Toyota 1KZ-TE Operating instructions

1999 TOYOTA MOTOR CORPORATION
All rightsreserved. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing; Jun. 11, 1999 01--990611--00--2
FOREWORD
This REPAIR MANUAL has been prepared to provide information covering general service repairs
for the 1KZ-TE ENGINE equipped on the TOYOTA HILUX.
Applicablemodels:KZN165 series
Pleasenotethatthepublicationsbelowhavealsobeenpreparedasrelevantservicemanualsforthecompo-
nents and system in this engine.
Manual Name Pub. No.
SHILUX Electrical Wiring Diagram EWD307F
All information in this manualis based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
Thismanualdoesnotincludeallthenecessaryitemsaboutrepairandservice.Thismanualismade
for the purpose of the use for the persons who have special techniques and certifications. In the
casesthatnon--specializedoruncertifiedtechniciansperformrepairorserviceonlyusingthismanu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages toyour customer’svehicle, besure to follow
the instruction shown below.
SMustreadthismanualthoroughly.It isespeciallyimportanttohave goodunderstandingallthe
contents written in the PRECAUTION of ”IN” section.
STheservicemethodwritteninthismanualisveryeffectivetoperform repairandservice.When
performingtheoperationsfollowingtheproceduresusingthismanual,besuretousetoolsspe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
SIfpartreplacementisnecessary,mustreplacethepartwiththesamepartnumberorequivalent
part. Do not replace it with inferior quality.
SIt is important to note that this manual contains various ”Cautions”and ”Notices”that must be
carefullyobserved in order to reduce the risk of personal injury duringservice or repair, or the
possibilitythatimproper serviceorrepairmaydamage thevehicle or renderitunsafe.Itisalso
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of allthe possible hazardous consequences that might result from failure to
follow these instructions.
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1KZ-TE
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INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
ENGINE MECHANICAL
TURBOCHARGER
EMISSION CONTROL
ELECTRONIC CONTROL DIESEL
ENGINE FUEL
COOLING
LUBRICATION
STARTING
CHARGING
ALPHABETICAL INDEX
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ENGINE 1KZ-TE: HILUX
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MAIN INDEX
June 2000
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INTRODUCTION
HOW TO USE THIS MANUAL IN--1.............
GENERAL INFORMATION IN--1..................
IDENTIFICATION INFORMATION IN--3..........
ENGINE SERIAL NUMBER IN--3.................
REPAIR INSTRUCTIONS IN--4.................
GENERAL INFORMATION IN--4..................
FOR ALL OF VEHICLES IN--8..................
PRECAUTION IN--8.............................
HOW TO TROUBLESHOOT
ECU CONTROLLED SYSTEMS IN--9.........
GENERAL INFORMATION IN--9..................
HOW TO PROCEED
WITH TROUBLESHOOTING IN--10..............
HOW TO USE THE DIAGNOSTIC CHART
AND INSPECTION PROCEDURE IN--20..........
TERMS IN--25.................................
ABBREVIATIONS USED IN THIS MANUAL IN--25....
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1KZ-TE

IN04V-- 04
B07996
B08237
N∙m (kgf∙cm, ft∙lbf) : Specified torque
zNon--reusable part
zCrankshaft Front Oil Seal
zGasket
Relief Valve
Spring
Plug
49 (500, 36)
Driven Rotor
--INTRODUCTION HOW TO USE THIS MANUAL
IN--1
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1.INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2.PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN--9.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5.REPAIRPROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
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1KZ-TE

Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Taskheading: what todo
SST 09350--30020 (09350--06120)
Set part No. Component partNo.
Detailed text : howtodotask
(b)
Piston stroke: 1.40 —1.70 mm (0.0551 — 0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392 —785kPa,4—8kgf/cm2or 57 —114 psi) as shown
in the illustration.
IN--2
--INTRODUCTION HOW TO USE THIS MANUAL
The procedures are presented in a step--by--step format:
SThe illustration shows what to do and where to do it.
SThe task heading tells what to do.
SThe detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6.REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8.CAUTIONS,NOTICES,HINTS:
SCAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
SNOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
SHINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9.SIUNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N∙m (310 kgf∙cm, 22 ft∙lbf)
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B09246
IN0E6-- 02
--INTRODUCTION IDENTIFICATION INFORMATION
IN--3
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
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P23717
IN0E7-- 02
IN--4
--INTRODUCTION REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASICREPAIRHINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Observe the following operations:
(1) Before performing electrical work, disconnect the
negative (--) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the negative
(--) terminal cable which is grounded to the vehicle
body.
(3) To prevent damage to the battery terminal, loosen
the cable nut and raise the cable straight up without
twisting or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals with
the nut loose, and tighten the nut after installation.
Do not use a hammer to tap the cable ends onto the
terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are secure and correct.
(e) Non--reusable parts
(1) Always replace cotter pins, gaskets, O--rings and oil
seals etc. with new ones.
(2) Non--reusable parts are indicated in the component
illustrations by the ”z” symbol.
(f) Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
(3) Precoated parts are indicated in the component il-
lustrations by the ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
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BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
AbbreviationPart NameSymbolIllustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER
FUSE
M--FUSE
H--FUSE
FL
CB
--INTRODUCTION REPAIR INSTRUCTIONS
IN--5
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in section PP (Preparation) in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations.
SCancel the parking brake on the level place and
shift the transmission in Neutral (or N position).
SWhen jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
SWhen jacking up the rear wheels of the vehicle at
first place stoppers behind the rear wheels.
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IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN--6
--INTRODUCTION REPAIR INSTRUCTIONS
SWhen either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
SAfter the vehicle is jacked up, be sure to support it
on rigid racks. It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission--related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter for adjustment. Once the hose has been
stretched, it may leak.
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IN0002
Example
--INTRODUCTION REPAIR INSTRUCTIONS
IN--7
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C(68˚F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
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IN0E8-- 02
IN--8
--INTRODUCTION FOR ALL OF VEHICLES
FOR ALL OF VEHICLES
PRECAUTION
1. IF VEHICLEIS EQUIPPED WITHMOBILECOMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with the other wiring as much as possible, and also
avoid running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
2.FORUSING HAND--HELD TESTER
CAUTION:
Observe the following items for safety reasons:
S
SS
SBefore using the hand--held tester, the hand--held tester’s operator manual should be read
throughly.
S
SS
SBe sure to route all cables securely when driving with the hand--held tester connected to the
vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
S
SS
STwo persons are required when test driving with the hand--held tester, one person to drive the
vehicle and one person to operate the hand--held tester.
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IN050-- 05
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
IN--9
HOW TOTROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the HILUX. In general, the ECU controlled system
is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to
troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of
these systems is not complex. If you have adequate understanding of the system and a basic knowledge
of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This
manual is designed through emphasis of the above standpoint to help service technicians perform accurate
and effective troubleshooting, and is compiled for the following major ECU controlled systems:
System Page
Engine DI--1
The troubleshooting procedure and how to make use of it are described on the above pages.
FORUSING HAND--HELD TESTER
SBefore using the hand--held tester, the hand held--tester’s operator manual should be read throughly.
SIf the hand--held tester cannot communicate with ECU controlled systems when you have connected
the cable of the hand--held tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Busline) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outlined in the Tester Operator’s
Manual.
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INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
HOW TO PROCEED WITH TROUBLESHOOTING IN-10
1. CUSTOMER PROBLEM ANALYSIS IN-11
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK IN-12/13
3. SYMPTOM SIMULATION IN-14/15
4. DIAGNOSTIC TROUBLE CODE CHART IN-16
5. PROBLEM SYMPTOMS TABLE IN-17
6. CIRCUIT INSPECTION IN-18/19
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IN051-- 0 5
Vehicle Brought to Workshop
Customer Problem
Analysis
Symptom Confirmation
and Diagnostic Trouble
Code Check Symptom Simulation
Diagnostic Trouble
Code Chart
Problem Symptoms Table
Circuit Inspection or Parts
Inspection
Repair
Confirmation Test
End
1
2
4
3
5
6
7
8
Ask the customer about the conditions and the
environment when the problem occurred.
1
Confirm the symptoms and the problem conditions,
and check the diagnostic trouble codes.
(When the problem symptoms do not appear
during confirmation, use the symptom simulation
method described later on.)
2, 3
Check the results obtained in Step 2, then confirm
the inspection procedure for the system or the part
which should be checked using the diagnostic
trouble code chart or the problem symptoms table.
4, 5, 6
Check and repair the affected system or part in
accordance with the instructions in Step 6.
7
After completing repairs, confirm that the problem
has been eliminated.
(If the problem is not reproduced, perform the
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.)
8
IN--10 --INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
HOW TOPROCEEDWITHTROUBLESHOOTING
Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro-
cedure is shown. Details are provided in each section, showing the most effective methods for each circuit.
Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that
circuit.
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Important Points in the Customer Problem Analysis
DWhat ---------- Vehicle model, system name
DWhen ---------- Date, time, occurrence frequency
DWhere ---------- Road conditions
DUnder what conditions? ---------- Running conditions, driving conditions, weather conditions
DHow did it happen? ---------- Problem symptoms
(Sample) Engine control system check sheet.
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Drive ability
Engine Stall
Others
Engine does not crank No initial combustion No complete combustion
Engine cranks slowly
Other
Incorrect first idle Idling rpm is abnormal High ( rpm) Low ( rpm)
Rough idling Other
Hesitation Back fire Muffler explosion (after--fire) Surging
Knocking Other
Soon after starting After accelerator pedal depressed
After accelerator pedal released During A/C operation
Shifting from N to D Other
Datas Problem
Constant Sometimes ( times per day/month)
Inspector’s
Name
CUSTOMER PROBLEM ANALYSIS CHECK
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
IN--11
1.CUSTOMERPROBLEMANALYSIS
In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it
is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Important Point in the Problem Analysis:
The following 5 items are important points in the problem analysis. Past problems which are thought to be
unrelated and the repair history, etc. may also help in some cases, so as much information as possible should
be gathered and its relationship with the problem symptoms should be correctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each
system for your use.
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DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear)
Confirmation
of Symptoms
Diagnostic Trouble
Code Check Problem Condition
Diagnostic Trouble
Code Display
Problem symptoms
exist
Same diagnostic
trouble code is
displayed
Problem is still occurring in the diagnostic
circuit
Normal code is
displayed
The problem is still occurring in a place
other than in the diagnostic circuit
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem)
No problem
symptoms exist
The problem occurred in the diagnostic
circuit in the past
Normal Code Display Problem symptoms
exist
Normal code is
displayed
The problem is still occurring in a place
other than in the diagnostic circuit
No problem
symptoms exist
Normal code is
displayed
The problem occurred in a place other
than in the diagnostic circuit in the past
IN--12 --INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
2.SYMPTOMCONFIRMATIONAND DIAGNOSTICTROUBLE CODE CHECK
The diagnostic system in the HILUX fulfills various functions. The first function is the Diagnostic Trouble
Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory
at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input
Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the HILUX.
System Diagnostic Trouble
Code Check
Input Signal Check
(Sensor Check)
Other Diagnosis
Function
Engine f
(with Test Mode)
fDiagnostic Test
Mode
In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag-
nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.
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Diagnostic trouble code check
Making a note of and clearing of the diagnostic trouble codes displayed
Symptom confirmation
No problem symptoms
exist
Problem symptoms
exist
Simulation test using the symptom
simulation methods
DNormal code displayed
DProblem symptoms exist DNormal code displayed
DNo problem symptoms exist
Diagnostic trouble code check
Troubleshooting of problem indicated
by diagnostic trouble code
DDiagnostic trouble code displayed
DProblem symptoms exist
System Normal
Troubleshooting of each
problem symptom If a diagnostic trouble code was
displayed in the initial diagnostic
trouble code check, it indicates
that the trouble may have occurred
in a wire harness or connector in
that circuit in the past. Therefore,
check the wire harness and con-
nectors(See page IN--20).
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
IN--13
Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the
diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble
code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic
trouble code troubleshooting or to troubleshooting of problem symptoms.
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V07268
VIBRATIONMETHOD: When vibrationseems tobethemajorcause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR
1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the
malfunction occurs.
Shake Slightly
Swing Slightly
Vibrate Slightly
HINT: Applying strong vibration to relays may result in open
relays.
IN--14 --INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer’s vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes of the symptom.
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V07469
HEATMETHOD: When theproblem seems tooccurwhen thesuspect area isheated.2
NOTICE:
(1) Do not heat to more than 60˚C (140˚F). (Temperature
is limitednot todamage the components.)
(2) Do not apply heat directly to parts in the ECU.
3WATER SPRINKLINGMETHOD:
NOTICE:
(1) Never sprinkle water directly into the engine
compartment, but indirectly change the temperature and
humidity by applying water spray onto the radiator front
surface.
(2) Never apply water directly onto the electronic
components.
4OTHER: When amalfunctionseems tooccurwhen electrical load isexcessive.
When themalfunctionseems tooccuronarainyday orina
high--humiditycondition.
Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.
ON
HINT:
Ifavehicle is subjecttowater leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
IN--15
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DDTC No.
Indicates the diagnostic trouble code.
DPage or Instructions
Indicates the page where the inspection procedure
for each circuit is to be found, or gives instructions
for checking and repairs.
DDetection Item
Indicates the system of the problem or
contents of the problem.
DTrouble Area
Indicates the suspect area of the
problem.
Crankshaft Position Sensor Circuit
Malfunction
Detection Item
DOpen or short in crankshaft position sensor circuit
DCrankshaft position sensor
DEngine ECU
DTC No.
(See page) Trouble Area
*1
Check Engine
Warming Light
Normal Mode/
Test Node
*2
Memory
(DI -- 12)
Engine Speed Sensor Circuit
Malfunction
Diesel Throttle Control Circuit
Malfunction
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other
factors.
If a malfunction code is displayed during the DTC check in check (test) mode, check the circuit for that code
listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the
respective ”DTC No.” in the DTC chart.
DOpen or short in engine speed sensor circuit
DEngine speed sensor
DEngine ECU
DOpen or short in E--VRV for main actuator circuit
DE--VRV for main actuator
DDiesel throttle position sensor circuit
DDiesel throttle position sensor
DMain actuator
DVacuum hose disconnected or blocked
DEngine ECU
12
(DI -- 28)
13
(DI -- 32)
15
ON / N.A
ON / N.A
ON / N.A
DEngine ECU
Interior IC Malfunction
IN--16 --INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
4.DIAGNOSTICTROUBLE CODE CHART
The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot-
ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble-
shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the
diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.
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1KZ-TE
CONTINUED