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training manual STEP / VOLUME TCCS (TOYOTA COMPUTERCONTROLLED SYSTEM) FOREWORD This Training Manual has been prepared for the use of technicians employed by Toyota's overseas distributors and dealers This manual, "TCCS (Toyota Computer-Controlled System)", is Volume of the thirteen Training Manuals which constitute Step of the program of skills which all Toyota New TEAM* technicians should master It should also be used by the instructor in conjunction with the accompanying Instruction Guide The titles of the New TEAM Step Training Manuals are as follows : VOL TRAINING MANUALS VOL TRAINING MANUALS TCCS ( Toyota Computer-Controlled System) NVH (Noise, Vibration & Harshness ) Turbocharger & Supercharger Fundamentals of Electronics Diesel Injection Pump 10 CCS (Cruise Control System ) ECT ( Electronically-Controlled Transmission) 11 Car Audio Syste m Full-Time 4WD 12 Automatic Air Conditioning Syste m TEMS & Air Suspension 13 SRS Airbag & Seat Belt Pretensione r ABS & Traction Control Syste m It is not enough just to "know" or "understand" - you need to master each task so that you can it For this reason, theory and practice have been combined in this Training Manual The top of each page is marked either with a Q symbol to indicate that it is a Theory page or a® symbol to indicate that it is a Practice page Note that in regards to inspection and other procedures mentioned in the Practice section, this Training Manual contains only the main points to be learned ; please refer to the relevant Repair Manual(s) for details The following notations often occur in this manual, with the meanings as explained : CAUTION NOTICE NOTE A potentially hazardous situation which could result in injury to people may occur i f instructions are not followed Damage to the vehicle or components may occur if instructions are not followed Notes or comments not included under the above two headings Information not required to pass the TEAM certification, but which may be useful t o REFERENCE instructors and to trainess who wish to gain a deeper knowledge of the subject *TEAM : TEAM stands for 'Technical Education for Automotive Maste ry' , which is a training program divided into three steps according to the technician's technical level This program makes it possible for technicians to receive the appropriate training for their level in a systematic manner so as to help them achieve the skills and efficiency of skilled technicians in the sho rtest possible time This Training Manual explains the TCCS engine control system based on the 4A-FE engine However, representative engines other than the 4A-FE engine have sometimes been selected to explain mechanisms not found" on the 4A-FE engine In this way, explanations of as many mechanisms as possible have been included All information contained in this manual is the most up-to-date at the time of publication However, we reserve the right to make changes without prior notice TOYOTA MOTOR CORPORATIO N ©1997 TOYOTA MOTOR CORPORATION All rights reserved This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation TABLE OF CONTENT S Page Page ABBREVIATIONS AND ECU TERMINAL SYMBOL S ABBREVIATIONS VEHICLE SPEED SENSOR Reed switch type 34 Photocoupler type 34 ECU TERMINAL SYMBOLS OUTLINE OF TCC S WHAT IS TCCS? HISTORY OF TCCS ENGINE CONTROL SYSTEM SYSTEM DESCRIPTION Functions of engine control system Construction of engine control system 10 Engine control system diagram ELECTRONIC CONTROL SYSTE M GENERAL 13 POWER CIRCUITRY 15 Engine without stepper motor typ e ISC valve 15 Engine with stepper motor type ISC valve 16 VC CIRCUITRY 16 GROUND CIRCUITRY 16 MANIFOLD PRESSURE SENSO R (VACUUM SENSOR) 17 AIR FLOW METER 18 Vane type 18 Optical Karman vortex type 21 Hot-wire type 21- THROTTLE POSITION SENSOR 22 On-off type 22 Linear type G AND NE SIGNAL GENERATORS 24 In-distributor type 24 Cam position sensor type 27 Separate type WATER TEMPERATURE SENSOR 30 INTAKE AIR TEMPERATURE SENSOR 30 OXYGEN SENSOR (02 SENSOR) 30- 1 Zirconia element type 30-1 Titania element type 32 LEAN MIXTURE SENSOR 33 Electromagnetic pickup type 35 MRE type STA SIGNAL 38 NSW SIGNAL 38 A/C SIGNAL 39 ELECTRICAL LOAD SIGNAL 39 FUEL CONTROL SWITCH O R CONNECTOR 40 EGR GAS TEMPERATURE SENSOR 40 VARIABLE RESISTOR 41 KICK-DOWN SWITCH 42 WATER TEMPERATURE SWITCH 42 CLUTCH SWITCH 42 KNOCK SENSOR 43 HAC SENSOR 44 VAPOR PRESSURE SENSOR 44 TURBOCHARGING PRESSURE SENSOR 44 STOP LAMP SWITCH 45 OIL PRESSURE SWITCH 45 COMMUNICATIONS SIGNALS Throttle opening angle signals 45 Throttle opening angle signals fo r TRC system 45 Cruise control syste m communications signal 46 TRC system communications signal 46 ABS communications signal 46 Intercooler system warning signal 46 EHPS system communication s signal 47 Engine speed signal 47 Engine immobiliser syste m communications signal 47 DIAGNOSTIC TERMINAL(S) • ••••• EFI (ELECTRONIC FUEL INJECTION ) GENERAL 49 TYPES OF EFI 52 D-type EFI 52 Z-L£ l II-080 i ndlno leulw i 9£1 a3 ldn J0 3A 'Z ti£L•••• suolioun} dwel „3NIJN3 )103H0„ L ££ """""""""' 1f1d1f10 lb'NIWa3 l3n dn (I Nb' dWt/l „ 3NIDN3 )103H0„ Z£ L"""' W31S A S 011SON O VIO 3O 3ldI0NI!!d L C L lb'a3 N3 SISONJtJI O IN31S )lS Oa1N00 IV 6Z l" * *"*'* " * '*- ' W31S A S 0a1N00 St/ 8Z L"""""""""""' VY31SAS 1N00 SdH3 8Z VY31SAS O 81 N00 3Jab'H 08 3dfl S LZl VY31SAS 10a1N0 3Fif1SS3 d NI at/H008!lfll t, Z I SI A- 6Zl Z adAl • Z ZZl L adAl • L OZL OZ l Slob' L LL VY31SAS AD S 1 """"""""""' 1N3WJOflf 3Nb'100 l3flj L L"""""' W31S lS Oa1N00 d30-1f10 !!J3 L L"""""' Ia}uoo AeIaJ 4o i n{o oi j au6eW • Z lojwoo }!o-3n0 5Ll L L-* VY31SAS 0lilN00 a3N011ION00 HIV t 'L l"""""""""""""" W31S lS 10 1N00 31b'3H 0SN3S 3af11XIW Nb'3 5L ti l l W31S lS 10H1N00 a31d3H >:IOSN3S N3D A X0 til L""""W31SAS 1O!l1N00 d30-1f10 00 10 It/U31\13 Ell SIN3ISAS OalN00 a3H1 Iw I uoo 110 -u0 • V L l"' anlen OSI adAl nOy lo il uoo- Ain(] •E 80l"' anlen OSI adA l pioualos A i e3oa •Z 90L"""""'anlen OSI adA l j o ;ow j adda l S I I L l""anIen OSI adAl ASA 90L""""""""" f103 3N10N3 30 SNOIl0Nf1 adA l ASA lo J woo };o-uO • t, tl Ol VOL adAi n0