Tài liệu hướng dẫn sửa chữa Hệ thống điều khiển động cơ trên xe Toyota camry hybrid xv50 2012 2017 engine control system điều khiển động cơ. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, kiểm tra, sửa chữa nhanh chóng, chính xác, hiệu quả
2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1 SFI SYSTEM PRECAUTION NOTICE: When disconnecting the negative (-) battery cable, initialize the following systems after the terminal is reconnected System See procedure SFI system ES-13 PRECAUTIONS FOR INSPECTING HYBRID CONTROL SYSTEM (a) Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system NOTICE: Turning the power switch on (READY) with the service plug grip removed could cause a malfunction Do not turn the power switch on (READY) unless instructed by the repair manual (b) After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the highvoltage connectors or terminals A142844 HINT: Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly (c) Turn the power switch off, wear insulated gloves, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system ES ES–2 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES (d) Turn the power switch off before performing any resistance checks (e) Turn the power switch off before disconnecting or reconnecting any connectors PRECAUTIONS FOR HYBRID CONTROL SYSTEM ACTIVATION (a) When the warning light is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the power switch on (READY) may not start the system (the system may not enter the READY-on state) on the first attempt If so, turn the power switch off and reattempt to turn the power switch on (READY) 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–3 DEFINITION OF TERMS Terms 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 ECM based on same malfunction detection logic Typical Enabling Condition Preconditions that allow ECM to detect malfunctions With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s) Sequence of Operation Order of monitor priority, applied if multiple sensors and components involved in single malfunction detection process Each sensor and component is monitored in turn and not monitored until previous detection operation is completed Required Sensor/Components Sensors and components used by ECM to detect each malfunction Frequency of Operation Number of times ECM checks for each malfunction during each driving cycle "Once per driving cycle" means ECM only performs checks for that malfunction once during single driving cycle "Continuous" means ECM performs checks for that malfunction whenever enabling conditions are met Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in order to set DTC Timing begins when Typical Enabling Conditions are met Malfunction Thresholds Value, beyond which, ECM determines malfunctions exist and sets DTCs MIL Operation Timing of MIL illumination after a malfunction is detected "Immediate" means ECM illuminates MIL as soon as malfunction is detected "2 driving cycle" means ECM illuminates MIL if same malfunction is detected second time during next sequential driving cycle ES ES–4 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION FUEL VAPOR CONTAINMENT VALVE PURGE VSV MASS AIR FLOW METER CANISTER ES HYBRID VEHICLE CONTROL ECU FUEL PUMP CANISTER PUMP MODULE IGCT RELAY ENGINE ROOM R/B AND ENGINE ROOM J/B IG2 RELAY EFI NO FUSE IGCT FUSE INTEGRATION RELAY - EFI RELAY - C/OPN RELAY A140989E02 ES–5 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM COMBINATION METER ES DLC3 INSTRUMENT PANEL J/B - IGN FUSE - STOP FUSE STOP LIGHT SWITCH IGNITION COIL WITH IGNITER CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY KNOCK SENSOR FUEL INJECTOR CAMSHAFT POSITION SENSOR AIR FUEL RATIO SENSOR THROTTLE POSITION SENSOR ENGINE COOLANT TEMPERATURE SENSOR CRANKSHAFT POSITION SENSOR HEATED OXYGEN SENSOR A140990E01 ES–6 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM IG2 IG2 GAUGE No IGN Main Body ECU AM2 HV Control ECU IGSW C/OPN ES FC Fuel Pump Combination Meter W EFI IGCT No +B2 SPD1 MIL +B EFI MAIN ETCS Camshaft Timing Oil Control Valve +BM BATT IGCT IGCT OC1+ OC1- MREL VCP2 EP2 EFI No Accelrator Position Sensor VCP1 EP1 A/F Sensor (Bank Sensor 1) MAIN HA1A A1A+ VPA VPA2 PS Pressure Switch A1A- Battery A PSW B A129107E03 ES–7 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM A B HV Control ECU Mass Air Flow (MAF) EVG VG #10 THA ETHA Fuel Injector (No 1) Fuel Injector (No 2) #20 Purge VSV ES Fuel Injector (No 3) PRG #30 Heated Oxygen Sensor (Bank Sensor 2) HT1B Fuel Injector (No 4) O1BOX1B- #40 EFI No To IG2 Relay Fuel Vapor Containment Valve CCV2 CANH CANL Canister Pump Module To Main Body ECU Stop Light Switch VPMP EPPM STP STOP IGN ST1- PPMP VCPP E03 E04 MPMP E01 E1 E12 A129108E02 ES–8 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HV Control ECU Throttle Body Assembly VTA1 NE+ VCTA VTA2 NE- ETA M+ M- ES Crankshaft Position Sensor Camshaft Position Sensor G2+ G2- Engine Coolant Temperature (ECT) Sensor GE01 THW VCPT PTNK ETHW Fuel Tank Pressure Sensor EPTK IGT1 Ignition Coil (No 1) IGF ID Code Box IGT2 Ignition Coil (No 2) IGT3 Ignition Coil (No 3) IGT4 Ignition Coil (No 4) IMO IMI DLC3 TACH TC To Main Body ECU ST2 Knock Control Sensor (Bank 1) To IG2 Relay KNK1 EKNK E02 ME01 A141008E01 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–9 HOW TO PROCEED WITH TROUBLESHOOTING HINT: The intelligent tester should be used in steps 3, 4, 5, and 10 VEHICLE BROUGHT TO WORKSHOP NEXT CUSTOMER PROBLEM ANALYSIS NEXT CONNECT INTELLIGENT TESTER TO THE DLC3 HINT: If the display indicates a communication fault in the tester, inspect the DLC3 NEXT CHECK DTC AND FREEZE FRAME DATA HINT: Record or print DTCs and freeze frame data, if necessary NEXT CLEAR DTC AND FREEZE FRAME DATA NEXT CONDUCT VISUAL INSPECTION NEXT SET CHECK MODE DIAGNOSIS NEXT CONFIRM PROBLEM SYMPTOMS HINT: If the engine does not start, perform steps 10 and 12 first ES ES–10 2AZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Result Proceed to Malfunction does not occur A Malfunction occurs B B GO TO STEP 10 A ES SIMULATE SYMPTOMS NEXT 10 CHECK FOR DTC Result B Result Proceed to Trouble code A No code B GO TO STEP 12 A 11 REFER TO DTC CHART NEXT GO TO STEP 14 12 CONDUCT BASIC INSPECTION Result Result Proceed to Malfunctioning parts not confirmed A Malfunctioning parts confirmed B B GO TO STEP 17 A 13 REFER TO PROBLEM SYMPTOMS TABLE Result Result Proceed to Malfunctioning circuit confirmed A ES–398 2AZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY INSTALLATION New Gasket INSTALL THROTTLE BODY (a) Install a new gasket onto the intake manifold A124566E01 (b) Connect the purge line hose to the throttle body (c) Connect the water by-pass hose to the throttle body (d) Connect the No water by-pass hose to the throttle body (e) Connect the No throttle body hose to the throttle body ES A143842 (f) Install the throttle body and fuel pipe clamp with the bolts Torque: 30 N*m (305 kgf*cm, 22 ft.*lbf) (g) Connect the fuel tube into the clamp A143841 (h) Connect the throttle position sensor connector (i) Connect the wire harness clamp A143840 INSTALL AIR CLEANER CAP SUB-ASSEMBLY (a) Install the air cleaner filter element onto the air cleaner case 2AZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–399 (b) Insert the hinges Install the air cleaner cap subassembly with the bolts ES A143839 (c) Align the matchmarks of the No air cleaner hose and throttle body Connect the air cleaner hose No to the throttle body and unfasten the No air cleaner hose clamp NOTICE: Make sure that the hose clamp is at the correct angle Unfasten (A) Side View: (A) 90° A135671E02 (d) Connect the No ventilation hose to the air cleaner hose A143837 (e) (f) (g) (h) (*1) (*2) (*3) (*3) INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-113) ADD ENGINE COOLANT (See page CO-5) INSPECT FOR COOLANT LEAK (See page CO-1) (*4) A135666E03 Connect the purge line hose to the clamp (*1) Connect the purge VSV vacuum hoses (*2) Connect the purge VSV connector (*3) Connect the mass air flow meter connector (*4) ES–400 2AZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY ES INSTALL NO ENGINE COVER SUB-ASSEMBLY (See page EM-114) ES–400 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR KNOCK SENSOR 2AZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH ES WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 7.5 (77, 66 in.*lbf) 85 (867, 63) x4 x5 FRONT FENDER TO COWL SIDE SEAL LH 5.0 (51, 44 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK 8.0 (82, 71 in.*lbf) COWL TOP PANEL OUTER SUB-ASSEMBLY BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A129008E01 ES–401 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR THROTTLE POSITION SENSOR CONNECTOR NO VENTILATION HOSE AIR CLEANER CAP SUB-ASSEMBLY FUEL PIPE SUPPORT x4 PURGE LINE HOSE 30 (305, 22) THROTTLE BODY GASKET FUEL TUBE NO THROTTLE BODY HOSE 9.0 (92, 80 in.*lbf) WATER BY-PASS HOSE NO WATER BY-PASS HOSE ES PURGE VSV VACUUM HOSE NO ENGINE COVER SUB-ASSEMBLY PURGE VSV VACUUM HOSE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A129007E01 ES–402 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR 30 (306, 22) x2 ES x5 INTAKE MANIFOLD GASKET 20 (204, 15) KNOCK SENSOR 20 (204, 15) FUEL DELIVERY PIPE WITH INJECTOR 20 (204, 15) FUEL TUBE SPACER INSULATOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A129009E01 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–403 REMOVAL DISCHARGE FUEL SYSTEM PRESSURE (See page FU-36) DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE NO ENGINE COVER SUB-ASSEMBLY (See page EM-90) DRAIN ENGINE COOLANT (See page CO-5) REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9) REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9) REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10) 10 SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 11 REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-10) 12 REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (a) Remove the bolts, nuts and cowl top panel outer sub-assembly 13 REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-395) 14 REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-90) A143843 15 REMOVE THROTTLE BODY (See page ES-396) 16 DISCONNECT FUEL TUBE (See page FU-12) 17 REMOVE FUEL DELIVERY PIPE WITH INJECTOR (See page FU-13) 18 REMOVE INTAKE MANIFOLD (a) Disconnect the union to check valve hose from the brake booster ES ES–404 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR (b) Disconnect the camshaft timing oil control valve connector (c) Remove the wire harness clamp (d) Remove the union to check valve hose from the vacuum hose clamp (e) Remove the bolts, nuts and intake manifold A143844 (f) Remove the gasket from the intake manifold ES A090130E01 19 REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector (b) Remove the nut and knock sensor A128922 INSPECTION KNOCK CONTROL SENSOR (a) Using an ohmmeter, measure the resistance between the terminals Standard resistance: 120 to 280 kΩ at 20°C (68°F) If the resistance is not specified, replace the sensor A065174 INSTALLATION Upper side 10q 10q A128924E01 INSTALL KNOCK SENSOR (a) Install the knock sensor with the nut Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTICE: Make sure that the knock sensor is in the correct position (b) Connect the knock sensor connector 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR New Gasket ES–405 INSTALL INTAKE MANIFOLD (a) Install a new gasket into the intake manifold A090130E02 (b) Install the intake manifold with the bolts and nuts Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) (c) Fit the union to check valve hose into the vacuum hose clamp (d) Install the wire harness clamp (e) Connect the camshaft timing oil control valve connector (f) Connect the union to check valve hose to the brake booster A143844 INSTALL FUEL DELIVERY PIPE WITH INJECTOR (See page FU-15) INSTALL FUEL TUBE (See page FU-16) INSTALL THROTTLE BODY (See page ES-397) INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-113) INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-398) INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-113) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-113) 10 ADD ENGINE COOLANT (See page CO-5) 11 INSPECT FOR COOLANT LEAK (See page CO-1) 12 INSPECT FOR FOR FUEL LEAK (See page FU-9) 13 INSTALL NO ENGINE COVER SUB-ASSEMBLY (See page EM-114) 14 INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (a) Install the cowl top panel outer sub-assembly with the bolts and nuts Torque: Bolt 5.0 N*m (51 kgf*cm, 44 in.*lbf) Nut 85 N*m (867 kgf*cm, 63 ft.*lbf) A143843 15 INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See page ES-383) ES ES–406 2AZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR 16 INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-13) 17 INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-14) 18 INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-14) 19 INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-14) 20 INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-14) ES 21 INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-15) 22 PERFORM INITIALIZATION (a) Perform initialization procedure (See page IN-43) NOTICE: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal ES–407 2AZ-FXE ENGINE CONTROL SYSTEM – EFI RELAY EFI RELAY Engine Room R/B Unit D: INSPECTION 1E INSPECT EFI RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below Standard resistance Tester Connection 12 10 Specified Condition 1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12 Below Ω (Battery voltage is applied between terminals 1E-9 and 1E-10) ES A137364E01 ES–408 2AZ-FXE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY Engine Room R/B Unit D: INSPECTION 12 1E INSPECT CIRCUIT OPENING RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below Standard resistance Tester Connection 1D ES 13 A137364E04 Specified Condition 1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13 Below Ω (Battery voltage is applied between terminals 1E-8 and 1D-12) 2AZ-FXE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–409 ACCELERATOR PEDAL ROD 2AZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES 5.4 (55, 48 in.*lbf) ACCELERATOR PEDAL ROD N*m (kgf*cm, ft.*lbf) : Specified torque A135645E01 ES–410 2AZ-FXE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ON-VEHICLE INSPECTION CHECK ACCELERATOR PEDAL ROD (a) Put the engine in inspection mode (See page ES35) (b) Warm up the engine (c) Turn the power switch off (d) (e) (f) (g) Connect the intelligent tester to the DLC3 Turn the power switch ON (IG) Turn the tester on Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST (h) Check the values by referring to the table below Intelligent Tester ES DLC CAN VIM A146110E01 Intelligent Tester Display Measurement: Range (Display) Normal Condition *1 Diagnostic Note ACCEL POS #1 (Accelerator pedal position #1) Accelerator pedal position sensor No / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - ACCEL POS #2 (Accelerator pedal position #2) Accelerator pedal position sensor No / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - REMOVAL A135676 REMOVE ACCELERATOR PEDAL ROD (a) Disconnect the accelerator pedal position sensor connector (b) Remove the bolts and accelerator pedal rod 2AZ-FXE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–411 INSTALLATION INSTALL ACCELERATOR PEDAL ROD NOTICE: • Avoid physical shock to the accelerator pedal assembly • Do not disassemble the accelerator pedal assembly (a) Install the accelerator pedal rod with the bolts Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Connect the accelerator pedal position sensor connector ES A135676