Tài liệu hướng dẫn sửa chữa hệ thống điều khiển động cơ trên xe 5 2005 2006 toyota hilux factory service manual engine control system he thong dieu khien dong co. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành sửa chữa nhanh chóng, chính xác, hiệu quả
ES–14 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR INTERMITTENT PROBLEMS ES HINT: Intelligent tester only: Inspect the vehicle's ECM using check mode Intermittent problems are easier to detect with an intelligent 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 Clear DTCs (See page ES-38) Switch the ECM from normal mode to check mode using an intelligent tester (See page ES-41) Perform a simulation test Check and wiggle the harness(es), connector(s) and terminal(s) ES–15 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When a malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently Therefore, using this check is essential when engine troubleshooting CHECK BATTERY VOLTAGE NOTICE: Carry out this check with the engine stopped and ignition switch OFF NG Result Proceed To 11 V or more OK Below 11 V NG CHARGE OR REPLACE BATTERY OK CHECK WHETHER ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE OK CHECK WHETHER ENGINE STARTS NG GO TO STEP OK CHECK AIR FILTER (a) Visually check that the air filter is not excessively contaminated with dirt or oil NG REPLACE AIR FILTER NG TROUBLESHOOT IDLING SPEED AND PROCEED TO NEXT STEP OK CHECK IDLING SPEED ES ES–16 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK CHECK FUEL PRESSURE NG TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP NG TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP OK ES CHECK FOR SPARK OK PROCEED TO PROBLEM SYMPTOMS TABLE 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–17 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 An intelligent tester is required to resister the VIN DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN (a) Input Instructions: Explains the general VIN input instructions using an intelligent tester (b) Read VIN: Explains the VIN reading process in a flowchart This process allows the VIN stored in the ECM to be read, in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle's ECM, are the same (c) Write VIN: Explains the VIN writing process in a flowchart This process allows the VIN to be input into the ECM If the ECM is changed, or the VIN and VIN not match, the VIN can be registered, or overwritten in the ECM by following this procedure INPUT INSTRUCTIONS (a) Intelligent tester (1) The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used, in order to input the VIN (b) Cursor Operation (1) To move the cursor around the tester screen, press the RIGHT and LEFT buttons (c) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character (2) After selection, the cursor should move (d) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input (2) After input, the cursor should move HINT: Numerical characters can be selected by using the UP and DOWN buttons (e) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT buttons (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons (f) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input (2) Press the ENTER button on the tester ES ES–18 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VIN (a) Confirm the vehicle VIN (b) Connect an intelligent tester to the DLC3 (c) Turn the ignition switch ON (d) Turn the tester ON (e) Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / VIN Menu Screen: Select VIN READ ES VIN Previously Stored DTC P0630 Set VIN Not Stored 17-digit VIN displayed [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 WRITE VIN (a) Confirm the vehicle VIN (b) Connect an intelligent tester to the DLC3 (c) Turn the ignition switch ON (d) Turn the tester ON ES–19 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / VIN Menu Screen: Select VIN WRITE ES VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 ES–20 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Input Instructions New Registration [ENTER] ES [ENTER] [ENTER] [ENTER] Input Error [EXIT] Continue to next illustration A103814E05 ES–21 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Writing Successful Writing Error Communication Error ES [ENTER] To Menu Screen [EXIT] To Menu Screen [EXIT] To Menu Screen A103815E03 ES–22 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECKING MONITOR STATUS ES The purpose of the monitor result (mode 06) is to allow access to the results for on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored Examples are catalyst, evaporative emission (EVAP) and thermostat The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit These data are displayed after the vehicle has been driven to run the monitor When the test value is not between the minimum test limit and maximum test limit, the ECM (PCM) interprets this as a malfunction When the component is not malfunctioning, if the difference of the test value and test limit is very small, the component will malfunction in the near future Perform the following instruction to view the monitor status Although this instruction reference the Lexus/Toyota diagnostic tester, it can be checked using a generic OBD II scan tool Refer to your scan tool operator's manual for specific procedures PERFORM MONITOR DRIVE PATTERN (a) Connect an intelligent tester to the DLC3 (b) Turn the ignition switch ON and the tester ON (c) Clear DTCs (See page ES-38) (d) Run the vehicle in accordance with the applicable drive pattern described in READINESS MONITOR DRIVE PATTERN (See page ES-23) Do not turn the ignition switch OFF NOTICE: The test results will be lost if the ignition switch is turned OFF ACCESS MONITOR RESULT (a) Select from the intelligent tester menus: DIAGNOSIS, ENHANCED OBDII, MONITOR INFO and MONITOR RESULT The monitor status appears after the component name • INCMP: The component has not been monitored yet • PASS: The component is functioning normally • FAIL: The component is malfunctioning (b) Confirm that the component is either PASS or FAIL (c) Select the component and press ENTER The accuracy test value appears if the monitor status is either PASS or FAIL CHECK COMPONENT STATUS (a) Compare the test value with the minimum test limit (MIN LIMIT) and maximum test limit (MAX LIMIT) ES–23 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) If the test value is between the minimum test limit and maximum test limit, the component is functioning normally If not, the component is malfunctioning The test value is usually significantly higher or lower than the test limit If the test value is on the borderline of the test limit, the component will malfunction in the near future HINT: The monitor result might on rare occasions be PASS even if the malfunction indicator lamp (MIL) is illuminated This indicates the system malfunctioned on a previous driving cycle This might be caused by an intermittent problem MONITOR RESULT INFORMATION If you use a generic scan tool, multiply the value by the scaling value listed below A/F Sensor Bank Monitor ID Test ID Scaling Unit Description Response rate deterioration level for bank sensor $01 $8E Multiply by 0.0003 No dimension $01 $91 Multiply by 0.004 mA Monitor ID Test ID Scaling Unit $05 $8E Multiply by 0.0003 No dimension Response rate deterioration level for bank $05 $91 Multiply by 0.004 mA A/F sensor current for bank Monitor ID Test ID Scaling Unit $02 $07 Multiply by 0.001 V Minimum sensor voltage $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.0003 Grams Maximum oxygen storage capacity Test ID Scaling Unit A/F sensor current A/F Sensor Bank Description HO2S Bank Sensor Description HO2S Bank Sensor Monitor ID Description $06 $07 Multiply by 0.001 V Minimum sensor voltage $06 $08 Multiply by 0.001 V Maximum sensor voltage $06 $8F Multiply by 0.0003 Grams Maximum oxygen storage capacity Monitor ID Test ID Scaling Unit $21 $A9 Multiply by 0.0003 No dimension Catalyst - Bank Description Oxygen storage capacity of catalyst Bank ES ES–470 2TR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE ACCELERATOR PEDAL ROD ASSEMBLY (a) Disconnect the accelerator position sensor connector (b) Remove the bolts, then remove the accelerator pedal G037703E01 ES INSPECTION Ohmmeter INSPECT ACCELERATOR PEDAL ROD ASSEMBLY (a) Check the resistance (1) Using an ohmmeter, measure the resistance between the terminals Standard Tester Connection Specified Condition (EP1) - (VCP1) 1M Ω or higher (EP2) - (VCP2) 1M Ω or higher If the result is not as specified, replace the accelerator pedal G037692E01 INSTALLATION INSTALL ACCELERATOR PEDAL ROD ASSEMBLY NOTICE: • Avoid any physical impact to the accelerator pedal assembly • Do not disassemble the accelerator pedal assembly (a) Install the accelerator pedal with the bolts Torque: N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the accelerator position sensor connector CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) G037703E01 ES–3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION ENGINE ROOM RELAY BLOCK CHARCOAL CANISTER ASSEMBLY - A/F SENSOR HEATER RELAY - CANISTER PUMP MODULE - EFI RELAY - FUEL PUMP RELAY - EFI FUSE CANISTER FILTER - ETCS FUSE ES - STARTER RELAY - STARTER NO FUSE PARK/ NEUTRAL POSITION SWITCH (FOR AUTOMATIC TRANSMISSION) ACIS VSV AIR FUEL RATIO SENSOR (BANK SENSOR 1) FUEL SUCTION WITH PUMP & GAUGE TUBE ASSEMBLY MASS AIR FLOW METER THROTTLE BODY HEATED OXYGEN SENSOR (BANK SENSOR 2) PURGE VSV AIR FUEL RATIO SENSOR (BANK SENSOR 1) HEATED OXYGEN SENSOR (BANK SENSOR 2) FUEL PUMP RESISTOR A115959E01 ES–4 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM KNOCK SENSOR (BANK 1) IGNITION COIL ASSEMBLY FUEL INJECTOR ASSEMBLY VVT SENSOR (BANK 1) ES CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 1) ENGINE COOLANT TEMPERATURE SENSOR KNOCK SENSOR (BANK 2) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2) VVT SENSOR (BANK 2) CRANKSHAFT POSITION SENSOR A115960E01 ES–5 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DRIVER SIDE JUNCTION BLOCK: STOP LIGHT SWITCH - IGN FUSE COMBINATION METER ECM ES IGNITION SWITCH DLC3 VOLTAGE INVERTER ACCELERATOR PEDAL CLUTCH START SWITCH (FOR MANUAL TRANSMISSION) G034987E04 ES–3 2TR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION AIR INJECTION CONTROL DRIVER (AID) MASS AIR FLOW (MAF) METER AIR PRESSURE SENSOR DUTY VACUUM SWITCHING VALVE (PURGE VSV) PARK/NEUTRAL POSITION SWITCH (FOR A/T) CANISTER: - CANISTER PUMP MODULE ES AIR PUMP AIR FILTER FUEL PUMP ENGINE ROOM R/B: - EFI RELAY AIR SWITCHING VALVE (ASV) - A/F HEATER RELAY - C/OPN RELAY - EFI FUSE AIR FUEL RATIO (A/F) SENSOR (SENSOR 1) HEATED OXYGEN (HO2) SENSOR (SENSOR 2) - A/F HEATER FUSE - AM2 FUSE - ETCS FUSE - EFI NO.2 FUSE A124247E01 ES–4 2TR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IGNITION COIL ASSEMBLY FUEL INJECTOR THROTTLE BODY ES CAMSHAFT POSITION (CMP) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR KNOCK SENSOR CAMSHAFT TIMING OIL CONTROL VALVE (OCV) CRANKSHAFT POSITION (CKP) SENSOR A124248E01 ES–5 2TR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DRIVER SIDE J/B: STOP LIGHT SWITCH COMBINATION METER - IGN FUSE ECM ES IGNITION SWITCH DLC3 VOLTAGE INVERTER ACCELERATOR PEDAL CLUTCH START SWITCH (FOR M/T) G034987E03 ES–6 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM Ignition Switch AM2 AM2 GAUGE IG2 ST2 ECM ACC AM1 Combination Meter IG1 ST1 STA (*1) NSW ES W AM1 TACH SPD Park/Neutral Position Switch (*1) MIL THWO PI OILW Clutch Start Switch (*2) ALT STARTER VVT OCV (Bank 1) OC1+ OC1STA VVT OCV (Bank 2) IGN IGSW OC2+ OC2- C/OPN M Knock Sensor (Bank 1) FC Starter KNK1 EKNK Knock Sensor (Bank 2) KNK2 Fuel Pump EKN2 FPR CKP Sensor NE+ NE- M Fuel Pump Fuel Pump Resistor *1: For Automatic Transmission *2: For Manual Transmission A B C D A115961E01 ES–7 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A B C D BATT E1 MREL E01 E02 E03 E04 E05 EFI +B EFI EFI No +B2 ETCS +BM ME01 SEL EOM ES ACIS VSV ACIS Purge VSV P/S Pressure Switch PRG PSW HO2S (Bank Sensor 2) OX1B HT1B APP Sensor HO2S (Bank Sensor 2) OX2B HT2B MAF Meter IAT Sensor THA VG VCPA VPA EPA VCP2 VPA2 EPA2 E2G MPMP Canister Pump Module DLC3 VPMP PPMP TC CANH VC CANL CAN BUS A B C D E A115962E01 ES–8 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A B C D E IMI VVT Sensor (Bank 1) VV1+ Immobilizer ECU IMO VV1Voltage Inverter ELS2 ES VVT Sensor (Bank 2) VV2+ VV2- AC1 A/C Amplifier Assembly ACT 4WD (*5) ADD Actuator (*6) 4WD Control ECU VTA1 VTA2 Throttle Position Sensor M+ MGE01 L4 Airbag Sensor Assembly F/PS THW ECT Sensor Stop Light Switch E2 IGN ST1(*4) STOP STP A/F HEATER (*3) (*3) (*3) A/F HEATER (*3) *3: With VSC Battery (*3) IG No STOP LP CTRL *4: Without VSC *5: For 4WD Skid Control ECU *6: For 4WD and Automatic Transmission A B C A115963E01 ES–9 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A B C A/F Sensor (Bank Sensor 1) A1A+ A1A- IG No D Cruise Control Clutch Switch (*2) HA1A A/F Sensor (Bank Sensor 1) A2A+ A2A- ES CCS Cruise Control Switch HA2A Fuel Injector #1 #10 R Fuel Injector #2 D #20 PNP Switch (*1) Fuel Injector #3 #30 Fuel Injector #4 #40 Fuel Injector #5 Combination Meter #50 L Fuel Injector #6 Shift Lock Relay (*1) #60 *1: For Automatic Transmission A B *2: For Manual Transmission A115964E01 ES–10 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A B Transmission Assembly (*1) Ignition Coil and Igniter No IGT1 S1 Shift Solenoid S2 Ignition Coil and Igniter No IGT2 SR ES Line Pressure Solenoid Ignition Coil and Igniter No IGT3 SLT+ SLTLock-up Solenoid Ignition Coil and Igniter No IGT4 SLU+ SLUC1 Clutch Solenoid SL1+ SL1- Ignition Coil and Igniter No IGT5 B1 Clutch Solenoid SL2+ SL2- Ignition Coil and Igniter No Oil Temperature Sensor IGT6 THO1 IGF1 TAIL Oil Temperature Sensor ELS THO2 Vehicle Speed Sensor (*1) SP2+ SP2Turbine Speed Sensor (*1) NT+ *1: For Automatic Transmission NT- A115965E01 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–11 HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester VEHICLE BROUGHT TO WORKSHOP NEXT CUSTOMER PROBLEM ANALYSIS NEXT CONNECT INTELLIGENT TESTER TO 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–12 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Proceed To Malfunction does not occur A Malfunction occurs B B GO TO STEP 10 A ES SIMULATE SYMPTOMS NEXT 10 CHECK DTC* B Result Proceed To Malfunction code A No code B GO TO STEP 12 A 11 REFER TO DTC CHART NEXT 12 CONDUCT BASIC INSPECTION 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 B A Proceed To Malfunctioning circuit confirmed A Malfunctioning parts confirmed B GO TO STEP 17 ES–13 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 14 CHECK ECM POWER SOURCE CIRCUIT NEXT 15 CONDUCT CIRCUIT INSPECTION Result Proceed To Malfunction not confirmed A Malfunction confirmed B B A 16 CHECK FOR INTERMITTENT PROBLEMS NEXT 17 CONDUCT PARTS INSPECTION NEXT 18 IDENTIFY PROBLEM NEXT 19 ADJUST AND/OR REPAIR NEXT 20 NEXT END CONDUCT CONFIRMATION TEST GO TO STEP 18 ES