training manual STEP 3 / VOLUME 1 TCCS (TOYOTA COMPUTER- CONTROLLED 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 1 of the thirteen Training Manuals which constitute Step 3 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 3 Training Manuals are as follows : VOL . TRAINING MANUALS VOL . TRAINING MANUALS 1 TCCS ( Toyota Computer-Controlled System) 8 NVH (Noise, Vibration & Harshness ) 2 Turbocharger & Supercharger 9 Fundamentals of Electronics 3 Diesel Injection Pump 10 CCS (Cruise Control System ) 4 ECT ( Electronically-Controlled Transmission) 1 1 Car Audio Syste m 5 Full-Time 4WD 12 Automatic Air Conditioning Syste m 6 TEMS & Air Suspension 13 SRS Airbag & Seat Belt Pretensione r 7 ABS & Traction Control Syste m It is not enough just to "know" or "understand" - you need to master each task so that you can do 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 : A potentially hazardous situation which could result in injury to people may occur if CAUTION instructions are not followed . NOTICE Damage to the vehicle or components may occur if instructions are not followed . NOTE 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 repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation . TABLE OF CONTENTS Page Page ABBREVIATIONS AND ECU TERMINAL SYMBOL S VEHICLE SPEED SENSOR . ... .... .. ..... 34 ABBREVIATIONS . ..... .... ... .... ..... 1 1 . Reed switch type ..... ... ..... 34 ECU TERMINAL SYMBOLS .. .... .... .. .... 2 2 . Photocoupler type ... .. ... ... 34 3 . Electromagnetic pickup type . ... 35 OUTLINE OF TCC S 4. MRE type .. ..... ... ... .. .......... .. .. 36 WHAT IS TCCS? ... ..... ..... ... .... 5 STA SIGNAL . ... .... .. ... ... ..... ..... .. 38 HISTORY OF TCCS ENGINE CONTROL NSW SIGNAL ... .... .. .... ... ... .. 38 SYSTEM . ... .... .... ..... .... ... 6 A/C SIGNAL ... .. .... .. ..... .... ... ... 39 SYSTEM DESCRIPTION .... .. .... .......... 7 ELECTRICAL LOAD SIGNAL .. .... ... .. 39 1 . Functions of engine control system . 8 FUEL CONTROL SWITCH O R 2. Construction of engine control CONNECTOR . .... .... ... ..... ......... 40 system . ..... .... ... .... ... 10 EGR GAS TEMPERATURE SENSOR ..... ... 40 3. Engine control system diagram . ... 1 2 VARIABLE RESISTOR .......... ... 41 ELECTRONIC CONTROL SYSTE M KICK-DOWN SWITCH ... ............ ..... ... 42 GENERAL ... .... ..... .. ... .... 13 WATER TEMPERATURE SWITCH .. .... ... 42 POWER CIRCUITRY .. ..... .. .... 15 CLUTCH SWITCH .. ... .... .. .... 42 1 . Engine without stepper motor typ e KNOCK SENSOR .... ...... .... ... .. 43 ISC valve .. ... .......... ..... ........ 15 HAC SENSOR ......... ..... .... ..... 44 2. Engine with stepper motor type VAPOR PRESSURE SENSOR ...... ... ... 44 ISC valve . .. ... ... ...... ..... .. 16 TURBOCHARGING PRESSURE SENSOR .. 44 VC CIRCUITRY . .... .... .... ... .. 16 STOP LAMP SWITCH .. ... ... ..... 45 GROUND CIRCUITRY .... ... ...... ... 16 OIL PRESSURE SWITCH .... ... ... ... 45 MANIFOLD PRESSURE SENSO R COMMUNICATIONS SIGNALS .. ... 45 (VACUUM SENSOR) . ...... .... .. .... 17 . ... 45 AIR FLOW METER .. ... .......... ... ... 18 1 . Throttle opening angle signals 2 . Throttle opening angle signals fo r 1 . Vane type ... ... ... ... .... ... ... 18 TRC system ... ... ..... ... ... 45 2 . Optical Karman vortex type ....... ... 21 3. Cruise control system 3 . Hot-wire type .. ... .. .... ..... 21- 1 communications signal .... ... ... 46 THROTTLE POSITION SENSOR .. .......... 22 4. TRC system communications signal . 46 1 . On-off type ... ... .... ... ... 22 5. ABS communications signal .... ..... 46 2 . Linear type ... ..... ... .... ... ... 23 6. Intercooler system warning signal .. 46 G AND NE SIGNAL GENERATORS .... 24 7 . EHPS system communication s 1 . In-distributor type ...... ... .... ... 24 signal .. ..... ..... ......... ..... ... 47 2 . Cam position sensor type . .... .... 27 8 . Engine speed signal . ..... ..... .... .. .. 47 3 . Separate type . ... ..... .... ..... .. ... 28 9 . Engine immobiliser syste m signal .. ... ... .. 47 WATER TEMPERATURE SENSOR .... ... 30 communications 8 INTAKE AIR TEMPERATURE SENSOR . .. 30 DIAGNOSTIC TERMINAL(S) ......... .• .••••• 4 .... 30- 1 OXYGEN SENSOR (02 SENSOR) EFI (ELECTRONIC FUEL INJECTION ) 1 . Zirconia element type . .... ... 30-1 GENERAL . ... .. ... ... ... .. ..... ... 49 2. Titania element type . .. ... ... .32 TYPES OF EFI .. .... ..... ... ... 52 LEAN MIXTURE SENSOR . ...... ... ... 33 1 . 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