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