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• Introduction

  4

• Check Piston Stroke of Overdrive Brake

  6

• Identification Information

  7

• Engine Serial Number

  7

• Repair Instructions

  8

• Basic Repair Hint

  8

• If Vehicle Is Equipped with Mobile Communication System

  12

• For Using Hand-Held Tester

  12

• How to Troubleshoot ECU Controlled Systems

  13

• How to Proceed with Troubleshooting

  14

• Customer Problem Analysis

  15

• Symptom Confirmation and Diagnostic Trouble Code Check

  16

• Symptom Simulation

  18

• Heat Method

  19

• Water Sprinkling Method

  19

• Diagnostic Trouble Code Chart

  20

• Problem Symptoms Table

  21

• Circuit Inspection

  22

• Wiring Diagram

  22

• Inspection Procedure

  23

• How to Use the Diagnostic Chart and Inspection

  24

• Connector Connection and Terminal Inspection

  24

• Continuity Check (Open Circuit Check)

  25

• Resistance Check/Short Circuit Check

  25

• Visual Check and Contact Pressure Check

  25

• Connector Handling

  26

• Check Open Circuit

  26

• Check Short Circuit

  27

• Check and Replace ECU

  28

• Terms

  29

• Abbreviations

  29

• Preparation

  31

• Engine Mechanical Special Service Tools

  32

• Engine Mechanical Recommended Tools

  36

• Engine Mechanical Equipment

  37

• Engine Mechanical Special Service Materials

  38

• Turbocharging Special Service Tools

  39

• Turbocharging Recommended Tools

  40

• Turbocharging Equipment

  41

• Electronic Control Diesel Special Service Tools

  42

• Electronic Control Diesel Recommended Tools

  43

• Electronic Control Diesel Equipment

  44

• Engine Fuel Special Service Tools

  45

• Engine Fuel Recommended Tools

  47

• Engine Fuel Equipment

  48

• Cooling Special Service Tools

  49

• Cooling Equipment

  50

• Coolant

  51

• Coolant Special Service Materials

  52

• Lubricant

  53

• Lubricant Special Service Materials

  54

• Starting Special Service Tools

  55

• Starting Recommended Tools

  56

• Starting Equipment

  57

• Charging Special Service Tools

  58

• Charging Recommended Tools

  59

• Charging Equipment

  60

• Service Specifications

  61

• Standard Bolt

  62

• How to Determine Bolt Strength

  62

• Specified Torque for Standard Bolts

  63

• How to Determine Nute Strength

  64

• Engine Mechanical Service Data

  65

• Engine Mechanical Torque Specification

  69

• Turbocharging Service Data

  70

• Turbocharging Torque Specification

  71

• Electronic Control Diesel Service Data

  72

• Electronic Control Diesel Torque Specification

  73

• Engine Fuel Service Data

  74

• Engine Fuel Torque Specification

  75

• Cooling Service Data

  76

• Cooling Torque Specification

  77

• Lubrication Service Data

  78

• Lubrication Torque Specification

  79

• Starting Service Data

  80

• Starting Torque Specification

  81

• Charging Service Data

  82

• Charging Torque Specification

  83

• Diagnostics

  84

• Engine

  85

• Customer Problem Analysis Check

  86

• Pre-Check

  87

• Diagnosis System

  87

• Diagnosis Inspection (Normal Mode)

  88

• Fail-Safe Chart

  91

• Check for Intermittent Problems

  91

• Basic Inspection

  92

• Reference Value of Engine ECU Data

  94

• Engine Diagnostic Trouble Code Chart

  96

• Engine Parts Location

  98

• Terminals of ECU

  99

• Engine Problem Symptoms Table

  101

• Engine Speed Sensor Circuit Malfunction (TDC or G1 Circuit)

  103

• Engine Circuit Inspection

  103

• Engine Circuit Description

  103

• Engine Wiring Diagram

  103

• Engine Inspection Procedure

  104

• Engine Speed Sensor Circuit Malfunction (NE Circuit)

  105

• Timing Control System Malfunction

  106

• Water Temp. Sensor Circuit Malfunction

  109

• Intake Air Temp. Sensor Circuit Malfunction

  112

• Injection Pump Correction System Malfunction

  115

• Turbo Pressure Sensor Circuit Malfunction

  117

• Fuel Temp. Sensor Circuit Malfunction

  120

• Throttle Position Sensor Circuit Malfunction

  123

• Vehicle Speed Sensor Signal Circuit Malfunction

  125

• Starter Signal Circuit Malfunction

  127

• First Gear Position Switch Circuit Malfunction

  129

• Back up Power Source Circuit

  131

• Engine ECU Power Source Circuit

  133

• TE1, TE2 Terminal Circuit

  137

• Pre-Heating Control Circuit

  139

• Spill Control Valve Relay Circuit

  144

• Air Filter Inspection

  149

• Compression Inspection

  150

• Valve Clearance Inspection

  152

• Adjusting Shim Selection Using Chart

  154

• Injection Timing Inspection

  156

• Adjust Injection Timing

  156

• Idle Speed and Maximum Speed Inspection

  157

• Intake Construction Control Inspection

  158

• Connect Vacuum Gauges

  158

• Inspect Hot Engine Condition

  159

• Remove Vacuum Gauges

  159

• Timing Belt Components

  160

• Timing Belt Removal

  161

• Remove Timing Belt Cover

  161

• Set No.4 Cylinder to Tdc/Compression

  161

• If Re-Using Timing Belt, Mark Timing Belt

  161

• Remove Timing Belt Idler Pulley

  162

• Remove Timing Belt

  162

• Remove Intake Pipe

  162

• Remove Cylinder Head Cover

  163

• Remove No.1 Camshaft Timing Pulley

  163

• Inspect Timing Belt

  164

• Inspect Idler Pulley

  164

• Inspect Timing Belt Tensioner

  165

• Timing Belt Installation

  166

• Install No.1 Camshaft Timing Pulley

  166

• Install Cylinder Head Cover

  166

• Install Intake Pipe

  166

• Install No.2 Camshaft Timing Pulley

  167

• Install Timing Belt

  167

• Install Timing Belt Idler Pulley

  167

• Set Timing Belt Tensioner

  168

• Install Timing Belt Tensioner

  168

• Check Valve Timing

  168

• Install Timing Belt Cover

  169

• Timing Gear Components

  170

• Timing Gear Removal

  172

• Remove Camshaft Oil Seal Retainer

  172

• Remove Vacuum Pump

  172

• Remove Crankshaft Pulley

  172

• Remove Timing Gear Cover

  173

• Check Thrust Clearance of Idler Gear

  174

• Remove Timing Gears

  174

• Disassembly Idler Gear

  175

• Timing Gear Inspection

  177

• Inspect Idler Gear

  177

• Inspect Injection Pump Drive Gear Bearing

  177

• Check Backlash of Timing Gears

  178

• Timing Gear Replacement

  179

• Replace Crankshaft Front Oil Seal

  179

• Replace Injection Pump Drive Gear Oil Seal

  180

• Replace Injection Pump Drive Gear Bearing

  180

• Timing Gear Installation

  182

• Assemble Idler Gear

  182

• Install Timing Gear

  183

• Install Timing Gear Cover

  186

• Check Injection Pump Drive Shaft Thrust Clearance

  187

• Install Crankshaft Pulley

  187

• Install Vacuum Pump

  187

• Cylinder Head Components

  189

• Cylinder Head Removal

  192

• Drain Engine Coolant

  192

• Remove Water Outlet

  192

• Remove Intake Manifold

  193

• Remove Nozzle Leakage Pipe

  193

• Remove Injection Nozzles

  193

• Cylinder Head Disassembly

  197

• Cylinder Head Inspection

  199

• Clean Top Surfaces of Pistons and Cylinder Block

  199

• Remove Gasket Material

  199

• Clean Combustion Chambers

  199

• Clean Cylinder Head

  200

• Inspect for Flatness

  200

• Inspect for Cracks

  200

• Clean Valves

  200

• Inspect Valve Stems and Guide Bushings

  201

• Inspect and Grind Valves

  201

• Inspect and Clean Valve Seats

  202

• Inspect Valve Springs

  203

• Inspect Camshaft for Runout

  204

• Inspect Cam Lobes

  204

• Inspect Camshaft Journals

  204

• Inspect Camshaft Bearings

  204

• Inspect Camshaft Journal Oil Clearance

  205

• Inspect Camshaft Thrust Clearance

  205

• Inspect Valve Lifters and Lifter Bores

  205

• Inspect Intake and Exhaust Manifolds

  206

• Inspect Cylinder Head Bolts

  206

• Cylinder Head Replacement

  207

• Replace Valve Guide Bushings

  207

• Replace Camshaft Oil Seal

  208

• Cylinder Head Reassembly

  209

• Select Combination Chamber Shim

  209

• Install Combustion Chambers

  210

• Install Valves

  210

• Install Valve Lifters and Shims

  211

• Install Semi Circular Plug

  211

• Install Heater Water Inlet Pipe

  211

• Install Front Engine Hanger

  211

• Cylinder Head Installation

  212

• Check Piston Protrusion and Select Cylinder Head Gasket

  212

• Place Cylinder Head on Cylinder Block

  213

• Install Cylinder Head Bolts

  214

• Install Camshaft

  214

• Install Camshaft Oil Seal Retainer

  215

• Cylinder Block Components

  220

• Cylinder Block Disassembly

  223

• Remove Piston Rings

  230

• Disconnect Connecting Rod from Piston

  230

• Cylinder Block Inspection

  231

• Cylinder Block Replacement

  239

• Replace Oversized (O/S) Pistons

  239

• Cylinder Block Reassembly

  242

• Turbocharging

  249

• Turbocharging Troubleshooting

  250

• Turbocharging Maintenance Precaution

  251

• Turbocharger On-Vehicle Inspection

  252

• Inspect Intake Air System

  252

• Inspect Exhaust System

  252

• Turbocharger Components

  253

• Turbocharger Removal

  255

• Turbocharger Disassembly

  256

• Turbocharger Inspection

  259

• Clean Compressor Housing

  260

• Turbocharger Reassembly

  261

• Turbocharger Installation

  265

• Emission Control System

  267

• Positive Crankcase Ventilation (PCV) System Inspection

  268

• Electronic Control Diesel

  269

• ECD System Precaution

  270

• Throttle Body On-Vehicle Inspection

  272

• Inspect Throttle Body Operation

  272

• Throttle Body Components

  273

• Throttle Body Removal

  274

• Throttle Body Inspection

  275

• Throttle Body Installation

  276

• Timing Control Valve Inspection

  277

• Spill Control Valve Inspection

  278

• ECD Main Relay Inspection

  279

• Spill Control Valve Relay Components

  280

• Spill Control Valve Relay Inspection

  281

• VSV for Intake Constructor Control Components

  282

• VSV for Intake Constructor Control Inspection

  283

• Water Temperature Sensor Inspection

  284

• Fuel Temperature Sensor Inspection

  285

• Intake Air Temperature Sensor Inspection

  286

• Turbo Pressure Sensor Inspection

  287

• Engine Speed Sensor Inspection

  289

• Crankshaft Position Sensor Inspection

  290

• First Gear Position Switch Inspection

  291

• First Gear Position Switch Replacement

  292

• Injection Pump Correction Resistor Inspection

  293

• Engine ECU Components

  294

• Engine ECU Inspection

  295

• Engine Fuel

  296

• Fuel Filter Replacement

  297

• Injection Nozzle Components

  299

• Injection Nozzle Removal

  301

• Injection Nozzle Disassembly

  303

• Injection Nozzle Inspection

  304

• Injection Nozzle Reassembly

  306

• Injection Nozzle Test

  307

• Injection Pressure Test

  307

• Leakage Test

  308

• Spray Pattern Test

  308

• Injection Nozzle Installation

  309

• Injection Pump On-Vehicle Inspection

  311

• Injection Pump Components

  312

• Injection Pump Removal

  314

• Injection Pump Disassembly

  316

• Injection Pump Inspection

  318

• Injection Pump Reassembly

  319

• Injection Pump Installation

  321

• Cooling

  323

• Coolant Inspection

  324

• Coolant Replacement

  325

• Fill Engine Coolant

  325

• Water Pump Components

  326

• Water Pump Removal

  328

• Water Pump Inspection

  330

• Water Pump Installation

  331

• Install Water Pump Assembly

  331

• Thermostat Components

  333

• Thermostat Removal

  334

• Thermostat Inspection

  335

• Thermostat Installation

  336

• Radiator On-Vehicle Cleaning

  337

• Radiator On-Vehicle Inspection

  338

• Remove Radiator Cap

  338

• Inspect Radiator Cap

  338

• Inspect Cooling System for Leaks

  338

• Radiator Components

  339

• Radiator Disassembly

  340

• Radiator Reassembly

  341

• Caulk Lock Plate

  342

• Lubrication

  344

• Oil and Filter Inspection

  345

• Oil and Filter Replacement

  346

• Oil Pump Components

  348

• Oil Pump Disassembly

  353

• Oil Pump Inspection

  354

• Oil Pump Reassembly

  355

• Oil Pump Installation

  356

• Oil Cooler Components

  360

• Oil Cooler Removal

  362

• Oil Cooler Inspection

  364

• Oil Cooler Installation

  365

• Oil Nozzle Components

  367

• Oil Nozzle Removal

  368

• Oil Nozzle Inspection

  369

• Oil Nozzle Installation

  370

• Starting

  371

• Pre-Heating System Components

  372

• Pre-Heating System Inspection

  373

• Pre-Heating System Replacement

  375

• Replace Glow Plugs

  375

• Starter Disassembly

  378

• Starter Inspection

  380

• Starter Replacement

  383

• Starter Reassembly

  387

• Test

  390

• Starter Relay Inspection

  391

• Charging

  392

• Charging System

  393

• Charging System On-Vehicle Inspection

  394

• Alternator Disassembly

  398

• Alternator Inspection

  400

• Alternator Replacement

  402

• Alternator Reassembly

  404

• Index

  406

• Alphabetical Index

  2

• Engine Mechanical

  2

• In04V

  4

• Repair Procedures

  4

• Check Piston Stroke of Overdrive Brake

  5

• Specifications

  5

• The Procedures Are Presented in a Step—By—Step Format

  5

• Engine Serial Number

  6

• Identification Information

  6

• Repair Instructions

  7

  • Example

    10

  • For All of Vehicles

    11

  • If Vehicle Is Equipped with Mobile Communication System

    11

  • How to Troubleshoot ECU Controlled Systems

    12

  • Symptom Confirmation and Diagnostic Trouble Code Check in

    13

  • How to Proceed with Troubleshooting

    14

  • Customer Problem Analysis

    15

  • Erence

    15

  • Symptom Confirmation and Diagnostic Trouble Code Check

    16

  • Example

    18

  • Symptom Simulation

    18

  • Diagnostic Trouble Code Chart

    20

  • Example

    20

  • Problem Symptoms Table

    21

  • Circuit Inspection

    22

  • Erence

    22

  • Connector Connection and Terminal Inspection

    24

  • How to Use the Diagnostic Chart and Inspection

    24

  • Continuity Check

    25

  • Resistance Check

    25

  • Visual Check and Contact Pressure Check

    25

  • Check Open Circuit

    26

  • Connector Handling

    26

  • Check Hot Circuit

    27

  • Check and Replace ECU

    28

  • Example

    28

  • Abbreviations

    29

  • Terms

    29

  • Preparation

    31

  • Engine Mechanical

    32

  • SST (Special Service Tools)

    32

  • Recommended Tools

    36

  • Equipment

    37

  • SSM (Special Service Materials)

    38

  • Turbocharging

    39

  • Electronic Control Diesel

    42

  • Engine Fuel

    45

  • Cooling

    49

  • Lubrication

    53

  • Starting

    58

  • Charging

    61

  • Service Specifications

    64

  • How to Determine Bolt Strength

    65

  • Standard Bolt

    65

  • Specified Torque for Standard Bolts

    66

  • Example

    67

  • How to Determine Nut Strength

    67

  • Erence

    68

  • Service Data

    68

  • Erence

    70

  • Erence

    71

  • Torque Specification

    72

  • Service Data

    73

  • Torque Specification

    74

  • Cooling Service Data

    79

  • Lubrication Service Data

    81

  • Starting Service Data

    83

  • Charging Service Data

    85

  • Erence

    85

  • Diagnostics

    87

  • Air Filter Inspection

    89

  • Paper Filter Type

    89

  • Compression Inspection

    90

  • Erence

    90

  • Adjust Valve Clearance

    92

  • Check Valve Clearance

    92

  • Valve Clearance Inspection

    92

  • Reinstall Cylinder Head Cover

    93

  • Adjusting Shim Selection Using Chart

    94

  • Example

    94

  • Example

    95

  • Injection Timing Inspection

    96

  • Idle Speed and Maximum Speed Inspection

    97

  • Initial Conditions

    97

  • Inspect Idle Speed

    97

  • Inspect Maximum Speed

    97

  • Connect Vacuum Gauges

    98

  • Inspect Cold Engine Condition

    98

  • Intake Constructor Control Inspection

    98

  • Inspect Hot Engine Condition

    99

  • Remove Vacuum Gauges

    99

  • Timing Belt Components

    101

  • Inspect Idler Pulley

    105

  • Inspect Timing Belt

    105

  • Inspect Timing Belt Tensioner

    106

  • Timing Belt Installation

    107

  • Timing Gear Components

    112

  • Timing Gear Removal

    114

  • Inspect Idler Gear

    119

  • Inspect Injection Pump Drive Gear Bearing

    119

  • Timing Gear Inspection

    119

  • Timing Gear Replacement

    121

  • Assemble Idler Gear

    124

  • Timing Gear Installation

    124

  • Install Timing Gear Cover

    128

  • Erence

    129

  • Cylinder Head

    131

  • Cylinder Head Components

    134

  • Cylinder Head Removal

    137

  • Remove Intake Pipe

    137

  • Cylinder Head Inspection

    144

  • Remove Gasket Material

    144

  • Clean Cylinder Head

    145

  • Clean Valves

    145

  • Inspect for Cracks

    145

  • Inspect for Flatness

    145

  • Inspect and Grind Valves

    146

  • Inspect Valve Stems and Guide Bushings

    146

  • Inspect and Clean Valve Seats

    147

  • Inspect Valve Springs

    148

  • Inspect Cam Lobes

    149

  • Inspect Camshaft Bearings

    149

  • Inspect Camshaft Journals

    149

  • Inspect Camshaft Journal Oil Clearance

    150

  • Inspect Camshaft Thrust Clearance

    150

  • Inspect Valve Lifters and Lifter Bores

    150

  • Inspect Cylinder Head Bolts

    151

  • Inspect Intake and Exhaust Manifolds

    151

  • Cylinder Head Replacement

    152

  • Cylinder Head Reassembly

    154

  • Erence

    154

  • Cylinder Head Installation

    157

  • Install Cylinder Head Bolts

    159

  • Install No.1 Camshaft Timing Pulley

    161

  • Install Timing Belt Idler Pulley

    161

  • Install Cylinder Head Cover

    162

  • Install Timing Belt Cover

    162

  • Install Timing Belt Tensioner

    162

  • Cylinder Block

    165

  • Cylinder Block Components

    167

  • Cylinder Block Disassembly

    170

  • Example

    173

  • Example

    175

  • Disconnect Connecting Rod from Piston

    177

  • Remove Piston Rings

    177

  • Piston Diameter

    180

  • Cylinder Block Replacement

    186

  • Cylinder Block Reassembly

    189

  • Install Cylinder Block Orifice

    190

  • Erence

    208

  • Vsv for Intake Constrictor Control

    219

  • Water Temperature Sensor Inspection

    220

  • Fuel Filter Replacement

    222

  • Injection Nozzle

    224

  • Injection Nozzle Components

    225

  • Injection Nozzle Disassembly

    229

  • Injection Nozzle Inspection

    230

  • Injection Pump

    237

  • Injection Pump

    238

  • Injection Pump Components

    239

  • Injection Pump Removal

    241

  • Injection Pump Disassembly

    243

  • Injection Pump Inspection

    245

  • Injection Pump Reassembly

    246

  • Install Timing Control Valv E

    247

  • Injection Pump Installation

    248

  • Erence

    249

  • Coolant Inspection

    251

  • Coolant Replacement

    252

  • Drain Engine Coolant

    252

  • Fill Engine Coolant

    252

  • Water Pump

    253

  • Water Pump Components

    254

  • Water Pump Removal

    256

  • Inspect Fluid Coupling

    258

  • Inspect Water Pump

    258

  • Water Pump Inspection

    258

  • Install Water Pump Assembly

    259

  • Thermostat Components

    261

  • Remove Water Inlet and Thermostat

    262

  • Thermostat Removal

    262

  • Thermostat Inspection

    263

  • Install Water Inlet to Cylinder Block

    264

  • Place Thermostat in Cylinder Block

    264

  • Thermostat Installation

    264

  • Radiator

    265

  • Radiator Cleaning

    266

  • Inspect Cooling System for Leaks

    267

  • Inspect Radiator Cap

    267

  • Radiator On-Vehicle Inspection

    267

  • Remove Radiator Cap

    267

  • Radiator Components

    268

  • Assemble SST

    269

  • Radiator Disassembly

    269

  • Inspect Lock Plate for Damage

    270

  • Radiator Reassembly

    270

  • Check Engine Oil Level

    274

  • Check Engine Oil Quality

    274

  • Check Oil Pressure

    274

  • Oil and Filter Inspection

    274

  • Oil and Filter Replacement

    275

  • Oil Pump

    277

  • Oil Pump Components

    278

  • Oil Pump Removal

    281

  • Remove Oil Level Sensor

    281

  • Remove Oil Pan

    281

  • Remove Oil Pump (Timing Gear Case)

    282

  • Remove Oil Strainer

    282

  • Oil Pump Disassembly

    283

  • Inspect Drive and Driven Rotors

    284

  • Inspect Relief Valve

    284

  • Oil Pump Inspection

    284

  • Install Relief Valve

    285

  • Oil Pump Reassembly

    285

  • Oil Pump Installation

    286

  • Install Oil Level Sensor

    289

  • Oil Cooler

    290

  • Oil Cooler Components

    291

  • Oil Cooler Removal

    293

  • Remove Oil Dipstick and Guide

    293

  • Separate Oil Cooler and Oil Cooler Cover

    293

  • Inspect Oil Cooler

    295

  • Oil Cooler Inspection

    295

  • Assembly Oil Cooler and Oil Cooler Cover

    296

  • Oil Cooler Installation

    296

  • Inspect Check Valves

    300

  • Inspect Oil Nozzles

    300

  • Pre-Heating System Components

    303

  • Inspect after Glow Time

    304

  • Inspect Lighting Time of Glow Indicator Light

    304

  • Pre-Heating System Inspection

    304

  • Inspect Water Temperature Sensor

    305

  • Pre-Heating System Replacement

    306

  • Starter

    308

  • Starter Components

    309

  • Starter Disassembly

    310

  • Inspect Armature Coil

    312

  • Inspect Commutator

    312

  • Starter Inspection

    312

  • Inspect Brushes

    313

  • Inspect Field Frame

    313

  • Inspect Bearings

    314

  • Inspect Clutch and Gears

    314

  • Inspect Magnetic Switch

    314

  • Starter Replacement

    315

  • Starter Reassembly

    319

  • Install Field Frame and Armature Assembly

    320

  • Inspect Clutch Pinion Gear Return

    322

  • Perform Hold — in Test

    322

  • Starter Test

    322

  • Inspect Starter Relay

    323

  • Starter Relay Inspection

    323

  • Charging System Precaution

    325

  • Charging System On-Vehicle Inspection

    326

  • Check Battery Electrolyte Level

    326

  • Erence

    327

  • Inspect Discharge Warning Light Circuit

    327

  • Inspect Drive Belts

    327

  • Inspect Charging Circuit with Load

    328

  • Inspect Charging Circuit Without Load

    328

  • Alternator

    329

  • Alternator Components

    330

  • Alternator Disassembly

    331

  • Remove Brush Holder and IC Regulator

    331

  • Remove Rear End Cover

    331

  • Remove Rectifier Holder

    331

  • Remove Rectifier End Frame

    332

  • Remove Rotor from Drive End Frame

    332

  • Alternator Inspection

    333

  • Inspect Rotor

    333

  • Inspect Stator (Drive End Frame)

    333

  • Inspect Rectifier (Rectifier Holder)

    334

  • Alternator Replacement

    335

  • Replace Brushes

    335

  • Replace Front Bearing

    335

  • Replace Rear Bearing

    335

  • Alternator Reassembly

    337

  • Install Rectifier End Frame

    337

  • Install IC Regulator and Brush Holder

    338

  • Install Rear End Cover

    338

  • Install Rectifier Holder

    338

  • How to Proceed with Troubleshooting in

    339

  • Index

    339

Brand: Toyota
|
Category: Engine
|
Size: 8.63 MB

Brand: Toyota
|
Category: Engine
|
Size: 9.62 MB

• Diagnistics

  2

• Pre-Check

  3

• Diagnosis System

  3

• Normal Mode

  5

• Inspect Diagnosis

  5

• Flashing

  6

• Fail-Safe Chart

  7

• Check for Intermittent Problems

  8

• Basic Inspection

  8

• Diagnostic Trouble Code Chart

  9

• Parts Location

  11

• Land Cruiser/Land Cruiser Prado, 4Runner

  11

• Hilux

  12

• Terminals of ECU

  13

• 4Runner

  13

• Engine ECU Terminals

  13

• Land Cruiser/Land Cruiser Prado

  17

• Problem Symptoms Table

  19

• Circuit Inspection

  21

• Circuit Description

  21

• Crankshaft Position Sensor Circuit Malfunction

  21

• Wiring Diagram

  22

• Inspection Procedure

  22

• Engine Speed Sensor Circuit Malfunction (Necircuit)

  24

• Timing Control System Malfunction

  25

• Throttle Control Motor Circuit Malfunction

  28

• Spill Control Valve Circuit

  32

• Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short)

  36

• When Using Hand-Held Tester

  39

• When Not Using Hand-Held Tester

  42

• Accelerator Pedal Position Sensor Circuit Malfunction (IDL Switch/Range)

  44

• Accelerator Pedal Closed Position Switch Circuit Malfunction (Short)

  49

• Accelerator Pedal Closed Position Switch Circuit Malfunction (Open)

  49

• Water Temp. Sensor Circuit Malfunction

  51

• Intake Air Temp. Sensor Circuit Malfunction

  57

• Hilux, Land Cruiser/Land Cruiser Prado

  58

• Injection Pump Correction System Malfunction

  63

• Turbo Pressure Sensor Circuit Malfunction

  65

• Fuel Temp. Sensor Circuit Malfunction

  72

• Vehicle Speed Sensor Signal Circuit Malfunction

  79

• ERG Valve Lift Sensor Circuit Malfunction

  82

• Back up Power Source Circuit

  84

• Diagnostic Connector (DLC3) Circuit

  89

• Starter Signal Circuit

  95

• EGR Control Circuit

  100

• Pre-Heating Control Circuit

  103

• 1St Gear Position Switch Circuit (Only for M/T)

  110

• A/C Signal Circuit

  112

• A/C Cut Control Circuit

  115