ENGINE CONTROL SYSTEMS II Course 874 Technician Handbook © 2010 Toyota Motor Sales, U.S.A., Inc TOYOTA Technical Training 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 Revision Date: April 9, 2010 Table of Contents 874 Engine Control Systems II Section 1: Introduction Course Topics .2 Diagnostic Tools and Resources Previous Troubleshooting Experience .3 Use of the On-Board Diagnostic System .4 Diagnostic Toolset General OBD II Scan Tool or Techstream Procedure How to Proceed with Troubleshooting Operation Flow DTC Check Operation Flow DTC Information Section 2: OBD (On-Board Diagnostics) OBD Generations 10 OBD 10 OBD II 10 CAN OBD II 10 TIS Techstream Diagnostic Trouble Codes Screen 11 Diagnostic Trouble Codes (DTCs) 11 Trip 12 OBD II Trip .12 Warm-Up Cycle 12 MIL ON One Trip 13 MIL ON Two Trip 14 MIL Blinking 15 MIL OFF 16 MIL & DTC Summary 16 Permanent DTC 17 Clearing Permanent DTCs 17 Confirmation Driving Pattern 18 Universal Trip Driving Pattern 18 OBD II Diagnostic Trouble Codes (DTC) 19 Freeze Frame 20 Data List 21 Data List Graphing 22 Snapshot 23 Active Test 24 Readiness Monitor 25 Readiness Monitors 26 Cumulative Monitor 27 Current Monitor .28 Continuous Monitors .29 Non-Continuous Monitors .30 Non-Continuous Readiness Monitor Drive Patterns 32 The Catalyst Monitor Drive Pattern 32 A/F and HO2 Sensor Monitor Drive Pattern 32 Interpreting Non-Continuous Readiness Monitors Status and Results 33 Interpreting Monitor Status .34 Technical Training i Table of Contents 874 Engine Control Systems II Readiness Monitor Test Results 35 Readiness Monitor Test Details – DTCs Cleared 37 Utility 39 Check Mode 40 ii Section 3: Comprehensive Components Monitor Diagnosis Comprehensive Components Monitor Overview 42 Mass Air Flow (MAF) Sensor Circuit 43 Comprehensive Components Monitor Diagnosis 43 Section 4: Engine Misfire Diagnosis Engine Misfire Diagnosis 45 Misfire DTCs .46 Misfire Monitor Types A and B .47 Misfire Monitor Type A .47 Misfire Monitor Type B .47 Ignition Counter 48 1998 and Earlier Models 48 1999 and Later Models 48 Misfire Data List 49 Ignition 49 Cylinder # Misfire Rate 49 Misfire Margin (CAN OBD II vehicles) .49 Cat OT MF F/C .49 Misfire Detection 50 Misfire Monitor 51 Duplicating Misfires 52 Misfire Margin .53 Single Cylinder Misfire Diagnosis .54 Compression Test 55 Active Test 55 Cylinder Speed Data List .56 Multiple Cylinder Misfire Diagnosis 57 Fuel 57 Mechanical .57 Inputs .57 Outputs 57 IGF Fail-Safe 58 Section 5: O2 and A/F Sensor Diagnosis O2 and A/F Sensor Diagnosis .61 Oxygen Sensor Construction and Operation .62 Oxygen Sensor Heater 63 A/F Sensor Construction and Operation 65 A/F Sensor Heater 69 Technical Training Table of Contents 874 Engine Control Systems II Comparisons Between A/F Sensor and O2 Sensor 71 O2 Sensor Monitors .73 O2 Sensor Monitor .74 Monitor Methods 74 A/F and O2 Sensor DTCs 75 O2 Sensor Heater Monitor 75 Heater DTCs 75 Catalytic Converter Overview 76 Catalytic Converter Monitor 77 Catalytic Converter Efficiency Below Threshold DTCs 77 O2 and A/F Sensor Activation .78 O2 and A/F Sensor Test 79 O2 and A/F Sensor Activation and Test Snapshot 80 O2 - A/F Sensor & Catalyst (OSC) Test 2: Injector Volume or A/F Control Active Test 81 O2 and A/F Sensor Test 3: Fuel Enrichment and Fuel Cut 83 Active Air/Fuel Ratio Control 84 Stage 1: A/F Learning 84 Stage 2: A/F Sensor Output Judgment 85 Stage 3: Active A/F Control .85 Active AF Control Capture-Good Catalyst Response 87 Active AF Control Capture-Failed Catalyst Response 88 Section 6: Fuel System Diagnosis Technical Training Fuel Trim Overview 91 Fuel Trim Basics 91 Calculated Load (Calc Load) 92 Stoichiometric Air/Fuel Ratio 93 Fuel Trim 94 Basic Injection Duration and 0% Fuel Trim 94 Fuel Trim DTCs 95 Closed Loop and Open Loop .96 Positive or Negative Fuel Trims 97 Short-Term and Long-Term Fuel Trim 97 Feedback-Related Issues 98 Mass Air Flow (MAF) Sensor .99 Operation 99 Airflow-Free VG Check .100 MAF Sensor Conditions .101 MAF Sensor or Intake System Leak Diagnosis Tips 103 Relationship between Fuel Injection Duration and MAF Malfunction or Air Leak 104 Fuel Trim DTCs Without Driveability Issues .104 Relationship between Fuel Injection Duration and Fuel System Malfunction 105 Where to Start Diagnosis 107 Check the Basics 107 iii Table of Contents 874 Engine Control Systems II Injector Volume Active Test 108 Fuel Trim Diagnosis Tips 109 System Too Lean –Both Banks Diagnosis and/or P0171 and P0174 114 System Too Lean –One Bank Diagnosis and/or P0171 and P0174 115 System Too Rich Diagnosis .116 Section 7: Evaporative Emissions (EVAP) System Diagnosis iv Evaporative Emissions (EVAP) System Overview 119 EVAP Systems Monitoring 119 EVAP Systems 119 EVAP Diagnosis Tips 120 Vapor Pressure Sensor Overview .122 Prepare Vapor Pressure Sensor for EVAP System Diagnosis 122 Vapor Pressure Sensor Diagnosis 122 EVAP Application Chart 123 Early Type EVAP System Overview 124 Early Type EVAP System Monitor 124 Early Type EVAP System Diagnosis Tips .124 Early Type EVAP System Diagnosis 125 P0440: Evaporative Emission Control System Malfunction 125 P0441: Evaporative Emission Control System Incorrect Purge Flow .125 P0446: Evaporative Emission Control System Vent Control Malfunction 126 Late Type EVAP System Overview 128 Vacuum in Tank/Relief via Canister .129 Vacuum in Tank/Relief via Tank Cap 130 Pressure in Tank/Relief via Canister .131 Purge 132 ORVR Operation 133 Late Type EVAP System Monitor .134 Late Type EVAP System Diagnosis 136 LEV-II EVAP System Overview 138 LEV-II EVAP System Monitor 139 LEV-II EVAP System Diagnosis .141 LEV-II with Vacuum Pump (Key-OFF) EVAP System Overview 142 LEV-II with Vacuum Pump (Key-OFF) EVAP System Pump Module 143 LEV-II with Vacuum Pump (Key-OFF) EVAP System Monitor Enabling Conditions 144 LEV-II with Vacuum Pump (Key-OFF) EVAP System Monitor 145 LEV-II with Vacuum Pump EVAP System Diagnosis .147 LEV-II with Vacuum Pump (Key-OFF) EVAP System Leak Diagnosis 148 Technical Training Table of Contents 874 Engine Control Systems II LEV-II with Vacuum Pump (Key-OFF) EVAP System Pump Diagnosis 149 Closed Fuel Tank EVAP System Overview .151 Closed Fuel Tank EVAP System Monitors 152 Fuel Tank Internal Pressure Higher or Lower Than Atmospheric 153 Fuel Tank Internal Pressure Same As Atmospheric 155 Closed Fuel Tank EVAP System Diagnosis .157 Section 8: Secondary Air Injection System Diagnosis Single Pump Secondary Air Injection System Overview 160 Single Pump Secondary Air Injection Monitor .160 Single Pump Secondary Air Injection DTCs 160 Single Pump Secondary Air Injection System Monitor Sequence .161 Single Pump Secondary Air Injection System Diagnosis 162 Single Pump Secondary Air Injection System Diagnosis Tips .162 Dual Pump Secondary Air Injection System Overview 164 Dual Pump Secondary Air Injection Monitor 165 Dual Pump Secondary Air Injection DTCs 165 Dual Pump Secondary Air Injection System Diagnosis 166 Dual Pump Secondary Air Injection System Diagnosis Tips 166 Section 9: Additional Systems Additional Systems 169 Thermostat Monitor 170 Thermostat Monitor Diagnosis 170 Exhaust Gas Recirculation (EGR) System Overview .171 Exhaust Gas Recirculation (EGR) System Monitor 171 Exhaust Gas Recirculation (EGR) System Diagnosis 171 VVT-i Diagnosis 172 VVT-i 172 Dual VVT-i .172 VVT-iE 172 VVT-i Monitors .173 Camshaft Position Over-Advanced, Over-Retarded, or System Performance 173 Crankshaft Position – Camshaft Position Correlation 173 Camshaft Position Sensor Circuit 173 Camshaft Position Actuator Circuit 173 VVT Diagnosis .174 Active Tests 174 ETCS-i Overview 175 ETCS-i Monitor .175 ETCS-i Diagnosis 175 PZEV Overview 176 Early PZEV Vehicles .176 Late PZEV Vehicles .176 PZEV Diagnosis 176 Technical Training v Table of Contents 874 Engine Control Systems II ECM Diagnosis Overview 177 Failure of Techstream to Establish Communications with ECM 177 ECM Circuit Diagnosis 177 ECU Reprogramming 178 ECU Reprogramming Tips .178 VC Circuit Diagnosis 180 Immobiliser System Overview 181 Immobiliser System Diagnosis .181 Immobiliser System Diagnosis Tips .181 Hybrid Systems 182 Hybrid System Diagnosis .182 Section 10: Appendix A: Late Type EVAP Component Locations vi Appendix A: Late Type EVAP Component Locations 184 Air Drain Port .185 Air Inlet Port .186 Purge Port 187 Air Inlet Control Valve Port 188 Bypass Valve .189 Bypass Valve Ports 190 EVAP Port 191 Vent (Fill Check Line) Port 192 Vapor Pressure Sensor .193 EVAP Application Chart 194 End of Presentation 195 Technical Training Technician Handbook 874 Engine Control Systems II Technical Training ... Chart 194 End of Presentation 195 Technical Training Technician Handbook 874 Engine Control Systems II Technical Training ... and Results 33 Interpreting Monitor Status .34 Technical Training i Table of Contents 874 Engine Control Systems II Readiness Monitor Test Results 35 Readiness Monitor Test... Construction and Operation 65 A/F Sensor Heater 69 Technical Training Table of Contents 874 Engine Control Systems II Comparisons Between A/F Sensor and O2 Sensor 71 O2 Sensor Monitors