TOYOTA Super Long Life Coolant” or similar high quality ethylene glycol based non−silicate, Engine coolant 11.6 liters (12.3 US qts, 10.2 lmp. qts) non−amine, non−nitrite, and non−borate coolant with long−life hybrid organic acid technology...
Page 84 PP−29 PREPARATION − COOLING (2UZ−FE) PP1AS−04 SSM (Special Service Materials) 08826−00100 Seal Packing 1282B, Water inlet housing THREE BOND 1282B or equivalent (FIPG)
Page 85 PP−30 PREPARATION − LUBRICATION (1GR−FE) LUBRICATION (1GR−FE) PP43L−01 SST (Special Service Tools) 09226−10010 Crankshaft Front & Rear Bearing OIL PUMP Replacer Oil Filter Wrench OIL AND FILTER 09228−07501...
Page 86 PP−31 PREPARATION − LUBRICATION (1GR−FE) PP43M−01 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit .
Page 87 PP−32 PREPARATION − LUBRICATION (1GR−FE) PP43N−01 EQUIPMENT Oil pressure gauge Drain hose...
Page 88 PP−33 PREPARATION − LUBRICATION (1GR−FE) PP43O−01 LUBRICANT Engine oil API grade SL, Energy−Conserving or ILSAC mul- Drain and refill w/ Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. Qts) tigrade engine oil. SAE 5W−30 is the best choise w/o Oil filter change 4.2 liters (4.4 US qts, 3.7 Imp.
Page 89 PP−34 PREPARATION − LUBRICATION (1GR−FE) PP43P−01 SSM (Special Service Materials) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent...
Page 90 PP−35 PREPARATION − LUBRICATION (2UZ−FE) LUBRICATION (2UZ−FE) PP24A−04 SST (Special Service Tools) 09032−00100 Oil Pan Seal Cutter Oil Filter Wrench 09228−07501 09316−60011 Transmission & Transfer Bearing Replacer Replacer Pipe Crankshaft front oil seal (09316−00011)
Page 91 PP−36 PREPARATION − LUBRICATION (2UZ−FE) PP1AU−04 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit . Snap Ring Pliers . 09905−00013...
Page 92 PP−37 PREPARATION − LUBRICATION (2UZ−FE) PP1AV−02 EQUIPMENT Oil pressure gauge Precision straight edge Torque wrench...
Page 93 PP−38 PREPARATION − LUBRICATION (2UZ−FE) PP1AW−09 LUBRICANT Item Capacity Classification Engine oil Dry fill 7.1 liters (7.5 US qts, 6.2 Imp. qts) API grade SL Energy−Conserving or ILSAC mul- Drain and refill tigrade engine oil. w/ Oil filter change 6.2 liters (6.6 US qts, 5.5 Imp. qts) w/o Oil filter change 5.7 liters (6.0 US qts, 5.0 Imp qts)
Page 94 PP−39 PREPARATION − LUBRICATION (2UZ−FE) PP1AX−04 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent Oil pump (FIPG) No.1 oil pan No.2 oil pan Adhesive 1344 Oil pressure switch 08833−00080 THREE BOND 1344 LOCTITE 242 or equivalent...
Page 95 PP−40 PREPARATION − IGNITION (1GR−FE) IGNITION (1GR−FE) PP43Q−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. Engine Adjust Kit . 09200−00010...
Page 96 PP−41 PREPARATION − IGNITION (1GR−FE) PP43R−01 EQUIPMENT Spark plug cleaner Torque wrench...
Page 97 PP−42 PREPARATION − IGNITION (2UZ−FE) IGNITION (2UZ−FE) PP3WQ−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. TOYOTA Electrical Tester. (09082−00040) 09200−00010 Engine Adjust Kit .
Page 98 PP−43 PREPARATION − IGNITION (2UZ−FE) PP1AM−01 EQUIPMENT Megger (Insulation resistance meter) Spark plug Spark plug cleaner Torque wrench...
Page 99 PP−44 PREPARATION − STARTING (1GR−FE) STARTING (1GR−FE) PP438−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. TOYOTA Electrical Tester. (09082−00040) 09904−00010 Expander Set . No. 4 Claw (09904−00050)
Page 100 PP−45 PREPARATION − STARTING (1GR−FE) PP439−01 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Armature bearing, Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush...
Page 101 PP−46 PREPARATION − STARTING (2UZ−FE) STARTING (2UZ−FE) PP1AZ−07 SST (Special Service Tools) 09286−46011 Injection Pump Spline Shaft Armature bearing Puller Starter Magnet Switch Nut Wrench 09810−38140 09820−00031 Alternator Rear Bearing Replacer Armature front bearing...
Page 102 PP−47 PREPARATION − STARTING (2UZ−FE) PP3WS−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. TOYOTA Electrical Tester. (09082−00040)
Page 103 PP−48 PREPARATION − STARTING (2UZ−FE) PP1B1−03 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Armature bearing, Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush...
Page 104 PP−49 PREPARATION − CHARGING (1GR−FE) CHARGING (1GR−FE) PP43C−01 SST (Special Service Tools) 09285−76010 Injection Pump Camshaft Bearing Cone Replacer Alternator Rear Bearing Puller 09820−00021 09820−00031 Alternator Rear Bearing Replacer Alternator Pulley Set Nut 09820−63011 Wrench Set 09950−40011 Puller B Set Hanger 200 (09951−04020) (09952−04010)
Page 105 PP−50 PREPARATION − CHARGING (1GR−FE) 09950−60010 Replacer Set Replacer 25 (09951−00250) (09951−00470) Replacer 47 Handle Set 09950−70010 (09951−07100) Handle 100...
Page 106 PP−51 PREPARATION − CHARGING (1GR−FE) PP43D−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. TOYOTA Electrical Tester. (09082−00040) (09083−00150) Test Lead Set...
Page 107 PP−52 PREPARATION − CHARGING (1GR−FE) PP43E−01 EQUIPMENT Ammeter (A) Dial indicator with magnetic base Ohmmeter...
Page 108 PP−53 PREPARATION − CHARGING (2UZ−FE) CHARGING (2UZ−FE) PP249−03 SST (Special Service Tools) 09285−76010 Injection Pump Camshaft Bearing Rotor rear bearing cover Cone Replacer Injection Pump Spline Shaft Rectifier end frame 09286−46011 Puller 09820−00021 Alternator Rear Bearing Puller Alternator Rear Bearing Replacer 09820−00031 09820−63011 Alternator Pulley Set Nut...
Page 109 PP−54 PREPARATION − CHARGING (2UZ−FE) PP3WU−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. TOYOTA Electrical Tester. (09082−00040)
Page 110 PP−55 PREPARATION − CHARGING (2UZ−FE) PP1B4−05 EQUIPMENT Battery specific gravity gauge+ Battery Torque wrench Vernier calipers Rotor (Slip ring)
Page 111 PP−56 PREPARATION − CLUTCH CLUTCH PP43G−01 SST (Special Service Tools) 09023−00101 Union Nut Wrench 10mm CLUTCH RELEASE CYLINDER CLUTCH MASTER CYLINDER Clutch Guide Tool CLUTCH UNIT 09301−00110 09333−00013 Clutch Diaphragm Spring Aligner CLUTCH UNIT...
Page 112 PP−57 PREPARATION − CLUTCH PP0EO−04 RECOMMENDED TOOLS 09031−00030 Pin Punch . Expander Set . 09904−00010...
Page 113 PP−58 PREPARATION − CLUTCH PP0EP−02 EQUIPMENT Vernier calipers Dial indicator...
Page 114 PP−59 PREPARATION − MANUAL TRANSMISSION (RA60) MANUAL TRANSMISSION (RA60) PP444−01 SST (Special Service Tools) 09023−00101 Union Nut Wrench 10mm MANUAL TRANSMISSION UNIT Crankshaft Rear Bearing Remover MANUAL TRANSMISSION 09255−10012 & Replacer ASSEMBLY 09308−14010 Replacer Pipe A COUNTER GEAR INPUT SHAFT Oil Seal Puller MANUAL TRANSMISSION...
Page 115 PP−60 PREPARATION − MANUAL TRANSMISSION (RA60) 09817−16011 Back−up Light Switch Tool MANUAL TRANSMISSION ASSEMBLY Variable Open Wrench MANUAL TRANSMISSION 09922−10010 ASSEMBLY 09950−00020 Bearing Remover COUNTER GEAR OUTPUT SHAFT INPUT SHAFT Replacer Set COUNTER GEAR 09950−60010 OUTPUT SHAFT MANUAL TRANSMISSION ASSEMBLY (09951−00540) Replacer 54 COUNTER GEAR...
Page 116 PP−61 PREPARATION − MANUAL TRANSMISSION (RA60) PP43Z−01 RECOMMENDED TOOLS 09905−00012 Snap Ring No.1 Expander Expander Set . 09904−00010 09031−00040 Pin Punch .
Page 117 PP−62 PREPARATION − MANUAL TRANSMISSION (RA60) PP43V−01 EQUIPMENT Plastic hammer Chisel Feeler gauge Dial indicator with magnetic base Belt Wooden block Hexagon wrench Vernier caliper Micrometer Cylinder gauge...
Page 118 PP−63 PREPARATION − MANUAL TRANSMISSION (RA60) PP43W−01 LUBRICANT API GL−4 or GL−5 Transmission oil 1.8 liters (1.9 US qts, 1.5 Imp. qts) SAE 75W−90...
Page 119 PP−64 PREPARATION − MANUAL TRANSMISSION (RA60) PP43X−01 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG)
Page 120 PP−65 PREPARATION − AUTOMATIC TRANSMISSION (A750E, A750F) AUTOMATIC TRANSMISSION (A750E, A750F) PP42O−01 SST (Special Service Tools) 09350−30020 TOYOTA Automatic Transmission Tool Set Stator Stopper Torpue converter clutch and drive (09351−32020) plate 09992−00095 Automatic Transmission Oil Pressure Gauge Set Adaptor C (09992−00231)
Page 121 PP−66 PREPARATION − AUTOMATIC TRANSMISSION (A750E, A750F) PP42P−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester.
Page 122 PP−67 PREPARATION − AUTOMATIC TRANSMISSION (A750E, A750F) PP42Q−01 EQUIPMENT OBD II scan tool Torque wrench Calipers Torque converter clutch Straight edge Torque converter clutch Dial indicator Drive plate runout...
Page 123 PP−68 PREPARATION − AUTOMATIC TRANSMISSION (A750E, A750F) PP42R−01 LUBRICANT Item Capacity Classification Automatic transmission fluid Dry fill 10.4 liters (11.0 US qts, 9.2 lmp qts) Toyota Genuine ATF WS Drain and refill 3.0 liters (3.2 US qts, 2.6 lmp qts)
Page 124 PP−69 PREPARATION − TRANSFER TRANSFER PP43Y−01 SST (Special Service Tools) 09223−15020 Oil Seal & Bearing Replacer PLANETARY GEAR Transmission & Transfer Bearing OIL SEAL 09316−60011 Replacer REAR OUTPUT SHAFT (09316−00011) Replacer Pipe OIL SEAL REAR OUTPUT SHAFT Replacer ”F” REAR OUTPUT SHAFT (09316−00071) 09330−00021 Companion Flange Holding Tool...
Page 125 PP−70 PREPARATION − TRANSFER 09950−40011 Puller B Set TRANSFER ASSEMBLY Hanger 200 TRANSFER ASSEMBLY (09951−04020) (09952−04010) Slide Arm TRANSFER ASSEMBLY Center Bolt 200 TRANSFER ASSEMBLY (09953−04030) (09954−04010) Arm 25 TRANSFER ASSEMBLY (09955−04051) Claw No.5 TRANSFER ASSEMBLY (09957−04010) Attachment TRANSFER ASSEMBLY (09958−04011) Holder TRANSFER ASSEMBLY...
Page 126 PP−71 PREPARATION − TRANSFER (09952−06010) Adapter OIL SEAL Handle Set OIL SEAL 09950−70010 PLANETARY GEAR (09951−07100) Handle 100 OIL SEAL PLANETARY GEAR...
Page 127 PP−72 PREPARATION − TRANSFER PP440−01 RECOMMENDED TOOLS 09040−00011 Hexagon Wrench Set . Torx Socket T30 . 09042−00010 (09082−00040) TOYOTA Electrical Tester. 09905−00012 Snap Ring No.1 Expander...
Page 128 PP−73 PREPARATION − TRANSFER PP441−01 EQUIPMENT Dial indicator Micrometer Torque wrench Feeler gauge Magnetic finger Steel square...
Page 129 PP−74 PREPARATION − TRANSFER PP442−01 LUBRICANT API GL−4 or GL−5 Transfer oil 1.0 liters (1.1 US qts, 0.9 Imp. Qts) SAE 75W−90...
Page 130 PP−75 PREPARATION − TRANSFER PP443−01 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Adhesive 1344 08833−00080 THREE BOND 1344 LOCTITE 242 or equivalent...
Page 131 PP−76 PREPARATION − PROPELLER SHAFT PROPELLER SHAFT PP0EY−04 SST (Special Service Tools) 09325−40010 Transmission Oil Plug PROPELLER SHAFT ASSEMBLY Companion Flange Holding Tool PROPELLER SHAFT ASSEMBLY 09330−00021 09332−25010 Universal Joint Bearing Remover SPIDER BEARING & Replacer Puller A Set PROPELLER SHAFT ASSEMBLY 09950−30012 (09951−03010) Upper Plate...
Page 132 PP−77 PREPARATION − PROPELLER SHAFT PP0EZ−03 EQUIPMENT Dial indicator Torque wrench...
Page 133 PP−78 PREPARATION − SUSPENSION AND AXLE SUSPENSION AND AXLE PP25D−04 SST (Special Service Tools) 09023−00101 Union Nut Wrench 10mm Rear axle Oil Seal & Bearing Replacer Front differential 09223−15020 09223−15030 Oil Seal & Bearing Replacer Front axle Crankshaft Rear Oil Seal Rear axle 09223−56010 Replacer...
Page 134 09318−12010 Transfer Bearing Adjusting Nut Front axle (2WD) Wrench Companion Flange Holding Tool Front differential 09330−00021 Rear differential 09350−20015 TOYOTA Automatic Transmission Front differential Tool Set Piston Spring Compressor Set (09369−20040) 09502−12010 Differential Bearing Replacer Front differential Front suspension 09504−22012...
Page 135 PP−80 PREPARATION − SUSPENSION AND AXLE 09521−25011 Rear Axle Shaft Puller Rear axle Rear Axle Hub Guide Tool Rear differential 09523−36010 09527−17011 Rear Axle Shaft Bearing Remover Front axle Differential Oil Seal Replacer Front differential 09554−22010 09556−22010 Drive Pinion Front Bearing Front differential Remover Rear differential...
Page 136 PP−81 PREPARATION − SUSPENSION AND AXLE 09628−62011 Ball Joint Puller Front drive shaft Front suspension Steering Rack Oil Seal Tool Set Rear suspension 09630−24014 (09620−24041) Seal Ring Guide Seal Ring Tool Front suspension 09631−12090 09631−20060 Bearing Guide Nut Wrench Front suspension 09632−36010 Steering Vane Pump Bearing Front suspension...
Page 137 PP−82 PREPARATION − SUSPENSION AND AXLE 09710−30041 Rear Suspension Bushing Tool Set Rear suspension Remover (09710−03211) 09727−30021 Coil Spring Compressor Front suspension Bolt Set (09727−00010) (09727−00021) Arm Set (09727−00031) Compressor 09922−10010 Variable Open Wrench Front suspension 09950−00020 Bearing Remover Front drive shaft Front differential Front suspension Rear differential...
Page 138 PP−83 PREPARATION − SUSPENSION AND AXLE (09956−03020) Adapter 18 Front differential Adapter 24 Rear differential (09956−03050) 09950−40011 Puller B Set Hanger 150 Front axle (09951−04010) Front differential Front suspension Rear differential (09951−04020) Hanger 200 Front axle (09952−04010) Slide Arm Front axle Front differential Front suspension Rear differential...
Page 139 PP−84 PREPARATION − SUSPENSION AND AXLE 09950−60010 Replacer Set Replacer 35 Rear suspension (09951−00350) (09951−00380) Replacer 38 Front differential Replacer 48 Front differential (09951−00480) Rear differential (09951−00540) Replacer 54 Front differential (09951−00560) Replacer 56 Rear axle (09951−00610) Replacer 61 Rear axle (09951−00640) Replacer 64 Rear differential...
Page 140 PP−85 PREPARATION − SUSPENSION AND AXLE (09951−00810) Replacer 81 Front axle Replacer 89 Rear axle (09951−00890) (09951−00910) Replacer 91 Front axle Rear differential Handle Set Front axle, Front differential 09950−70010 Rear axle Rear differential Rear suspension (09951−07150) Handle 150...
Page 141 PP099−05 RECOMMENDED TOOLS 09025−00010 Torque Wrench (30 kgf−cm) Pin Punch . 09031−00030 09044−00010 Torx Socket E14 . 09082−00040 TOYOTA Electrical Tester. 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers . Torx is a registered trademark of Textron Inc.
Page 142 PP−87 PREPARATION − SUSPENSION AND AXLE PP09A−03 EQUIPMENT Dial indicator with magnetic base Torque wrench Micrometer Voltmeter Ohmmeter...
Page 143 PP−88 PREPARATION − SUSPENSION AND AXLE PP09B−08 LUBRICANT Item Capacity Application Front drive shaft Outboard joint grease (Color = Black) 205 − 225 g (7.23 − 7.94 oz.) Inboard joint grease (Color = Black) 190 − 210 g (6.70 − 7.41 oz.) Front differential Hypoid gear oil API GL−5 1.15 liters (1.22 US qts., 1.01 lmp.
Page 144 PP−89 PREPARATION − SUSPENSION AND AXLE PP25E−01 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, Front differential THREE BOND 1281 or equivalent (FIPG) Adhesive 1324, Front differential 08833−00070 THREE BOND 1324 or equivalent 08833−00100 THREE BOND 1360K or equivalent Rear differential...
Page 145 PP−90 PREPARATION − BRAKE BRAKE PP446−01 SST (Special Service Tools) 09023−00101 Union Nut Wrench 10mm Brake Shoe Return Spring Tool 09703−30010 09709−29018 LSPV Gauge Set Shoe Hold Down Spring Driver 09718−00010 09737−00011 Brake Booster Push Rod Gauge Brake Booster Push Rod Wrench 09737−00020 09751−36011 Brake Line Union Nut 10 x 12 mm...
Page 146 PP−91 PREPARATION − BRAKE PP0FB−04 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. Snap Ring Pliers . 09905−00013...
Page 147 PP−92 PREPARATION − BRAKE PP0FC−02 EQUIPMENT Torque wrench Micrometor Brake disc Dial indicator Brake disc Vernier calipers Brake drum...
Page 148 PP−93 PREPARATION − BRAKE PP0FD−02 LUBRICANT Item Capacity Classification Brake fluid − SAE J1703 or FMVSS No.116 DOT 3...
Page 149 PP−94 PREPARATION − STEERING STEERING PP447−01 SST (Special Service Tools) 09023−12701 Union Nut Wrench 17mm PS gear Union Nut Wrench 14mm PS gear 09023−38401 09521−24010 Drive Shaft Boot Clamping Tool PS gear Rear Axle Shaft Bearing Remover PS gear 09527−20011 09612−00012 Rack &...
Page 150 PP−95 PREPARATION − STEERING 09631−12071 Steering Rack Oil Seal Test Tool PS gear Cylinder End Stopper Nut Wrench PS gear 09631−16010 09631−20051 Steering Rack Cover ”C” PS gear Seal Ring Tool PS gear 09631−20081 09640−10010 Power Steering Pressure Gauge (09641−01010) Gauge Assy Power steering fluid (09641−01030)
Page 151 PP−96 PREPARATION − STEERING 09950−50013 Puller C Set Hanger 150 Steering column (09951−05010) (09952−05010) Slide Arm Steering column Center Bolt 150 Steering column (09953−05020) (09954−05021) Claw No.2 Steering column 09950−60010 Replacer Set (09951−00180) Replacer 18 PS gear (09951−00250) Replacer 25 PS gear Replacer 26 PS gear...
Page 152 PP−97 PREPARATION − STEERING (09951−00330) Replacer 33 PS vane pump (2UZ−FE) Replacer 34 PS gear (09951−00340) (09951−00360) Replacer 36 PS gear Replacer 40 Steering column (Double Cab) (09951−00400) (09951−00430) Replacer 43 Steering column (Standard Cab, Access Cab) (09951−00460) Replacer 46 Steering column PS gear (09951−00490)
Page 153 PP−98 PREPARATION − STEERING PP25I−02 RECOMMENDED TOOLS 09025−00010 Small Torque Wrench (30 kgf−cm) PS vane pump PS gear Torx Socket T30 . Steering column 09042−00010 Torx is a registered trademark of Textron Inc.
Page 154 PP−99 PREPARATION − STEERING PP0FW−04 EQUIPMENT Caliper gauge PS vane pump (1GR−FE, 2UZ−FE) Vernier calipers PS vane pump (1GR−FE, 2UZ−FE) Dial indicator PS gear Feeler gauge PS vane pump (1GR−FE, 2UZ−FE) Micrometer PS vane pump (1GR−FE, 2UZ−FE) Torque wrench...
Page 155 PP−100 PREPARATION − STEERING PP0FX−03 LUBRICANT Item Capacity Classification Power steering fluid 1.0 liters (1.1 US qts, 0.9 Imp.qts) ATF DEXRON® II or III Total...
Page 156 PP−101 PREPARATION − STEERING PP1B9−08 SSM (Special Service Materials) 08833−00080 Adhesive 1344 PS gear THREE BOND 1344 LOCTITE 242 or equivalent...
Page 157 PP−102 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP420−02 SST (Special Service Tools) 09082−00700 SRS Airbag Deployment Tool Airbag Deployment Wire 09082−00750 Sub−harness No.3 09082−00760 Airbag Deployment Wire Sub−harness No.4 Airbag Deployment Wire 09082−00780 Sub−Harness No.6 09082−00802 Airbag Deployment Wire Sub−Harness No.8 Wire A (09082−10801)
Page 158 PP−103 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP0FS−03 RECOMMENDED TOOLS 09042−00010 Torx Socket T30 . TOYOTA Electrical Tester. 09082−00040 Torx is a registered trademark of Textron lnc.
Page 159 PP−104 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP0FT−02 EQUIPMENT Torque wrench Bolt: Length: 35 mm (1.387 in.) Airbag disposal Pitch: 1.0 mm (0.039 in.) Diam.: 6.0 mm (0.236 in.) Tire Width: 185 mm (7.28 in.) Airbag disposal Inner diam.: 360mm (14.17 in.) Tire with disc wheel Width: 185 mm (7.28 in.) Airbag disposal...
Page 160 PP−105 PREPARATION − BODY ELECTRICAL BODY ELECTRICAL PP06F−12 SST (Special Service Tools) 09843−18020 Diagnosis Check Wire...
Page 161 PP−106 PREPARATION − BODY ELECTRICAL PP06G−10 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. Torx Driver T30 . For removing and installing steering 09041−00030 wheel pad 09042−00010 Torx Socket T30 . For removing and installing steering wheel pad...
Page 162 PP−107 PREPARATION − BODY ELECTRICAL PP06H−05 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb (3.4 W) Torque wrench...
Page 163 PP−108 PREPARATION − BODY BODY PP25L−02 SST (Special Service Tools) 09082−00700 SRS Airbag Deployment Tool Airbag Deployment Wire 09082−00740 Sub−harness No.2 09812−00020 Door Hinge Set Bolt Wrench...
Page 164 PP−109 PREPARATION − BODY PP25M−03 RECOMMENDED TOOLS 09041−00030 Torx Driver T30 . Torx Socket T30 . 09042−00010 09042−00020 Torx Socket T40 . Torx is a registered trademark of Textron Inc.
Page 165 PP−110 PREPARATION − BODY PP0MV−22 EQUIPMENT Clip remover Torque wrench Torx® driver 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...
Page 166 PP−111 PREPARATION − BODY PP0MW−03 LUBRICANT Item Capacity Classification MP grease − −...
Page 167 PP−112 PREPARATION − BODY PP0TC−11 SSM (Special Service Materials) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent Three cement black or equivalent 08833−00030 08850−00801 Windshield Glass Adhesive Set or equivalent...
Page 168 PP−113 PREPARATION − AIR CONDITIONING AIR CONDITIONING PP43F−01 SST (Special Service Tools) 07110−58060 Air Conditioner Service Tool Set Refrigerant Drain Service Valve (07117−58060) (07117−58070) T−Joint Quick Disconnect Adapter (07117−58080) (07117−58090) Quick Disconnect Adapter Refrigerant Charging Hose (07117−88060) (07117−88070) Refrigerant Charging Hose (07117−88080) Refrigerant Charging Hose Magnetic Clutch Remover...
Page 169 PP−114 PREPARATION − AIR CONDITIONING 09960−10010 Variable Pin Wrench Set Variable Pin Wrench Arm Assy (09962−01000) (09963−00500) Pin 5 Snap Ring Pliers 95994−10020 (DENSO Part No.)
Page 170 PP−115 PREPARATION − AIR CONDITIONING PP0E3−04 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. Belt Tension Gauge . 09216−00021 09216−00030 Belt Tension Gauge Cable .
Page 171 PP−116 PREPARATION − AIR CONDITIONING PP0E4−03 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch Hexagon wrench Expansion valve...
Page 172 PP−117 PREPARATION − AIR CONDITIONING PP0E5−09 LUBRICANT Item Capacity Classification Compressor oil − ND−OIL 8 or equivalent When replacing receiver 20 cc (0.71 fl.oz.) When replacing condenser 40 cc (1.4 fl. oz.) When replacing evaporator 40 to 50 cc (1.4 to 1.7 fl. oz.)
Page 173 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...
Page 174 SS−2 SERVICE SPECIFICATIONS − STANDARD BOLT SS0ZT−01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class 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 175 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 176 SS−4 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (1GR−FE) ENGINE MECHANICAL (1GR−FE) SS1MH−01 SERVICE DATA Compression 1.3 MPa (13.3 kgf·cm , 189 psi) or more pressure Minimum 1.0 MPa (10.2 kgf·cm , 145 psi) Difference of pressure between each cylinder 0.1 MPa (1.0 kgf·cm , 15 psi) or less Valve clearance at cold...
Page 177 SS−5 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (1GR−FE) Chain tensioner No. 2 depth Maximum 1.0 mm (0.039 in.) Slipper depth Maximum 1.0 mm (0.039 in.) Chain vibration Depth Maximum 1.0 mm (0.039 in.) damper Warpage Maximum 0.10 mm (0.0039 in.) Cylinder head Cylinder head bolt thread outside diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Page 178 SS−6 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (1GR−FE) Connecting rod Thrust clearance Standard 0.15 to 0.30 mm (0.0059 to 0.0118 in.) Maximum 0.35 mm (0.0138 in.) Connecting rod oil clearance Standard 0.026 to 0.046 mm (0.0010 to 0.0018 in.) Maximum 0.066 mm (0.0025 in.) Connecting rod bolt tension portion diameter Standard 7.2 to 7.3 mm (0.283 to 0.287 in.)
Page 179 SS−7 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (1GR−FE) Cylinder block Cylinder head surface warpage Maximum 0.05 mm (0.0020 in.) Cylinder bore diameter Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum 94.132 mm (3.7060 in.) Piston and piston Piston diameter 93.910 to 93.920 mm (3.6972 to 3.6976 in.) ring Piston oil clearance...
Page 180 SS−8 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (1GR−FE) SS1MI−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Bearing cap x Cylinder head for 10 mm (0.39 in.) head 80 in.·lbf Bearing cap x Cylinder head for 12 mm (0.47 in.) head Chain tensioner No.
Page 181 SS−9 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (1GR−FE) RH front exhaust pipe x Center exhaust pipe Water by−pass joint x Cylinder head 80 in.·lbf LH front exhaust pipe x Center exhaust pipe Intake manifold x Cylinder head Oil filter cap housing x Cylinder head cover 80 in.·lbf Camshaft timing oil control valve x Cylinder head 80 in.·lbf...
Page 182 SS−10 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (2UZ−FE) ENGINE MECHANICAL (2UZ−FE) SS0OQ−13 SERVICE DATA Compression at 250 rpm STD 1,373 kPa (14.0 kgf/cm , 199 psi) or more pressure Minimum 1,030 kPa (10.5 kgf/cm , 149 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm , 14 psi) or less Valve...
Page 183 SS−11 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (2UZ−FE) Cylinder head Warpage Maximum 0.10 mm (0.039 in.) Valve seat Refacing angle 30°, 45°, 60° Contacting angle 45° Contacting width 1.0 to 1.4 mm (0.039 to 0.055 in.) Valve guide bushing bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Page 184 SS−12 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (2UZ−FE) Cylinder block Cylinder head surface warpage Maximum 0.07 mm (0.0028 in.) Cylinder bore diameter STD Mark 2 94.010 to 94.023 mm (3.7012 to 3.7017 in.) Maximum STD 94.223 mm (3.7096 in.) O/S 050 94.723 mm (3.7292 in.) Main bearing cap bolt tension portion diameter 10.760 to 10.970 mm (0.4236 to 0.4319 in.)
Page 185 SS−13 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (2UZ−FE) Crankshaft Main bearing center wall thickness (Reference) (cont’d) No.1 and No.5 Mark 3 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark 4 2.490 to 2.493 mm (0.0980 to 0.0981 in.) Mark 5 2.493 to 2.496 mm (0.0981 to 0.0983 in.) Mark 6 2.496 to 2.499 mm (0.0983 to 0.0984 in.)
Page 186 SS−14 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (2UZ−FE) SS0OR−14 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fan shroud x Radiator assembly 43 in.·lbf Radiator bracket x Radiator assembly A/C Compressor x Cylinder block Generator x Generator bracket No.1 idler pulley, No.2 idler pulley x Cylinder Block 34.5 Camshaft timing pulley x Camshaft timing tube 72 in.·lbf...
Page 187 SS−15 SERVICE SPECIFICATIONS − ENGINE MECHANICAL (2UZ−FE) Front exhaust pipe x Exhaust manifold Center exhaust pipe x Front exhaust pipe Heated oxygen sensor (Bank 1, 2 sensor 2) x Front exhaust pipe...
Page 188 SS−16 SERVICE SPECIFICATIONS − EMISSION CONTROL (1GR−FE) EMISSION CONTROL (1GR−FE) SS1MJ−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf PCV valve x LH cylinder head cover Charcoal canister x Charcoal canister cover 14.7 Heated oxygen sensor x Front exhaust pipe A/F sensor x Front exhaust pipe Exhaust manifold x Cylinder head Manifold stay x Exhaust manifold Front exhaust pipe x Exhaust manifold...
Page 189 SS−17 SERVICE SPECIFICATIONS − EMISSION CONTROL (2UZ−FE) EMISSION CONTROL (2UZ−FE) SS1M8−02 SERVICE DATA at 20°C (68°F) 33 to 39 Ω VSV for air injec- Resistance tion system...
Page 190 SS−18 SERVICE SPECIFICATIONS − EMISSION CONTROL (2UZ−FE) SS0O5−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center pipe Heated oxygen sensor x Front exhaust pipe Air pump assembly x Cylinder head Air switching valve No.2 x Cylinder head Air tube No.3 x Cylinder head...
Page 191 SS−19 SERVICE SPECIFICATIONS − SFI (1GR−FE) SFI (1GR−FE) SS1MK−01 SERVICE DATA Fuel pressure Fuel pressure at idle 281 to 287 kPa (2.87 to 2.93 kgf·cm , 40.8 to 41.7 psi) remains for 5 minutes after engine has stopped 147 kPa (1.5 kgf·cm , 21 psi) or more at 20°C (68°F) 0.2 to 3.0 Ω...
Page 192 SS−20 SERVICE SPECIFICATIONS − SFI (1GR−FE) SS1ML−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fuel tank band x Body Fuel pressure regulator x Fuel delivery pipe 80 in.·lbf V−bank cover 66 in.·lbf Air cleaner Fuel delivery pipe x Intake manifold Intake air surge tank x surge tank stay Intake air surge tank x throttle body bracket Intake air surge tank x Intake manifold...
Page 193 SS−21 SERVICE SPECIFICATIONS − SFI (2UZ−FE) SFI (2UZ−FE) SS0CB−24 SERVICE DATA at 20°C (68°F) 0.2 to 3.0 Ω Fuel pump Resistance Fuel pressure Fuel pressure at no vacuum 265 to 304 kPa regulator (2.7 to 3.1 kgf/cm , 38 to 44 psi) 13.4 to 14.2 Ω...
Page 194 SS−22 SERVICE SPECIFICATIONS − SFI (2UZ−FE) SS0CC−23 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fuel pressure pulsation damper x Delivery pipe for use with SST Fuel pressure regulator x RH delivery pipe 66 in.·lbf Front fuel pipe x Lower intake manifold 66 in.·lbf Fuel return pipe x Delivery pipe 66 in.·lbf...
Page 195 SS−23 SERVICE SPECIFICATIONS − COOLING (1GR−FE) COOLING (1GR−FE) SS1MD−01 SERVICE DATA Water inlet w/ thermostat 80 to 84 _C (176 to 183 _F) Valve opening temperature at 95 _C (203 _F) Valve lift 8 mm (0.31 in.) or more Radiator cap Relief valve opening pressure Standard 93 to 123 kPa (0.95 to 1.25 kgf/cm...
Page 196 SS−24 SERVICE SPECIFICATIONS − COOLING (1GR−FE) SS1ME−01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Cylinder block water drain cock plug x Cylinder block water drain cock Water pump assy x Timing chain or belt cover sub−assy 10 mm (0.39 in.) head 80 in.
Page 197 SS−25 SERVICE SPECIFICATIONS − COOLING (2UZ−FE) COOLING (2UZ−FE) SS0O9−06 SERVICE DATA Thermostat Valve opening temperature 80 to 84°C (176 to 183°F) Valve lift at 95°C (203°F) 10 mm (0.39 in.) or more Radiator cap Relief valve opening pressure Standard 74 to 103 kPa (0.75 to 1.05 kgf/cm , 10.7 to 14.9 psi) Minimum 59 kPa (0.6 kgf/cm...
Page 198 SS−26 SERVICE SPECIFICATIONS − COOLING (2UZ−FE) SS0OA−05 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Drain plug x Union on cylinder block 12.7 Fan x Fluid coupling 47 in.·lbf Water pump x Cylinder block Bolt Stud bolt and nut Water inlet housing x Water pump Water inlet x Water inlet housing Radiator x Radiator support 12.7...
Page 199 SS−27 SERVICE SPECIFICATIONS − LUBRICATION (1GR−FE) LUBRICATION (1GR−FE) SS1MM−01 SERVICE DATA Oil pressure at idle speed 29 kPa (0.3 kgf·cm , 4.3 psi) or more at 3,000 rpm 294 to 588 kPa (3.0 to 6.0 kgf·cm , 43 to 85 psi) Oil pump Tip clearance Standard...
Page 200 SS−28 SERVICE SPECIFICATIONS − LUBRICATION (1GR−FE) SS1MN−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pressure switch Drain plug x Oil pan No. 2 Oil pipe x Timing chain cover 80 in.·lbf Oil pump cover x Timing chain cover 80 in.·lbf Relief valve plug x Oil pump cover Union bolt x Oil filter bracket Oil filter bracket x Timing chain cover...
Page 201 SS−29 SERVICE SPECIFICATIONS − LUBRICATION (2UZ−FE) LUBRICATION (2UZ−FE) SS0OB−06 SERVICE DATA Oil pressure at idle speed 29 kPa (0.3 kgf/cm , 4.3 psi) or more at 3,000 rpm 294 to 588 kPa (3.0 to 6.0 kgf/cm , 43 to 85 psi) Oil pump Tip clearance Standard...
Page 202 SS−30 SERVICE SPECIFICATIONS − LUBRICATION (2UZ−FE) SS0OC−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf No.2 oil pan x Drain plug Oil pump body cover x Oil pump body Oil pump x Cylinder block 14 mm head 30.5 Others 15.5 Relief valve x Oil pump body Oil strainer x Cylinder block, Oil pump 66 in.·lbf No.1 oil pan x Oil pump, Oil seal retainer, Cylinder block...
Page 203 SS−31 SERVICE SPECIFICATIONS − IGNITION (1GR−FE) IGNITION (1GR−FE) SS1MO−01 SERVICE DATA Spark plug Recommended spark plug NGK made LFR6C−11 DENSO made K20HR−U11 Electrode gap Standard 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum 1.46 mm (0.057 in.) 1,630 to 2,740 Ω Crankshaft posi- Resistance Cold...
Page 204 SS−32 SERVICE SPECIFICATIONS − IGNITION (1GR−FE) SS1MP−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Ignition coil x Cylinder head cover V−bank cover 66 in.·lbf Air cleaner assy 71 in.·lbf Throttle body bracket x Intake air surge tank Intake air surge tank x Intake manifold Surge tank stay x Intake air surge tank Oil baffle plate x Surge tank stay No.
Page 205 SS−33 SERVICE SPECIFICATIONS − IGNITION (2UZ−FE) IGNITION (2UZ−FE) SS0O6−08 SERVICE DATA Firing order − 1 − 8 − 4 − 3 − 6 − 5 − 7 − 2 Spark plug Recommended spark plug DENSO made SK20R11 NGK made IFR6A11 Electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) 1,630 to 2,740 Ω...
Page 206 SS−34 SERVICE SPECIFICATIONS − IGNITION (2UZ−FE) SS0O7−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head 17.5 Ignition coil (with igniter) x Cylinder head cover 66 in.·lbf Camshaft position sensor x LH cylinder head 66 in.·lbf Crankshaft position sensor x Oil pump 58 in.·lbf...
Page 207 SS−35 SERVICE SPECIFICATIONS − STARTING (1GR−FE) STARTING (1GR−FE) SS1MB−01 SERVICE DATA Starter (1.6 kW type) Rated voltage and output power 12 V 1.6 kW No−load characteristics Current 90 A or less at 11.5 V Starter armature assy Commutator length Standard 3.1 mm (0.122 in.) Minimum 3.8 mm (0.150 in.)
Page 208 SS−36 SERVICE SPECIFICATIONS − STARTING (1GR−FE) SS1MC−01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Starter assy x Transmission housing Starter assy x Terminal 30 Starter commutator end frame assy x Starter drive housing assy 53 in. lbf (Starter Assy 1.6 kW) Starter drive housing assy x Repair service starter kit 66 in.
Page 209 SS−37 SERVICE SPECIFICATIONS − STARTING (2UZ−FE) STARTING (2UZ−FE) SS0OD−03 SERVICE DATA Starter Rated voltage and output power 12 V 1.4 kW (1.4 kW type) No−load characteristics Current 90 A or less at 11.5 V 3,000 rpm or more Brush length Standard 15.5 mm (0.610 in.) Minimum...
Page 210 SS−38 SERVICE SPECIFICATIONS − STARTING (2UZ−FE) SS0OE−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Terminal 30 nut, Terminal C nut x Terminal bolt End cover x Magnetic switch housing 1.4 kW type 22 in.·lbf 2.0 kW type 32 in.·lbf End cover x Brush holder 1.4 kW type 13 in.·lbf 2.0 kW type...
Page 211 SS−39 SERVICE SPECIFICATIONS − CHARGING (1GR−FE) CHARGING (1GR−FE) SS1MF−01 SERVICE DATA Battery Voltage at 20°C (68°F) 12.5 to 12.9 V 1.25 to 1.29 at 20 _C (68 _F) Except maintenance−free battery Standard specific gravity Voltage regulator Regulating voltage 13.2 to 14.8 V Generator brush holder assy Brush length Standard...
Page 212 SS−40 SERVICE SPECIFICATIONS − CHARGING (1GR−FE) SS1MG−01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Generator assy x V−ribbed belt tensioner and cylinder head Generator assy x Wire harness clamp bracket 71 in. lbf Generator assy x Terminal B Wire harness stay x Body 71 in.
Page 213 SS−41 SERVICE SPECIFICATIONS − CHARGING (2UZ−FE) CHARGING (2UZ−FE) SS0OF−06 SERVICE DATA Battery Exept maintenance−free Specific gravity at 20°C (68°F) 1.25 to 1.29 Maintenance−free Voltage at 20°C (68°F) 12.5 to 12.9 V Generator Rated output 12V 100A 2.1 to 2.5 Ω Rotor coil resistance at 20°C (68°F) Slip ring diameter...
Page 214 SS−42 SERVICE SPECIFICATIONS − CHARGING (2UZ−FE) SS0OG−03 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 without Cord clip 39 in.·lbf with Cord clip 48 in.·lbf Generator pulley x Rotor 110.5 1,125 Rectifier holder x Lead wire on rectifier end frame...
Page 215 SS−43 SERVICE SPECIFICATIONS − CLUTCH CLUTCH SS07T−04 SERVICE DATA Pedal height from dash panel 170.2 to 180.2 mm (6.701 to 7.095 in.) Pedal height from dash insulator 157.7 to 167.7 mm (6.209 to 6.602 in.) Push rod play at pedal top 1.0 to 5.0 mm (0.039 to 0.197 in.) Pedal freeplay 5.0 to 15.0 mm (0.197 to 0.591 in.)
Page 216 SS−44 SERVICE SPECIFICATIONS − CLUTCH SS07U−04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder mounting nut Clutch line union Bleeder plug x Release cylinder body Release cylinder installation bolt Clutch accumulator installation bolt Clutch housing cover installation bolt Clutch cover x Flywheel Release fork support x Transmission...
Page 217 SS−45 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION (RA60) MANUAL TRANSMISSION (RA60) SS1MQ−01 SERVICE DATA Reverse idle gear thrust clearance Standard 0.10 to 0.55 mm (0.0039 to 0.0217 in.) Maximum 0.55 mm (0.0217 in.) Reverse idle gear radial clearance Standard 0.015 to 0.050 mm (0.0006 to 0.0020 in.) Maximum 0.050 mm (0.0020 in.) Input shaft gear thrust clearance...
Page 218 SS−46 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION (RA60) Input shaft bearing snap ring thickness Standard clearance 0.1 mm (0.0039 in.) or less Mark 2.65 to 2.70 mm (0.1043 to 0.1063 in.) 2.70 to 2.75 mm (0.1063 to 0.1083 in.) 2.75 to 2.80 mm (0.1083 to 0.1102 in.) 2.80 to 2.85 mm (0.1102 to 0.1122 in.) 2.85 to 2.90 mm (0.1122 to 0.1142 in.) 2.90 to 2.95 mm (0.1142 to 0.1161 in.)
Page 219 SS−47 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION (RA60) Synchronizer ring set No. 1 to 2nd gear clearance Standard Inner 1.48 to 2.12 mm (0.0583 to 0.0835 in.) Middle 0.68 to 1.92 mm (0.0268 to 0.0756 in.) Outer 0.88 to 1.72 mm (0.0346 to 0.0677 in.) Minimum Inner 1.48 mm (0.0583 in.)
Page 220 SS−48 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION (RA60) Needle roller bearing inner race snap ring thickness Standard 0.1 mm (0.0039 in.) or less Mark 2.35 to 2.40 mm (0.0925 to 0.0945 in.) 2.40 to 2.45 mm (0.0945 to 0.0965 in.) 2.45 to 2.50 mm (0.0965 to 0.0984 in.) 2.50 to 2.55 mm (0.0984 to 0.1004 in.) 2.55 to 2.60 mm (0.1004 to 0.1024 in.) 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
Page 221 SS−49 SERVICE SPECIFICATIONS − MANUAL TRANSMISSION (RA60) SS1MR−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Transmission x Engine Bolt A (See page MT−7) Bolt B Transmission cover x Transmission Engine rear mounting x Transmission Crossmember x Frame Engine rear mounting x Crossmember Starter x Transmission Starter wire x Starter Clutch release cylinder x Transmission...
Page 222 SS−50 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION (A750E, A750F) AUTOMATIC TRANSMISSION (A750E, A750F) SS1MV−01 SERVICE DATA 2UZ−FE (A750E) Line pressure (Wheel locked) Engine idling D position 361 − 421 kPa (3.7 − 4.3 kgf cm , 52 − 61 psi) R position 495 −...
Page 223 SS−51 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION (A750E, A750F) 2UZ−FE (A750F) Line pressure (Wheel locked) Engine idling D position 361 − 421 kPa (3.7 − 4.3 kgf cm , 52 − 61 psi) R position 495 − 576 kPa (5.0 − 5.9 kgf cm , 72 −...
Page 224 SS−52 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION (A750E, A750F) 1GR−FE (A750E) Line pressure (Wheel locked) Engine idling D position 363 − 423 kPa (3.7 − 4.3 kgf cm , 53 − 61 psi) R position 484 − 564 kPa (4.9 − 5.8 kgf cm , 70 −...
Page 225 SS−53 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION (A750E, A750F) SS1MW−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Drain plug x Oil pan Overflow plug x Oil pan Refill plug x Transmission case Speed sensor NT x Automatic transmission 48 in. lbf Speed sensor SP2 x Automatic transmission 48 in.
Page 226 SS−54 SERVICE SPECIFICATIONS − TRANSFER TRANSFER SS1MT−01 SERVICE DATA Transfer unit Hose installation depth 13 mm (0.51 in.) or more Input shaft Input shaft snap ring thickness Mark 2.10 to 2.15 mm (0.0827 to 0.0846 in.) 2.15 to 2.20 mm (0.0846 to 0.0866 in.) 2.20 to 2.25 mm (0.0866 to 0.0886 in.) 2.25 to 2.30 mm (0.0886 to 0.0906 in.) 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
Page 227 SS−55 SERVICE SPECIFICATIONS − TRANSFER Rear output shaft Drive sprocket thrust clearance Standard 0.10 to 0.25 mm (0.0039 to 0.0098 in.) Maximum 0.25 mm (0.0098 in.) Rear output shaft journal outer diameter Part A Minimum 27.98 mm (1.1016 in.) Part B Minimum 36.98 mm (1.4561 in.) Drive sprocket radial clearance...
Page 228 SS−56 SERVICE SPECIFICATIONS − TRANSFER SS1MU−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Rear propeller shaft x Rear differential Center support bearing x Body Rear propeller shaft x Transfer Transfer x Transfer adaptor Front propeller shaft x Front differential Front propeller shaft x Transfer Engine rear mounting x Transfer Engine rear mounting x Crossmember Crossmember x Frame...
Page 229 SS−57 SERVICE SPECIFICATIONS − PROPELLER SHAFT PROPELLER SHAFT SS1MS−01 SERVICE DATA Propeller shaft runout Maximum 0.8 mm (0.031 in.) Spider bearing ax- 2WD and 4WD front propeller shaft Maximum 0.05 mm (0.0020 in.) ial play 4WD rear propeller shaft Maximum 0 mm (0 in.) 4WD rear propel- Snap ring thickness...
Page 230 SS−58 SERVICE SPECIFICATIONS − PROPELLER SHAFT SS07Z−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf PROPELLER SHAFT ASSEMBLY (2WD) Center support bearing x Body Propeller shaft x Differential Intermediate shaft x Center support bearing x Center yoke 1,845 Loosen nut PROPELLER SHAFT ASSEMBLY (4WD) Rear propeller shaft x Rear differential Rear propeller shaft x Transfer Front propeller shaft x Front differential...
Page 231 SS−59 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE SUSPENSION AND AXLE SS051−14 SERVICE DATA D B, C−cab type Tire size: P245/70R16 Front 200 kPa (2.0 kgf/cm , 29 psi) Rear 240 kPa (2.4 kgf/cm , 35 psi) Tire size: P265/70R16 Front 180 kPa (1.8 kgf/cm , 26 psi) Rear...
Page 232 SS−60 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK41L−PRBSKA Tire size: P245/70R16 Front: A − B 56.7 mm (2.232 in.) Rear: C − D −57.1 mm (−2.248 in.) Tire size: P265/70R16 Front: A − B 57.0 mm (2.244 in.) Rear: C −...
Page 233 SS−61 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK30L−ASBSKA Tire size: P265/70R16 Front: A − B 70.4 mm (2.772 in.) Rear: C − D −24.8 mm (−0.976 in.) Tire size: P265/70R16 (B2BB (ORP)) Front: A − B 68.6 mm (2.701 in.) Rear: C −...
Page 234 SS−62 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE D Vehicle height (For CANADA) GSK30L−TRBDKK Tire size: P245/70R16 Front: A − B 75.2 mm (2.961 in.) Rear: C − D −50.8 mm (−2.000 in.) UCK40L−TRBDKK Tire size: P245/70R16 Front: A − B 51.5 mm (2.028 in.) Rear: C −...
Page 235 SS−63 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK41L−PRBLKK Tire size: P265/70R16 Front: A − B 57.4 mm (2.260 in.) Rear: C − D −54.1 mm (−2.130 in.) Front wheel Tire size: P265/70R16 (B2BB (ORP)) Front: A − B 55.0 mm (2.165 in.) alignment Rear: C −...
Page 236 SS−64 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE D Camber (B−cab for U.S.A.) Right−left error: 30’ (0.5°) or less GSK30L−TRFDKA Tire size: P245/70R16 −0°08’±45’ (−0.14°±0.75°) GSK30L−TRBDKA Tire size: P245/70R16 −0°10’±45’ (−0.18°±0.75°) UCK30L−TRBDKA Tire size: P245/70R16 −0°10’±45’ (−0.16°±0.75°) UCK40L−TRBDKA Tire size: P245/70R16 0°11’±45’...
Page 237 SS−65 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK30L−ASBLKA −0°05’±45’ (−0.08°±0.75°) Tire size: P265/70R16 −0°03’±45’ (−0.05°±0.75°) Tire size: P265/70R16 (B2BB (ORP)) −0°05’±45’ (−0.08°±0.75°) Tire size: P265/65R17 −0°16’±45’ (−0.27°±0.75°) Tire size: P265/65R17 (B2BC (SPORT)) D Camber (C−cab for U.S.A. 4WD models) Right−left error: 30’ (0.5°) or less UCK40L−ARBSKA 0°14’±45’...
Page 238 SS−66 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE D Caster (B−cab for U.S.A.) Right−left error: 30’ (0.5°) or less GSK30L−TRFDKA 2°00’±45’ (2.00°±0.75°) Tire size: P245/70R16 GSK30L−TRBDKA 2°03’±45’ (2.05°±0.75°) Tire size: P245/70R16 UCK30L−TRBDKA 1°56’±45’ (1.93°±0.75°) Tire size: P245/70R16 UCK40L−TRBDKA 1°25’±45’ (1.42°±0.75°) Tire size: P245/70R16 D Caster (D−cab for U.S.A.) Right−left error: 30’...
Page 239 SS−67 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK30L−ASBLKA 2°31’±45’ (2.52°±0.75°) Tire size: P265/70R16 2°34’±45’ (2.56°±0.75°) Tire size: P265/70R16 (B2BB (ORP)) 2°36’±45’ (2.60°±0.75°) Tire size: P265/65R17 2°44’±45’ (2.73°±0.75°) Tire size: P265/65R17 (B2BC (SPORT)) D Caster (C−cab for U.S.A. 4WD models) Right−left error: 30’ (0.5°) or less UCK40L−ARBSKA 1°26’±45’...
Page 240 SS−68 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE D Steering axis inclination (B−cab for U.S.A.) Right−left error: 30’ (0.5°) or less GSK30L−TRFDKA 10°31’±45’ (10.51°±0.75°) Tire size: P245/70R16 GSK30L−TRBDKA 10°34’±45’ (10.56°±0.75°) Tire size: P245/70R16 UCK30L−TRBDKA 10°32’±45’ (10.54°±0.75°) Tire size: P245/70R16 UCK40L−TRBDKA 10°10’±45’ (10.17°±0.75°) Tire size: P245/70R16 D Steering axis inclination (D−cab for U.S.A.) Right−left error: 30’...
Page 241 SS−69 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK30L−ASBLKA 10°26’±45’ (10.44°±0.75°) Tire size: P265/70R16 10°25’±45’ (10.42°±0.75°) Tire size: P265/70R16 (B2BB (ORP)) 10°26’±45’ (10.44°±0.75°) Tire size: P265/65R17 10°38’±45’ (10.64°±0.75°) Tire size: P265/65R17 (B2BC (SPORT)) D Steering axis inclination (C−cab for U.S.A. 4WD models) Right−left error: 30’...
Page 242 SS−70 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE D Toe−in (total) (B−cab for U.S.A.) Rack end length difference: 1.5 mm (0.059 in.) or less GSK30L−TRFDKA 0°05’±45’ (0.08°±0.2°, 1.38±2 mm, 0.05±0.08 in.) Tire size: P245/70R16 GSK30L−TRBDKA 0°04’±45’ (0.07°±0.2°, 1.20±2 mm, 0.05±0.08 in.) Tire size: P245/70R16 UCK30L−TRBDKA 0°05’±45’...
Page 243 SS−71 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK30L−ASBLKA 0°06’±45’ (0.10°±0.2°, 1.67±2 mm, 0.07±0.08 in.) Tire size: P265/70R16 0°06’±45’ (0.10°±0.2°, 1.79±2 mm, 0.07±0.08 in.) Tire size: P265/70R16 (B2BB (ORP)) 0°06’±45’ (0.10°±0.2°, 1.67±2 mm, 0.07±0.08 in.) Tire size: P265/65R17 0°03’±45’ (0.05°±0.2°, 0.86±2 mm, 0.03±0.08 in.) Tire size: P265/65R17 (B2BC (SPORT)) D Toe−in (total) (C−cab for U.S.A.
Page 244 SS−72 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE D Wheel angle (B−cab for U.S.A.) GSK30L−TRFDKA Tire size: P245/70R16 Inside wheel −35°24’ (−35.40°) 32°13’ (32.21°) Outside wheel: Reference GSK30L−TRBDKA −35°21’ (−35.35°) Tire size: P245/70R16 32°10’ (32.16°) UCK30L−TRBDKA −35°22’ (−35.37°) Tire size: P245/70R16 32°11’...
Page 245 SS−73 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE GSK30L−ARBSKA −35°37’ (−35.62°) Tire size: P245/70R16 32°24’ (32.40°) −35°37’ (−35.61°) Tire size: P265/70R16 32°24’ (32.40°) UCK30L−ARBSKA −35°26’ (−35.44°) Tire size: P245/70R16 32°14’ (32.24°) −35°26’ (−35.44°) Tire size: P265/70R16 32°14’ (32.24°) −35°28’ (−35.47°) Tire size: P265/70R16 (B2BB (ORP)) 32°16’...
Page 246 SS−74 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK40L−ARBLKA −36°07’ (−36.11°) Tire size: P265/70R16 32°37’ (32.61°) −35°34’ (−35.57°) Tire size: P265/70R16 (B2BB (ORP)) 32°11’ (32.18°) −36°07’ (−36.11°) Tire size: P265/65R17 32°37’ (32.61°) UCK40L−ASBSKA −36°06’ (−36.10°) Tire size: P265/70R16 32°36’ (32.60°) −35°34’ (−35.56°) Tire size: P265/70R16 (B2BB (ORP)) 32°10’...
Page 247 SS−75 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE UCK31L−PRBSKK −35°29’ (−35.49°) Tire size: P245/70R16 32°17’ (32.29°) −35°29’ (−35.49°) Tire size: P265/70R16 32°17’ (32.29°) −35°29’ (−35.49°) Tire size: P265/65R17 32°17’ (32.29°) UCK41L−PRBSKK −35°49’ (−35.81°) Tire size: P245/70R16 32°28’ (32.47°) −35°49’ (−35.81°) Tire size: P265/70R16 Front wheel 32°28’...
Page 248 SS−76 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE Companion flange vertical runout Maximum 0.10 mm (0.0039 in.) Companion flange lateral runout Maximum 0.10 mm (0.0039 in.) Drive pinion preload (at starting) New bearing 1.2 − 1.9 N·m (12 − 19 kgf·cm, 10.4 − 16.5 in.·lbf) Reused bearing 0.6 −...
Page 249 SS−77 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE 1.69 − 1.71 mm (0.0665 − 0.0673 in.) 1.72 − 1.74 mm (0.0677 − 0.0685 in.) 1.75 − 1.77 mm (0.0689 − 0.0697 in.) 1.78 − 1.80 mm (0.0701 − 0.0709 in.) 1.81 − 1.83 mm (0.0713 − 0.0720 in.) 1.84 −...
Page 250 SS−78 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE Differential case to rotation torque Standard 27.5 − 43.0 N·m (281 − 439 kgf·cm, 20 − 32 ft·lbf) Ring gear runout Maximum 0.05 mm (0.0020 in.) Drive pinion oil seal drive in depth 0 mm (0 in.) 1.80 mm (0.0709 in.) 1.86 mm (0.0732 in.)
Page 251 SS−79 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE 2.58 mm (0.1015 in.) 2.60 mm (0.1024 in.) 2.62 mm (0.1031 in.) 2.64 mm (0.1039 in.) 2.66 mm (0.1047 in.) 2.68 mm (0.1055 in.) 2.70 mm (0.1063 in.) 2.72 mm (0.1071 in.) 2.74 mm (0.1079 in.) 2.76 mm (0.1087 in.) 2.78 mm (0.1094 in.) 2.80 mm (0.1102 in.)
Page 252 SS−80 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE 1.87 mm (0.0736 in.) 1.88 mm (0.0740 in.) 1.89 mm (0.0744 in.) 1.90 mm (0.0748 in.) 1.91 mm (0.0752 in.) 1.92 mm (0.0756 in.) 1.93 mm (0.0760 in.) 1.94 mm (0.0764 in.) 1.95 mm (0.0768 in.) 1.96 mm (0.0772 in.) 1.97 mm (0.0776 in.) 1.98 mm (0.0780 in.)
Page 253 SS−81 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE SS052−13 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf TIRE PRESSURE MONITOR RECEIVER Tire pressure monitor receiver set bolt 66 in.·lbf TIRE PRESSURE MONITOR VALVE Tire pressure monitor valve set nut 35 in.·lbf FRONT AXLE Hub nut 1,150 Tie rod end lock nut...
Page 254 SS−82 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE No.1, No. 2 spring bumper 31 (23) 315 (235) 23 (17) Lower suspension arm x Stabilizer bar link ( ) For use with SST Part tightened N·m kgf·cm ft·lbf Stabilizer bar x Stabilizer bar link Stabilizer bar bracket x Chassis frame REAR AXLE Hub nut...
Page 255 SS−83 SERVICE SPECIFICATIONS − BRAKE BRAKE SS084−04 SERVICE DATA Brake pedal height (from dash panel) (w/o VSC, standard, access cab) 163.6 to 173.6 mm (6.44 to 6.83 in.) Brake pedal height (from dash panel) (w/ VSC, standard, access cab) 164.0 to 174.0 mm (6.46 to 6.85 in.) Brake pedal height (from dash panel) (double cab) 151.1 to 165.1 mm (5.95 to 6.50 in.) Stop light switch clearance...
Page 256 SS−84 SERVICE SPECIFICATIONS − BRAKE SS085−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder x Piston stopper bolt Master cylinder x Reservoir 16 in.·lbf Master cylinder x Booster (w/o VSC) Brake master cylinder x Master cylinder body (w/ VSC) Bleeder plug Parking brake wire lock nut x Adjust nut 48 in.·lbf...
Page 257 SS−85 SERVICE SPECIFICATIONS − STEERING STEERING SS08W−05 SERVICE DATA POWER STEERING FLUID Oil level rise Maximum 5 mm (0.20 in.) Oil pressure at idle speed with valve closed Minimum 8,336 kPa (85 kgf/cm , 1,209 psi) STEERING WHEEL Steering wheel freeplay Maximum 30 mm (1.18 in.) Steering effort at idle speed Reference: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
Page 258 SS−86 SERVICE SPECIFICATIONS − STEERING SS08X−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf STEERING COLUMN (Standard Cab, Access Cab) Steering wheel pad set screw (Torx® screw) 78 in.·lbf Steering wheel set nut Control valve shaft x No. 2 intermediate shaft assembly No.
Page 259 SS−87 SERVICE SPECIFICATIONS − STEERING Pressure port union Front housing x Rear housing PS GEAR Turn pressure tube union nut 13 (15) 135 (150) 10 (11) Tie rod end lock nut Rack x Rack end 76 (103) 770 (1,050) 56 (76) Rack guide spring cap lock nut 51 (69) 520 (700)
Page 260 SS−88 SERVICE SPECIFICATIONS − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS08D−04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf STEERING WHEEL PAD AND SPIRAL CABLE Steering wheel set nut Steering wheel pad set screw (Torx® screw) 78 in.·lbf FRONT PASSENGER AIRBAG ASSEMBLY Front passenger airbag assembly x Instrument panel 44 in.·lbf Front passenger airbag assembly x Instrument panel...
Page 261 SS−89 SERVICE SPECIFICATIONS − BODY ELECTRICAL BODY ELECTRICAL SS03A−06 SERVICE DATA SPEEDOMETER (On−vehicle) USA: Standard indication (mph) Allowable range (mph) 19 − 22 39 − 42.5 59.5 − 63.5 79.5 − 84 100 − 105 CANADA: Standard indication (km/h) Allowable range (km/h) 17.5 −...
Page 262 SS−90 SERVICE SPECIFICATIONS − BODY ELECTRICAL SE: Approx. 100 (3.90) ± 2.5 (0.10) Approx. 110.0 ± 2.5 ENGINE COOLANT TEMPERATURE RECEIVER GAUGE Temperature °C (°F) Resistance (kΩ) −20 (−4) 13.54 to 16.63 20 (68) 2.28 to 2.63 80 (176) 0.31 to 0.33 110 (230) 0.138 to 0.15...
Page 263 SS−91 SERVICE SPECIFICATIONS − BODY BODY SS13G−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT BUMPER Steel bumper type: Front bumper arm x Body Front bumper reinforcement x Body Front bumper bar x Front bumper side mounting bracket 43 in.·lbf Front bumper side mounting bracket x Front bumper arm Front bumper bar x Front balance panel 43 in.·lbf...
Page 264 SS−92 SERVICE SPECIFICATIONS − BODY Part tightened N·m kgf·cm ft·lbf Door hinge x Door panel Door check x Body Door check x Door panel 49 in.·lbf Door striker x Body Outside handle x Door panel 49 in.·lbf Door lock x Door panel Torx®...
Page 265 SS−93 SERVICE SPECIFICATIONS − BODY Part tightened N·m kgf·cm ft·lbf Service hole cover x Body SLIDING ROOF Sliding roof housing x Body 49 in.·lbf INSTRUMENT PANEL Front passenger airbag assembly x Instrument panel reinforcement Front passenger airbag assembly x Instrument panel 44 in.·lbf Steering wheel set nut Steering wheel x Steering wheel pad...
Page 266 SS−94 SERVICE SPECIFICATIONS − BODY Part tightened N·m kgf·cm ft·lbf Front seat center belt x Seat cushion frame Bolt 49 in.·lbf Seatback frame x Seat cushion frame Torx® screw Bolt A Bolt B w/ Side airbag: 49 in.·lbf Seatback cover bracket x Seatback frame Center armrest assembly x Seatback frame Seat position sensor (for passenger seat) x Inner seat track 71 in.·lbf...
Page 267 SS−95 SERVICE SPECIFICATIONS − BODY Part tightened N·m kgf·cm ft·lbf Front seat outer belt floor anchor x Body Front seat outer belt retractor x ELR bracket Upper bolt 75 in.·lbf Lower bolt Front seat inner belt x Body Part tightened N·m kgf·cm ft·lbf...
Page 268 SS−96 SERVICE SPECIFICATIONS − AIR CONDITIONING AIR CONDITIONING SS08B−05 SERVICE DATA Refrigerant charge volume Access cab, Standard cab 600 ± 50 g (21.16 ± 1.76 oz.) Double cab 530 ± 50 g (18.69 ± 1.76 oz.) Idle−up speed (1GR−FE) Magnetic clutch not engaged 700 ± 50 rpm Magnetic clutch engaged 700 ±...
Page 269 SS−97 SERVICE SPECIFICATIONS − AIR CONDITIONING SS08C−04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Compressor x Compressor bracket 1GR−FE engine 2UZ−FE engine Compressor bracket x Engine Idle pulley lock nut Compressor x Discharge hose Compressor x Suction hose Cooling unit x Suction tube Expansion valve x Evaporator 48 in.·lbf Receiver x Liquied tube...
Page 270 DI−1 DIAGNOSTICS − ENGINE (1GR−FE) ENGINE (1GR−FE) DIDSK−01 PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly, engine assembly or ECM (see page DI−961). HINT: RESET MEMORY (AT initialization) can not be completed by only removing the battery.
Page 271 DI−2 DIAGNOSTICS − ENGINE (1GR−FE) DIDSL−01 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Diagnostic code Preconditions that allow the ECM to detect malfunctions. Typical enabling condition With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s).
Page 272 DI−5 DIAGNOSTICS − ENGINE (1GR−FE) DIDSO−01 LOCATION Combination Meter Assy Park/Neutral Position Switch VSV for EVAP DLC3 VSV for ACIS Air Fuel Ratio Sensor (Bank 1) Fuel Suction w/ Pump & Gauge Tube Assy Mass Air Flow Accelerator Pedal Rod Assy Meter (Accelerator Pedal Position Sensor) Throttle w/ Motor...
Page 273 DI−6 DIAGNOSTICS − ENGINE (1GR−FE) DIDSN−01 SYSTEM DIAGRAM IG SW Combination Meter IGSW To Battery STSW OC1+ VVT OCV ST Relay PNP SW (Bank 1) OC1− OC2+ VVT OCV (Bank 2) OC2− To Starter To Battery Knock Sensor EFI No.1 KNK1 (Bank 1) To Battery...
Page 274 DI−7 DIAGNOSTICS − ENGINE (1GR−FE) To Battery To A/F Relay HA1A A/F Sensor (Bank 1 Sensor 1) A1A+ Fuel Injector #1 A1A− HA2A Fuel Injector #2 A/F Sensor (Bank 2 Sensor 1) A2A+ A2A− Fuel Injector #3 To EFI Relay HT1B HO2 Sensor Fuel Injector #4...
Page 275 DI−8 DIAGNOSTICS − ENGINE (1GR−FE) ACC Cut Relay ACCR To Battery GE01 Throttle Body To IG SW M− Stop Light SW To IGN Fuse STI− VTA1 To Battery To E2 Terminal VTA2 C/OPN Relay To Battery To EFI ME01 Relay DLC3 Fuel Pump Relay Fuel Pump Resister...
Page 276 DI−9 DIAGNOSTICS − ENGINE (1GR−FE) DIDSP−01 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. See the indicated pages for detailed explanations.
Page 277 DI−10 DIAGNOSTICS − ENGINE (1GR−FE) DIDSQ−01 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 278 DI−11 DIAGNOSTICS − ENGINE (1GR−FE) DIDSR−01 CHECK FOR INTERMITTENT PROBLEMS HINT: Hand−held tester only: Inspect the vehicle’s ECM using check mode. Intermittent problems are easier to detect with a hand−held tester when the ECM is in check mode. In check mode, the ECM uses 1trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2trip detection logic.
Page 279 DI−12 DIAGNOSTICS − ENGINE (1GR−FE) DIDSS−01 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 280 DI−13 DIAGNOSTICS − ENGINE (1GR−FE) Check air filter. PREPARATION: Remove the air filter. CHECK: Visual check that the air filter is not excessively dirty or oily. air filter Repair or replace Check idle speed (See page EM−25). Proceed to problem symptoms table on page DI−33.
Page 281 DI−14 DIAGNOSTICS − ENGINE (1GR−FE) DIDST−01 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is in the form of a 17−digit alphanumeric vehicle identification number. A hand−held tester is re- quired to resister the VIN. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN.
Page 282 DI−15 DIAGNOSTICS − ENGINE (1GR−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 283 DI−16 DIAGNOSTICS − ENGINE (1GR−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 284 DI−17 DIAGNOSTICS − ENGINE (1GR−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 285 DI−18 DIAGNOSTICS − ENGINE (1GR−FE) DIDSU−01 LIST OF DISABLE A MONITOR 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. As for the ”X” mark, when the DTC on the left is stored, detection of the DTC in the upper column is not per- formed.
Page 286 DI−19 DIAGNOSTICS − ENGINE (1GR−FE) A21571...
Page 287 DI−20 DIAGNOSTICS − ENGINE (1GR−FE) A21572...
Page 288 DI−21 DIAGNOSTICS − ENGINE (1GR−FE) A21573...
Page 289 DI−22 DIAGNOSTICS − ENGINE (1GR−FE) A21575...
Page 290 DI−23 DIAGNOSTICS − ENGINE (1GR−FE) A21576...
Page 291 DI−24 DIAGNOSTICS − ENGINE (1GR−FE) DIDSV−01 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. Based on this, you can find the O2S’s conditions.
Page 292 DI−25 DIAGNOSTICS − ENGINE (1GR−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 293 DI−26 DIAGNOSTICS − ENGINE (1GR−FE) DIDSW−01 CHECKING MONITOR STATUS OUTLINE The monitor results and the test values can be checked with the hand−held tester. The engine control module (ECM) monitors the emissions−related components as the thermostat, catalyst converter and evaporative emissions (EVAP), and determines whether they are functioning normally or not. When finished and monitoring, the ECM stores the monitor results and the test values.
Page 294 DI−27 DIAGNOSTICS − ENGINE (1GR−FE) DIDUH−01 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 295 DI−28 DIAGNOSTICS − ENGINE (1GR−FE) CATALYST MONITOR (ACTIVE AIR−FUEL RATIO CONTROL TYPE) Vehicle Speed NOTICE: This test will not be completed Between if the vehicle is driven under 40 mph and 70 mph (64 km/h and 113 km/h) absolute constant speed condition such as with cruise control activated.
Page 296 DI−29 DIAGNOSTICS − ENGINE (1GR−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 (2,400 m) or less...
Page 297 DI−30 DIAGNOSTICS − ENGINE (1GR−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 298 DI−31 DIAGNOSTICS − ENGINE (1GR−FE) AIR−FUEL RATIO (A/F) AND OXYGEN SENSOR (HO2) MONITOR (ACTIVE AIR−FUEL RATIO CONTROL TYPE) Preconditions The monitor will not run unless: 2 minutes or more have elapsed since the engine was started. The Engine Coolant Temperature (ECT) is 75_C (167_F) or higher. Air−fuel ratio feedback control is performed.
Page 299 DI−32 DIAGNOSTICS − ENGINE (1GR−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 OBD II scan tool to the DLC3 to check monitor status and preconditions (refer to (a)).
Page 300 DI−33 DIAGNOSTICS − ENGINE (1GR−FE) DIDSX−01 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page 1. Cranking holding function circuit DI−404 2. Starter ST−1 Engine does not crank (Does not start) 3. Starter relay ST−26 4. Park/neutral position switch DI−993 1. ECM power source circuit DI−409 No initial combustion (Does not start) 2.
Page 301 DI−34 DIAGNOSTICS − ENGINE (1GR−FE) DIDSY−01 TERMINALS OF ECM B17410 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 voltage between the terminals is shown under ”STD Voltage”.
Page 302 DI−35 DIAGNOSTICS − ENGINE (1GR−FE) KNK1 (E6−29) − EKNK (E6−28) G − R Pulse generation Pulse generation M i t i Maintain engine speed at 4,000 rpm after warming up d t 4 000 (See waveform 2) KNK2 (E6−21) − EKN2 (E6−20) W −...
Page 303 DI−36 DIAGNOSTICS − ENGINE (1GR−FE) IG switch ON, Other shift position in P, N 9 to 14 V NSW (E6 8) NSW (E6−8) − E1 (E5−1) E1 (E5 1) L R BR L−R − BR IG switch ON, Shift position in P, N 0 to 3.0 V Idling 9 to 14 V...
Page 304 DI−37 DIAGNOSTICS − ENGINE (1GR−FE) WAVEFORM 3 5 V/DIV VVT OCV Between OC1+ and OC1− ECM Terminal Name Between OC2+ and OC2− Tester Range 0.2 V/DIV, 200 msec./DIV Ground Condition Accelerate slowly after engine warmed−up HINT: In the DATA LIST, the items VVT OCV DUTY B1 and B2 show 200 msec./DIV the duty ratio of voltage flowing to the OCV (see illustration on A23649...
Page 305 DI−38 DIAGNOSTICS − ENGINE (1GR−FE) WAVEFORM 6 5 V/DIV Throttle actuator positive terminal ECM Terminal Name Between M+ and ME01 Tester Range 5 V/DIV, 1 msec./DIV Condition Idle after engine warmed−up HINT: Ground The duty ratio varies depending on the throttle opening opera- tion.
Page 306 DI−39 DIAGNOSTICS − ENGINE (1GR−FE) DIDSZ−01 DIAGNOSIS SYSTEM Description When troubleshooting On−Board Diagnostic (OBD ll) ve- hicles, the vehicle must be connected to the hand−held tester. Various data output from the vehicle’s ECM can then be read. OBD ll regulations require that the vehicle’s on−board computer illuminates the Malfunction Indicator Light (MIL) FI0534 on the instrument panel when the computer detects a...
Page 307 DI−40 DIAGNOSTICS − ENGINE (1GR−FE) Freeze frame data: The freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when a malfunc- tion is detected. When troubleshooting, freeze frame data can help determine 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...
Page 308 DI−41 DIAGNOSTICS − ENGINE (1GR−FE) If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. INSPECT BATTERY VOLTAGE Battery Voltage: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding.
Page 309 DI−42 DIAGNOSTICS − ENGINE (1GR−FE) DIDT0−01 DTC CHECK / CLEAR Hand−Held Tester CHECK DTC DTCs which are stored in the ECM can be displayed with the hand−held tester or generic OBD II scan tool. These scan tools can display pending DTCs and current DTCs. Some DTCs are not stored if the ECM does not detect a mal- function during consecutive driving.
Page 310 DI−43 DIAGNOSTICS − ENGINE (1GR−FE) DIDT1−01 CHECK MODE PROCEDURE HINT: Hand−held tester only: Check mode has a higher sensitivity to detect malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect.
Page 311 DI−44 DIAGNOSTICS − ENGINE (1GR−FE) CLEAR DTC (Not using the hand−held tester) Remove the EFI No. 1 and ETCS fuses from the engine room J/B for more than 60 seconds, or disconnect the bat- tery terminal for more than 60 seconds. After disconnecting the battery terminal, perform the ”INI- TIALIZE”...
Page 312 DI−45 DIAGNOSTICS − ENGINE (1GR−FE) DIDT2−01 FAIL−SAFE CHART If any of the following code is recorded, the ECM enters fail−safe mode. DTC No. Fail−Safe Operation Fail−Safe Deactivation Conditions P0031 P0032 P0037 The heater circuit in which an abnormality is detected is P0038 Ignition switch OFF turned off...
Page 313 DI−46 DIAGNOSTICS − ENGINE (1GR−FE) P0351 P0352 P0353 P0354 Fuel cut ”Pass” condition detected P0355 P0356 P0357 P0358 The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the P2120 sensor circuits, the ECM detects the abnormal signal volt- P2121 age difference between the two sensor circuits and P2122...
Page 314 DI−47 DIAGNOSTICS − ENGINE (1GR−FE) DIDT3−01 DATA LIST / ACTIVE TEST DATA LIST HINT: By reading the DATA LIST displayed on a hand−held tester, you can check values, including those of the switches, sensors, and actuators, without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one method of shortening diagnostic time.
Page 315 DI−48 DIAGNOSTICS − ENGINE (1GR−FE) Purge flow: PURGE FLOW 0 to 100 %: Idling Min.: 0 %, Max.: 102.4 % EVAP (Purge) VSV control duty: EVAP PURGE VSV 0 to 100 %: During idling Order signal from ECM Min.: 0 %, Max.: 100 % Pressure inside fuel tank moni- Vapor pressure: VAPOR PRESS...
Page 316 DI−49 DIAGNOSTICS − ENGINE (1GR−FE) System guard: SYSGUARD JUDGE ETCS service data ON or OFF Open side malfunction: OPN MALFUNCTION ETCS service data ON or OFF S 10 to 24 %: Throttle fully closed Absolute throttle position sensor: Read the value with intrusive op- THROTTLE POS S 64 to 96 %: Throttle fully open Min.: 0 %, Max.: 100 %...
Page 317 DI−50 DIAGNOSTICS − ENGINE (1GR−FE) Performing the INJ VOL or A/F Heated oxygen sensor output volt- 0.1 to 0.9 V: CONTROL function of the ACTIVE O2S B1 S2 age for bank 1 sensor 2: Driving 44 mph (70 km/h) TEST enables the technician to Min.: 0 V, Max.: 1.275 V check voltage output of the sensor Performing the INJ VOL or A/F...
Page 318 DI−51 DIAGNOSTICS − ENGINE (1GR−FE) S OL (Open Loop): Has not yet sa- tisfied conditions to go closed loop S CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control. S OL DRIVE: Open loop due to Fuel system status (Bank1): FUEL SYS #2 OL or CL or OL DRIVE or CL: Idling after warming up...
Page 319 DI−52 DIAGNOSTICS − ENGINE (1GR−FE) ON: When steering wheel first Power steering signal: This signal status usually ON until PS SIGNAL turned after ignition switch turned ON or OFF ignition switch turned to OFF to ON S ON: Throttle fully closed Closed throttle position switch: CTP SW S OFF: Throttle open...
Page 320 DI−53 DIAGNOSTICS − ENGINE (1GR−FE) VVT OCV operation duty: Requested duty value for intrusive VVT OCV DUTY B1 0 %: Idling Min.: 0 %, Max.: 100 % operation VVT OCV operation duty: Requested duty value for intrusive VVT OCV DUTY B2 0 %: Idling Min.: 0 %, Max.: 100 % operation...
Page 321 DI−54 DIAGNOSTICS − ENGINE (1GR−FE) Engine run time: ENG RUN TIME Min.: 0 second, Time after engine start Service data Max.: 65,535 seconds Time after DTC cleared: Equivalent to time after DTCs TIME DTC CLEAR Min.: 0 minute, were erased Max.: 65,535 minutes Distance after DTC cleared: Equivalent to drive distance after...
Page 322 DI−55 DIAGNOSTICS − ENGINE (1GR−FE) ACTIVE TEST HINT: Performing an ACTIVE TEST enables components including the relays, VSV (Vacuum Switching Valve), and actuators, to be operated without removing any parts. The ACTIVE TEST can be performed with a hand−held tester. Performing an ACTIVE TEST as the first step of troubleshooting is one method of shorten- ing diagnostic time.
Page 323 DI−56 DIAGNOSTICS − ENGINE (1GR−FE) This test is possible when the fol- lowing conditions are met: S Ignition switch ON ETCS OPEN SLOW Throttle actuator ON: throttle valve opens slowly S Engine does not start S Fully depressing accelerator ped- al (APP: 58 degrees or more) ETCS CLOSE SLOW Throttle actuator...
Page 324 DI−57 DIAGNOSTICS − ENGINE (1GR−FE) DIDX7−01 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 325 DI−58 DIAGNOSTICS − ENGINE (1GR−FE) S Open in heater circuit of A/F sensor Oxygen (A/F) Sensor Heater S A/F sensor heater P0051 Control Circuit Low (Bank 2 Sen- S A/F relay (DI−84) sor 1) S ECM S Short in heater circuit of A/F sensor Oxygen (A/F) Sensor Heater S A/F sensor heater P0052...
Page 326 DI−59 DIAGNOSTICS − ENGINE (1GR−FE) S Short in throttle control motor and sensor circuit S Throttle control motor and sensor P0122 Throttle/Pedal Position Sensor/ S Short in VTA1 circuit (DI−123) Switch ”A” Circuit Low Input S Open in VC circuit S ECM S Open in throttle control motor and sensor circuit S Throttle control motor and sensor...
Page 327 DI−60 DIAGNOSTICS − ENGINE (1GR−FE) S Injector leak, blockage S Mass air flow meter S Engine coolant temperature sensor S Ignition system S Fuel pressure P0172 System too Rich (Bank 1) S Gas leakage in exhaust system (DI−160) S Open or short in heated oxygen sensor (bank 1 sensor 1) circuit S Heated oxygen sensor (bank 1 sensor 1) S ECM...
Page 328 DI−61 DIAGNOSTICS − ENGINE (1GR−FE) S Open or short in engine wire S Connector connection S Vacuum hose connection S Ignition system S Injector S Fuel pressure P0300 Random/Multiple Cylinder Misfire S Mass air flow meter (DI−179) Detected S Engine coolant temperature sensor S Compression pressure S Valve clearance S Valve timing...
Page 329 DI−62 DIAGNOSTICS − ENGINE (1GR−FE) S Open or short in engine wire S Connector connection S Vacuum hose connection S Ignition system S Injector S Fuel pressure P0304 S Mass air flow meter Cylinder 4 Misfire Detected (DI−179) S Engine coolant temperature sensor S Compression pressure S Valve clearance S Valve timing...
Page 330 DI−63 DIAGNOSTICS − ENGINE (1GR−FE) S Open or short in crankshaft position sensor circuit S Crankshaft position sensor P0339 Crankshaft Position Sensor ”A” − S Signal plate (DI−203) Circuit Intermittent S ECM S Open or short in camshaft position sensor circuit S Camshaft position sensor P0340 Camshaft Position Sensor ”A”...
Page 331 DI−64 DIAGNOSTICS − ENGINE (1GR−FE) S Gas leakage on exhaust system P0430 Catalyst System Efficiency Be- S Heated oxygen sensor (bank 2 sensor 1, 2) (DI−228) low Threshold (Bank 2) S Three−way catalytic converter S Pump module P043E Evaporate Emission System S ECM (DI−353) Reference Orifice Clog Up...
Page 332 DI−65 DIAGNOSTICS − ENGINE (1GR−FE) S ETCS (Electronic Throttle Control System) S Air induction system P050B Cold Start Ignition S PCV hose connections (DI−269−1) Timing Performance S ECM S Back−up power source circuit P0560 S EFI No. 1 fuse System Voltage (DI−270) S ECM P0604...
Page 333 DI−66 DIAGNOSTICS − ENGINE (1GR−FE) P0781 S Electronic control automatic transmission (ECT) 1−2 Shift (1−2 Shift Valve) (DI−1053) P0973 Shift Solenoid ”A” Control Circuit S Electronic control automatic transmission (ECT) (DI−1058) Low (Shift solenoid Valve S1) P0974 Shift Solenoid ”A” Control Circuit S Electronic control automatic transmission (ECT) (DI−1058) High (Shift solenoid Valve S1)
Page 334 DI−67 DIAGNOSTICS − ENGINE (1GR−FE) S Open in accelerator pedal position sensor circuit S Accelerator pedal position sensor P2127 Throttle/Pedal Position Sensor/ S VCP2 circuit open (DI−299) Switch ”E” Circuit Low Input S VPA2 circuit open or ground short S ECM S Short in accelerator pedal position sensor circuit (+B circuit) S Accelerator pedal position sensor P2128...
Page 335 DI−68 DIAGNOSTICS − ENGINE (1GR−FE) S Open or short in A/F sensor (sensor 1) circuit S A/F sensor (sensor 1) Oxygen Sensor Pumping Cur- P2239 S A/F sensor heater (sensor 1) rent Circuit High (For A/F Sen- (DI−330) S A/F relay sor) (Bank 1 Sensor 1) S A/F sensor heater and EFI relay circuits S Open or short in A/F sensor (sensor 1) circuit...
Page 336 DI−69 DIAGNOSTICS − ENGINE (1GR−FE) P2742 Transmission Fluid Temperature S Electronic control automatic transmission (ECT) (DI−1083) Sensor ”B” Circuit Low Input P2743 Transmission Fluid Temperature S Electronic control automatic transmission (ECT) (DI−1083) Sensor ”B” Circuit High Input Torque Converter clutch Pres- P2757 sure Control Solenoid Perfor- S Electronic control automatic transmission (ECT)
Page 337 DI−70 DIAGNOSTICS − ENGINE (1GR−FE) DIDT4−01 CIRCUIT INSPECTION P0010 Camshaft Position ”A” Actuator circuit (Bank 1) P0020 Camshaft Position ”A” Actuator circuit (Bank 2) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT control- ler.
Page 338 DI−71 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION After the ECM sends the ”target” duty−cycle signal to the OCV (Oil Control Valve), the ECM monitors the OCV current to establish an ”actual” duty−cycle. When the actual duty−cycle ratio varies from the target duty−cycle, the ECM sets a DTC.
Page 339 DI−72 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM OCV (Bank 1) W−R OC1+ G−B OC1− OCV (Bank 2) L−R OC2+ OC2− A07621 A09776 INSPECTION PROCEDURE HINT: If DTC P0010 displayed, check left bank OCV circuit. If DTC P0020 displayed, check right bank OCV circuit. Read freeze frame data using hand−held tester.
Page 340 DI−73 DIAGNOSTICS − ENGINE (1GR−FE) Check OCV circuit. PREPARATION: Connect the hand−held tester to the DLC3. Start the engine and warm it up. Turn the ignition switch to ON and turn the hand−held tester ON. CHECK: Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. Using the hand−held tester, operate the OCV and check the engine speed.
Page 341 DI−74 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminals OC1+ and OC1−, OC2+ and OC2− of ECM con- nector. CHECK: OCV Signal Waveform Inspection using the oscilloscope. 5 V/ During idling, check the waveform between the specified Division terminals of the E5 ECM connector. HINT: The waveform frequency (A) is lengthened as the engine speed becomes higher.
Page 342 DI−75 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between OCV and ECM. PREPARATION: Wire Harness Side Disconnect the C19 or C20 OCV connector. Disconnect the E5 ECM connector. CHECK: Check for resistance between the wire harness side connec- tors.
Page 343 DI−76 DIAGNOSTICS − ENGINE (1GR−FE) DIDT5−01 P0011 Camshaft Position ”A” −Timing Over− Advanced or System Performance (Bank 1) P0012 Camshaft Position ”A” −Timing Over− Retarded (Bank 1) P0021 Camshaft Position ”A” −Timing Over− Advanced or System Performance (Bank 2) P0022 Camshaft Position ”A”...
Page 344 DI−77 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY P0011 VVT system advance (Bank 1) P0012 VVT system retard (Bank 1) R l t d DTC Related DTCs P0021 VVT system advance (Bank 2) P0022 VVT system retard (Bank 2) Main sensors/components Camshaft position sensor Required sensors/components Engine coolant temperature sensor,...
Page 345 DI−78 DIAGNOSTICS − ENGINE (1GR−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 to ON and turn the hand−held tester ON. CHECK: Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. Using the hand−held tester, operate the OCV and check the engine speed.
Page 346 DI−79 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminals OCV+ and OCV− of ECM connector. CHECK: OCV Signal Waveform Inspection using the oscilloscope. 5 V/ During idling, check the waveform between the specified Division terminals of the E5 ECM connector. HINT: The waveform frequency (A) is lengthened as the engine speed becomes higher.
Page 347 DI−80 DIAGNOSTICS − ENGINE (1GR−FE) Check oil control valve filter. Replace oil control valve filter. Check whether or not DTC P0010, P0012, P0021 or P0022 is stored. PREPARATION: Clear the DTC (See page DI−42). Perform simulation test. CHECK: Check whether or not DTC P0011, P0012, P0021 or P0022 is stored (See page DI−42). Standard: DTC P0011, P0012, P0021 or P0022 is not stored.
Page 348 DI−81 DIAGNOSTICS − ENGINE (1GR−FE) DIDT6−01 P0016 Crankshaft Position − Camshaft Position Correlation (Bank 1 Sensor A) P0018 Crankshaft Position − Camshaft Position Correlation (Bank 2 Sensor A) CIRCUIT DESCRIPTION The crankshaft position sensor (CKP) system consists of a crankshaft position sensor plate and a pick−up coil.
Page 349 DI−82 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Deviation in crankshaft position sensor signal P0016 and camshaft position sensor signal (Bank 1) R l t d DTC Related DTCs Deviation in crankshaft position sensor signal P0018 and camshaft position sensor signal (Bank 2) Required sensors/components Crankshaft position sensor, Camshaft position sensor k h ft...
Page 350 DI−83 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: If DTC P0016 is displayed, check left bank VVT sensor. If DTC P0018 is displayed, check right bank VVT sensor. Read freeze frame data using hand−held tester. Because freeze frame records the engine conditions when the malfunction is detected.
Page 351 DI−84 DIAGNOSTICS − ENGINE (1GR−FE) DIDUI−01 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1)
Page 352 DI−85 DIAGNOSTICS − ENGINE (1GR−FE) HINT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No.1. Sensor 1 refers to the sensor closest to the engine assembly. Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The ECM uses the Air−Fuel Ratio sensor (A/F sensor) information to regulate the air−fuel ratio close to the stoichiomentric ratio.
Page 353 DI−86 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present P0031, P0051 (Low current): Battery voltage 10.5 V − A/F sensor heater duty ratio − Time after engine start 10 sec.
Page 354 DI−87 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using a hand−held tester. Freeze frame data record the engine condition when mal- functions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was mov- ing or stationary, 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 355 DI−88 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminals HA1A, HA2A of ECM connectors and body ground. PREPARATION: HA1A HA2A Turn the ignition switch to ON. CHECK: Measure the voltage between terminals of the ECM connectors and body ground. HINT: Connect terminal HA1A to the bank 1 sensor 1.
Page 356 DI−89 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short circuit in harness and connector between A/F sensor and ECM, A/F sensor and A/F relay. PREPARATION: Wire Harness Side: Disconnect the A10 or A30 A/F sensor connector. A/F Sensor Connector Disconnect the E6 ECM connector.
Page 357 DI−90 DIAGNOSTICS − ENGINE (1GR−FE) DIDT7−01 P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2)
Page 358 DI−91 DIAGNOSTICS − ENGINE (1GR−FE) CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three−way cata- lytic converter is used, but for the most efficient use of the three−way catalytic converter, the air−fuel ratio must be precisely controlled so that it is always close to the stoichiometric air−fuel ratio.
Page 359 DI−92 DIAGNOSTICS − ENGINE (1GR−FE) DTC No. DTC Detecting Condition Trouble Area S Open in heater circuit of heated oxygen sensor S Heated oxygen sensor heater S Heated oxygen sensor heater P0037 P0037 Heater current is less than 0.3 A when the heater operates with Heater current is less than 0.3 A when the heater o erates with S EFI relay P0057...
Page 360 DI−93 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present P0037, P0057 (Low current): Battery voltage 10.5 V − Engine Running Starter Intrusive heating Not operating All heater is turned OFF and intrusive heating is operated when the following Condition (a) and (b)
Page 361 DI−94 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR RESULT 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−27). TID (Test Identification Data) is assigned to each emissions−related component. TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit.
Page 362 DI−95 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM J8 J/C Heated Oxygen Sensor (Bank 1 Sensor 2) Engine Room HT1B No. 2 OX1B B−W W−L (*1) (*1) W−L GR−G Heated Oxygen Sensor Engine Room (Bank 2 Sensor 2) HT2B Relay G−B OX2B B−W B−R...
Page 363 DI−96 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using hand−held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful to determine whether the vehicle was running or stopped, the engine was warmed up or not, the air−fuel ratio was lean or rich, etc. when a malfunction occurred.
Page 364 DI−97 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminals HT1B, HT2B of ECM connectors and body ground. PREPARATION: HT1B HT2B Turn the ignition switch ON. CHECK: Measure the voltage between terminals of the ECM connectors and body ground. Standard: Tester Connection Specified Condition B17411 HT1B (E7−1) −...
Page 365 DI−98 DIAGNOSTICS − ENGINE (1GR−FE) DIDT8−01 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 Mass Air Flow (MAF) 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 366 DI−99 DIAGNOSTICS − ENGINE (1GR−FE) HINT: After confirming DTC P0100, P0102 or P0103, use the hand−held tester to confirm the MAF ratio from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Mass Air Flow Value (gm/sec.) Malfunction S Mass air flow meter power source circuit open...
Page 367 DI−100 DIAGNOSTICS − ENGINE (1GR−FE) COMPONENT OPERATING RANGE Parameter Standard Value Mass air flow meter voltage 0.4 to 2.2 V WIRING DIAGRAM GR−G GR−G MREL Mass Air Flow Meter Engine Room R/B R−L EFI No. 2 W−L Engine Room R/B Engine Room R/B EFI Relay EFI No.
Page 368 DI−101 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 369 DI−102 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage of mass air flow meter power source. PREPARATION: Wire Harness Side: Disconnect the M1 mass air flow meter connector. Mass Air Flow Meter Connector Turn the ignition switch to ON. CHECK: Measure voltage between terminal 1 of the mass air flow meter connector and body ground.
Page 370 DI−103 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between mass air flow meter and ECM. PREPARATION: Wire Harness Side: Disconnect the M1 mass air flow meter connector. Mass Air Flow Meter Connector Disconnect the E7 ECM connector. CHECK: Check the resistance between the wire harness side connec- tors.
Page 371 DI−104 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between mass air flow meter and EFI relay. PREPARATION: Engine Room J/B: Remove the EFI No. 1 fuse from the engine room J/B. CHECK: Check for resistance in the EFI No. 1 fuse. Standard: Below 1 Ω...
Page 372 DI−105 DIAGNOSTICS − ENGINE (1GR−FE) Check continuity between terminal E2G of ECM connector and body ground. CHECK: E7 ECM Connector Check the resistance between terminal of the E7 ECM connec- tor and body ground. Standard: Tester Connection Specified Condition Below 1 Ω E2G (E7−29) −...
Page 373 DI−106 DIAGNOSTICS − ENGINE (1GR−FE) DIDT9−01 P0101 Mass or Volume Air Flow Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100, P0102 and P0103 on page DI−98. DTC No. DTC Detecting Condition Trouble Area After engine is warmed up, conditions (a), (b), (c) and (d) con- tinue for more than 10 seconds: (2 trip detection logic) (a) Throttle valve fully closed...
Page 374 DI−107 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−18 not present High voltage: Engine speed − 2,000 rpm MAF meter voltage − 4.9 V Engine coolant temperature 70_C (158_F) −...
Page 375 DI−108 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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−109 DIAGNOSTICS − ENGINE (1GR−FE) DIDTA−01 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 377 DI−110 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT (Intake Air Temperature) sensor and sets a DTC.
Page 378 DI−111 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Intake Air Temp. Sensor (Built into Mass Air Flow Meter) Y−G B−W A15651 INSPECTION PROCEDURE HINT: If DTCs related to different systems that have terminal E2 as the ground terminal are output simulta- neously, terminal E2 may have an open circuit.
Page 379 DI−112 DIAGNOSTICS − ENGINE (1GR−FE) Connect hand−held tester, and read value of intake air temperature. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR.
Page 380 DI−113 DIAGNOSTICS − ENGINE (1GR−FE) Check for open in harness or ECM. PREPARATION: Mass Air Disconnect the M1 mass air flow meter connector. Flow Meter Connect terminals 4 and 5 of the mass air flow meter wire harness side connector. Turn the ignition switch to ON.
Page 381 DI−114 DIAGNOSTICS − ENGINE (1GR−FE) Check for short in harness and ECM. PREPARATION: Mass Air Flow Disconnect the M1 mass air flow meter connector. Meter Turn the ignition switch to ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / IN- TAKE AIR.
Page 382 DI−115 DIAGNOSTICS − ENGINE (1GR−FE) DIDTB−01 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 in the Engine Coolant Temperature (ECT) sensor and changes the resistance value ac- cording to the engine coolant temperature.
Page 383 DI−116 DIAGNOSTICS − ENGINE (1GR−FE) Example: When the ECM calculates that the ECT is less than −40_C (−40_F), or more than 140_C (284_F), and if either the condition continues for 0.5 sec. or more, the ECM will set a DTC. MONITOR STRATEGY Engine coolant temperature sensor range check P0115...
Page 384 DI−117 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Engine Coolant Temp. Sensor G−Y B−W FI6448 INSPECTION PROCEDURE HINT: If DTCs related to different system that have terminal E2 as the ground terminal are output simulta- neously, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester.
Page 385 DI−118 DIAGNOSTICS − ENGINE (1GR−FE) Connect hand−held tester, and read value of engine coolant temperature. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 386 DI−119 DIAGNOSTICS − ENGINE (1GR−FE) Check for open in harness or ECM. PREPARATION: Engine Coolant Disconnect the E2 engine coolant temperature (ECT) Temp. Sensor sensor connector. Connect terminals 1 and 2 of the engine coolant tempera- ture sensor wire harness side connector. Turn the ignition switch to ON.
Page 387 DI−120 DIAGNOSTICS − ENGINE (1GR−FE) Confirm good connection at ECM. If OK, re- place ECM (See page SF−66). Check for short in harness and ECM. PREPARATION: Engine Coolant Disconnect the E2 engine coolant temperature sensor Temp. Sensor connector. Turn the ignition switch to ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 388 DI−121 DIAGNOSTICS − ENGINE (1GR−FE) DIDTC−01 P0116 Engine Coolant Temperature Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−115. DTC No. DTC Detecting Condition Trouble Area If the engine coolant temperature was 35°C (95°F) or more but less than 60°C (140°F) when the engine is started, and if conditions (a) and (b) are met: (a) Vehicle has accelerated and decelerated.
Page 389 DI−122 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−18 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 390 DI−123 DIAGNOSTICS − ENGINE (1GR−FE) DIDTD−01 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 391 DI−124 DIAGNOSTICS − ENGINE (1GR−FE) 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 392 DI−125 DIAGNOSTICS − ENGINE (1GR−FE) DTC No. DTC Detection Condition Condition (a) of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues Trouble Area for 2 sec. (Open or short in the throttle control motor and sensor circuit) S Open or short in throttle control motor and sensor circuit Detection conditions for DTCs P0122 and P0123 are not satis- S Throttle control motor and sensor P0120...
Page 393 DI−126 DIAGNOSTICS − ENGINE (1GR−FE) 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 394 DI−127 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these See page DI−18 DTCs are not present Throttle control motor power TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0120: VTA1 voltage 0.2 V or less, or 4.535 V or more P0122: VTA1 voltage 0.2 V or less...
Page 395 DI−128 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Throttle Position Sensor (Built in Throttle w/ Motor Body) G−B VTA1 VTA1 R−B VTA2 VTA2 B−W cmc0485 INSPECTION PROCEDURE HINT: If DTCs related to different system that have terminal E2 as the ground terminal are output simulta- neously, terminal E2 may have an open circuit.
Page 396 DI−129 DIAGNOSTICS − ENGINE (1GR−FE) Connect hand−held tester, and read the voltage for throttle position sensor data. PREPARATION: Enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / THROTTLE POS and THROTTLE POS #2. CHECK: Read voltage value displayed on the hand−held tester.
Page 397 DI−130 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and throttle position sensor. PREPARATION: Wire Harness Side Disconnect the T14 throttle control motor and sensor con- Throttle Control Motor and Sensor nector. Disconnect the E7 ECM connector. CHECK: Check the resistance between the wire harness side connec- tors.
Page 398 DI−131 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminals VC and E2 of ECM connector. PREPARATION: Disconnect the T14 throttle control motor and sensor con- E7 ECM Connector nector. Turn the ignition switch to ON. CHECK: Measure the voltage between the specified terminals of the E7 ECM connector.
Page 399 DI−132 DIAGNOSTICS − ENGINE (1GR−FE) Check if DTC output recur. PREPARATION: Clear the DTC (See page DI−42). Start the engine. Run the engine at idle for 15 seconds or more. CHECK: Read the DTC. RESULT: Display (DTC Output) Proceed to ”P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135”...
Page 400 DI−133 DIAGNOSTICS − ENGINE (1GR−FE) DIDTE−01 P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem HINT: This is the purpose of the ”throttle position sensor”. CIRCUIT DESCRIPTION Refer to DTC P0120 on page DI−123. DTC No. DTC Detecting Condition Trouble Area Condition (a) continues for 2.0 sec.: (a) Difference between VTA1 and VTA2 deviates from the P0121...
Page 401 DI−134 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−18 not present Either of the following conditions is met Condition (a) or (b) (a) Ignition switch (b) Electric throttle motor power TP sensor malfunction (P0120, P0122, Not detected P0123, P0220, P0222, P0223, P2135)
Page 402 DI−135 DIAGNOSTICS − ENGINE (1GR−FE) DIDTF−01 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−115. DTC No. DTC Detection Condition Trouble Area If THW or THA is less than −19.45°C (−3°F) at engine start and 20 min.
Page 403 DI−136 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−18 not present Fuel cut Engine Running 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 Engine coolant temperature is less than ”closed−loop enable temperature”...
Page 404 DI−137 DIAGNOSTICS − ENGINE (1GR−FE) Inspect thermostat (See page CO−11). CHECK: Check the valve opening temperature of the thermostat. Valve opening temperature is 80 to 84_C (176 to 183_F) HINT: Also check that the valve is completely closed under opening temperature as above. Replace thermostat (See page CO−11).
Page 405 DI−138 DIAGNOSTICS − ENGINE (1GR−FE) DIDTG−01 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) HINT: This is the purpose of ”thermostat” malfunction detection. CIRCUIT DESCRIPTION If the engine coolant temperature does not reach 75°C (167°F) despite sufficient warm−up time has elapsed.
Page 406 DI−139 DIAGNOSTICS − ENGINE (1GR−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 407 DI−140 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 408 DI−141 DIAGNOSTICS − ENGINE (1GR−FE) Inspect thermostat (See page CO−11). CHECK: Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) Replace thermostat (See page CO−11). Replace ECM (See page SF−66).
Page 409 DI−142 DIAGNOSTICS − ENGINE (1GR−FE) DIDTH−01 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) P0157 Oxygen Sensor Circuit Low Voltage (Bank 2...
Page 410 DI−143 DIAGNOSTICS − ENGINE (1GR−FE) ing improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air−fuel ratio control. Atmospheric Air Ideal Air−Fuel Mixture Housing Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Richer −...
Page 411 DI−144 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION Active Air−Fuel Ratio Control The ECM usually performs air−fuel ratio feedback control so that the Air−Fuel Ratio (A/F) sensor output indi- cates a near stoichiometric air−fuel level. This vehicle includes active air−fuel ratio control in addition to regu- lar air−fuel ratio control.
Page 412 DI−145 DIAGNOSTICS − ENGINE (1GR−FE) Open or Short in the Heated Oxygen (HO2) Sensor Circuit (DTC P0137, P0157, P0138 or P0158) During active air−fuel ratio control, the ECM calculates the Oxygen Storage Capacity (OSC)* of the Three− Way Catalytic Converter (TWC) by forcibly regulating the air−fuel ratio to become rich or lean. If the HO2 sensor has an open or short, or the voltage output of the sensor noticeably decreases, the OSC indicates an extraordinarily high value.
Page 413 DI−146 DIAGNOSTICS − ENGINE (1GR−FE) High or Low Impedance of Heated Oxygen (HO2) Sensor (DTC P0136, P0156, P0137 or P0157) During normal air−fuel ratio feedback control, there are small Interrelation between temperature of variations in the exhaust gas oxygen concentration. In order to the element and impedance: continuously monitor the slight variation of the HO2 sensor sig- nal while the engine is running, the impedance* of the sensor...
Page 414 DI−147 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Heated rear oxygen sensor (Bank 1) output volt- age (Output voltage) P0136 P0136 Heated rear oxygen sensor (Bank 1) impedance (Low) Heated rear oxygen sensor (Bank 1) output volt- age (Low voltage) P0137 P0137 Heated rear oxygen sensor (Bank 1) impedance (High)
Page 415 DI−148 DIAGNOSTICS − ENGINE (1GR−FE) Fuel system status Closed loop Fuel−cut Engine load 10 to 70% Heated oxygen sensor impedance (Low): Battery voltage 11 V − Estimated sensor temperature − 700°C (1,292°F) ECM monitor Completed P0606 Not set Heated oxygen sensor impedance (High): Battery voltage 11 V −...
Page 416 DI−149 DIAGNOSTICS − ENGINE (1GR−FE) Heated oxygen sensor output voltage (Extremely high): Duration of following condition 10 sec. or more Rear oxygen sensor voltage More than 1.2 V COMPONENT OPERATING RANGE Parameter Standard Value Rear oxygen sensor voltage 1.2 V or more O2S TEST RESULT Refer to page DI−24...
Page 417 DI−150 DIAGNOSTICS − ENGINE (1GR−FE) Connect a hand−held tester to the DLC3. READINESS TESTS Turn the ignition switch to ON. MISFIRE MON ..... AVAIL Turn the tester ON. FUEL SYS MON ....AVAIL COMP MON ......AVAIL Clear DTCs (where set) (see page DI−42). CAT EVAL ......
Page 418 DI−151 DIAGNOSTICS − ENGINE (1GR−FE) 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 few seconds delay in the sensor 1 (front sensor) output. And there is approximately 20 seconds delay in the sensor 2 (rear sensor).
Page 419 DI−152 DIAGNOSTICS − ENGINE (1GR−FE) Read output DTC. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 420 DI−153 DIAGNOSTICS − ENGINE (1GR−FE) Check for short in harness and connector between terminal OX1B and HT1B, OX2B and HT2B of ECM. PREPARATION: ECM Connector Turn the ignition switch to OFF and wait for 5 minutes. Disconnect the E6 and E7 ECM connectors. CHECK: Check the resistance.
Page 421 DI−154 DIAGNOSTICS − ENGINE (1GR−FE) Check whether DTC output recurs (DTC P0138, P0158) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read DTCs. RESULT: Display (DTC Output) Proceed To P0138 or P0158 No output...
Page 422 DI−155 DIAGNOSTICS − ENGINE (1GR−FE) Check whether DTC output recurs (DTC P0136, P0156) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read DTCs. RESULT: Display (DTC Output) Proceed To P0136 or P0156 No output...
Page 423 DI−156 DIAGNOSTICS − ENGINE (1GR−FE) Perform active test (injection volume). PREPARATION: Connect the hand−held tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. CHECK: Change the fuel injection volume using the tester, monitoring the voltage output of Air−Fuel Ratio (A/F) and HO2 sensors displayed on the tester.
Page 424 DI−157 DIAGNOSTICS − ENGINE (1GR−FE) Check and repair extremely rich or lean actu- arial air fuel ratio (injector, fuse pressure, gas leakages from exhaust system, etc.) Check for exhaust gas leakage. CHECK: Check for exhaust gas leakage from the exhaust manifold and pipe. No exhaust gas leakage.
Page 425 DI−158 DIAGNOSTICS − ENGINE (1GR−FE) Check EFI relay. PREPARATION: EFI Relay Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Standard: Terminal No. Condition Specified Condition 3 − 5 Usually 10 KΩ or higher A19288 Apply B+ between Below 1 Ω...
Page 426 DI−159 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and heated oxygen sensor. PREPARATION: Component Side: Disconnect the heated oxygen sensor connector. HO2 Sensor Disconnect the E6 and E7 ECM connectors. CHECK: Measure the resistance between the wire harness side connec- tors.
Page 427 DI−160 DIAGNOSTICS − ENGINE (1GR−FE) DIDTI−01 P0171 System too Lean (Bank 1) P0172 System too Rich (Bank 1) P0174 System too Lean (Bank 2) P0175 System too Rich (Bank 2) CIRCUIT DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim con- sists of both the short−term and long−term fuel trims.
Page 428 DI−161 DIAGNOSTICS − ENGINE (1GR−FE) DTC No. DTC Detecting Condition Trouble Area S Air induction system S Injector blockage S Mass air flow meter S Engine coolant temperature sensor S Fuel pressure S Gas leakage in exhaust system When air−fuel ratio feedback is stable after warming up the P0171 S Open or short in heated oxygen sensor (bank 1, 2 sensor 1) engine, fuel trim is considered to be in error on LEAN side...
Page 429 DI−162 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION Under closed−loop fuel control, fuel injection volumes that deviate from those estimated by the ECM cause changes in the long−term fuel trim compensation value. The long−term fuel trim is adjusted when there are persistent deviations in the short−term fuel trim values.
Page 430 DI−163 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present Battery voltage 11 V − Fuel system status Closed−loop Either of the following conditions is met: Condition 1 or 2 1.
Page 431 DI−164 DIAGNOSTICS − ENGINE (1GR−FE) Standard: Tester Display Injection Volumes Status Voltages (Sensor) AFS B1S1 (AFS B2S1) +25 % Rich Less than 3.0 (A/F) AFS B1S1 (AFS B2S1) −12.5 % Lean More than 3.35 (A/F) O2S B1S2 (O2S B2S2) +25 % Rich More than 0.55 (HO2)
Page 432 DI−165 DIAGNOSTICS − ENGINE (1GR−FE) HINT: Read freeze frame data using a hand−held tester or OBD II scan tool. Freeze frame data record the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, 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 433 DI−166 DIAGNOSTICS − ENGINE (1GR−FE) Check air induction system (See page SF−1). CHECK: Check the air induction system for vacuum leaks. Repair or replace air induction system. Perform active test (A/F control). Connect the hand−held tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds.
Page 434 DI−167 DIAGNOSTICS − ENGINE (1GR−FE) Result: Status Status A/F Condition and AFS B1S1 O2S B1S2 Misfires Suspected Trouble Areas Proceed To A/F Sensor Condition (AFS B2S1) (O2S B2S2) Lean/Rich Lean/Rich Normal S PCV valve and hose S PCV hose connections S Injector blockage S Gas leakage from exhaust system S Air induction system...
Page 435 DI−168 DIAGNOSTICS − ENGINE (1GR−FE) Read value of mass air flow meter. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF and COOLANT TEMP.
Page 436 DI−169 DIAGNOSTICS − ENGINE (1GR−FE) Check for spark and ignition (See page IG−1). HINT: If the spark plugs or ignition system malfunction, engine misfire may occur. The misfire counter can be read with the hand−held tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MIS- FIRE / CYL#1 (to CYL#8).
Page 437 DI−170 DIAGNOSTICS − ENGINE (1GR−FE) Check A/F relay. PREPARATION: A/F Relay Remove the A/F relay from the engine room J/B. CHECK: Inspect the A/F relay. Standard: Terminal No. Condition Specified Condition 3 − 5 Usually 10 KΩ or higher A19288 Apply B+ between Below 1 Ω...
Page 438 DI−171 DIAGNOSTICS − ENGINE (1GR−FE) Standard (Check for short): Tester Connections Specified Conditions HT (A10−1) or HA1A (E6−2) − Body ground 10 kΩ or higher HT (A30−1) or HA2A (E6−1) − Body ground AF+ (A10−3) or A1A+ (E6−22) − Body ground 10 kΩ...
Page 439 DI−172 DIAGNOSTICS − ENGINE (1GR−FE) Perform confirmation driving pattern. Vehicle Speed Between 38 mph and 75 mph (60 km/h and 120 km/h) Idling Ignition Switch OFF 2 minutes 3 to 5 minutes Time (a), (b), (c) B17397 Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON.
Page 440 DI−173 DIAGNOSTICS − ENGINE (1GR−FE) Check whether DTC output recurs (DTC P0171, P0172, P0174 or P0175) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read DTCs. RESULT: Display (DTC Output) Proceed To P0171, P0172, P0174 or P0175...
Page 441 DI−174 DIAGNOSTICS − ENGINE (1GR−FE) DIDTJ−01 P0230 Fuel Pump Primary Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal STAR of the ECM 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, the Tr1 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 oper- ates.
Page 442 DI−175 DIAGNOSTICS − ENGINE (1GR−FE) DTC No. DTC Detecting Condition Trouble Area S Open or short in fuel pump relay circuit S Fuel pump relay S Circuit opening relay P0230 Open or short in fuel pump relay circuit S Fuel pump S ECM...
Page 443 DI−176 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Ignition SW W−R B−R GR−G GR−G MREL R−G R−G R−G E5 FPR 1K 6 W−R W−L B−O F/PMP C/OPN Relay Relay Fuel Relay Pump Resistor L−O L−O B−W B−W W−R B−R L−O L−O Fuel Pump W−B W−B...
Page 444 DI−177 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 445 DI−178 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between fuel pump relay and ECM. PREPARATION: Engine Room R/B: Remove the fuel pump relay from the engine room J/B. Disconnect the E5 ECM connector. CHECK: Measure the resistance between wire harness side connectors.
Page 446 DI−179 DIAGNOSTICS − ENGINE (1GR−FE) DIDTK−01 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 P0305 Cylinder 5 Misfire Detected P0306 Cylinder 6 Misfire Detected CIRCUIT DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) enter the exhaust in high concentrations.
Page 447 DI−180 DIAGNOSTICS − ENGINE (1GR−FE) DTC No. DTC Detecting Condition Trouble Area S Open or short in engine wire S Connector connection P0300 Misfiring of random cylinders is detected S Vacuum hose connection S Ignition system S Ignition system S Injector S Fuel pressure P0301 S Mass air flow meter...
Page 448 DI−181 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION Camshaft position sensor Crankshaft position sensor (36−2 teeth or 12 teeth) A20490 The ECM illuminates the MIL (2 trip detection logic) if: The ECM will illuminate the MIL when the percentage of misfire exceeds the specified limit per 1,000 engine revolutions.
Page 449 DI−182 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum All: The monitor will run whenever these See page DI−18 DTCs are not present Battery voltage − VVT system Not operate by scan tool 450 to 5,400rpm (Manual transmission) Engine RPM 400 to 5,400rpm (Automatic transmission) Either of the following conditions is met:...
Page 450 DI−183 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Refer to DTC P0351 on page DI−216 for the wiring diagram of the ignition system. Engine Room J/B Injector No. 1 W−R B−R W−R Ignition Switch Injector No. 3 B−R IG2 AM2 B−R B−R Driver Side...
Page 451 DI−184 DIAGNOSTICS − ENGINE (1GR−FE) CONFIRMATION DRIVING PATTERN Connect the hand−held tester to the DLC3. Record DTC and the freeze frame data. Use the hand−held tester to set the check mode (See page DI−43). 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 452 DI−185 DIAGNOSTICS − ENGINE (1GR−FE) Are there any other codes (besides DTC P0300, P0301, P0302, P0303, P0304 P0305 or P0306) being output? PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 453 DI−186 DIAGNOSTICS − ENGINE (1GR−FE) Check connection of PCV hose. PCV hose is connected correctly and is not damaged. Repair or replace PCV hose. Connect hand−held tester, and read the number of misfire. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON.
Page 454 DI−187 DIAGNOSTICS − ENGINE (1GR−FE) Check spark plug and spark of misfiring cylinder. PREPARATION: Remove the ignition coil assembly. Remove the spark plug. CHECK: Check the electrode for carbon deposits. Check the spark plug type (See page IG−1). Check electrode gap. 1.0 to 1.1 mm No large carbon deposit present.
Page 455 DI−188 DIAGNOSTICS − ENGINE (1GR−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 another spark plug to the ignition coil assem- bly.
Page 456 DI−189 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ignition coil and ECM. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil connector. Ignition Coil Connector Disconnect the E7 ECM connector. CHECK: Check the resistance between the wire harness side connec- tors.
Page 457 DI−190 DIAGNOSTICS − ENGINE (1GR−FE) PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil connector. Ignition Coil Connector Disconnect the E7 ECM connector. CHECK: Check the resistance between the wire harness side connec- tors. Standard: A21025 Tester Connection...
Page 458 DI−191 DIAGNOSTICS − ENGINE (1GR−FE) Check ECM terminal of misfiring cylinder. PREPARATION: Turn the ignition switch to ON. #40(+) CHECK: Measure the voltage between the terminals of the E5 and E7 ECM connectors. Standard: E01 (−) Tester Connection Specified Condition B17411 #10 (E5−2) −...
Page 459 DI−192 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ignition SW and in- jector, injector and ECM of misfiring cylinder. PREPARATION: Wire Harness Side: Disconnect the I14, I15, I16, I17, I18 or I19 injector con- Injector Connector nector.
Page 460 DI−193 DIAGNOSTICS − ENGINE (1GR−FE) PREPARATION: Wire Harness Side: Disconnect the I14, I15, I16, I17, I18 or I19 injector con- Injector Connector nector. I14 I15 Disconnect the I23 ignition switch connector. CHECK: Measure the resistance of the wire harness side connectors be- tween the injector and ignition switch.
Page 461 DI−194 DIAGNOSTICS − ENGINE (1GR−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, and proceed to each step. RESULT: High misfire rate cylinder Proceed to 1 or 2 cylinders...
Page 462 DI−195 DIAGNOSTICS − ENGINE (1GR−FE) Check fuel pressure (See page SF−5). Check and replace fuel pump, pressure regula- tor, fuel pipe line and filter (See page SF−1). Check intake air temperature and mass air flow rate. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON.
Page 463 DI−196 DIAGNOSTICS − ENGINE (1GR−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. Resistance: Tester Connection Specified Condition 1 − 2 2.32 to 2.59 kΩ (20_C (68_F)) Acceptable 1 −...
Page 464 DI−197 DIAGNOSTICS − ENGINE (1GR−FE) DIDUJ−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) P0332 Knock Sensor 2 Circuit Low Input (Bank 2) P0333 Knock Sensor 2 Circuit High Input (Bank 2) CIRCUIT DESCRIPTION A flat type knock sensor (non−resonant type) has the structure that can detect the vibration in a wider band...
Page 465 DI−198 DIAGNOSTICS − ENGINE (1GR−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. If there is a defect in the knock sensor or an open or short circuit, the voltage level will deviate outside the normal operating range.
Page 466 DI−199 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Knock Sensor 1 (Bank 1) KNK1 (*1) EKNK (*1) (*1) (*1) Knock Sensor 2 (*1) (Bank 2) (*1) (*1) KNK2 (*1) (*1) EKN2 *1: Shielded A23569 INSPECTION PROCEDURE HINT: DTC P0327 and P0328 are for the bank 1 knock sensor circuit. DTC P0332 and P0333 are for the bank 2 knock sensor circuit.
Page 467 DI−200 DIAGNOSTICS − ENGINE (1GR−FE) Connect hand−held tester, and check knock sensor circuit. PREPARATION: Disconnect the EF2 connector. Using lead wires, connect the EF2 connectors as follows. Knock Sensor KNK1 Male Connector − Female Connector Terminal 5 − Terminal 6 EKNK Terminal 2 −...
Page 468 DI−201 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between EF2 connector and ECM (See page IN−30). Repair or replace harness or connector. Measure voltage between terminals KNK1 and EKNK, KNK2 and EKN2 of ECM. PREPARATION: Disconnect the E6 ECM connector.
Page 469 DI−202 DIAGNOSTICS − ENGINE (1GR−FE) Check knock sensor. PREPARATION: Wire Harness Side: Disconnect the EF2 connector. Male Connector CHECK: Check the resistance between the terminals of the EF2 male connector. Standard: Front View Tester Connection Specified Condition EF2 male connector 2 −5 120 to 280 kΩ...
Page 470 DI−203 DIAGNOSTICS − ENGINE (1GR−FE) DIDTL−01 P0335 Crankshaft Position Sensor ”A” Circuit P0339 Crankshaft Position Sensor ”A” Circuit In- termittent CIRCUIT DESCRIPTION The crankshaft position sensor system consists of a crankshaft position sensor plate and a pick−up coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pick−up coil is made of an iron core and magnet.
Page 471 DI−204 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION If there are no signals from the crankshaft sensor even though the engine is revolving, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Crankshaft position sensor range check or ratio- Related DTCs P0335 nality...
Page 472 DI−205 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM V 17 VVT Sensor RH E5 VV1+ VV1− G−B V 16 VVT Sensor LH VV2+ G−B VV2− G−B Crankshaft Position Sensor NE− (Shielded) A23578...
Page 473 DI−206 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame records the engine conditions when a malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped. the engine was warmed up or not, the air−fuel ratio lean or rich, etc. at the time of the malfunction.
Page 474 DI−207 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and crankshaft position sensor. PREPARATION: Wire Harness Side Disconnect the C2 crankshaft position sensor connector. Disconnect the E5 ECM connector. CHECK: Measure the resistance between the wire harness side connec- tors.
Page 475 DI−208 DIAGNOSTICS − ENGINE (1GR−FE) Inspect teeth of sensor plate. PREPARATION: Remove the crankshaft angle sensor plate (See page EM−111). CHECK: Check the teeth of sensor plate. Replace sensor plate. Replace ECM (See page SF−66).
Page 476 DI−209 DIAGNOSTICS − ENGINE (1GR−FE) DIDTM−01 P0340 Camshaft Position Sensor ”A” Circuit (Bank 1 or Single Sensor) P0342 Camshaft Position Sensor ”A” Circuit Low Input (Bank 1 or Single Sensor) P0343 Camshaft Position Sensor ”A” Circuit High Input (Bank 1 or Single Sensor) P0345 Camshaft Position Sensor ”A”...
Page 477 DI−210 DIAGNOSTICS − ENGINE (1GR−FE) S Open or short in camshaft position sensor circuit Input voltage to ECM remains 0.3 V or less, or 4.7 V or S Camshaft position sensor P0340 higher for more than 5 seconds, when 2 or more seconds S Camshaft timing pulley P0345 have elapsed after turning the ignition switch ON.
Page 478 DI−211 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Camshaft position sensor range check Camshaft position/crankshaft position misalign- ment P0340 P0340 Camshaft position sensor range check (Fluctuat- ing) Camshaft position sensor range check (Low volt- P0342 age) Related DTCs Camshaft position sensor range check (High volt- P0343 age) VVT sensor range check (While starting engine)
Page 479 DI−212 DIAGNOSTICS − ENGINE (1GR−FE) VVT sensor range check (After starting engine): Engine RPM 600 rpm − Battery voltage − Ignition switch Starter VVT sensor range check (Fluctuating, Low voltage, High voltage): Starter Ignition switch ON and time after ignition 2 sec.
Page 480 DI−213 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 481 DI−214 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and camshaft position sensor. PREPARATION: Wire Harness Side Disconnect the camshaft position sensor connector. Disconnect the E5 ECM connector. CHECK: Measure the resistance between the wire harness side connec- 1 2 3 tors.
Page 482 DI−215 DIAGNOSTICS − ENGINE (1GR−FE) Inspect teeth of camshaft timing belt pulley. PREPARATION: Remove the camshaft timing belt pulley (See page EM−53). CHECK: Check the camshaft timing belt pulley. Replace camshaft timing pulley. Replace Camshaft position sensor (See page IG−11).
Page 483 DI−216 DIAGNOSTICS − ENGINE (1GR−FE) DIDTN−01 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 P0355 Igniter Coil ”E” Primary/Secondary Circuit P0356 Igniter Coil ”F” Primary/Secondary Circuit HINT: These DTCs indicate a malfunction related to primary circuit.
Page 484 DI−217 DIAGNOSTICS − ENGINE (1GR−FE) CIRCUIT DESCRIPTION These DTCs indicate a malfunction related to primary circuit. The DIS is a 1−cylinder ignition system which ignites one cylinder with one ignition coil. In the 1−cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug.
Page 485 DI−218 DIAGNOSTICS − ENGINE (1GR−FE) DTC No. DTC Detecting Condition Trouble Area P0351 S Open or short in IGF1 and IGT1 to IGT6 circuit from ignition P0352 coil with igniter to ECM P0353 S No. 1 to No. 6 ignition coil with igniter (primary ignition) No IGF1 signal to ECM while engine is running P0354 S Ignition system...
Page 486 DI−219 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY P0351 No. 1 ignition coil with igniter circuit malfunction P0352 No. 2 ignition coil with igniter circuit malfunction P0353 No. 3 ignition coil with igniter circuit malfunction R l t d DTC Related DTCs P0354 No.
Page 487 DI−220 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM I3 Ignition Coil Assy (with igniter No. 1) IGT1 B−L B−R B−R B−R B−R W−B B−Y B−Y IGF1 B−R I4 Ignition Coil Assy Driver (with igniter No. 2) Side IGT2 B−R L−W B−R W−B B−Y B−R...
Page 488 DI−221 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 489 DI−222 DIAGNOSTICS − ENGINE (1GR−FE) Repair or replace harness or connector. Disconnect ignition coil with igniter connector, and check voltage between ter- minals IGF1 and E1 of ECM connector. PREPARATION: Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil with igniter connector.
Page 490 DI−223 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector in IGT signal circuit between ECM and ignition coil with igniter. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil connector. Disconnect the E7 ECM connector.
Page 491 DI−224 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminals IGT1 to IGT6 and E1 of ECM connector. PREPARATION: IGT3 IGT4 Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil with igniter con- (−) IGT2 IGT5 nector. IGT1 CHECK: Measure the voltage between terminals the E5 and E7 ECM connectors when the engine is cranked.
Page 492 DI−225 DIAGNOSTICS − ENGINE (1GR−FE) Disconnect ignition coil with igniter connector, and check voltage between ter- minals IGT1 to IGT6 and E1 of ECM connector. PREPARATION: IGT3 IGT4 Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil with igniter (−) IGT2 IGT5...
Page 493 DI−226 DIAGNOSTICS − ENGINE (1GR−FE) Check ignition coil with igniter power source circuit. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil with igniter connector. Turn the ignition switch to ON. CHECK: Measure the voltage between the terminal of the wire harness side connector and body ground.
Page 494 DI−227 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ignition switch and ignition coil with igniter. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7 or I8 ignition coil with igniter connector. Disconnect the I23 ignition switch connector.
Page 495 DI−228 DIAGNOSTICS − ENGINE (1GR−FE) DIDTO−01 P0420 Catalyst System Efficiency Below Threshold (Bank 1) P0430 Catalyst System Efficiency Below Threshold (Bank 2) MONITOR DESCRIPTION The ECM uses the two sensors, mounted in front of and behind the Three−way Catalytic Converter (TWC), to monitor its efficiency.
Page 496 DI−229 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present Battery voltage 11 V − −10_C (14_F) − 75°C (167°F) − Atmospheric pressure coefficient 0.75 −...
Page 497 DI−230 DIAGNOSTICS − ENGINE (1GR−FE) WAVEFORMS OF AIR−FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SEN- SORS HINT: Perform the operation with the engine speeds and time durations described below prior to check the wave- forms of the A/F and HO2 sensors. This is in order to activate the sensors sufficiently to obtain the appropri- ate inspection results.
Page 498 DI−231 DIAGNOSTICS − ENGINE (1GR−FE) If the Three−Way Catalytic Converter (TWC) has deteriorated, the HO2 sensor (located behind the TWC) voltage output fluctuates up and down frequently, even under normal driving conditions (active air−fuel ratio control is not performed). Voltage output when active air−fuel ratio control not performed Normal Catalyst Deteriorated Catalyst 3.5 V...
Page 499 DI−232 DIAGNOSTICS − ENGINE (1GR−FE) Standard: Tester Display Injection Volumes Status Voltages (Sensor) AFS B1S1 +25 % Rich Less than 3.0 (A/F) AFS B1S1 −12.5 % Lean More than 3.35 (A/F) O2S B1S2 +25 % Rich More than 0.55 (HO2) O2S B1S2 −12.5 % Lean...
Page 500 DI−233 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 501 DI−234 DIAGNOSTICS − ENGINE (1GR−FE) Check heated oxygen sensor (bank 1, 2 sensor 2) (See page SF−64). HINT: Refer to the HINT following the end of this flowchart. Replace heated oxygen sensor. Replace front and rear three−way catalytic converter in the bank a malfunction is de- tected.
Page 502 DI−235 DIAGNOSTICS − ENGINE (1GR−FE) NOTICE: There is a few second delay in the sensor 1 (front sensor) output. And there is approximately 20 se- conds delay in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspected sensor (sensor 1: front sensor) sensor (sensor 2: rear sensor)
Page 503 DI−236 DIAGNOSTICS − ENGINE (1GR−FE) DIDTP−01 P0441 Evaporative Emission Control System Incor- rect Purge Flow DTC SUMMARY Detection Detection DTCs Monitoring Items Malfunction Detection Conditions Trouble Areas Timings Logic Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP sys- S Purge VSV tem pressure measured.
Page 504 DI−237 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION The two monitors, Key−Off and Purge Flow, are used to detect malfunctions relating to DTC P0441. The Key−Off monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours* after the ignition switch is turned to OFF.
Page 505 DI−238 DIAGNOSTICS − ENGINE (1GR−FE) Operation A: Atmospheric Pressure Measurement Operation B: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF (vent) Vent Valve: OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Air Filter Pump Module Vacuum Pump: OFF Operation C: EVAP Leak Check Operation D: Purge VSV monitor ON (closed)
Page 506 DI−239 DIAGNOSTICS − ENGINE (1GR−FE) Purge VSV stuck closed In operation D, the pressure sensor measures the EVAP system pressure. The pressure measurement for purge VSV monitor is begun when the purge VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally.
Page 507 DI−240 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Purge VSV stuck open Purge VSV stuck closed Related DTCs Related DTCs P0441 P0441 Purge flow Required sensors/components Purge VSV, Pump module Frequency of operation Once per driving cycle Purge VSV stuck open and closed: Within 15 min. (varies with amount of fuel in tank) Duration Purge flow: Within 10 min.
Page 508 DI−241 DIAGNOSTICS − ENGINE (1GR−FE) 3. EVAP canister vent valve close stuck − check Next sequence is run if the following − condition is set EVAP pressure change after vent valve is 0.3 kPa (2.25 mmHg) − 4. Vacuum introduction −...
Page 509 DI−242 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Purge VSV stuck open: EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 Purge VSV stuck closed: EVAP pressure change after EVAP canister purge valve is Less than 0.3 kPa (2.25 mmHg) open Purge flow:...
Page 510 DI−243 DIAGNOSTICS − ENGINE (1GR−FE) DIDTQ−01 P0450 Evaporative Emission Control System Pres- sure Sensor/Switch 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 DTC SUMMARY Detection Tim- Detection...
Page 511 DI−244 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION DTC P0450: Pressure sensor voltage abnormal fluctua- Pressure Sensor Specification: tion. Malfunction Area If the pressure sensor voltage output rapidly fluctuates Output Voltage between less than 0.45 V and more than 4.9 V, the ECM 4.900 V interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP...
Page 512 DI−245 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Evaporative emission control system pressure P0450 sensor/switch chattering Evaporative emission control system pressure sensor noise P0451 P0451 Evaporative emission control system pressure Related DTCs sensor stuck Evaporative emission control system pressure P0452 sensor/switch low input Evaporative emission control system pressure P0453 sensor/switch high input...
Page 513 DI−246 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Pressure sensor noise: Frequency that EVAP pressure change is 0.3 kPa (2.3 10 times or more for 10 sec. mmHg) or more Pressure sensor stuck: EVAP pressure change during reference pressure measure- Less than 0.65 kPa (4.9 mmHg) ment Pressure sensor chattering:...
Page 514 DI−247 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE NOTICE: When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condi- tion. For example, do not tighten the fuel tank cap. Do not disassemble the pump module. A hand−held tester is required to conduct the following diagnostic troubleshooting procedure.
Page 515 DI−248 DIAGNOSTICS − ENGINE (1GR−FE) Measure resistance between terminal PPMP of ECM and body ground. PREPARATION: Turn the ignition switch to OFF. Disconnect the E3 ECM connector. CHECK: Measure the resistance between PPMP terminal of the ECM connector and the body ground. PPMP B17417 RESULT:...
Page 516 DI−249 DIAGNOSTICS − ENGINE (1GR−FE) Measure resistance between terminal PPMP of ECM and body ground. PREPARATION: Disconnect the L4 canister connector. Disconnect the E3 ECM connector. CHECK: Check the resistance between PPMP terminal of the ECM con- nector and the body ground. A23446 PPMP B17417...
Page 517 DI−250 DIAGNOSTICS − ENGINE (1GR−FE) Measure voltage and resistance of pump module connector. PREPARATION: Disconnect the L4 canister connector. Turn the ignition switch to ON. CHECK: Measure the voltage and resistance of the L4 connector. Standard: Tester Connections Specified Conditions L4−4 −...
Page 518 DI−251 DIAGNOSTICS − ENGINE (1GR−FE) Replace ECM (See page SF−66). NEXT Check whether DTC output recurs. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Wait for at least 60 seconds. CHECK: On the tester, select the following menu items: DIAGNOSIS/ENHANCED OBD II/DTC INFO/PENDING CODES.
Page 519 DI−252 DIAGNOSTICS − ENGINE (1GR−FE) DIDTR−01 P0455 Evaporative Emission Control System Leak Detected (Gross Leak) P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY Detection Detection Monitoring Items Malfunction Detection Conditions Trouble Areas Timings Logic Vacuum pump creates negative pressure S Fuel tank cap (loose) (vacuum) in EVAP system and EVAP sys- S Leakage from EVAP line...
Page 520 DI−253 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacu- um) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35_C (95_F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later.
Page 521 DI−254 DIAGNOSTICS − ENGINE (1GR−FE) P0455: EVAP (Evaporative Emission) gross leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak pres- sure standard x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic).
Page 522 DI−255 DIAGNOSTICS − ENGINE (1GR−FE) Vehicle speed − 2.5 mph (4 km/h) Ignition switch EVAP pressure sensor malfunction Not detected (P0450, P0452, P0453) EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met...
Page 523 DI−256 DIAGNOSTICS − ENGINE (1GR−FE) 6. Second reference pressure measure- − ment Next sequence is run if all of the following Condition 1, 2, 3 and 4 conditions are set 1. EVAP pressure just after reference − −1 kPa (−7.5 mmHg) pressure measurement 2.
Page 524 DI−257 DIAGNOSTICS − ENGINE (1GR−FE) DIDTS−01 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 525 DI−258 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Related DTCs P0500 Vehicle speed sensor ”A” pulse input error Main sensors Vehicle speed sensor Required sensors/components Park/Neutral position switch, Engine coolant tem- Related sensors perature sensor, Combination meter Frequency of operation Continuous Case 1: 500 times Duration Case 2: 8 sec.
Page 526 DI−259 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 527 DI−260 DIAGNOSTICS − ENGINE (1GR−FE) Check voltage between terminal SPD and E1 of ECM connector. PREPARATION: Shift the shift lever to neutral. Jack up the rear wheel on one side. Turn the ignition switch to ON. CHECK: Measure the voltage between the specified terminal of the E4 and E5 ECM connectors when the wheel is turned slowly.
Page 528 DI−261 DIAGNOSTICS − ENGINE (1GR−FE) DIDTT−01 P0504 Brake Switch ”A”/”B” Correlation CIRCUIT DESCRIPTION In addition to turning on the stop lamps, the stop lamp switch signals are used for a variety of engine, trans- mission, and suspension functions as well as being an input for diagnostic checks. It is important that the switch operates properly, therefore this switch is designed with two complementary signal outputs: STP and STI−.
Page 529 DI−262 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Driver Side J/B I23 Ignition SW ECU−IG GR−G (*3) B−Y Driver Side J/B B−R B−O B−O W−R Stop Light SW GR−G (*3) G−Y (*4) Driver STI− G−Y (*3) G−Y (*3) Side G−W G−W (*3) G−W Stop Light STOP...
Page 530 DI−263 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 531 DI−264 DIAGNOSTICS − ENGINE (1GR−FE) Check STP signal and STI− voltage. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON. Brake Pedal Brake Pedal Select the item ”DIAGNOSIS / ENHANCED OBD II / Depressed Released DATA LIST / ALL / STOP LIGHT SW”.
Page 532 DI−265 DIAGNOSTICS − ENGINE (1GR−FE) Check harness and connector between ECM and stop light switch. PREPARATION: Wire Harness Side: Disconnect the S4 stop light switch connector. Disconnect the E3 ECM connector. CHECK: Measure the resistance between the wire harness side connec- tors.
Page 533 DI−266 DIAGNOSTICS − ENGINE (1GR−FE) DIDTU−01 P0505 Idle Air Control System CIRCUIT 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 534 DI−267 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Related DTCs P0505 Idle air control malfunction Main sensors/components Crankshaft position sensor Required sensors/components Vehicle speed sensor, Engine coolant tempera- Related sensors/components ture sensor Frequency of operation Once per driving cycle Duration 10 min. MIL operation 2 driving cycles Sequence of operation...
Page 535 DI−268 DIAGNOSTICS − ENGINE (1GR−FE) 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 P0505 will possibly be detected.
Page 536 DI−269 DIAGNOSTICS − ENGINE (1GR−FE) Check air induction system (See page SF−1). CHECK: Check for vacuum leaks in air induction system. No leakage. Repair or replace air induction system. Check electric throttle control system (See page SF−39).
Page 537 DI−269−1 DIAGNOSTICS − ENGINE (1GR−FE) P050A Cold Start Idle Air Control System Performance P050B Cold Start Ignition Timing Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed.
Page 538 DI−269−2 DIAGNOSTICS − ENGINE (1GR−FE) The ECM monitors the intake air amount during idling and the ignition timing. When the engine coolant temperature is between −10_C and 50_C (14_F and 122_F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts. When the accumulated value is below the threshold, the ECM interprets this as a malfunction in the Idle Speed Control (ISC) system at cold start.
Page 539 DI−269−3 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present P050A: Battery voltage − Time after engine start 3 seconds − Starter ECT at engine start −10°C (14°F) −...
Page 540 DI−269−4 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read the freeze frame data using the intelligent tester. The freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, the freeze frame data can help determine if the ve- hicle was moving or stationary, 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 541 DI−269−5 DIAGNOSTICS − ENGINE (1GR−FE) Go to step 8. Check PCV hose connections. PCV hose is connected correctly and is not damaged. Go to step 5. Check air induction system. Check the air induction system for vacuum leakage. No leakage from the air induction system. Go to step 6.
Page 542 DI−269−6 DIAGNOSTICS − ENGINE (1GR−FE) Check throttle valve. Check for deposits around the throttle valve. No deposits around the throttle valve. Go to step 9. Go to step 10. Replace ECM. NEXT Go to step 11. Replace throttle body assembly. NEXT Check whether DTC output recurs (DTC P050A and/or P050B).
Page 543 DI−270 DIAGNOSTICS − ENGINE (1GR−FE) DIDTV−01 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 544 DI−271 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Engine Room R/B EFI No. 1 B−R BATT B−R Battery A23573 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 545 DI−272 DIAGNOSTICS − ENGINE (1GR−FE) Check EFI No. 1 fuse of engine room J/B. PREPARATION: Engine Room J/B: Remove the EFI No. 1 fuse from the engine room J/B. CHECK: Check the resistance of the EFI No. 1 fuse. Standard: Below 1 Ω Check for short in all harness and components No.
Page 546 DI−273 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and EFI No. 1 fuse, EFI No. 1 fuse and battery. PREPARATION: Engine Room J/B: Remove the EFI No. 1 fuse from the engine room J/B. Disconnect the E3 ECM connector.
Page 547 DI−274 DIAGNOSTICS − ENGINE (1GR−FE) DIDTW−01 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 548 DI−275 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0604: RAM check fail 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 549 DI−276 DIAGNOSTICS − ENGINE (1GR−FE) DIDTX−01 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 550 DI−277 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Driver Side J/B Ignition SW B−W G−B G−B G−B W−R G−R W−R G−Y G−R B−W TVIP SRLY Engine Room Engine Room Relay Clutch Start SW G−R B−W B−L (*1) B−W B (*2) W−B B−W Starter Battery...
Page 551 DI−278 DIAGNOSTICS − ENGINE (1GR−FE) ACC Cut Relay V−W V−W ACCR Ignition SW L−O L−R V−W Driver Sid R/B B−W 3 R−L R−L STSW W−R G−Y L−R IA9 8 G−Y G−R G−Y W−R Park/ Neutral Position SW Short W−B G−R G−R Relay TVIP...
Page 552 DI−279 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 553 DI−280 DIAGNOSTICS − ENGINE (1GR−FE) Connect hand−held tester, and check STA signal. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON, and push the hand−held tester main switch ON. On the hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG.
Page 554 DI−281 DIAGNOSTICS − ENGINE (1GR−FE) DIDTY−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 555 DI−282 DIAGNOSTICS − ENGINE (1GR−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 inputting the VIN. If DTCs other than P0630 are present, check them first.
Page 556 DI−283 DIAGNOSTICS − ENGINE (1GR−FE) DIDTZ−01 P2102 Throttle Actuator Control Motor Circuit Low P2103 Throttle Actuator Control Motor Circuit High CIRCUIT DESCRIPTION The throttle motor is operated by the ECM. 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 557 DI−284 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Throttle actuator control motor current P2102 (Low current) R l t d DTC Related DTCs Throttle actuator control motor current P2103 (High current) Required sensors/components Throttle actuator motor Frequency of operation Continuous Duration 2 sec.
Page 558 DI−285 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Refer to DTC P0120 on page DI−123. Throttle Control Motor (Shielded) (Built in Throttle w/ Motor Body) M− M− GE01 A23572 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected.
Page 559 DI−286 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between throttle control mo- tor and ECM. PREPARATION: Wire Harness Side: Disconnect the T14 throttle control motor and sensor con- Throttle Control Motor and Sensor nector. Disconnect the E7 ECM connector.
Page 560 DI−287 DIAGNOSTICS − ENGINE (1GR−FE) DIDU0−01 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 561 DI−288 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY P2111 Throttle motor actuator lock (Open) R l t d DTC 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.
Page 562 DI−289 DIAGNOSTICS − ENGINE (1GR−FE) Check any other DTC output (in addition to DTC P2111 or P2112). PREPARATION: Connect a hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. CHECK: Read DTCs.
Page 563 DI−290 DIAGNOSTICS − ENGINE (1GR−FE) Check throttle control motor. PREPARATION: Component Side: Disconnect the throttle control motor and sensor connector. Throttle Control Motor and Sensor CHECK: Measure the resistance between terminals of the throttle con- trol motor. Standard: M− Tester Connection Specified Condition 0.3 to100 Ω...
Page 564 DI−291 DIAGNOSTICS − ENGINE (1GR−FE) DIDU1−01 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 4V), the ECM concludes that the ETCS has a fault and current to the throttle control motor is cut.
Page 565 DI−292 DIAGNOSTICS − ENGINE (1GR−FE) 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 566 DI−293 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Engine Room R/B ETCS Battery cmc0490...
Page 567 DI−294 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 568 DI−295 DIAGNOSTICS − ENGINE (1GR−FE) Check for open or short in harness or connector between battery and ETCS fuse, ETCS fuse and ECM. PREPARATION: Engine Room J/B: Remove the ETCS fuse from the engine room J/B. Disconnect the E3 ECM connector. CHECK: Measure the resistance between the wire harness side connec- tor.
Page 569 DI−296 DIAGNOSTICS − ENGINE (1GR−FE) DIDU2−01 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 570 DI−297 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is See page DI−18 not present System guard* *System guard is ON when the following − conditions are met: Throttle actuator Throttle actuator duty calculation Executing Throttle position sensor Fail determined...
Page 571 DI−298 DIAGNOSTICS − ENGINE (1GR−FE) Are there any other codes (besides DTC P2119) being output? PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 572 DI−298−1 DIAGNOSTICS − ENGINE (1GR−FE) Replace ECM and clear DTC (Check if DTC outputs reoccur). PREPARATION: Replace ECM. Clear the DTC (See page DI−42). Start and warm up the engine. Run the engine at idle for 15 seconds or more. CHECK: Read the DTC using the hand−held tester (See page DI−42).
Page 573 DI−299 DIAGNOSTICS − ENGINE (1GR−FE) DIDU3−01 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 574 DI−300 DIAGNOSTICS − ENGINE (1GR−FE) CIRCUIT DESCRIPTION HINT: This electrical throttle control system does not use a throttle cable. This accelerator pedal position sensor is a non−contact type. The accelerator pedal position sensor is mounted in the accelerator pedal to detect the angle of the accelera- tor pedal.
Page 575 DI−301 DIAGNOSTICS − ENGINE (1GR−FE) DTC Detection Condition DTC No. Main trouble Area (Open or short in accelerator pedal position sensor circuit) S Accelerator pedal position sensor Condition (a) continues for 0.5 seconds or more: P2120 (a) VPA x 0.4 V or VPA y 4.8 V S ECM S Accelerator pedal position sensor Condition (a) and (b) continues for 0.5 seconds or more:...
Page 576 DI−302 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY Accelerator position sensor 1 (VPA) range check P2120 (Fluttering) Accelerator position sensor 1 (VPA) range check P2122 (Low voltage) Accelerator position sensor 1 (VPA) range check P2123 (High voltage) Accelerator position sensor 2 (VPA2) range P2125 Related DTCs check (Fluttering)
Page 577 DI−303 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P2120: Either of the following conditions is met Condition 1 or 2 1. VPA1 voltage when VPA2 voltage is 0.04 V or more 0.4 V or less 2. VPA1 voltage 4.8 V or more P2122: VPA1 voltage when VPA2 voltage is 0.04 V or more...
Page 578 DI−304 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM Accelerator Pedal Position Sensor R−G 6 (*1) 5 (*2) V−R 5 (*1) 1 (*2) P−G VCPA VCPA 4 (*1) 4 (*2) VPA2 VPA2 3 (*1) 2 (*2) LG−R EPA2 EPA2 2 (*1) 3 (*2) G−R VCP2 VCP2...
Page 579 DI−305 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 580 DI−306 DIAGNOSTICS − ENGINE (1GR−FE) 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. PREPARATION: Wire Harness Side: Disconnect the A20 accelerator pedal position sensor Accelerator Pedal Position Sensor (M/T) connector.
Page 581 DI−307 DIAGNOSTICS − ENGINE (1GR−FE) Repair or replace harness and connector. Check voltage between terminals VCPA and EPA, and VCP2 and EPA2 of ECM terminals. PREPARATION: Disconnect the A20 accelerator pedal position sensor connector. Accelerator Pedal Turn the ignition switch to ON. Position Sensor Connector CHECK:...
Page 582 DI−308 DIAGNOSTICS − ENGINE (1GR−FE) Check whether DTC output recurs (DTC P2120, P2122, P2123, P2125, P2127, P2128 or P2138) PREPARATION: Connect the hand−held tester to the DLC3. Disconnect the battery terminals or remove the EFI No. 1 fuse and ETCS fuse (Clear DTCs). Start the engine.
Page 583 DI−309 DIAGNOSTICS − ENGINE (1GR−FE) DIDU4−01 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−299. DTC No. DTC Detecting Condition Trouble Area S Accelerator pedal position sensor circuit Conditions (a) and (b) continue for 0.5 seconds: S Accelerator pedal position sensor...
Page 584 DI−310 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−18 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 585 DI−311 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between accelerator pedal position sensor and ECM. PREPARATION: Wire Harness Side: Disconnect the A20 accelerator pedal position sensor Accelerator Pedal Position Sensor (M/T) connector. Disconnect the E3 ECM connector. CHECK: Measure the resistance between the wire harness side connec- tors.
Page 586 DI−311−1 DIAGNOSTICS − ENGINE (1GR−FE) Repair or replace harness or connector. Replace accelerator pedal pedal assembly.
Page 587 DI−312 DIAGNOSTICS − ENGINE (1GR−FE) DIDU5−01 P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) HINT:...
Page 588 DI−313 DIAGNOSTICS − ENGINE (1GR−FE) CIRCUIT DESCRIPTION The A/F sensor generates a voltage* that corresponds to the actual air−fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air−fuel ratio. The ECM determines the deviation from the stoichiometric air−fuel ratio level, and regulates the fuel injection time.
Page 589 DI−314 DIAGNOSTICS − ENGINE (1GR−FE) HINT: When any of these DTCs are set, check the A/F sensor voltage output by selecting the following menu items on a hand−held tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / AFS B1S1. Short−term fuel trim values can also be read using a hand−held tester.
Page 590 DI−315 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present P2195, P2197 (A/F sensor signal stuck lean): Duration while all of following conditions 2 sec. −...
Page 591 DI−316 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR RESULT Refer to page DI−26 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−27). TID (Test Identification Data) is assigned to each emissions−related component.
Page 592 DI−317 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM GR−G GR−G MREL W−L A30 A/F Ratio Sensor (Bank2 Sensor1) W−L HA2A Y−G (Shielded) A2A+ Engine Room Relay Relay AF− W−R A2A− HA1A L−B B−R W−R W−B W−B (Shielded) A1A+ W−R AF− W−R W−R A1A−...
Page 593 DI−318 DIAGNOSTICS − ENGINE (1GR−FE) CONFIRMATION DRIVING PATTERN HINT: This confirmation driving pattern is used in steps 2, 4, 7, 17 and 21 of the following diagnostic troubleshooting procedure when using a hand−held tester. 75_C (167_F) or higher ECT: Accelerator Pedal Accelerator Pedal Released (Fuel−cut) Depressed...
Page 594 DI−319 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air−Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using a hand−held tester.
Page 595 DI−320 DIAGNOSTICS − ENGINE (1GR−FE) NOTICE: The Air−Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. A/F Sensor (Sensor 1) HO2 Sensor (Sensor 2) Main Suspected Case Output Voltage...
Page 596 DI−321 DIAGNOSTICS − ENGINE (1GR−FE) Check any other DTCs output (in addition to DTC P2195, P2196, P2197 or P2198). PREPARATION: Connect a hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. CHECK: Read DTCs.
Page 597 DI−322 DIAGNOSTICS − ENGINE (1GR−FE) Read value output voltage of A/F sensor. PREPARATION: Connect the OBD II scan tool to the DLC3. Start the engine and turn the scan tool ON. Warm up the Air−Fuel Ratio (A/F) sensor at an engine speed of 2,500 rpm for 90 seconds. CHECK: Using the scan tool, check the A/F sensor voltage 3 times, once when the engine is in each of the fol- lowing conditions:...
Page 598 DI−323 DIAGNOSTICS − ENGINE (1GR−FE) The ECM must establish a closed throttle valve position learning value to perform fuel cut. If the battery terminal has been reconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle valve position.
Page 599 DI−324 DIAGNOSTICS − ENGINE (1GR−FE) Replace air fuel ratio sensor. NEXT Perform confirmation driving pattern. NEXT Check whether DTCoutput recurs (DTC P2195, P2196, P2197 or P2198) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 600 DI−325 DIAGNOSTICS − ENGINE (1GR−FE) Check resistance of air−fuel ratio (A/F) sensor heater. PREPARATION: Component Side: Disconnect the air−fuel ratio (A/F) sensor connector. A/F Sensor CHECK: Measure resistance between the terminals of the A/F sensor connector. Sensor 1 AF− Tester Connection Specified Condition Between 1.8 Ω...
Page 601 DI−326 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and A/F sen- sor. PREPARATION: Wire Harness Side: Disconnect the A10 or A30 A/F sensor connector. A/F Sensor Connector Turn the ignition switch to ON. CHECK: Measure the voltage between the +B terminal of the A/F sensor connector and body ground.
Page 602 DI−327 DIAGNOSTICS − ENGINE (1GR−FE) Replace or replace harness or connector. Check air induction system (See page SF−1). CHECK: Check the air induction system for vacuum leaks. Repair or replace air induction system. Check fuel pressure (See page SF−5). CHECK: Check the fuel pressure (high or low pressure).
Page 603 DI−328 DIAGNOSTICS − ENGINE (1GR−FE) Replace air fuel ratio sensor. NEXT Perform confirmation driving pattern. NEXT Check whether DTCoutput recurs (DTC P2195, P2196, P2197 or P2198) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
Page 604 DI−329 DIAGNOSTICS − ENGINE (1GR−FE) Replace air fuel ratio sensor. NEXT Perform confirmation driving pattern. NEXT Check whether DTC output recurs (DTC P2195, P2196, P2197 or P2198) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
Page 605 DI−330 DIAGNOSTICS − ENGINE (1GR−FE) DIDU6−01 P2238 Oxygen Sensor Pumping Current Circuit Low (For A/F Sensor)(Bank 1 Sensor1) P2239 Oxygen Sensor Pumping Current Circuit High (For A/F Sensor)(Bank 1 Sensor1) P2241 Oxygen Sensor Pumping Current Circuit Low (For A/F Sensor)(Bank 2 Sensor1) P2242 Oxygen Sensor Pumping Current Circuit High (For A/F Sensor)(Bank 2 Sensor1)
Page 606 DI−331 DIAGNOSTICS − ENGINE (1GR−FE) CIRCUIT DESCRIPTION Refer to DTC P2195 on page DI−312. DTC No. DTC Detection Conditions Trouble Areas S Case 1: S Open or short in A/F sensor (sensor 1) circuit Condition (a) or (b) continues for 5.0 seconds or more S A/F sensor (sensor 1) (1 trip detection logic): S A/F sensor heater...
Page 607 DI−332 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY A/F sensor (Bank 1) open circuit between AF+ and AF− A/F sensor (Bank 1) short circuit between AF+ P2238 and AF− A/F sensor (Bank 1) short circuit between AF+ and GND A/F sensor (Bank 1) short circuit between AF+ P2239 and +B A/F sensor (Bank 2) open circuit between AF+...
Page 608 DI−333 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present P2238, P2241 (A/F sensor open circuit between AF+ and AF−): AF+ terminal voltage 0.5 to 4.5 V AF−...
Page 609 DI−334 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Hand−held tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air−Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning.
Page 610 DI−335 DIAGNOSTICS − ENGINE (1GR−FE) NOTICE: The Air−Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors.
Page 611 DI−336 DIAGNOSTICS − ENGINE (1GR−FE) Check resistance of air−fuel ratio (A/F) sensor heater. PREPARATION: Component Side: Disconnect the air−fuel ratio (A/F) sensor connector. A/F Sensor CHECK: Measure resistance between the terminals of the A/F sensor connector. Sensor 1 AF− Tester Connection Specified Condition 1.8 Ω...
Page 612 DI−337 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and A/F sen- sor. PREPARATION: Wire Harness Side: Disconnect the A10 or A30 A/F sensor connector. A/F Sensor Connector Turn the ignition switch to ON. CHECK: Measure the voltage between the +B terminal of the A/F sensor connector and body ground.
Page 613 DI−338 DIAGNOSTICS − ENGINE (1GR−FE) Replace or replace harness or connector. Replace ECM (See page SF−66).
Page 614 DI−339 DIAGNOSTICS − ENGINE (1GR−FE) DIDU7−01 P2401 Evaporative Emission System Leak Detec- tion Pump Control Circuit Low P2402 Evaporative Emission System Leak Detec- tion Pump Control Circuit High CIRCUIT DESCRIPTION Refer to EVAP Inspection Procedure (see page DI−368). Detection Detection DTCs Monitoring Item DTC Detection Condition...
Page 615 DI−340 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacu- um) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35_C (95_F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later.
Page 616 DI−341 DIAGNOSTICS − ENGINE (1GR−FE) Operation A: Atmospheric Pressure Measurement Operation B: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF (vent) Vent Valve: OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Air Filter Pump Module Vacuum Pump: OFF Operation C: EVAP Leak Check Operation D: Purge VSV monitor ON (closed)
Page 617 DI−342 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY P2401 Vacuum pump stuck OFF R l t d DTC Related DTCs P2402 Vacuum pump stuck ON Required sensors/components Purge VSV and pump module Frequency of operation Once per driving cycle Duration Within 2 minutes MIL operation 2 driving cycles Sequence of operation...
Page 618 DI−343 DIAGNOSTICS − ENGINE (1GR−FE) 3. EVAP canister vent valve close stuck − check Next sequence is run if the following − condition is set EVAP pressure change after vent valve is 0.3 kPa (2.25 mmHg) − 4. Vacuum introduction −...
Page 619 DI−344 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR RESULT (MODE 06 DATA) Refer to the EVAP Inspection Procedure (see page DI−368). INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure (see page DI−368).
Page 620 DI−345 DIAGNOSTICS − ENGINE (1GR−FE) DIDU8−01 P2419 Evaporate Emission System Switching Valve Control Circuit Low P2420 Evaporate Emission System Switching Valve Control Circuit High CIRCUIT DESCRIPTION Refer to the EVAP Inspection Procedure (see page DI−368). Detection Detection DTCs Monitoring Item DTC Detection Conditions Trouble Areas Timing...
Page 621 DI−346 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacu- um) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35_C (95_F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later.
Page 622 DI−347 DIAGNOSTICS − ENGINE (1GR−FE) P2419: Vent valve stuck ON (Closed) In sequence B and E, to determine the leak criterion, the vacuum pump creates negative pressure in the canister pump module through the 0.02 inch orifice. If the pressure is out of specified range or is not saturated, the ECM illuminates the MIL and sets DTCs P043E, P043F, P2401, P2402 and P2419 (2−trip detection logic).
Page 623 DI−348 DIAGNOSTICS − ENGINE (1GR−FE) P2420: Vent valve stuck OFF (vent) In sequence C, the vent valve turns ON (closes) and the EVAP (Evaporative Emission) system pressure is then measured by the ECM, using the pressure sensor, to conduct an EVAP leak check. If the pressure does not increase when the vent valve turned ON (closed), the ECM interprets this as the vent valve being stuck OFF (vent).
Page 624 DI−349 DIAGNOSTICS − ENGINE (1GR−FE) Both of the following conditions are met Condition 1 and 2 before IG switch OFF 1. Duration that vehicle is driven 5 min. − 2. EVAP purge operation Performed 4.4 to 35°C (40 to 95°F) 4.4 to 35°C (40 to 95°F) Time after key off 5 or 7 or 9.5 hours...
Page 625 DI−350 DIAGNOSTICS − ENGINE (1GR−FE) 7. Leak check − Next sequence is run if the following − condition is set EVAP pressure when vacuum introduction − Second reference pressure is complete 8. Atmospheric pressure − EVAP monitor is complete is the following −...
Page 626 DI−351 DIAGNOSTICS − ENGINE (1GR−FE) DIDU9−01 P2610 ECM/PCM Internal Engine OFF Timer Perfor- mance DTC SUMMARY Detection Detection Monitoring Items Malfunction Detection Conditions Trouble Areas Timings Logic Engine P2610 Soak timer (built into ECM) ECM internal malfunction 2 trip running CIRCUIT DESCRIPTION To ensure the accuracy of the EVAP (Evaporative Emission) monitor values, the soak timer, which is built into the ECM, measures 5 hours ("15 minutes) from when the ignition switch is turned OFF, before the moni-...
Page 627 DI−352 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present Battery voltage − Ignition switch Starter Engine Running TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Soak time measurement when ECM CPU clock counts 10 Less than 7 min., or more than 13 min.
Page 628 DI−353 DIAGNOSTICS − ENGINE (1GR−FE) DIDUA−01 P043E Evaporate Emission System Reference Ori- fice Clog Up P043F Evaporate Emission System Reference Ori- fice High Flow CIRCUIT DESCRIPTION Refer to the EVAP Inspection Procedure (see page DI−368). Detection Detection Monitoring Item Detection Conditions Trouble Areas Timing Logic...
Page 629 DI−354 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR DESCRIPTION 5 hours after the ignition switch is turned to OFF, the electric vacuum pump creates negative pressure (vacu- um) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure.
Page 630 DI−355 DIAGNOSTICS − ENGINE (1GR−FE) Operation A: Atmospheric Pressure Measurement Operation B: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF (vent) Vent Valve: OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Air Filter Pump Module Vacuum Pump: OFF Operation C: EVAP Leak Check Operation D: Purge VSV monitor ON (closed)
Page 631 DI−356 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR STRATEGY P043E 0.02 inch orifice clog (built−in pump module) R l t d DTC Related DTCs P043F 0.02 inch orifice high−flow (built−in pump module) Required sensors/components Pump module Frequency of operation Once per driving cycle Duration Within 2 min.
Page 632 DI−357 DIAGNOSTICS − ENGINE (1GR−FE) 3. EVAP canister vent valve close stuck − check Next sequence is run if the following con- − dition is set EVAP pressure change after vent valve is 0.3 kPa (2.25 mmHg) − 4. Vacuum introduction −...
Page 633 DI−358 DIAGNOSTICS − ENGINE (1GR−FE) MONITOR RESULT (MODE 06 DATA) Refer to page DI−26 for detailed information on Monitor Result. INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure (see page DI−368).
Page 634 DI−359 DIAGNOSTICS − ENGINE (1GR−FE) DIDUB−01 P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P2195 on page DI−312. DTC No. DTC Detection Conditions Trouble Areas S Open or short in A/F sensor (sensor 1) circuit P2A00...
Page 635 DI−360 DIAGNOSTICS − ENGINE (1GR−FE) CONFIRMATION DRIVING PATTERN Vehicle speed 25 − 75 mph) (40 −120 km/h) Warm up 3 minutes Connect the hand−held tester to the DLC3. Turn the ignition switch to ON. Turn the hand−held tester ON. Clear DTCs. Select the following menu items: DIAGNOSIS/ENHANCED OBD II/MONITOR INFO/MONITOR RE- SULT.
Page 636 DI−361 DIAGNOSTICS − ENGINE (1GR−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−18 DTCs are not present Active A/F control is performed when the − following conditions are set Battery voltage 11 V −...
Page 637 DI−362 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Hand−held tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air−Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning.
Page 638 DI−363 DIAGNOSTICS − ENGINE (1GR−FE) NOTICE: The Air−Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors.
Page 639 DI−364 DIAGNOSTICS − ENGINE (1GR−FE) Check any other DTCs output (in addition to DTC P2A00 or P2A03). PREPARATION: Connect a hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. CHECK: Read DTCs.
Page 640 DI−365 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between ECM and A/F sen- sor. PREPARATION: Wire Harness Side: Disconnect the A10 or A30 A/F sensor connector. A/F Sensor Connector Turn the ignition switch to ON. CHECK: Measure the voltage between the +B terminal of the A/F sensor connector and body ground.
Page 641 DI−366 DIAGNOSTICS − ENGINE (1GR−FE) Replace or replace harness or connector. Perform confirmation driving pattern. NEXT Check whether DTC output recurs (DTC P2A00 or P2A03) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
Page 642 DI−367 DIAGNOSTICS − ENGINE (1GR−FE) Check whether DTC output recurs (DTC P2A00 or P2A03) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Read DTCs. RESULT: Display (DTC Output) Proceed To P2A00 or P2A03 No output...
Page 643 DI−368 DIAGNOSTICS − ENGINE (1GR−FE) DIDUC−01 EVAP (Evaporative Emission) Inspection Procedure DTCS RELATING TO EVAP SYSTEM DTCs Monitoring Items See Page P043E 0.02 inch orifice clogged (built into pump module) DI−353 P043F 0.02 inch orifice high−flow (built into pump module) DI−353 S Purge VSV (Vacuum Switching Valve) stuck closed S Purge VSV stuck open...
Page 644 DI−369 DIAGNOSTICS − ENGINE (1GR−FE) CIRCUIT DESCRIPTION Location of EVAP (Evaporative Emission) system: Pump Module Refueling Valve Pressure Sensor Purge VSV Vacuum Pump (Vacuum Switching Valve) Canister Vent Valve EVAP Hose Air Filter (From Canister) Fuel Tank Air Inlet Port Breeding Purge Line EVAP Hose...
Page 645 DI−370 DIAGNOSTICS − ENGINE (1GR−FE) Key−off monitor This monitor checks for EVAP (Evaporative Emission) system leaks and pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned OFF. More than 5 hours are required to allow enough time for the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system moni- tor more accurate.
Page 646 DI−371 DIAGNOSTICS − ENGINE (1GR−FE) Components Operations Canister Contains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank. Cut−off valve Located in fuel tank. Valve floats and closes when fuel tank is 100 % full. Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order Purge VSV (Vacuum to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV.
Page 647 DI−372 DIAGNOSTICS − ENGINE (1GR−FE) Pump Module (fig. 1): : Airflow Condition: Leak Check Condition: Purge Flow Vent Valve: ON Vent Valve: OFF (closed) (vent) To Air Filter (Atmosphere) Canister 0.02 Inch Orifice Pressure Sensor From Refueling Valve Vacuum Pump: ON Vacuum Pump: OFF A23494 Pressure Sensor Specification (fig.
Page 648 DI−373 DIAGNOSTICS − ENGINE (1GR−FE) WIRING DIAGRAM GR−G GR−G MREL Engine Room R/B (EVAP) EFI No. 2 W−L G−W W−L Engine Room Relay Leak Detection Pump Assy L−W L−W PPMP B−R L−B L−B VPMP R−W R−W MPMP No. 1 W−B W−B G−B G−B...
Page 649 DI−374 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE NOTICE: A hand−held tester is required to conduct the following diagnostic troubleshooting procedure. HINT: Using hand−held tester monitor results enables the EVAP (Evaporative Emission) system to be con- firmed. Read freeze frame data using a hand−held tester Freeze frame data record the engine condition when malfunctions are detected.
Page 650 DI−375 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system check. NOTICE: In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps is performed automatically by the hand−held tester. It takes a maximum of approximately 18 minutes. Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut−off valve may be closed and making the leak check of the fuel tank unavailable.
Page 651 DI−376 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system manual operation check. EVAP SYSTEM CHECK ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Vacuum Pump EVAP Pressure Positive Gross Leak Negative Second 0.02 inch Leak Pressure Small Leak Standard x 0.2 First 0.02 inch Leak Pressure...
Page 652 DI−377 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 1/5 check. ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Vacuum Pump Pressure Sensor Noise EVAP Pressure Positive Negative First 0.02 inch Leak Pressure Standard Steps Time (Reference) A23499 Check the EVAP pressure in step 1/5.
Page 653 DI−378 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 1/5 to 2/5 check. ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Vacuum Pump EVAP Pressure Positive Negative Vacuum Pump Stuck ON First 0.02 inch Leak Pressure Standard Steps Time...
Page 654 DI−379 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 2/5 check. ON: Open Purge VSV OFF: Closed Vent Valve ON: Closed OFF: Vent Vacuum Pump Vacuum Pump Stuck OFF 0.02 inch Orifice High−flow EVAP Pressure 4 sec Positive Vent Valve Stuck closed Negative First 0.02 inch Leak Pressure...
Page 655 DI−380 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 2/5 to 3/5 check. ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Vacuum Pump EVAP Pressure Positive Negative Vent Valve Stuck open (vent) First 0.02 inch Leak Pressure Standard Steps Time...
Page 656 DI−381 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 3/5 check. ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Vacuum Pump EVAP Pressure Positive Negative First 0.02 inch Leak Pressure Standard Steps Within 15 minutes Time (Reference) A23502 Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds.
Page 657 DI−382 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 4/5 check. ON: Open Purge VSV OFF: Closed Vent Valve ON: Closed OFF: Vent Vacuum Pump EVAP Pressure Positive Negative Purge VSV Stuck Closed First 0.02 inch Leak Pressure Standard Steps Time (Reference) A23504...
Page 658 DI−383 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 5/5 check. ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Vacuum Pump EVAP Pressure Gross Leak Positive Negative Second 0.02 inch Small Leak Leak Pressure First 0.02 inch Standard x 0.2 Leak Pressure No Leak...
Page 659 DI−384 DIAGNOSTICS − ENGINE (1GR−FE) Perform EVAP system step 3/5 check. ON: Open Purge VSV OFF: Closed Vent Valve ON: Closed OFF: Vent Vacuum Pump Vacuum Pump Stuck OFF EVAP Pressure Positive Negative 0.02 inch Orifice High−flow 0.02 inch Leak Pressure Standard Steps Time...
Page 660 DI−385 DIAGNOSTICS − ENGINE (1GR−FE) Perform active test of purge VSV. PREPARATION: Purge VSV On the hand−held tester, select the following menu items: Hose DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST / EVAP VSV. Disconnect the hose (connected to the canister) from the purge VSV.
Page 661 DI−386 DIAGNOSTICS − ENGINE (1GR−FE) Check fuel tank cap. CHECK: Check that the fuel tank cap is correctly installed and confirm the fuel tank cap meets OEM specifica- tion. HINT: If an EVAP tester is available, check the fuel tank cap using the tester. Tighten the fuel tank cap.
Page 662 DI−387 DIAGNOSTICS − ENGINE (1GR−FE) Inspect EVAP VSV. PREPARATION: Hose Purge VSV Turn the ignition switch to OFF. Disconnect the V4 purge VSV connector. Disconnect the hose (connected to the canister) from the purge VSV. Start the engine. CHECK: Use your finger to confirm that the purge VSV has no suction. cmc0690 RESULT: Test Results...
Page 663 DI−388 DIAGNOSTICS − ENGINE (1GR−FE) Inspect EVAP VSV. PREPARATION: Remove the purge VSV. Apply battery voltage to the terminals of the purge VSV. CHECK: Battery Using an air gun, confirm that air flows from port A to port B. B02272 RESULT: Test Results Suspected Trouble Areas...
Page 664 DI−389 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short circuit in harness and connector between purge VSV and ECM. PREPARATION: Disconnect the E7 ECM connector and the V4 purge VSV con- nector. CHECK: Check the resistance. Standard: Tester Connections Specified Conditions Below 1 Ω...
Page 665 DI−390 DIAGNOSTICS − ENGINE (1GR−FE) Perform active test for vent valve. PREPARATION: Turn the ignition switch to ON. On the hand−held tester, select the following menu items: DIAGNOSIS/ ENHANCED OBD II/ ACTIVE TEST/ VENT VALVE (ALONE). CHECK: Measure the voltage between terminal VPMP of the ECM con- nector and the body ground when the vent valve is turned ON VPMP (close) and OFF (vent) using the tester.
Page 666 DI−391 DIAGNOSTICS − ENGINE (1GR−FE) Inspect pump module power source circuit. PREPARATION: Turn the ignition switch to OFF. Disconnect the L4 canister connector. Turn the ignition switch to ON. CHECK: Measure the voltage between terminal 9 of the canister connec- tor and the body ground.
Page 667 DI−392 DIAGNOSTICS − ENGINE (1GR−FE) Inspect vent valve operation of pump module. PREPARATION: Charcoal Canister Assy: 8 (−) 9 (+) Disconnect the L4 canister connector. Turn the ignition switch to OFF. Apply the battery voltage to terminals 9 and 8 of the pump module.
Page 668 DI−393 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short circuit in harness and connector between pump mod- ule and ECM. PREPARATION: Turn the ignition switch to OFF. Disconnect the L4 canister connector. Turn the ignition switch to ON. On the hand−held tester, select the following menu items:DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
Page 669 DI−394 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between pump module and ECM. PREPARATION: Wire Harness Side: Disconnect the L4 canister connector. Canister Connector Turn the ignition switch to OFF. CHECK: Check the resistance between terminal 6 of the canister con- nector and the body ground.
Page 670 DI−395 DIAGNOSTICS − ENGINE (1GR−FE) Correctly reinstall or replace fuel tank cap. HINT: When reinstalling the fuel tank cap, tighten it until a few click sounds are heard. When replacing the fuel tank cap, use a fuel tank cap that meets OEM specifications, and install it until a few click sounds are heard.
Page 671 DI−396 DIAGNOSTICS − ENGINE (1GR−FE) Connect the EVAP pressure tester tool to the canister with the adapter. Canister Pressure Gauge Adapter cmc0489 Pressurize the EVAP system by 3.2 to 3.7 kPa (24 to 28 mmHg). Apply soapy water to the piping and the connecting parts of the EVAP system. Look for areas where bubbles appear.
Page 672 DI−397 DIAGNOSTICS − ENGINE (1GR−FE) Replace EVAP hose between EVAP VSV and throttle body. NEXT Go to step 37. Inspect throttle body. Remove the throttle body (see page SF−40). Check that the EVAP purge port of the throttle body is not clogged. If necessary, replace the throttle body.
Page 673 DI−398 DIAGNOSTICS − ENGINE (1GR−FE) NEXT Completed Monitor Confirmation HINT: After a repair, check Monitor Status by performing the Key−Off Monitor Confirmation and Purge Flow Monitor Confirmation described below. KEY−OFF MONITOR CONFIRMATION Preconditions The monitor will not run unless: The vehicle has been driven for 10 minutes or more (in a city area or on a free way) The fuel tank is less than 90 % full The altitude is less than 8,000 ft (2,400 m) The Engine Coolant Temperature (ECT) is between 4.4_C and 35_C (40_F and 95_F)
Page 674 DI−399 DIAGNOSTICS − ENGINE (1GR−FE) Monitor Status Turn the ignition switch to OFF (where ON or the engine is running). Connect a hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS.
Page 675 DI−400 DIAGNOSTICS − ENGINE (1GR−FE) Key−off Monitor Monitor Start ON (Open) Purge VSV ON (Close) Vent Valve Pump EVAP Pressure Atmosphere (Reference) (0 kPa (0 mmHg)) Criterion 2 (Criterion 4 x 0.2) Criterion 1 (−1.2 kPa (−9 mmHg)) Criterion 3 (0.3 kPa (2.25 mmHg)) Criterion 4 Criterion 5...
Page 676 DI−401 DIAGNOSTICS − ENGINE (1GR−FE) DIDX8−01 IACV Control VSV Circuit CIRCUIT DESCRIPTION This circuit opens and closes the Intake Air Control Valve (IACV) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is between 2,200 and 4,100 rpm and the throttle valve opening angle is 60°...
Page 677 DI−402 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE Connect hand−held tester and check operation of VSV for ACIS. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and hand−held tester main switch ON. VSV is ON VSV is OFF Select the item: DIAGNOSIS / ENHANCED OBD II / AC- TIVE TEST / INTAKE CTL VSV1.
Page 678 DI−403 DIAGNOSTICS − ENGINE (1GR−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM. Check the wire harness between the VSV for ACIS and Wire Harness Side connector the ECM connector. Disconnect the VSV for ACIS connector. Disconnect the E5 and E7 ECM connector.
Page 679 DI−404 DIAGNOSTICS − ENGINE (1GR−FE) DIDUD−01 Cranking Holding Function Control Circuit CIRCUIT DESCRIPTION The system detects the ignition switch’s starting signal (STSW signal) and then supplies current to the starter until the ECM judges that the engine has started successfully. The purpose is to reduce the holding time of the ignition key.
Page 680 DI−405 DIAGNOSTICS − ENGINE (1GR−FE) Connect hand−held tester, and check STA signal. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON, and push the hand−held tester main switch ON. On the hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG.
Page 681 DI−406 DIAGNOSTICS − ENGINE (1GR−FE) Check park/neutral position switch assembly. Disconnect the park/neutral position switch connector. Component Side: Check for resistance between each terminal shown below when the shift lever is moved to each range. Standard: Shift range Terminal No. Specified condition 1 −...
Page 682 DI−407 DIAGNOSTICS − ENGINE (1GR−FE) Check harness and connector park/neutral position switch and starter relay. Check the harness and the connector between the park/ Wire Harness Side neutral position switch connector and the starter relay. Disconnect the park/neutral position switch con- nector.
Page 683 DI−408 DIAGNOSTICS − ENGINE (1GR−FE) Check STA fuse. Remove the starter relay from the engine room R/B. Engine Room R/B Measure the voltage between the terminal of the engine room R/B and the body ground. Standard: Symbols (Terminal No.) Specified condition Starter relay (5) −...
Page 684 DI−409 DIAGNOSTICS − ENGINE (1GR−FE) DIDUE−01 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to terminal IGSW of the ECM and the EFI relay control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI relay.
Page 685 DI−410 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE Check voltage between terminals +B and E1 of ECM connector. PREPARATION: Turn the ignition switch to ON. CHECK: Measure the voltage between terminals +B and E1 of the ECM connectors. Standard: 9 to 14 V (−) Proceed to next circuit inspection shown in the B17411...
Page 686 DI−411 DIAGNOSTICS − ENGINE (1GR−FE) Check IGN fuse. PREPARATION: Driver Side J/B: Remove the IGN fuse from the instrument panel J/B. CHECK: Check the resistance of the IGN fuse. Below 1 Ω Check for short in all harness and components A23469 connected to IGN fuse, and replace the fuse.
Page 687 DI−412 DIAGNOSTICS − ENGINE (1GR−FE) Check EFI No. 1 fuse of engine room J/B. PREPARATION: Engine Room J/B: Remove the EFI No. 1 fuse from the engine room J/B. CHECK: Check resistance of EFI No. 1 fuse. Below 1 Ω Check for short in all harness and components No.
Page 688 DI−413 DIAGNOSTICS − ENGINE (1GR−FE) Check and repair harness or connector be- tween EFI No. 1 fuse and battery.
Page 689 DI−414 DIAGNOSTICS − ENGINE (1GR−FE) DIDUF−01 Fuel Pump Control Circuit CIRCUIT DESCRIPTION Refer to DTC P0230 on page DI−174. WIRING DIAGRAM Refer to DTC P0230 on page DI−174. INSPECTION PROCEDURE Check fuel pump operation (See page SF−5). Go to step 8. Connect hand−held tester, and check operation of fuel pump relay.
Page 690 DI−415 DIAGNOSTICS − ENGINE (1GR−FE) Check fuel pump relay. PREPARATION: Remove the fuel pump relay from the engine room R/B. CHECK: Inspect the fuel pump relay. Terminal No. Condition Specified Condition Apply B+ between 3 − 4 10 KΩ or higher terminals 1 and 2 Below 1 Ω...
Page 691 DI−416 DIAGNOSTICS − ENGINE (1GR−FE) Check for open in harness and connector between EFI relay and fuel pump, and fuel pump and body ground (See page IN−30). Repair or replace harness or connector. Check voltage between terminal FC and E1 of ECM connector. PREPARATION: Turn the ignition switch to ON.
Page 692 DI−417 DIAGNOSTICS − ENGINE (1GR−FE) DIDUG−01 MIL Circuit CIRCUIT DESCRIPTION If the ECM detects a trouble, the MIL lights up. At this time, the ECM records a DTC in the memory. WIRING DIAGRAM W−R W−R V−G V−G Ignition Engine Switch Room B−R Malfunction...
Page 693 DI−418 DIAGNOSTICS − ENGINE (1GR−FE) INSPECTION PROCEDURE HINT: Troubleshoot each trouble symptom in accordance with the chart below. MIL remains on Start inspection from step 1 MIL does not light up Start inspection from step 3 Clear DTC. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and push the hand−held tester main switch ON.
Page 694 DI−419 DIAGNOSTICS − ENGINE (1GR−FE) Check that MIL lights up. CHECK: Check that MIL lights up when turning the ignition switch to ON. MIL lights up (Engine stopped) System OK. Inspect combination meter assy (MIL circuit). See the combination meter troubleshooting on page BE−86. Repair or replace bulb or combination meter as- sembly.
Page 695 DI−420 DIAGNOSTICS − ENGINE (2UZ−FE) ENGINE (2UZ−FE) DIDQQ−01 PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assem- bly, engine assembly or ECM (See page DI−1126). HINT: Initialization can not be completed by only removing the battery.
Page 696 DI−421 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQR−01 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic. Preconditions that allow the ECM to detect malfunctions.
Page 697 DI−424 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQT−01 LOCATION VSV for Air Injection Charcoal Canister Assembly Control (Bank 1) EVAP VSV Combination Meter Knock Sensor 1 VSV for Air Injection Control (Bank 2) ACIS VSV DLC3 Mass Air Flow Meter Fuel Pump Fuel Pump Resister Heated Oxygen Sensor (Bank 2 Sensor 2)
Page 698 DI−425 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQU−01 SYSTEM DIAGRAM IG SW Combination Meter IGSW To Battery STSW OC1+ VVT OCV ST Relay PNP SW (Bank 1) OC1− OC2+ VVT OCV (Bank 2) OC2− To Starter To Battery Knock Sensor EFI No.1 KNK1 (Bank 1) To Battery...
Page 699 DI−426 DIAGNOSTICS − ENGINE (2UZ−FE) To IG SW To A/F Relay HA1A A/F Sensor (Bank 1 Sensor 1) A1A+ Fuel Injector #1 A1A− Fuel Injector #2 HA2A A/F Sensor (Bank 2 Sensor 1) A2A+ Fuel Injector #3 To EFI Relay A2A−...
Page 700 DI−427 DIAGNOSTICS − ENGINE (2UZ−FE) To EFI Relay To Battery ACC Cut Relay AI Driver ACCR To Battery AIDI To IG SW AIPP To ACC Fuse AIRV Stop Light SW Air Pump To IGN Fuse STI− To Battery Pressure Sensor To E2 Terminal GE01...
Page 701 DI−428 DIAGNOSTICS − ENGINE (2UZ−FE) DI078−25 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. See the indicated pages for detailed explanations.
Page 702 DI−429 DIAGNOSTICS − ENGINE (2UZ−FE) DI079−19 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 703 DI−430 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQV−01 CHECK FOR INTERMITTENT PROBLEMS HINT: Hand−held tester only: Inspect the vehicle’s ECM using check mode. Intermittent problems are easier to detect with a hand−held tester when the ECM is in check mode. In check mode, the ECM uses 1trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic.
Page 704 DI−431 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQW−01 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 705 DI−432 DIAGNOSTICS − ENGINE (2UZ−FE) Check air filter. PREPARATION: Remove the air filter. CHECK: Visual check that the air filter is not excessively dirty or oily. air filter Repair or replace Check idle speed (See page EM−11). Proceed to problem symptoms table on page DI−452.
Page 706 DI−433 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQX−01 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is in the form of a 17−digit alphanumeric vehicle identification number. A hand−held tester is re- quired to register the VIN. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN.
Page 707 DI−434 DIAGNOSTICS − ENGINE (2UZ−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 708 DI−435 DIAGNOSTICS − ENGINE (2UZ−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 709 DI−436 DIAGNOSTICS − ENGINE (2UZ−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 710 DI−437 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQY−01 LIST OF DISABLE A MONITOR 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. As for the ”X” mark, when the DTC on the left is stored, detection of the DTC in the upper column is not per- formed.
Page 711 DI−438 DIAGNOSTICS − ENGINE (2UZ−FE) A21571...
Page 712 DI−439 DIAGNOSTICS − ENGINE (2UZ−FE) A21572...
Page 713 DI−440 DIAGNOSTICS − ENGINE (2UZ−FE) A21573...
Page 714 DI−441 DIAGNOSTICS − ENGINE (2UZ−FE) A21575...
Page 715 DI−442 DIAGNOSTICS − ENGINE (2UZ−FE) A21576...
Page 716 DI−443 DIAGNOSTICS − ENGINE (2UZ−FE) DIDQZ−01 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 717 DI−444 DIAGNOSTICS − ENGINE (2UZ−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 718 DI−445 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR0−01 CHECKING MONITOR STATUS OUTLINE The monitor results and the test values can be checked with the OBD II scan tool. The engine control module (ECM) monitors the emissions−related components as the thermostat, catalyst converter and evaporative emissions (EVAP), and determines whether they are functioning normally or not. When finished and monitoring, the ECM stores the monitor results and the test values.
Page 719 DI−446 DIAGNOSTICS − ENGINE (2UZ−FE) DICMO−02 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 720 DI−447 DIAGNOSTICS − ENGINE (2UZ−FE) CATALYST MONITOR (ACTIVE AIR−FUEL RATIO CONTROL TYPE) Vehicle Speed NOTICE: This test will not be completed Between if the vehicle is driven under 40 mph and 70 mph (64 km/h and 113 km/h) absolute constant speed condition such as with cruise control activated.
Page 721 DI−448 DIAGNOSTICS − ENGINE (2UZ−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 (2,400 m) or less...
Page 722 DI−449 DIAGNOSTICS − ENGINE (2UZ−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 723 DI−450 DIAGNOSTICS − ENGINE (2UZ−FE) AIR−FUEL RATIO (A/F) AND OXYGEN SENSOR (HO2) MONITOR (ACTIVE AIR−FUEL RATIO CONTROL TYPE) Preconditions The monitor will not run unless: 2 minutes or more have elapsed since the engine was started. The Engine Coolant Temperature (ECT) is 75_C (167_F) or higher. Air−fuel ratio feedback control is performed.
Page 724 DI−451 DIAGNOSTICS − ENGINE (2UZ−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 OBD II scan tool to the DLC3 to check monitor status and preconditions (refer to (a)).
Page 725 DI−452 DIAGNOSTICS − ENGINE (2UZ−FE) DI1L9−17 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page 1. Starter ST−1 Engine does not crank (Does not start) 2. Starter relay ST−20 3. Park/neutral position switch DI−1159 1. ECM power source circuit DI−918 No initial combustion (Does not start) 2.
Page 726 DI−453 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR1−01 TERMINALS OF ECM B17410 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 voltage between the terminals is shown under ”STD Voltage”.
Page 727 DI−454 DIAGNOSTICS − ENGINE (2UZ−FE) VCP2 (E3−27) − EPA2 (E3−21) G−R − LG−R IG switch ON 4.5 to 5.5 V #10 (E5−2) − E01 (E7−7) R − W−B #20 (E5−3) − E01 (E7−7) W − W−B IG switch ON 9 to 14 V #30 (E5−4) −...
Page 728: Fuel Injector
DI−455 DIAGNOSTICS − ENGINE (2UZ−FE) Pulse generation OX2B (E6−33) − E2 (E7−28) W − B−W Idling (See waveform 10) Brake pedal is depressed 7.5 to 14 V G−W − BR* G−W − BR STP (E3 15) STP (E3−15) − E1 (E5−1) E1 (E5 1) W−R −...
Page 729 DI−456 DIAGNOSTICS − ENGINE (2UZ−FE) WAVEFORM 2 KNK1 Signal Waveform 1V/ DIV Knock sensor Between KNK1 and EKNK ECM Terminal Name Between KNK2 and EKN2 Tester Range 1 V/DIV, 1 msec./DIV Condition Maintain engine RPM at 2,000 rpm after engine warmed−up HINT: The wavelength becomes shorter as engine rpm in- 1 msec./ Division...
Page 730 DI−457 DIAGNOSTICS − ENGINE (2UZ−FE) WAVEFORM 5 5 V/DIV Camshaft position sensor Crankshaft position sensor Ground (a) Between G2+ and G2− ECM Terminal Name (b) Between NE+ and NE− Tester Range 5 V/DIV, 20 msec./DIV Ground Condition Idle after engine warmed−up HINT: 20 msec./DIV The wavelength becomes shorter as the engine rpm increases.
Page 731 DI−458 DIAGNOSTICS − ENGINE (2UZ−FE) WAVEFORM 10 0.2 V/DIV Heated oxygen sensor ECM Terminal Names Between OX1B and E2 Tester Ranges 0.2 V/DIV, 200 msec./DIV Engine speed maintained 2,500 rpm for 2 minutes after Conditions warming up sensor HINT: Ground In the DATA LIST, item O2S B1S2 shows the ECM input values 200 msec./DIV from the heated oxygen sensor.
Page 732 DI−459 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR2−01 DIAGNOSIS SYSTEM Description When troubleshooting On−Board Diagnostic (OBD ll) ve- hicles, the vehicle must be connected to the hand−held tester. Various data output from the vehicle’s ECM can then be read. OBD ll regulations require that the vehicle’s on−board computer illuminates the Malfunction Indicator Light (MIL) FI0534 on the instrument panel when the computer detects a...
Page 733 DI−460 DIAGNOSTICS − ENGINE (2UZ−FE) Freeze frame data: The freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when a malfunc- tion is detected. When troubleshooting, freeze frame data can help determine 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...
Page 734 DI−461 DIAGNOSTICS − ENGINE (2UZ−FE) If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. INSPECT BATTERY VOLTAGE Battery Voltage: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding.
Page 735 DI−462 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR3−01 DTC CHECK / CLEAR Hand−Held Tester CHECK DTC DTCs which are stored in the ECM can be displayed with the hand−held tester. These scan tools can display pending DTCs and current DTCs. Some DTCs are not stored if the ECM does not detect a mal- function during consecutive driving.
Page 736 DI−463 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR4−01 CHECK MODE PROCEDURE HINT: Hand−held tester only: Check mode has a higher sensitivity to detect malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect.
Page 737 DI−464 DIAGNOSTICS − ENGINE (2UZ−FE) CLEAR DTC (Not using the hand−held tester) Remove the EFI No. 1 and ETCS fuses from the engine room J/B for more than 60 seconds, or disconnect the bat- tery terminal for more than 60 seconds. After disconnecting the battery terminal, perform the ”INI- TIALIZE”...
Page 738 DI−465 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR5−01 FAIL−SAFE CHART If any of the following code is recorded, the ECM enters fail−safe mode. DTC No. Fail−Safe Operation Fail−Safe Deactivation Conditions P0031 P0032 P0037 The heater circuit in which an abnormality is detected is P0038 Ignition switch OFF turned off...
Page 739 DI−466 DIAGNOSTICS − ENGINE (2UZ−FE) P2440 and Restrict the throttle opening angle: Ga x 30 g/s P1441 and/or P1444 Restrict the throttle opening angle: Ga x 50 g/s P1441 and P1444 P1441 Restrict the throttle opening angle: Ga x 100 g/s P1444 P2430 P2431...
Page 740 DI−467 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR6−01 DATA LIST / ACTIVE TEST DATA LIST HINT: By reading the DATA LIST displayed on a hand−held tester, you can check values, including those of the switches, sensors, and actuators, without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one method of shortening diagnostic time.
Page 741 DI−468 DIAGNOSTICS − ENGINE (2UZ−FE) Learning value of purge density/ PURGE DENSITY Idling: −40 to 0 % Service data Min.: −50, Max.: 350 Purge flow: PURGE FLOW 0 to 100 %: Idling Min.: 0 %, Max.: 102.4 % EVAP (Purge) VSV control duty: EVAP PURGE VSV 0 to 100 %: During idling Order signal from ECM...
Page 742 DI−469 DIAGNOSTICS − ENGINE (2UZ−FE) Starter signal: ON: Cranking ON or OFF System guard: SYSGUARD JUDGE ETCS service data ON or OFF Open side malfunction: OPN MALFUNCTION ETCS service data ON or OFF S 10 to 24 %: Throttle fully closed Absolute throttle position sensor: Read the value with intrusive op- THROTTLE POS...
Page 743 DI−470 DIAGNOSTICS − ENGINE (2UZ−FE) Throttle motor duty ratio (close): THRTL MOT (CLS) ETCS service data Min.: 0 %, Max.: 100 % Performing the INJ VOL or A/F Heated oxygen sensor output volt- 0.1 to 0.9 V: CONTROL function of the ACTIVE O2S B1 S2 age for bank 1 sensor 2: Driving 44 mph (70 km/h)
Page 744 DI−471 DIAGNOSTICS − ENGINE (2UZ−FE) S OL (Open Loop): Has not yet sa- tisfied conditions to go closed loop S CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control. S OL DRIVE: Open loop due to Fuel system status (Bank 2): FUEL SYS #2 OL or CL or OL DRIVE or CL: Idling after warming up...
Page 745 DI−472 DIAGNOSTICS − ENGINE (2UZ−FE) A/C SIG A/C signal: ON or OFF ON: A/C ON Electrical load signal: ON: Headlights or defogger is ELECT LOAD SIG ON or OFF turned ON Stop lamp switch: STOP LIGHT SW ON: brake pedal is depressed. ON or OFF Whether or not electric throttle control system power inputted:...
Page 746 DI−473 DIAGNOSTICS − ENGINE (2UZ−FE) The fuel cut being performed un- Fuel cut TAU: Fuel cut during very der very light load to prevent the FC TAU light load: ON: Fuel cut operating engine combustion from becoming ON or OFF incomplete Ignition counter: IGNITION...
Page 747 DI−474 DIAGNOSTICS − ENGINE (2UZ−FE) Distance after DTC cleared: Equivalent to drive distance after DIST DTC CLEAR Min.: 0 km/h, Max.: 65535 km/h DTCs were erased Warm−up cycle after DTC cleared: Number of warm−up cycles after WU CYC DTC CLEAR Min.: 0, Max.: 255 DTC cleared Identifying the model code:...
Page 748 DI−475 DIAGNOSTICS − ENGINE (2UZ−FE) ACTIVE TEST HINT: Performing an ACTIVE TEST enables components including the relays, VSV (Vacuum Switching Valve), and actuators, to be operated without removing any parts. The ACTIVE TEST can be performed with a hand−held tester. Performing an ACTIVE TEST as the first step of troubleshooting is one method of shorten- ing diagnostic time.
Page 749 DI−476 DIAGNOSTICS − ENGINE (2UZ−FE) This test is possible during vehicle FUEL CUT #1 Cylinder #1 injector fuel cut ON/OFF stopping and engine idling. FUEL CUT #2 Cylinder #2 injector fuel cut ON/OFF Same as above FUEL CUT #3 Cylinder #3 injector fuel cut ON/OFF Same as above FUEL CUT #4...
Page 750 DI−477 DIAGNOSTICS − ENGINE (2UZ−FE) DI1L4−25 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 the check mode, check the circuit for the listed in the table below.
Page 751 DI−478 DIAGNOSTICS − ENGINE (2UZ−FE) S Open in heater circuit of A/F sensor Oxygen (A/F) Sensor Heater S A/F sensor heater P0051 Control Circuit Low (Bank 2 Sen- S A/F relay (DI−507) sor 1) S ECM S Short in heater circuit of A/F sensor Oxygen (A/F) Sensor Heater S A/F sensor heater P0052...
Page 752 DI−479 DIAGNOSTICS − ENGINE (2UZ−FE) S Short in throttle control motor and sensor circuit S Throttle control motor and sensor P0122 Throttle/Pedal Position Sensor/ S Short in VTA1 circuit (DI−548) Switch ”A” Circuit Low Input S Open in VC circuit S ECM S Open in throttle control motor and sensor circuit S Throttle control motor and sensor...
Page 753 DI−480 DIAGNOSTICS − ENGINE (2UZ−FE) S Air induction system S Injector blockage S Mass air flow meter S Engine coolant temperature sensor S Fuel pressure S Gas leakage on exhaust system P0171 S Open or short in heated oxygen sensor (bank 1 sensor 1) System too Lean (Bank 1) (DI−586) circuit...
Page 754 DI−481 DIAGNOSTICS − ENGINE (2UZ−FE) S Open or short in fuel pump relay circuit S Fuel pump relay P0230 S Circuit opening relay Fuel Pump Primary Circuit − (DI−600) S Fuel pump S ECM S Open or short in engine wire S Connector connection S Vacuum hose connection S Ignition system...
Page 755 DI−482 DIAGNOSTICS − ENGINE (2UZ−FE) S Open or short in engine wire S Connector connection S Vacuum hose connection S Ignition system S Injector S Fuel pressure P0304 S Mass air flow meter Cylinder 4 Misfire Detected (DI−605) S Engine coolant temperature sensor S Compression pressure S Valve clearance S Valve timing...
Page 756 DI−483 DIAGNOSTICS − ENGINE (2UZ−FE) S Open or short in engine wire S Connector connection S Vacuum hose connection S Ignition system S Injector S Fuel pressure P0308 S Mass air flow meter Cylinder 8 Misfire Detected (DI−605) S Engine coolant temperature sensor S Compression pressure S Valve clearance S Valve timing...
Page 757 DI−484 DIAGNOSTICS − ENGINE (2UZ−FE) S Open or short in IGF 2 and IGT 2 circuit from No. 2 ignition coil with igniter to ECM P0352 Ignition Coil ”B” Primary/Second- S No. 2 ignition coil with igniter (DI−642) ary Circuit S Ignition system S ECM S Open or short in IGF 2 and IGT 3 circuit from No.
Page 758 DI−485 DIAGNOSTICS − ENGINE (2UZ−FE) S Purge valve S Purge valve circuit (between purge valve and ECM) S Leakage from EVAP line (between purge valve and intake P0441 Evaporative Emission Control (DI−680) System Incorrect Purge Flow manifold) S EVAP line (between purge valve and canister) clogged S ECM Evaporative Emission Control P0450...
Page 759 DI−486 DIAGNOSTICS − ENGINE (2UZ−FE) P0607 S ECM Control Module Performance (DI−721) S Park/neutral position switch S Starter relay circuit P0617 Starter Relay Circuit High S Ignition switch (DI−723) S ECM P0630 VIN not Programmed or Mis- S ECM (DI−728) match−ECM/PCM P0657 Actuator Supply Voltage Circuit/...
Page 760 DI−487 DIAGNOSTICS − ENGINE (2UZ−FE) P0985 Shift Solenoid ”E” Control Circuit S Electronic control automatic transmission (ECT) (DI−1236) Low (Shift Solenoid Valve SR) P0986 Shift Solenoid ”E” Control Circuit S Electronic control automatic transmission (ECT) (DI−1236) High (Shift Solenoid Valve SR) S Open or short in camshaft position sensor circuit S Camshaft position sensor P1340...
Page 761 DI−488 DIAGNOSTICS − ENGINE (2UZ−FE) S Throttle control motor and sensor circuit S Throttle control motor and sensor P2112 Throttle Actuator Control System S Throttle valve (DI−782) − Stuck Closed S Throttle body S Open in throttle control motor and sensor power source circuit P2118 Throttle Actuator Control Motor S ETCS fuse...
Page 762 DI−489 DIAGNOSTICS − ENGINE (2UZ−FE) S Open or short in A/F sensor (sensor 1) circuit S A/F sensor (sensor 1) S A/F sensor heater (sensor 1) S A/F relay P2197 Oxygen (A/F) Sensor Signal S A/F sensor heater and EFI relay circuits (DI−806) Stuck Lean (Bank 2 Sensor 1) S Air induction system...
Page 763 DI−490 DIAGNOSTICS − ENGINE (2UZ−FE) S Pump module Evaporative Emission System P2401 S Connector/Wire harness (between pump module and ECM) Leak Detection Pump Control (DI−834) S ECM Circuit Low S Pump module Evaporative Emission System P2402 S Connector/Wire harness (between pump module and ECM) Leak Detection Pump Control (DI−834) S ECM...
Page 764 DI−491 DIAGNOSTICS − ENGINE (2UZ−FE) S Air pump fuse S Vacuum hose S Air pump assembly S Open in air pump circuit P2445 Secondary Air Injection System S Air injection system piping (DI−850) Pump Stuck On Bank 1 S Pressure sensor S Open or short in pressure sensor circuit S ECM P2610...
Page 765 DI−492 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR7−01 CIRCUIT INSPECTION P0010 Camshaft Position ”A” Actuator circuit (Bank 1) P0020 Camshaft Position ”A” Actuator circuit (Bank 2) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT control- ler.
Page 766 DI−493 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION After the ECM sends the ”target” duty−cycle signal to the OCV (Oil Control Valve), the ECM monitors the OCV current to establish an ”actual” duty−cycle. When the actual duty−cycle ratio varies from the target duty−cycle, the ECM sets a DTC.
Page 767 DI−494 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM OCV (Bank 1) G−B OC1+ L−Y OC1− OCV (Bank 2) P−L OC2+ W−R OC2− A07621 A09776 INSPECTION PROCEDURE HINT: If DTC P0010 displayed, check left bank OCV circuit. If DTC P0020 displayed, check right bank OCV circuit. Read freeze frame data using hand−held tester.
Page 768 DI−495 DIAGNOSTICS − ENGINE (2UZ−FE) Check OCV circuit. PREPARATION: Connect the hand−held tester to the DLC3. Start the engine and warm it up. Turn the ignition switch to ON and turn the hand−held tester ON. CHECK: Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. Using the hand−held tester, operate the OCV and check the engine speed.
Page 769 DI−496 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminals OC1+ and OC1−, OC2+ and OC2− of ECM con- nector. CHECK: OCV Signal Waveform Inspection using the oscilloscope. 5 V/ During idling, check the waveform between the specified Division terminals of the E5 ECM connector. HINT: The waveform frequency (A) is lengthened as the engine speed becomes higher.
Page 770 DI−497 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between OCV and ECM. PREPARATION: Wire Harness Side Disconnect the C19 or C20 OCV connector. Disconnect the E5 ECM connector. CHECK: Check for resistance between the wire harness side con- nectors.
Page 771 DI−498 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR8−01 P0011 Camshaft Position ”A” −Timing Over− Actuator or System Performance (Bank 1 P0012 Camshaft Position ”A” −Timing Over− Retarded (Bank 1) P0021 Camshaft Position ”A” −Timing Over− Actuator or System Performance (Bank 2) P0022 Camshaft Position ”A”...
Page 772 DI−499 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY P0011 VVT system advance (Bank 1) P0012 VVT system retard (Bank 1) R l t d DTC Related DTCs P0021 VVT system advance (Bank 2) P0022 VVT system retard (Bank 2) Main sensors/components Camshaft position sensor Required sensors/components Engine coolant temperature sensor,...
Page 773 DI−500 DIAGNOSTICS − ENGINE (2UZ−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 to ON and turn the hand−held tester ON. CHECK: Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. Using the hand−held tester, operate the OCV and check the engine speed.
Page 774 DI−501 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminals OCV+ and OCV− of ECM connector. CHECK: OCV Signal Waveform Inspection using the oscilloscope. 5 V/ During idling, check the waveform between the specified Division terminals of the E5 ECM connector. HINT: The waveform frequency (A) is lengthened as the engine speed becomes higher.
Page 775 DI−502 DIAGNOSTICS − ENGINE (2UZ−FE) Check VVT controller assembly. PREPARATION: Remove the timing belt (See page EM−16). Remove the cylinder head cover. Remove the OCV (See page SF−48). Drain the oil in the VVT controller assembly (See page EM−46). CHECK: Check whether the oil in VVT controller assembly is drained or not.
Page 776 DI−503 DIAGNOSTICS − ENGINE (2UZ−FE) Check whether or not DTC P0010, P0012, P0021 or P0022 is stored. PREPARATION: Clear DTCs (see page DI−462). Perform simulation test. CHECK: Check whether or not DTC P0011, P0012, P0021 or P0022 is stored (See page DI−462). Standard: DTC P0011, P0012, P0021 or P0022 is not stored.
Page 777 DI−504 DIAGNOSTICS − ENGINE (2UZ−FE) DIDR9−01 P0016 Crankshaft Position − Camshaft Position Correlation (Bank 1 Sensor A) P0018 Crankshaft Position − Camshaft Position Correlation (Bank 2 Sensor A) CIRCUIT DESCRIPTION VVT sensor (VVL or VVR signal) consist of a signal plate and pickup coil. The VVL or VVR signal plate has 1 tooth on its outer circumference and is mounted on the intake camshafts.
Page 778 DI−505 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY Deviation in crankshaft position sensor signal P0016 and camshaft position sensor signal (Bank 1) R l t d DTC Related DTCs Deviation in crankshaft position sensor signal P0018 and camshaft position sensor signal (Bank 2) Required sensors/components Crankshaft position sensor, Camshaft position sensor k h ft...
Page 779 DI−506 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: If DTC P0016 is displayed, check left bank VVT sensor. If DTC P0018 is displayed, check right bank VVT sensor. Read freeze frame data using hand−held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected.
Page 780 DI−507 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRA−01 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1)
Page 781 DI−508 DIAGNOSTICS − ENGINE (2UZ−FE) HINT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No.1. Sensor 1 refers to the sensor closest to the engine assembly. Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The ECM uses the Air−Fuel Ratio sensor (A/F sensor) information to regulate the air−fuel ratio close to the stoichiometric ratio.
Page 782 DI−509 DIAGNOSTICS − ENGINE (2UZ−FE) P0032, P0052 (High current): Time after engine start 10 sec. − TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0031, P0051 (Low current): A/F sensor heater current Less than 0.8 A P0032, P0052 (High current): A/F sensor heater current More than 10 A COMPONENT OPERATING RANGE Parameter...
Page 783 DI−510 DIAGNOSTICS − ENGINE (2UZ−FE) Check A/F relay. PREPARATION: Remove the A/F relay from the engine room R/B No.2. CHECK: Inspect the A/F relay. Standard: Terminal No. Condition Specified Condition 3 − 5 Always 10 KΩ or higher A19288 Apply B+ between Below 1 Ω...
Page 784 DI−511 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ECM and A/F sen- sor. PREPARATION: Wire Harness Side: Turn the ignition switch to OFF. A/F Sensor Connector Disconnect the A10 or A30 A/F sensor connector. Disconnect the E6 ECM connector.
Page 785 DI−512 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRB−01 P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2)
Page 786 DI−513 DIAGNOSTICS − ENGINE (2UZ−FE) CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three−way cata- lytic converter is used, but for the most efficient use of the three−way catalytic converter, the air−fuel ratio must be precisely controlled so that it is always close to the stoichiometric air−fuel ratio.
Page 787 DI−514 DIAGNOSTICS − ENGINE (2UZ−FE) DTC No. DTC Detecting Condition Trouble Area S Open in heater circuit of heated oxygen sensor S Heated oxygen sensor heater S Heated oxygen sensor heater P0037 P0037 Heater current is 0.25 A or less when the heater operates with Heater current is 0.25 A or less when the heater o erates with S EFI relay P0057...
Page 788 DI−515 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present All: Battery voltage 10.5 V − Engine Running Starter Catalyst intrusive monitoring Not operating Intrusive heating Not operating P0037, P0057 (Low current): When the following conditions are met:...
Page 789 DI−516 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0037, P0057 (Low current): Heater Heater current Less than 0.3 A Intrusive heating Operating P0038, P0058 (High current): Either of the following conditions is met: Condition 1 or 2 1.
Page 790 DI−517 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Access Cab, Standard Cab: Engine Room R/B EFI Relay W−B GR−G GR−G E3 MREL B−R Heated Oxygen Sensor W−L (Bank 2 Sensor 2) Engine Room R/B Y−B +B HT HT2B EFI No. 2 (Shielded) B−W OX2B...
Page 791 DI−518 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: B−W B−W MREL IA10 Heated Oxygen Sensor (Bank1 Sensor2) No. 2 R−L HT1B (Shielded) B−W OX1B Relay Heated Oxygen Sensor No. 1 (Bank2 Sensor2) Y−B HT2B (Shielded) B−W OX2B W−B B−W Block W−B Battery A23606...
Page 792 DI−519 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using hand−held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful to determine whether the vehicle was running or stopped, the engine was warmed up or not, the air−fuel ratio was lean or rich, etc. when a malfunction occurred.
Page 793 DI−520 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminals HT1B, HT2B of ECM connectors and body ground. PREPARATION: HT1B HT2B Turn the ignition switch ON. CHECK: Measure the voltage between terminals of the ECM connectors and body ground. HINT: Connect terminal HT1B to the bank 1 sensor 2. Connect terminal HT2B to the bank 2 sensor 2.
Page 794 DI−521 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ECM and heated oxygen sensor, heated oxygen sensor − EFI relay. PREPARATION: Wire Harness Side: Turn the ignition switch to OFF. Disconnect the H4 or H6 oxygen sensor connector. Disconnect the E6 and E7 ECM connector.
Page 795 DI−522 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRC−01 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 Mass Air Flow (MAF) 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 796 DI−523 DIAGNOSTICS − ENGINE (2UZ−FE) HINT: After confirming DTC P0100, P0102 or P0103, use the hand−held tester or the OBD II scan tool to confirm the MAF ratio from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL).
Page 797 DI−524 DIAGNOSTICS − ENGINE (2UZ−FE) COMPONENT OPERATING RANGE Parameter Standard Value Mass air flow meter voltage 0.4 to 2.2 V WIRING DIAGRAM Access Cab, Standard Cab: Engine Room R/B EFI Relay W−B GR−G GR−G MREL B−R W−L Mass Air Flow Meter Engine Room R/B R−Y EFI No.
Page 798 DI−525 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: B−W B−W IA10 MREL M1 Mass Air Flow Meter R−Y B−Y Engine Room J/B EFI Relay EFI No. 2 EFI No. 1 W−B W−B Fusible Link Block W−B Battery A23604...
Page 799 DI−526 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 800 DI−527 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage of mass air flow meter power source. PREPARATION: Wire Harness Side: Disconnect the M1 mass air flow meter connector. Mass Air Flow Meter Connector Turn the ignition switch ON. CHECK: Measure voltage between terminal 1 of the mass air flow meter connector and body ground.
Page 801 DI−528 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between mass air flow meter and ECM. PREPARATION: Wire Harness Side: Disconnect the M1 mass air flow meter connector. Mass Air Flow Meter Connector Disconnect the E7 ECM connector. CHECK: Check the resistance between the wire harness side connec- tors.
Page 802 DI−529 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between mass air flow meter and EFI relay. PREPARATION: Engine Room J/B: Remove the EFI No. 2 fuse from the engine room J/B. CHECK: Check the resistance in the EFI No. 2 fuse. Standard: Below 1 Ω...
Page 803 DI−530 DIAGNOSTICS − ENGINE (2UZ−FE) Check continuity between terminal E2G of ECM connector and body ground. CHECK: E7 ECM Connector Check the resistance between terminal of the E7 ECM connec- tor and body ground. Standard: Tester Connection Specified Condition Below 1 Ω E2G (E7−29) −...
Page 804 DI−531 DIAGNOSTICS − ENGINE (2UZ−FE) DI1LC−19 P0101 Mass or Volume Air Flow Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100, P0102 and P0103 on page DI−522. DTC No. DTC Detecting Condition Trouble Area After engine is warmed up, conditions (a), (b), (c) and (d) con- tinue for more than 10 seconds: (2 trip detection logic) (a) Throttle valve fully closed...
Page 805 DI−532 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present High voltage: Engine speed − 2,000 rpm Engine coolant temperature 70_C (158_F) − Low voltage: Engine speed 300 rpm −...
Page 806 DI−533 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 807 DI−534 DIAGNOSTICS − ENGINE (2UZ−FE) DIA80−03 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 808 DI−535 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT (Intake Air Temperature) sensor and sets a DTC.
Page 809 DI−536 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Intake Air Temp. Sensor (Built into Mass Air Flow Meter) Y−G B−W A15651 INSPECTION PROCEDURE HINT: If DTCs related to different systems that have terminal E2 as the ground terminal are output simulta- neously, terminal E2 may have an open circuit.
Page 810 DI−537 DIAGNOSTICS − ENGINE (2UZ−FE) Connect hand−held tester, and read value of intake air temperature. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR.
Page 811 DI−538 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open in harness or ECM. PREPARATION: Mass Air Disconnect the M1 mass air flow meter connector. Flow Meter Connect terminals 4 and 5 of the mass air flow meter wire harness side connector. Turn the ignition switch ON.
Page 812 DI−539 DIAGNOSTICS − ENGINE (2UZ−FE) Check for short in harness and ECM. PREPARATION: Mass Air Flow Disconnect the M1 mass air flow meter connector. Meter Turn the ignition switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / IN- TAKE AIR.
Page 813 DI−540 DIAGNOSTICS − ENGINE (2UZ−FE) DIA81−03 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 in the Engine Coolant Temperature (ECT) sensor and changes the voltage value accord- ing to the engine coolant temperature.
Page 814 DI−541 DIAGNOSTICS − ENGINE (2UZ−FE) Example: When the ECM calculates that the ECT is less than −40_C (−40_F), or more than 140_C (284_F), and if either the condition continues for 0.5 sec. or more, the ECM will set a DTC. MONITOR STRATEGY Engine coolant temperature sensor range check P0115...
Page 815 DI−542 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Engine Coolant Temp. Sensor B−W FI6448 INSPECTION PROCEDURE HINT: If DTCs related to different system that have terminal E2 as the ground terminal are output simulta- neously, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester.
Page 816 DI−543 DIAGNOSTICS − ENGINE (2UZ−FE) Connect hand−held tester, and read value of engine coolant temperature. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 817 DI−544 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open in harness or ECM. PREPARATION: Engine Coolant Disconnect the E2 engine coolant temperature (ECT) Temp. Sensor sensor connector. Connect terminals 1 and 2 of the engine coolant tempera- ture sensor wire harness side connector. Turn the ignition switch ON.
Page 818 DI−545 DIAGNOSTICS − ENGINE (2UZ−FE) Confirm good connection at ECM. If OK, re- place ECM (See page SF−82). Check for short in harness and ECM. PREPARATION: Engine Coolant Disconnect the E2 engine coolant temperature sensor Temp. Sensor connector. Turn the ignition switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 819 DI−546 DIAGNOSTICS − ENGINE (2UZ−FE) DICMR−02 P0116 Engine Coolant Temperature Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−540. DTC No. DTC Detecting Condition Trouble Area If the engine coolant temperature was 35°C (95°F) or more but less than 60°C (140°F) when the engine is started, and if conditions (a) and (b) are met: (a) Vehicle has accelerated and decelerated.
Page 820 DI−547 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 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 821 DI−548 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRD−01 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 822 DI−549 DIAGNOSTICS − ENGINE (2UZ−FE) 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 823 DI−550 DIAGNOSTICS − ENGINE (2UZ−FE) DTC No. DTC Detection Condition Condition (a) of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues Trouble Area for 2 sec. (Open or short in the throttle control motor and sensor circuit) S Open or short in throttle control motor and sensor circuit Detection conditions for DTCs P0122 and P0123 are not satis- S Throttle control motor and sensor P0120...
Page 824 DI−551 DIAGNOSTICS − ENGINE (2UZ−FE) 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 825 DI−552 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is See page DI−437 not present Electronic throttle actuator power TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0120: VTA1 voltage 0.2 V or less, or 4.535 V or more P0122: VTA1 voltage 0.2 V or less...
Page 826 DI−553 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Throttle Control Motor and Position Sensor B−W G−B P−L VTA2 VTA2 VTA1 VTA1 M− M− (Shielded) L−R GE01 A19212 INSPECTION PROCEDURE HINT: If DTCs related to different system that have terminal E2 as the ground terminal are output simulta- neously, terminal E2 may have an open circuit.
Page 827 DI−554 DIAGNOSTICS − ENGINE (2UZ−FE) Connect hand−held tester, and read the voltage for throttle position sensor data. PREPARATION: Enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / THROTTLE POS and THROTTLE POS #2. CHECK: Read voltage value displayed on the hand−held tester.
Page 828 DI−555 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ECM and throttle position sensor. PREPARATION: Wire Harness Side Disconnect the T14 throttle control motor and sensor con- Throttle Control Motor and Sensor nector. Disconnect the E7 ECM connector. CHECK: Check the resistance between the wire harness side connec- tors.
Page 829 DI−556 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminals VC and E2 of ECM connector. PREPARATION: Disconnect the T14 throttle control motor and sensor con- E7 ECM Connector nector. Turn the ignition switch ON. CHECK: Measure the voltage between the specified terminals of the E7 ECM connector.
Page 830 DI−557 DIAGNOSTICS − ENGINE (2UZ−FE) Replace ECM (See page SF−82).
Page 831 DI−558 DIAGNOSTICS − ENGINE (2UZ−FE) DI1LI−24 P0121 Throttle Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem HINT: This is the purpose of the ”throttle position sensor”. CIRCUIT DESCRIPTION Refer to DTC P0120 on page DI−548. DTC No. DTC Detecting Condition Trouble Area Condition (a) continues for 2.0 sec.: (a) Difference between VTA1 and VTA2 deviates from the P0121...
Page 832 DI−559 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present Either of the following condition is met: Condition 1 or 2 1. Ignition switch 2. Electric throttle motor power TP sensor malfunction (P0120, P0122, Not detected P0123, P0220, P0222, P0223, P2135)
Page 833 DI−560 DIAGNOSTICS − ENGINE (2UZ−FE) DICMT−02 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−540. DTC No. DTC Detection Condition Trouble Area If THW or THA is less than −19.45°C (−3°F) at engine start and 20 min.
Page 834 DI−561 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present Fuel cut Engine Running 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 Engine coolant temperature is less than ”closed−loop enable temperature”...
Page 835 DI−562 DIAGNOSTICS − ENGINE (2UZ−FE) Inspect thermostat (See page CO−11). CHECK: Check the valve opening temperature of the thermostat. Valve opening temperature is 80 to 84_C (176 to 183_F) HINT: Also check that the valve is completely closed under opening temperature as above. Replace thermostat (See page CO−12).
Page 836 DI−563 DIAGNOSTICS − ENGINE (2UZ−FE) DICMU−02 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) HINT: This is the purpose of ”thermostat” malfunction detection. CIRCUIT DESCRIPTION If the engine coolant temperature does not reach 75°C (167°F) despite sufficient warm−up time has elapsed.
Page 837 DI−564 DIAGNOSTICS − ENGINE (2UZ−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 838 DI−565 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 839 DI−566 DIAGNOSTICS − ENGINE (2UZ−FE) Check thermostat (See page CO−12). CHECK: Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) Replace thermostat. Replace ECM (See page SF−82).
Page 840 DI−567 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRE−01 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) P0157 Oxygen Sensor Circuit Low Voltage (Bank 2...
Page 841 DI−568 DIAGNOSTICS − ENGINE (2UZ−FE) Atmospheric Air Ideal Air−Fuel Mixture Housing Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Richer − Air Fuel Ratio − Leaner Exhaust Gas B17386 DTC No. DTC Detecting Condition Trouble Area During active air−fuel ratio control, following conditions (a) and (b) met for certain period of time (2 trip detection logic): S Open or short in HO2 sensor (sensor 2) circuit P0136...
Page 842 DI−569 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION Active Air−Fuel Ratio Control The ECM usually performs air−fuel ratio feedback control so that the Air−Fuel Ratio (A/F) sensor output indi- cates a near stoichiometric air−fuel level. This vehicle includes active air−fuel ratio control in addition to regu- lar air−fuel ratio control.
Page 843 DI−570 DIAGNOSTICS − ENGINE (2UZ−FE) Open or Short in the Heated Oxygen (HO2) Sensor Circuit (DTC P0137, P0157, P0138 or P0158) During active air−fuel ratio control, the ECM calculates the Oxygen Storage Capacity (OSC)* of the Three− Way Catalytic Converter (TWC) by forcibly regulating the air−fuel ratio to become rich or lean. If the HO2 sensor has an open or short, or the voltage output of the sensor noticeably decreases, the OSC indicates an extraordinarily high value.
Page 844 DI−571 DIAGNOSTICS − ENGINE (2UZ−FE) High or Low Impedance of Heated Oxygen (HO2) Sensor (DTC P0136, P0156, P0137 or P0157) During normal air−fuel ratio feedback control, there are small Interrelation between temperature of variations in the exhaust gas oxygen concentration. In order to the element and impedance: continuously monitor the slight variation of the HO2 sensor sig- nal while the engine is running, the impedance* of the sensor...
Page 845 DI−572 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY Heated rear oxygen sensor (Bank 1) output volt- age (Output voltage) P0136 P0136 Heated rear oxygen sensor (Bank 1) impedance (Low) Heated rear oxygen sensor (Bank 1) output volt- age (Low voltage) P0137 P0137 Heated rear oxygen sensor (Bank 1) impedance (High)
Page 846 DI−573 DIAGNOSTICS − ENGINE (2UZ−FE) Engine RPM − 3,200 rpm A/F sensor status Activated Fuel system status Closed loop Fuel−cut Engine load 10 to 70% Shift position − Heated oxygen sensor impedance (Low): Battery voltage 11 V − Estimated rear oxygen sensor tempera- −...
Page 847 DI−574 DIAGNOSTICS − ENGINE (2UZ−FE) Heated oxygen sensor impedance (Low): Duration of following condition 30 sec. or more Less than 5 Ω Heated oxygen sensor impedance Heated oxygen sensor impedance (High): Duration of following condition 90 sec. or more Heated oxygen sensor impedance 15 kΩ...
Page 848 DI−575 DIAGNOSTICS − ENGINE (2UZ−FE) CONFIRMATION DRIVING PATTER HINT: This confirmation driving pattern is used in steps 5, 8 and 11 of the following diagnostic troubleshooting procedure when using either a hand−held tester. Performing this confirmation pattern will activate the Heated Oxygen (HO2) sensor monitor. (The cata- lyst monitor is performed simultaneously.) This is very useful for verifying the completion of a repair.
Page 849 DI−576 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Hand−held tester only: Narrowing down the trouble area is possible by performing ACTIVE TEST of the following ”A/F CONTROL” (Heated oxygen sensor or another can be distinguished). Perform ACTIVE TEST by hand−held tester (A/F CONTROL). HINT: ”A/F CONTROL”...
Page 850 DI−577 DIAGNOSTICS − ENGINE (2UZ−FE) The following A/F CONTROL procedure enables the technician to check and graph the voltage output of the heated oxygen sensors. For displaying the graph indication, first enter ”ACTIVE TEST / A/F CONTROL / USER DATA,” then select ”A/F B1,2S1and O2S B1,2S2”...
Page 851 DI−578 DIAGNOSTICS − ENGINE (2UZ−FE) Read output DTC. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 852 DI−579 DIAGNOSTICS − ENGINE (2UZ−FE) Check for short in harness and connector between terminal OX1B and HT1B, OX2B and HT2B of ECM. PREPARATION: Turn the ignition switch to OFF and wait for 5 minutes. ECM Connector Disconnect the E6 and E7 ECM connector. CHECK: Check the resistance.
Page 853 DI−580 DIAGNOSTICS − ENGINE (2UZ−FE) Check whether DTC output recurs (DTC P0138, P0158) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Read DTCs. RESULT: Display (DTC Output) Proceed To P0138 or P0158 No output...
Page 854 DI−581 DIAGNOSTICS − ENGINE (2UZ−FE) Check whether DTC output recurs (DTC P0136, P0156) CHECK: On the hand−held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Read DTCs. RESULT: Display (DTC Output) Proceed To P0136 or P0156 No output...
Page 855 DI−582 DIAGNOSTICS − ENGINE (2UZ−FE) Perform active test (injection volume). PREPARATION: Connect the hand−held tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. CHECK: Change the fuel injection volume using the tester, monitoring the voltage output of Air−Fuel Ratio (A/F) and HO2 sensors displayed on the tester.
Page 856 DI−583 DIAGNOSTICS − ENGINE (2UZ−FE) Check and repair extremely rich or lean actu- arial air fuel ratio (injector, fuel pressure, gas leakages from exhaust system, etc.) Check for exhaust gas leakage. CHECK: Check for exhaust gas leakage from the exhaust manifold and pipe. OK: No exhaust gas leakage.
Page 857 DI−584 DIAGNOSTICS − ENGINE (2UZ−FE) Check EFI relay. PREPARATION: EFI Relay Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Standard: Terminal No. Condition Specified Condition 3 − 5 Always 10 KΩ or higher A19288 Apply B+ between Below 1 Ω...
Page 858 DI−585 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ECM and heated oxygen sensor. PREPARATION: Wire Harness Side: Disconnect the heated oxygen sensor connector. Disconnect the E6 and E7 ECM connector. CHECK: Measure the resistance between the wire harness side connec- tors.
Page 859 DI−586 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRF−01 P0171 System too Lean (Bank 1) P0172 System too Rich (Bank 1) P0174 System too Lean (Bank 2) P0175 System too Rich (Bank 2) CIRCUIT DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim con- sists of both the short−term and long−term fuel trims.
Page 860 DI−587 DIAGNOSTICS − ENGINE (2UZ−FE) DTC No. DTC Detecting Condition Trouble Area S Air induction system S Injector blockage S Mass air flow meter S Engine coolant temperature sensor S Fuel pressure S Gas leakage in exhaust system When air−fuel ratio feedback is stable after warming up the P0171 S Open or short in heated oxygen sensor (bank 1, 2 sensor 1) engine, fuel trim is considered to be in error on LEAN side...
Page 861 DI−588 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION Under closed−loop fuel control, fuel injection volumes that deviate from those estimated by the ECM cause changes in the long−term fuel trim compensation value. The long−term fuel trim is adjusted when there are persistent deviations in the short−term fuel trim values.
Page 862 DI−589 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present Battery voltage 11 V − Fuel system status Closed−loop Either of the following conditions is met: Condition 1 or 2 1.
Page 863 DI−590 DIAGNOSTICS − ENGINE (2UZ−FE) Standard: Tester Display Injection Volumes Status Voltages (Sensor) AFS B1S1 (AFS B2S1) +25 % Rich Less than 3.0 (A/F) AFS B1S1 (AFS B2S1) −12.5 % Lean More than 3.35 (A/F) O2S B1S2 (O2S B2S2) +25 % Rich More than 0.55 (HO2)
Page 864 DI−591 DIAGNOSTICS − ENGINE (2UZ−FE) HINT: Read freeze frame data using a hand−held tester. Freeze frame data record the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, 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 865 DI−592 DIAGNOSTICS − ENGINE (2UZ−FE) Check air induction system (See page SF−1). CHECK: Check the air induction system for vacuum leaks. Repair or replace air induction system. Perform active test (A/F control). Connect the hand−held tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds.
Page 866 DI−593 DIAGNOSTICS − ENGINE (2UZ−FE) S Injector leakage or blockage S Gas leakage from exhaust system S Ignition system Rich Rich Actual air−fuel ratio rich S Fuel pressure S MAF meter S ECT sensor S A/F sensor Lean Lean/Rich A/F sensor malfunction S A/F sensor Rich Lean/Rich...
Page 867 DI−594 DIAGNOSTICS − ENGINE (2UZ−FE) Read value of mass air flow meter. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF and COOLANT TEMP.
Page 868 DI−595 DIAGNOSTICS − ENGINE (2UZ−FE) Check for spark and ignition (See page IG−1). HINT: If the spark plugs or ignition system malfunction, engine misfire may occur. The misfire counter can be read with the hand−held tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MIS- FIRE / CYL#1 (to CYL#8).
Page 869 DI−596 DIAGNOSTICS − ENGINE (2UZ−FE) Check A/F relay. PREPARATION: A/F Relay Remove the A/F relay from the engine room J/B. CHECK: Inspect the A/F relay. Standard: Terminal No. Condition Specified Condition 3 − 5 Always 10 KΩ or higher A19288 Apply B+ between Below 1 Ω...
Page 870 DI−597 DIAGNOSTICS − ENGINE (2UZ−FE) Standard (Check for short): Tester Connections Specified Conditions HT (A10−1) or HA1A (E6−2) − Body ground 10 kΩ or higher HT (A30−1) or HA2A (E6−1) − Body ground AF+ (A10−3) or A1A+ (E6−22) − Body ground 10 kΩ...
Page 871 DI−598 DIAGNOSTICS − ENGINE (2UZ−FE) Perform confirmation driving pattern. Vehicle Speed Between 38 mph and 75 mph (60 km/h and 120 km/h) Idling Ignition Switch OFF 2 minutes 3 to 5 minutes Time (a), (b), (c) B17397 Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON.
Page 872 DI−599 DIAGNOSTICS − ENGINE (2UZ−FE)
Page 873 DI−600 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRG−01 P0230 Fuel Pump Primary Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal STAR of the ECM 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, the Tr1 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 oper- ates.
Page 874 DI−601 DIAGNOSTICS − ENGINE (2UZ−FE) DTC No. DTC Detecting Condition Trouble Area S Open or short in fuel pump relay circuit S Fuel pump relay S Circuit opening relay P0230 Open or short in fuel pump relay circuit S Fuel pump S ECM...
Page 875 DI−602 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Fuel Pump Engine Room J/B Resister G−R G−R L−O Fuel Pump Relay L−B C/OPN Relay G−R B−O G−O G−O G−R W−R B−R W−R Ignition SW EFI Relay No.1 Fuel Pump B−W B−W Fusible MREL Link Block...
Page 876 DI−603 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 877 DI−604 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between fuel pump relay and ECM. PREPARATION: Engine Room J/B: Remove the fuel pump relay from the engine room J/B. Disconnect the E5 ECM connector. CHECK: Measure the resistance between wire harness side connectors.
Page 878 DI−605 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRH−01 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 P0305 Cylinder 5 Misfire Detected P0306 Cylinder 6 Misfire Detected P0307 Cylinder 7 Misfire Detected P0308...
Page 879 DI−606 DIAGNOSTICS − ENGINE (2UZ−FE) DTC No. DTC Detecting Condition Trouble Area S Open or short in engine wire S Connector connection P0300 Misfiring of random cylinders is detected S Vacuum hose connection S Vacuum hose connection S Ignition system S Injector P0301 S Fuel pressure...
Page 880 DI−607 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION Camshaft position sensor Crankshaft position sensor (36−2 teeth or 12 teeth) A20490 The ECM illuminates the MIL (2 trip detection logic) if: The ECM will illuminate the MIL when the percentage of misfire exceeds the specified limit per 1,000 engine revolutions.
Page 881 DI−608 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present Battery voltage − Throttle position learning Completed VVT system Normal operate by scan tool Engine RPM 400 rpm 5,700rpm All of the following conditions are met:...
Page 882 DI−609 DIAGNOSTICS − ENGINE (2UZ−FE) Misfire monitor − All cylinders Scaling Description of Test Value Minimum Test Limit Maximum Test Limit Exponential Weighted Moving Average Multiply by 1 misfire counts for last 10 driving cycles 65535 (time) − total Multiply by 1 Misfire counts for last and current driv- 65535 (time)
Page 883 DI−610 DIAGNOSTICS − ENGINE (2UZ−FE) Misfire monitor − Cylinder 7 Scaling Description of Test Value Minimum Test Limit Maximum Test Limit Exponential Weighted Moving Average Multiply by 1 misfire counts for last 10 driving cycles 65535 (time) − total Multiply by 1 Misfire counts for last and current driv- 65535 (time)
Page 884 DI−611 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Refer to DTC P0351 on page DI−642 for the wiring diagram of the ignition system. Access Cab, Standard Cab: I14 Injector No. 1 B−R I15 Injector No. 2 B−R B−R I16 Injector No. 3 B−R B−R I17 Injector No.
Page 885 DI−612 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: I14 Injector No. 1 B−R I15 Injector No. 2 B−R I16 Injector No. 3 B−R B−R B−R I17 Injector No. 4 R−B B−R Driver Side J/B Ignition SW B−R I18 Injector No. 5 IGN2 B−R B−R...
Page 886 DI−613 DIAGNOSTICS − ENGINE (2UZ−FE) CONFIRMATION DRIVING PATTERN Connect the hand−held tester to the DLC3. Record DTC and the freeze frame data. Use the hand−held tester to set the check mode (See page DI−463). 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 887 DI−614 DIAGNOSTICS − ENGINE (2UZ−FE) Are there any other codes (besides DTC P0300, P0301, P0302, P0303, P0304 P0305, P0306, P0307 or P0308) 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. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 888 DI−615 DIAGNOSTICS − ENGINE (2UZ−FE) Check connection of PCV piping. PCV hose is connected correctly and is not damaged. Repair or replace PCV piping. Connect hand−held tester, and read the number of misfire. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON.
Page 889 DI−616 DIAGNOSTICS − ENGINE (2UZ−FE) Check spark plug and spark of misfiring cylinder. PREPARATION: Remove the ignition coil assembly. Remove the spark plug. CHECK: Check the electrode for carbon deposits. Check the spark plug type (See page IG−1). Check electrode gap. 0.8 mm No large carbon deposit present.
Page 890 DI−617 DIAGNOSTICS − ENGINE (2UZ−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 another spark plug to the ignition coil assem- bly.
Page 891 DI−618 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ignition coil and ECM. Check the harness and connector between the ignition coil Wire Harness Side: and the ECM (IGF terminal) connectors: Ignition Coil Connector PREPARATION: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil connector.
Page 892 DI−619 DIAGNOSTICS − ENGINE (2UZ−FE) Check the harness and connector between the ignition coil Wire Harness Side: and the ECM (IGT terminal) connectors: Ignition Coil Connector PREPARATION: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil connector.
Page 893 DI−620 DIAGNOSTICS − ENGINE (2UZ−FE) Check ECM terminal of misfiring cylinder. PREPARATION: Turn the ignition switch ON. #40(+) CHECK: Measure the voltage between the terminals of the E5 and E7 ECM connectors. Standard: E01 (−) Tester Connection Specified Condition B17411 #10 (E5−2) −...
Page 894 DI−621 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ignition SW and in- jector, injector and ECM of misfiring cylinder. PREPARATION: Wire Harness Side: Disconnect the I14, I15, I16, I17, I18, I19, I20 or I21 injec- Injector Connector tor connector.
Page 895 DI−622 DIAGNOSTICS − ENGINE (2UZ−FE) PREPARATION: Wire Harness Side: Disconnect the I14, I15, I16, I17, I18, I19, I20 or I21 injec- Injector Connector tor connector. Disconnect the I23 ignition switch connector. CHECK: Measure the resistance the wire harness side connectors be- tween the injector and ignition switch.
Page 896 DI−623 DIAGNOSTICS − ENGINE (2UZ−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. Switch step by number of misfire cylinder (Refer to the result of step 4). High misfire rate cylinder Proceed to 1 or 2 cylinders...
Page 897 DI−624 DIAGNOSTICS − ENGINE (2UZ−FE) Check fuel pressure (See page SF−7). Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF−1). Check intake air temperature and mass air flow rate. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON.
Page 898 DI−625 DIAGNOSTICS − ENGINE (2UZ−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. Resistance: Tester Connection Specified Condition 1 − 2 2.32 to 2.59 kΩ (20_C (68_F)) Acceptable 1 −...
Page 899 DI−626 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRI−02 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) P0332 Knock Sensor 2 Circuit Low Input (Bank 2) P0333 Knock Sensor 2 Circuit High Input (Bank 2) CIRCUIT DESCRIPTION A flat type knock sensor (non−resonant type) has the structure that can detect the vibration in a wider band...
Page 900 DI−627 DIAGNOSTICS − ENGINE (2UZ−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. If there is a defect in the knock sensor or an open or short circuit, the voltage level will deviate outside the normal operating range.
Page 901 DI−628 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Knock Sensor (*1) (*1) (Bank 2) EKN2 KNK2 Knock Sensor (*1) (*1) (Bank 1) EKNK KNK1 (*1) (*1) EY (*2) EW (*3) *1: Shielded *2: Double Cab *3: Access Cab, Standard Cab A23600...
Page 902 DI−629 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: DTC P0325, P0327 and P0328 are for the bank 1 knock sensor circuit. DTC P0330, P0332 and P0333 are for the bank 2 knock sensor circuit. Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected.
Page 903 DI−630 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between EC3 connector and ECM (See page IN−30). Repair or replace harness or connector. Measure voltage between terminals KNK1 and EKNK, KNK2 and EKN2 of ECM. PREPARATION: Disconnect the E6 ECM connector.
Page 904 DI−631 DIAGNOSTICS − ENGINE (2UZ−FE) Replace knock sensor (See page SF−68). Check knock sensor. PREPARATION: Wire Harness Side: Disconnect the EC3 connector. Male Connector CHECK: Check the resistance between the terminals of the EC3 male connector. Standard: Tester Connection Specified Condition Front View EC3 male connector 3 −4 120 to 280 kΩ...
Page 905 DI−632 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRJ−01 P0335 Crankshaft Position Sensor ”A” Circuit P0339 Crankshaft Position Sensor ”A” Circuit In- termittent CIRCUIT DESCRIPTION The crankshaft position sensor system consists of a crankshaft position sensor plate and a pick−up coil. The sensor plate has 32 teeth and is installed on the crankshaft. The pick−up coil is made of an iron core and magnet.
Page 906 DI−633 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION If there are no signals from the crankshaft sensor even though the engine is revolving, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Crankshaft position sensor range check or ratio- Related DTCs P0335 nality...
Page 907 DI−634 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Camshaft Position Sensor G−B (*1) G− G2− J64 J/C (*1) NE− Crankshaft Position Sensor *1:Shielded *2: Double Cab *3: Access Cab, Standard Cab EY (*2) EW (*3) A23586 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame records the engine conditions when a malfunction is detected.
Page 908 DI−635 DIAGNOSTICS − ENGINE (2UZ−FE) Check resistance of crankshaft position sensor. PREPARATION: Component Side Disconnect the C2 crankshaft position sensor connector. CHECK: Measure the resistance between terminals 1 and 2. Standard: Tester Connection Specified Condition 985 to 1,600 Ω at cold 1 −...
Page 909 DI−636 DIAGNOSTICS − ENGINE (2UZ−FE) Check sensor installation (crankshaft position sensor). CHECK: Check the crankshaft position sensor installation. The crankshaft position sensor is installed properly. Clearance BR3795 Tighten sensor installation bolt. Inspect teeth of sensor plate. PREPARATION: Remove the crankshaft angle sensor plate (See page EM−98). CHECK: Check the teeth of sensor plate.
Page 910 DI−637 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRK−01 P0340 Camshaft Position Sensor ”A” Circuit P0341 Camshaft Position Sensor ”A” Circuit Range/Performance P0345 Camshaft Position Sensor ”A” Circuit (Bank 2) P0346 Camshaft Position Sensor ”A” Circuit Range/Performance (Bank 2) CIRCUIT DESCRIPTION The camshaft position sensor consists of a magnet, an iron core and a pick−up coil. This sensor monitors a timing rotor located on the camshaft and is used by the ECM to detect the camshaft angle.
Page 911 DI−638 DIAGNOSTICS − ENGINE (2UZ−FE) Reference: Inspection using the oscilloscope. VV1, VV2 and NE Signal Waveforms 2 V/DIV The correct waveform is as shown. Ground Tester Connection Specified Condition G2+ (E5−27) − G2− (E5−32) Ground Correct waveform is as shown NE+ (E5−25) −...
Page 912 DI−639 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0340, P0345 Case 1: VVT sensor signal No signal P0340, P0345 Case 2: VVT sensor signal No signal P0341, P0346: VVT sensor count 12 or more / 720_CA (= Engine 2 revolutions) COMPONENT OPERATING RANGE Parameter Standard Value...
Page 913 DI−640 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 914 DI−641 DIAGNOSTICS − ENGINE (2UZ−FE) Check sensor installation (VVT sensor). CHECK: Check the VVT sensor installation. The VVT sensor is installed properly. Clearance Tighten sensor installation bolt. BR3795 Inspect teeth of camshaft. PREPARATION: Remove the cylinder head cover (See page EM−36). CHECK: Check the tooth of the camshaft.
Page 915 DI−642 DIAGNOSTICS − ENGINE (2UZ−FE) DICN4−02 P0351 Ignition Coil ”A” Primary/Secondary Circuit P0352 Ignition Coil ”B” Primary/Secondary Circuit P0353 Ignition Coil ”C” Primary/Secondary Circuit P0354 Ignition Coil ”D” Primary/Secondary Circuit P0355 Ignition Coil ”E” Primary/Secondary Circuit P0356 Ignition Coil ”F” Primary/Secondary Circuit P0357 Ignition Coil ”G”...
Page 916 DI−643 DIAGNOSTICS − ENGINE (2UZ−FE) CIRCUIT DESCRIPTION These DTCs indicate a malfunction related to primary circuit. The DIS is a 1−cylinder ignition system which ignites one cylinder with one ignition coil. In the 1−cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug.
Page 917 DI−644 DIAGNOSTICS − ENGINE (2UZ−FE) DTC No. DTC Detecting Condition Trouble Area P0351 P0352 S Open or short in IGF1 or IGF2 and IGT1 to IGT8 circuit from P0353 ignition coil with igniter to ECM P0354 S No. 1 to No. 8 ignition coil with igniter (primary ignition) No IGF signal to ECM while engine is running P0355 S Ignition system...
Page 918 DI−645 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY P0351 No. 1 ignition coil with igniter circuit malfunction P0352 No. 2 ignition coil with igniter circuit malfunction P0353 No. 3 ignition coil with igniter circuit malfunction P0354 No. 4 ignition coil with igniter circuit malfunction R l t d DTC Related DTCs P0355...
Page 919 DI−646 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Access Cab, Standard Cab: L−B IGF1 L−W IGF2 Ignition Coil with Igniter No. 8 L−W IGT8 W−B B−R Ignition Coil with Igniter No. 7 L−B IGT7 B−R W−B L−B B−R W−B Ignition Coil with Igniter No. 6 L−B IGT6 B−R...
Page 920 DI−647 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: L−B IGF1 L−W IGF2 Ignition Coil with Igniter No. 8 L−W IGT8 W−B B−R Ignition Coil with Igniter No. 7 L−B IGT7 B−R W−B L−B B−R W−B Ignition Coil with Igniter No. 6 L−B IGT6 W−B...
Page 921 DI−648 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: If DTCs P0351, P0354, P0356 and P0357 are output simultaneously, IGF1 circuit may be open or short. If DTCs P0352, P0353, P0355 and P0358 are output simultaneously, IGF2 circuit may be open or short.
Page 922 DI−649 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector in IGF signal circuits be- tween ECM and ignition coil with igniter. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil will igniter connector.
Page 923 DI−650 DIAGNOSTICS − ENGINE (2UZ−FE) Disconnect ignition coil with igniter connector, and check voltage between ter- minals IGF1, IGF2 and E1 of ECM connector. PREPARATION: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil with igniter connector. Turn the ignition switch ON.
Page 924 DI−651 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector in IGT signal circuit between ECM and ignition coil with igniter. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil connector.
Page 925 DI−652 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminals IGT1 − IGT8 and E1 of ECM connector. PREPARATION: IGT4 IGT3 Turn the ignition switch to ON. (−) IGT8 IGT6 CHECK: IGT1 Measure the voltage between terminals the E7 and E5 ECM connectors when the engine is cranked.
Page 926 DI−653 DIAGNOSTICS − ENGINE (2UZ−FE) Disconnect ignition coil with igniter connector, and check voltage between ter- minals IGT1 − IGT8 and E1 of ECM connector. PREPARATION: IGT4 IGT3 Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil (−) IGT8 IGT6...
Page 927 DI−654 DIAGNOSTICS − ENGINE (2UZ−FE) Check ignition coil with igniter power source circuit. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil with igniter connector. Turn the ignition switch to ON. CHECK: Measure the voltage between the terminal of the wire harness side connector and body ground.
Page 928 DI−655 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between ignition switch and ignition coil with igniter. PREPARATION: Wire Harness Side: Disconnect the I3, I4, I5, I6, I7, I8, I9 or I10 ignition coil with igniter connector. Disconnect the I23 ignition switch connector.
Page 929 DI−656 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRL−01 P0412 Secondary Air Injection System Air Switch- ing Valve ”A” Circuit CIRCUIT DESCRIPTION The secondary air injection system pumps air to the exhaust port to accelerate the activation of the catalyst. The secondary air injection system consists of the ECM, air pump, Air Switching Valve (ASV) (EASV), Air Switching Valve No.2 (ASV No.2) (ASV1, 2), pressure sensor and air injection driver (AID).
Page 930 DI−657 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION The air injection driver (AID) detects an open or short in the circuit according to the voltage of the air pump terminal (VP) and electromagnetic air switching valve terminal (VV), and sends a signal as diagnostic in- formation to the ECM.
Page 931 DI−658 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Access Cab, Standard Cab: GR−G GR−G MREL V14 VSV (Air Switching Valve Bank2) B−L AIV1 V15 VSV (Air Switching Valve Bank2) G−Y Engine AIV2 Room Air Injection No.2 Control Driver AIRP G−B G−B AIRV W−L GR−B...
Page 932 DI−659 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: B−W B−W MREL IA10 V14 VSV (Air Switching Valve Bank2) B−L AIV1 V15 VSV (Air Switching Valve Bank2) B−R G−Y AIV2 Air Injection Control Driver No. 2 AIRP IA10 G−B G−B AIRV IA10 Relay GR−R GR−R...
Page 933 DI−660 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: The diagnostic information output from AID can be confirmed by connecting an oscilloscope to the diagnostic information terminal of the AID. It narrows a trouble area search to read the waveform on the oscilloscope when performing the AI system intrusive operation function provided in the SYSTEM CHECK.
Page 934 DI−661 DIAGNOSTICS − ENGINE (2UZ−FE) DTCs AID Diagnostic Signal Waveforms Suspected Trouble Areas (ECM Output) Commands 100 % Duty ratio Open in diagnostic signal circuit Almost Battery Voltage Any Air Injection Air Injection Control Driver (AID) (AI) System op- Open in AID+B circuit (AID power source) P1613 eration Short between +B circuit and diagnostic signal circuit...
Page 935 DI−662 DIAGNOSTICS − ENGINE (2UZ−FE) HINT: Using the AIR INJ CHECK operation of the SYSTEM CHECK provided in the hand−held tester func- tion, conditions for air−fuel ratio and pressure in the secondary air injection system passage can be checked while the secondary air injection system operating. It helps technicians to troubleshoot the system when it malfunctioning.
Page 936 DI−663 DIAGNOSTICS − ENGINE (2UZ−FE) Check air switching valve. PREPARATION: Component Side: Remove the intake manifold (see page EM−36). ASV Connector Disconnect the ASV connector. CHECK: Measure the resistance of the ASV. Standard: Tester Connections Specified Conditions Front View 4.5 to 5.5 Ω ASV (B13−1) −...
Page 937 DI−664 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between air injection driver and air switching valve. PREPARATION: Wire Harness Side: Remove the intake manifold (see page EM−36). Air Injection Driver Connector Disconnect the A32 air injection driver connector. Disconnect the A31 air switching valve connector.
Page 938 DI−665 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRM−01 P0418 Air Injection System Air Pump Malfunction CIRCUIT DESCRIPTION Refer to DTC P0412 on page DI−656. DTC No. DTC Detection Condition Trouble Area All of the following conditions are met, when idling just after S Open in air pump drive circuit cold start.
Page 939 DI−666 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−437 not present Case 1: Air pump Operating Air switching valve Operating Battery voltage − Ignition switch Starter Case 2: Air pump Not operating...
Page 940 DI−667 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: The diagnostic information output from the AID can be confirmed by connecting an oscilloscope to the diag- nostic information terminal of the AID. It narrows the trouble area search to read the waveform on the oscillo- scope when performing the AI system intrusive operation function provided in the SYSTEM CHECK.
Page 941 DI−668 DIAGNOSTICS − ENGINE (2UZ−FE) DTCs AID Diagnostic Signal Waveforms Suspected Trouble Areas (ECM Output) Commands 100 % Duty ratio Open in diagnostic signal circuit Almost Battery Voltage Any Air Injection Air Injection Control Driver (AID) (AI) System op- Open in AID+B circuit (AID power source) P1613 eration Short between +B circuit and diagnostic signal circuit...
Page 942 DI−669 DIAGNOSTICS − ENGINE (2UZ−FE) HINT: Using the AIR INJ CHECK operation of the SYSTEM CHECK provided in the hand−held tester func- tion, conditions for air−fuel ratio and pressure in the secondary air injection system passage can be checked while the secondary air injection system operating. It helps technicians to troubleshoot the system when it malfunctioning.
Page 943 DI−670 DIAGNOSTICS − ENGINE (2UZ−FE) Check air pump resistance. PREPARATION: Component Side: Remove the intake manifold (see page EM−36). Air Pump Connector Disconnect the air pump connector. CHECK: Measure the resistance of the air pump. Standard: Tester Connections Specified Conditions Front View 0.4 to 1.0 Ω...
Page 944 DI−671 DIAGNOSTICS − ENGINE (2UZ−FE) Check for open and short in harness and connector between air injection driver and air pump. PREPARATION: Wire Harness Side: Remove the intake manifold (see page EM−36). Air Injection Driver Connector Disconnect the A33 air injection driver connector. Disconnect the A35 air pump connector.
Page 945 DI−672 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRN−01 P0420 Catalyst System Efficiency Below Threshold (Bank 1) P0430 Catalyst System Efficiency Below Threshold (Bank 2) MONITOR DESCRIPTION The ECM uses the two sensors, mounted in front of and behind the Three−way Catalytic Converter (TWC), to monitor its efficiency.
Page 946 DI−673 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY P0420 Bank 1 catalyst is deteriorated R l t d DTC Related DTCs P0430 Bank 2 catalyst is deteriorated Main sensors/components Front and rear heated oxygen sensor Mass air flow meter, Engine coolant temperature Required sensors/components Related sensors/components sensor, Engine speed sensor, Intake air tempera-...
Page 947 DI−674 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR RESULT Refer to page DI−445 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 (refer to ”Confirmation Monitor”). MID (Monitor Identification Data) is assigned to each emissions−related component.
Page 948 DI−675 DIAGNOSTICS − ENGINE (2UZ−FE) HINT: If either of the voltage outputs of the Air−Fuel Ratio (A/F) or Heated Oxygen (HO2) sensors does not fluctuate, or either of the sensors makes a noise, the sensor may be malfunctioning. If the voltage outputs of both the sensors remain lean or rich, the air−fuel ratio may be extremely lean or rich.
Page 949 DI−676 DIAGNOSTICS − ENGINE (2UZ−FE) Standard: Tester Display Injection Volumes Status Voltages (Sensor) AFS B1S1 +25 % Rich Less than 3.0 (A/F) AFS B1S1 −12.5 % Lean More than 3.35 (A/F) O2S B1S2 +25 % Rich More than 0.55 (HO2) O2S B1S2 −12.5 % Lean...
Page 950 DI−677 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 951 DI−678 DIAGNOSTICS − ENGINE (2UZ−FE) Standard: Tester Display Injection Volumes Status Voltages (Sensor) AFS B1S1 +25 % Rich Less than 3.0 (A/F) AFS B1S1 −12.5 % Lean More than 3.35 (A/F) O2S B1S2 +25 % Rich More than 0.55 (HO2) O2S B1S2 −12.5 % Lean...
Page 952 DI−679 DIAGNOSTICS − ENGINE (2UZ−FE) Check gas leakage on exhaust system. No exhaust gas leakage. Repair or replace exhaust gas leakage point. Replace front and rear three−way catalytic converter in the bank a malfunction is de- tected.
Page 953 DI−680 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRO−01 P0441 Evaporative Emission Control System Incor- rect Purge Flow DTC SUMMARY Detection Detection DTCs Monitoring Items Malfunction Detection Conditions Trouble Areas Timings Logic Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP sys- S Purge VSV tem pressure measured.
Page 954 DI−681 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION The two monitors, Key−Off and Purge Flow, are used to detect malfunctions relating to DTC P0441. The Key−Off monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours* after the ignition switch is turned to OFF.
Page 955 DI−682 DIAGNOSTICS − ENGINE (2UZ−FE) Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF (vent) Vent Valve: OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Air Filter Pump Module Vacuum Pump: OFF Operation D: Purge VSV monitor Operation C: EVAP System Pressure Measurement ON (closed)
Page 956 DI−683 DIAGNOSTICS − ENGINE (2UZ−FE) Purge VSV stuck closed In operation D, the pressure sensor measures the EVAP system pressure. The pressure measurement for purge VSV monitor is begun when the purge VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally.
Page 957 DI−684 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY Purge VSV stuck open Purge VSV stuck closed Related DTCs Related DTCs P0441 P0441 Purge flow Required sensors/components Purge VSV, Pump module Frequency of operation Once per driving cycle Purge VSV stuck open and closed: Within 15 min. (varies with amount of fuel in tank) Duration Purge flow: Within 10 min.
Page 958 DI−685 DIAGNOSTICS − ENGINE (2UZ−FE) 3. EVAP canister vent valve close stuck − check Next sequence is run if the following con- − dition is set EVAP pressure change after vent valve is 0.3 kPa (2.25 mmHg) − 4. Vacuum introduction −...
Page 959 DI−686 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Purge VSV stuck open: EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 Purge VSV stuck closed: EVAP pressure change after EVAP canister purge valve is Less than 0.3 kPa (2.25 mmHg) open Purge flow:...
Page 960 DI−687 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRP−01 P0450 Evaporative Emission Control System Pres- sure Sensor/Switch 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 DTC SUMMARY Detection Tim- Detection...
Page 961 DI−688 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION DTC P0450: Pressure sensor voltage abnormal fluctua- Pressure Sensor Specification: tion. Malfunction Area If the pressure sensor voltage output rapidly fluctuates Output Voltage between less than 0.45 V and more than 4.9 V, the ECM 4.900 V interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP...
Page 962 DI−689 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY Evaporative emission control system pressure P0450 sensor/switch chattering Evaporative emission control system pressure sensor noise P0451 P0451 Evaporative emission control system pressure Related DTCs sensor stuck Evaporative emission control system pressure P0452 sensor/switch low input Evaporative emission control system pressure P0453 sensor/switch high input...
Page 963 DI−690 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Pressure sensor noise: Frequency that EVAP pressure change is 0.3 kPa or more 10 times or more for 10 sec. Pressure sensor stuck: EVAP pressure change during reference pressure measure- Less than 0.65 kPa (4.9 mmHg) ment Pressure sensor chattering:...
Page 964 DI−691 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE NOTICE: When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condi- tion. For example, do not tighten the fuel tank cap. Do not disassemble the pump module. A hand−held tester is required to conduct the following diagnostic troubleshooting procedure.
Page 965 DI−692 DIAGNOSTICS − ENGINE (2UZ−FE) Measure resistance between terminal PPMP of ECM and body ground. PREPARATION: Turn the ignition switch to OFF. Disconnect the E3 ECM connector. CHECK: Measure the resistance between PPMP terminal of the ECM connector and the body ground. PPMP B17417 RESULT:...
Page 966 DI−693 DIAGNOSTICS − ENGINE (2UZ−FE) Measure resistance between terminal PPMP of ECM and body ground. PREPARATION: Disconnect the L4 canister connector. Disconnect the E3 ECM connector. CHECK: Check the resistance between PPMP terminal of the ECM con- nector and the body ground. A23446 PPMP B17417...
Page 967 DI−694 DIAGNOSTICS − ENGINE (2UZ−FE) Measure voltage and resistance of pump module connector. PREPARATION: Disconnect the L4 canister connector. Turn the ignition switch to ON. CHECK: Measure the voltage and resistance of the L4 connector. Standard: Tester Connections Specified Conditions L4−4 −...
Page 968 DI−695 DIAGNOSTICS − ENGINE (2UZ−FE) Replace ECM (See page SF−82). NEXT Check whether DTC output recurs. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Wait for at least 60 seconds. CHECK: On the tester, select the following menu items: DIAGNOSIS/ENHANCED OBD II/DTC INFO/PEND- ING CODES.
Page 969 DI−696 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRQ−01 P0455 Evaporative Emission Control System Leak Detected (Gross Leak) P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY Detection Detection Monitoring Items Malfunction Detection Conditions Trouble Areas Timings Logic Vacuum pump creates negative pressure S Fuel tank cap (loose) (vacuum) in EVAP system and EVAP sys- S Leakage from EVAP line...
Page 970 DI−697 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacu- um) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35_C (95_F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later.
Page 971 DI−698 DIAGNOSTICS − ENGINE (2UZ−FE) P0455: EVAP (Evaporative Emission) gross leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak pres- sure standard x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic).
Page 972 DI−699 DIAGNOSTICS − ENGINE (2UZ−FE) Time after key off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction Not detected (P0450, P0452, P0453) EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2...
Page 973 DI−700 DIAGNOSTICS − ENGINE (2UZ−FE) 6. Second reference pressure measure- − ment Next sequence is run if the following con- Condition 1, 2, 3 and 4 ditions are set 1. EVAP pressure just after reference − −1 kPa (−7.5 mmHg) pressure 2.
Page 974 DI−701 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRR−01 P0500 Vehicle Speed Sensor ”A” P0503 Vehicle Speed Sensor ”A” Intermittent/Errat- ic/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 975 DI−702 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY Related DTCs P0500 Vehicle speed sensor ”A” pulse input error Main sensors Vehicle speed sensor Required sensors/components Park/Neutral position switch, Engine coolant tem- Related sensors perature sensor, Combination meter Frequency of operation Continuous Duration 500 times MIL operation...
Page 976 DI−703 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: Combination Meter G−O G−O A23570 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 977 DI−704 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminal SPD and E1 of ECM connector. PREPARATION: Shift the shift lever to neutral. Jack up the rear wheel on one side. Turn the ignition switch ON. CHECK: Measure the voltage between the specified terminal of the E4 and E5 ECM connector when the wheel is turned slowly.
Page 978 DI−705 DIAGNOSTICS − ENGINE (2UZ−FE) Check sensor installation (Vehicle speed sensor). CHECK: Check the vehicle speed sensor installation. The vehicle speed sensor is installed properly. Clearance Tighten sensor installation bolt. BR3795 Check for open and short in harness and connector between combination meter and ECM.
Page 979 DI−706 DIAGNOSTICS − ENGINE (2UZ−FE) DICN8−02 P0504 Brake Switch ”A”/”B”Correlation CIRCUIT DESCRIPTION In addition to turning on the stop lamps, the stop lamp switch signals are used for a variety of engine, trans- mission, and suspension functions as well as being an input for diagnostic checks. It is important that the switch operates properly, therefore this switch is designed with two complementary signal outputs: STP and ST1−.
Page 980 DI−707 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Access Cab, Standard Cab: Driver Side J/B I23 Ignition SW ECU−IG GR−R (*3) B−Y B−R B−O B−O W−R GR−R (*3) Stop Light SW G−Y (*4) ST1− G−Y (*3) G−W G−Y (*3) Stop Light Relay STOP G−W (*3) G−W...
Page 981 DI−708 DIAGNOSTICS − ENGINE (2UZ−FE) Double Cab: Sop Light SW W (*1) W (*2) Driver Side J/B Sub J/B No.3 IGN1 B−O B−O B−O ST1− Driver Side J/B Engine Room J/B I23 Ignition SW B−R W−R W−R Driver Side J/B F13 FL Block W−L STOP...
Page 982 DI−709 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 983 DI−710 DIAGNOSTICS − ENGINE (2UZ−FE) Check STP signal and ST1− voltage. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON. Brake Pedal Brake Pedal Select the item ”DIAGNOSIS / ENHANCED OBD II / Depressed Released DATA LIST / ALL / STOP LIGHT SW”. CHECK: Read the signal displayed on the hand−held tester.
Page 984 DI−711 DIAGNOSTICS − ENGINE (2UZ−FE) Check harness and connector between ECM and stop light switch. PREPARATION: Wire Harness Side: Disconnect the S4 stop light switch connector. Stop Light Switch Connector Disconnect the E3 ECM connector. CHECK: Measure the resistance between the wire harness side connec- tors.
Page 985 DI−712 DIAGNOSTICS − ENGINE (2UZ−FE) DICN9−02 P0505 Idle Air Control System CIRCUIT 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 986 DI−713 DIAGNOSTICS − ENGINE (2UZ−FE) MONITOR STRATEGY Related DTCs P0505 Idle air control malfunction Main sensors/components Crankshaft position sensor Required sensors/components Vehicle speed sensor, Engine coolant tempera- Related sensors/components ture sensor Frequency of operation Once per driving cycle Duration 10 min. MIL operation 2 driving cycles Sequence of operation...
Page 987 DI−714 DIAGNOSTICS − ENGINE (2UZ−FE) 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 P0505 will possibly be detected.
Page 988 DI−715 DIAGNOSTICS − ENGINE (2UZ−FE) Check air induction system (See page SF−1). CHECK: Check for vacuum leaks in air induction system. No leakage. Repair or replace air induction system. Check electric throttle control system (See page SF−41).
Page 989 DI−715−1 DIAGNOSTICS − ENGINE (2UZ−FE) P050A Cold Start ldle Air Control System Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed.
Page 990 DI−715−2 DIAGNOSTICS − ENGINE (2UZ−FE) The ECM monitors the intake air amount during idling and the ignition timing. When the engine coolant temperature is between −10_C and 50_C (14_F and 122_F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts. When the accumulated value is below the threshold, the ECM interprets this as a malfunction in the Idle Speed Control (ISC) system at cold start.
Page 991 DI−715−3 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL MALFUNCTION THRESHOLDS P050A: Accumulated air flow amount Varies with ECT (Example: Less than 102 g) INSPECTION PROCEDURE HINT: Read the freeze frame data using the intelligent tester. The freeze frame data records the engine condition when malfunctions are detected.
Page 992 DI−715−4 DIAGNOSTICS − ENGINE (2UZ−FE) Read value using intelligent tester (Fuel trim). HINT: Calculate the total fuel trim values to check the characteristic deviation of the mass air flow meter. Connect the intelligent tester to the DLC3. Turn the ignition switch ON. Turn the tester ON.
Page 993 DI−715−5 DIAGNOSTICS − ENGINE (2UZ−FE) Repair or replace PCV hose. NEXT Go to step 11. Replace mass air flow meter. NEXT Go to step 11. Repair or replace air induction system. NEXT Go to step 11. Check throttle valve. Check for deposits around the throttle valve. No deposits around the throttle valve.
Page 994 DI−715−6 DIAGNOSTICS − ENGINE (2UZ−FE) Check whether DTC output recurs (DTC P050A). NOTICE: In this operation, the engine must be cold (the same level as the engine coolant temperature recorded in the freeze frame data). Connect the intelligent tester to the DTC3. Turn the ignition switch ON.
Page 995 DI−716 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRS−01 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 996 DI−717 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Access Cab, Standard Cab: Engine Room R/B B−L (*1) EFI No. 1 BATT B (*2) B−R B−R Battery *1: Towing Package *2: Except Towing Package A23590 Double Cab: Engine Room R/B EFI No. 1 BATT B−Y B−Y...
Page 997 DI−718 DIAGNOSTICS − ENGINE (2UZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine 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 998 DI−719 DIAGNOSTICS − ENGINE (2UZ−FE) Check voltage between terminal BATT and E1 of ECM connector. CHECK: Measure the voltage between terminals of the E5 and E3 ECM connector. Standard: Tester Connection Specified Condition BATT (E3−3) − E1 (E5−1) 9 to 14 V E1 (−) BATT(+) B17411...
Page 999 DI−720 DIAGNOSTICS − ENGINE (2UZ−FE) Check the battery (See page CH−1). Replace battery. Check and replace engine room J/B.
Page 1000 DI−721 DIAGNOSTICS − ENGINE (2UZ−FE) DIA8I−03 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 1001 DI−722 DIAGNOSTICS − ENGINE (2UZ−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0604: RAM mirror check fail 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 1002 DI−723 DIAGNOSTICS − ENGINE (2UZ−FE) DIDRT−01 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 1003 DI−724 DIAGNOSTICS − ENGINE (2UZ−FE) WIRING DIAGRAM Access Cab, Standard Cab: V−W (*2) ACC Cut Relay V−W (*1) V−W (*1) V−W ACCR L−R To ACC Fuse Ignition SW Driver Side J/B R−L STSW L−R W−R Park/Neutral Position SW *1: w/ Engine Immobiliser System *2: w/o Engine Immobiliser System cmc0491...

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