Engine Control System (Diagnostics - Introduction) (Plug-In): Diagnosis Toyota Prius Plug-in

HOW TO PROCEED WITH TROUBLESHOOTING

HINT

*: Use the Techstream.

1. VEHICLE BROUGHT TO WORKSHOP NEXT: Go to next step
2. CUSTOMER PROBLEM ANALYSIS NEXT: Go to next step
3. CONNECT TECHSTREAM TO DLC3* HINT: If the display indicates a communication fault in the Techstream, inspect the DLC3. When any CAN communication system DTCs are output, perform troubleshooting on the CAN communication system first. NEXT: Go to next step
4. CHECK DTC AND FREEZE FRAME DATA* Check for DTCs. Refer to «DTC CHECK / CLEAR»(ref-553305-S22976237422013051700000) and freeze frame data. Refer to «FREEZE FRAME DATA»(ref-553305-S17750320872013051700000) . HINT: Record or print DTCs and freeze frame data if necessary. NEXT: Go to next step
5. CLEAR DTC AND FREEZE FRAME DATA* Clear the DTCs and freeze frame data. Refer to «DTC CHECK / CLEAR»(ref-553305-S22976237422013051700000) . NEXT: Go to next step
6. CONDUCT VISUAL INSPECTION NEXT: Go to next step
7. SELECT CHECK MODE DIAGNOSIS* Switch the ECM from normal mode to check mode. HINT: Refer to Check Mode Procedure. Refer to «CHECK MODE PROCEDURE»(ref-553305-S15065568862013051700000) . NEXT: Go to next step
8. CONFIRM PROBLEM SYMPTOMS Confirm problem symptoms. HINT: If the engine does not start, first perform the "Check DTC" procedure and "Conduct Basic Inspection" procedure below. RESULT Result Proceed to Malfunction does not occur A Malfunction occurs B B --> GO TO STEP 10 A: Go to next step
9. SIMULATE SYMPTOMS HINT: Refer to Symptom Simulation. Refer to «HOW TO PROCEED WITH TROUBLESHOOTING»(ref-553290-S23053163842013051700000) . NEXT: Go to next step
10. CHECK DTC* Check for DTCs. HINT: Refer to DTC Check / Clear. Refer to «DTC CHECK / CLEAR»(ref-553305-S22976237422013051700000) . RESULT Result Proceed to DTC is output A DTC is not output B B --> GO TO STEP 12 A: Go to next step
11. REFER TO DTC CHART HINT: Refer to Diagnostic Trouble Code Chart. Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-553305-S14271064972013051700000) . NEXT: Go to next step
12. CONDUCT BASIC INSPECTION Conduct basic inspection. HINT: Refer to Basic Inspection. Refer to «BASIC INSPECTION»(ref-553305-S21037761592013051700000) . RESULT Result Proceed to Malfunctioning parts not confirmed A Malfunctioning parts confirmed B B --> GO TO STEP 17 A: Go to next step
13. REFER TO PROBLEM SYMPTOMS TABLE HINT: Refer to Problem Symptoms Table. Refer to «PROBLEM SYMPTOMS TABLE»(ref-553305-S38527219082013051700000) . RESULT Result Proceed to Malfunctioning circuit confirmed A Malfunctioning parts confirmed B B --> GO TO STEP 17 A: Go to next step
14. CHECK ECM POWER SOURCE CIRCUIT Check the ECM power source circuit. HINT: Refer to ECM Power Source Circuit. Refer to «ECM Power Source Circuit»(ref-553432-S39174371242013051700000) . NEXT: Go to next step
15. CONDUCT CIRCUIT INSPECTION RESULT Result Proceed to Malfunction not confirmed A Malfunction confirmed B B --> GO TO STEP 18 A: Go to next step
16. CHECK FOR INTERMITTENT PROBLEMS Check for intermittent problems. HINT: Refer to Check for Intermittent Problems. Refer to «CHECK FOR INTERMITTENT PROBLEMS»(ref-553305-S14896367972013051700000) . NEXT: Go to next step
17. CONDUCT PARTS INSPECTION NEXT: Go to next step
18. IDENTIFY PROBLEM NEXT: Go to next step
19. ADJUST AND/OR REPAIR NEXT: Go to next step
20. CONDUCT CONFIRMATION TEST NEXT --> END

BASIC INSPECTION

When a malfunction is not confirmed by the DTC check, troubleshooting should be carried out for all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following procedure, the location of the problem can be found quickly and efficiently. Therefore, using this check is essential when engine troubleshooting.

1. CHECK AUXILIARY BATTERY VOLTAGE NOTE: Carry out this check with the engine stopped and the power switch off. RESULT Result Proceed to 11 V or higher OK Below 11 V NG NG --> CHARGE OR REPLACE AUXILIARY BATTERY OK: Go to next step
2. CHECK WHETHER ENGINE CRANKS NG --> PROCEED TO PROBLEM SYMPTOMS TABLE. Refer to «PROBLEM SYMPTOMS TABLE»(ref-553305-S38527219082013051700000) OK: Go to next step
3. CHECK WHETHER ENGINE STARTS NG --> GO TO STEP 6 OK: Go to next step
4. CHECK AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Visually check that the air cleaner filter element sub-assembly is not excessively contaminated with dirt or oil. NG --> REPLACE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY OK: Go to next step
5. CHECK IDLE SPEED Check the engine idle speed. Refer to «ON-VEHICLE INSPECTION - Step 7»(ref-553433-S21182483422013051700000) . NG --> TROUBLESHOOT IDLE SPEED AND PROCEED TO NEXT STEP OK: Go to next step
6. CHECK FUEL PRESSURE Check the fuel pressure. Refer to «ON-VEHICLE INSPECTION - Step 2»(ref-553434-S00186218912013051700000) . NG --> TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP OK: Go to next step
7. CHECK FOR SPARK Perform a spark test. Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-553424-S41937506812013051700000) . NG --> TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP OK --> PROCEED TO PROBLEM SYMPTOMS TABLE. Refer to «PROBLEM SYMPTOMS TABLE»(ref-553305-S38527219082013051700000)

PROBLEM SYMPTOMS TABLE

HINT

1. Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary.
2. Inspect the fuses and relays related to this system before inspecting the suspected areas below.

SFI SYSTEM

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HINT

The standard normal voltage between each pair of the ECM terminals is shown in the table below. The appropriate conditions for checking each pair of the terminals are also indicated. The result of checks should be compared with the standard normal voltage for that pair of the terminals, and displayed in the "Specified Condition" column. The illustration above can be used as a reference to identify the ECM terminal locations.

HINT

*1: The ECM terminal voltage is constant regardless of the output voltage from the sensor.

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1. WAVEFORM 1 IGNITION COIL ASSEMBLY SIGNAL (IGT AND IGF1 SIGNAL) ECM Terminal Name CH1: Between IGT (1 to 4) and E1 CH2: Between IGF1 and E1 Tester Range 2 V/DIV., 20 ms./DIV. Condition Idling HINT: The wavelength becomes shorter as the engine speed increases.
2. WAVEFORM 2 CRANKSHAFT POSITION SENSOR SIGNAL ECM Terminal Name Between NE+ and NE- Tester Range 5 V/DIV., 20 ms./DIV. Condition Idling with warm engine HINT: The wavelength becomes shorter as the engine speed increases.
3. WAVEFORM 3 CAMSHAFT POSITION SENSOR SIGNAL ECM Terminal Name Between G2+ and G2- Tester Range 5 V/DIV., 20 ms./DIV. Condition Idling with warm engine HINT: The wavelength becomes shorter as the engine speed increases.
4. WAVEFORM 4 NO. 1 (TO NO. 4) FUEL INJECTOR ASSEMBLY SIGNAL ECM Terminal Name Between #10 (to #40) and E01 Tester Range 20 V/DIV., 20 ms./DIV. Condition Idling HINT: The wavelength becomes shorter as the engine speed increases.
5. WAVEFORM 5 AIR FUEL RATIO SENSOR (SENSOR 1) HEATER SIGNAL ECM Terminal Name Between HA1A and E04 Tester Range 5 V/DIV., 10 ms./DIV. Condition Idling
6. WAVEFORM 6 HEATED OXYGEN SENSOR (SENSOR 2) SIGNAL ECM Terminal Name Between OX1B and O1B- Tester Range 0.2 V/DIV. 200 ms./DIV. Condition Engine speed maintained at 2500 rpm for 2 minutes after warming up engine HINT: In the Data List, the items O2S B1S2 show the values input to the ECM from the heated oxygen sensor.
7. WAVEFORM 7 KNOCK CONTROL SENSOR SIGNAL ECM Terminal Name Between KNK1 and EKNK Tester Range 1 V/DIV., 1 ms./DIV. Condition Engine speed maintained at 2500 rpm after warming up engine HINT: The wavelength becomes shorter as the engine speed increases. The waveforms and amplitudes displayed differ slightly depending on the vehicle condition.
8. WAVEFORM 8 THROTTLE ACTUATOR POSITIVE TERMINAL SIGNAL ECM Terminal Name Between M+ and ME01 Tester Range 5 V/DIV., 1 ms./DIV. Condition Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation.
9. WAVEFORM 9 THROTTLE ACTUATOR NEGATIVE TERMINAL SIGNAL ECM Terminal Name Between M- and ME01 Tester Range 5 V/DIV., 1 ms./DIV. Condition Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation.
10. WAVEFORM 10 PURGE VSV SIGNAL ECM Terminal Name Between PRG and E1 Tester Range 10 V/DIV., 20 ms./DIV. Condition Idling, under purge control HINT: If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more.
11. WAVEFORM 11 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY SIGNAL ECM Terminal Name Between OC1+ and OC1- Tester Range 5 V/DIV., 1 ms./DIV. Condition Idling
12. WAVEFORM 12 CAN COMMUNICATION SIGNAL (REFERENCE) ECM Terminal Name Between CANH and E1, CANP and E1 Tester Range 1 V/DIV., 10 μsec./DIV. Condition Power switch on (IG) HINT: The waveform varies depending on the CAN communication signal.
13. WAVEFORM 13 CAN COMMUNICATION SIGNAL (REFERENCE) ECM Terminal Name Between CANL and E1, CANN and E1 Tester Range 1 V/DIV., 10 μsec./DIV. Condition Power switch on (IG) HINT: The waveform varies depending on the CAN communication signal.
14. WAVEFORM 14 ENGINE WATER PUMP ASSEMBLY SIGNAL (FROM ECM TO ENGINE WATER PUMP ASSEMBLY) ECM Terminal Name Between WPO and E1 Tester Range 5 V/DIV., 20 ms./DIV. Condition Idling with warm engine HINT: The wavelength becomes shorter as the engine water pump speed increases.
15. WAVEFORM 15 ENGINE WATER PUMP ASSEMBLY SIGNAL (FROM ENGINE WATER PUMP ASSEMBLY TO ECM) ECM Terminal Name Between WPI and E1 Tester Range 5 V/DIV., 20 ms./DIV. Condition Idling with warm engine HINT: The wavelength becomes shorter as the engine water pump speed increases.
16. WAVEFORM 16 EGR VALVE ASSEMBLY SIGNAL ECM Terminal Name Between EGR1 and E1, EGR2 and E1, EGR3 and E1, EGR4 and E1 Tester Range 20 V/DIV., 50 ms./DIV. Condition EGR valve operating
17. WAVEFORM 17 CAMSHAFT REVOLUTION SIGNAL FROM ECM TO POWER MANAGEMENT CONTROL ECU AND INVERTER WITH CONVERTER ASSEMBLY ECM Terminal Name Between G2O and E1 Tester Range 5 V/DIV., 20 ms./DIV. Condition Idling HINT: The wavelength becomes shorter as the engine speed increases.
18. WAVEFORM 18 FUEL LID OPERATION SIGNAL (FOR COMBINATION METER) ECM Terminal Name Between LSTM and E1 Tester Range 5 V/DIV., 250 ms./DIV. Condition Power switch on (IG), fuel lid opened

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1. DESCRIPTION When troubleshooting OBD II (On-Board Diagnostics) vehicles, the Techstream (complying with SAE J1987) must be connected to the DLC3 (Data Link Connector 3) of the vehicle. Various data in the vehicle's ECM (Engine Control Module) can be then read. OBD II regulations require that the vehicle's on-board computer illuminates the MIL (Malfunction Indicator Lamp) on the instrument panel when the computer detects a malfunction in: The emission control system and components. The powertrain control components (which affect vehicle emissions). The computer itself. In addition, the applicable DTCs prescribed by SAE J2012 are stored in the ECM memory. If the malfunction does not recur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain stored in the ECM memory. To check the DTCs, connect the Techstream to the DLC3. The Techstream displays output DTCs, freeze frame data, and a variety of engine data. The DTCs and freeze frame data can be cleared with the Techstream. In order to enhance OBD function on vehicles and develop the Off-Board diagnosis system, Controller Area Network (CAN) communication is used in this system. CAN is a network which uses a pair of data transmission lines spanning multiple computers and sensors. It allows for high speed communications between the systems and simplification of the wire harness connections.
2. NORMAL MODE AND CHECK MODE The diagnosis system operates in normal mode during normal vehicle use. In normal mode, 2 trip detection logic is used to ensure accurate detection of malfunctions. Check mode is also available as an option for technicians. In check mode, 1 trip detection logic is used for duplicating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent problems (Techstream only).
3. 2 TRIP DETECTION LOGIC When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is detected during the next subsequent drive cycle, the MIL is illuminated (2nd trip).
4. DLC3 (Data Link Connector 3) Check the DLC3. Refer to «GENERAL INFORMATION»(ref-553290-S09713524732013051700000) .
5. FREEZE FRAME DATA The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was moving or stationary, whether the engine was warmed up or not, whether the air fuel ratio was lean or rich, as well as other data stored at the time of a malfunction.
6. AUXILIARY BATTERY VOLTAGE Standard voltage 11 to 16 V If voltage is below 11 V, replace or recharge the auxiliary battery.
7. MIL (Malfunction Indicator Lamp) The MIL is illuminated when the power switch is turned on (IG). The MIL turns off when the power switch is turned on (READY). If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the power switch is turned on (IG), check the MIL circuit. Refer to «MIL Circuit»(ref-553432-S04503381752013051700000) .
8. ALL READINESS HINT: With "All Readiness", you can check whether or not the DTC judgment has been completed by using the Techstream. You should check "All Readiness" after simulating malfunction symptoms or for validation after finishing repairs. Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR»(ref-553305-S22976237422013051700000) . Turn the power switch off and wait for at least 30 seconds. Turn the power switch on (IG) and turn the Techstream on. Perform the DTC judgment driving pattern to run the DTC judgment. Enter the following menus: Powertrain / Engine and ECT / Utility / All Readiness. Input the DTCs to be confirmed. Check the DTC judgment result. Techstream Display Description NORMAL DTC judgment completed System normal ABNORMAL DTC judgment completed System abnormal INCOMPLETE DTC judgment not completed Perform the driving pattern after confirming DTC enabling conditions N/A Unable to perform DTC judgment Number of DTCs which do not fulfill DTC preconditions has reached ECU memory limit

DTC CHECK / CLEAR

Note. When the diagnosis system is changed from normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are cleared. Before changing modes, always check and make a note of DTCs and freeze frame data.

HINT

1. DTCs which are stored in the ECM can be displayed on the Techstream. The Techstream can display the current, pending and permanent DTCs.
2. If a malfunction is detected during the current driving cycle, current and permanent DTCs are stored.
3. Some DTCs are not stored if the ECM does not detect the same malfunction again during a second consecutive driving cycle. However, such malfunctions, detected on only one occasion, are stored as pending DTCs.
4. Current and pending DTCs can be cleared by using the Techstream or by disconnecting the cable from the negative (-) auxiliary battery terminal. However, permanent DTCs cannot be cleared using either of these two methods.
5. After clearing current DTCs using the Techstream (or by disconnecting the cable from the negative (-) auxiliary battery terminal), permanent DTCs can be cleared when the system is determined to be normal for the relevant DTCs and then the universal trip is performed. The driving pattern to obtain a normal judgment is described under the "Confirmation Driving Pattern" for the respective DTC.

2 TRIP DETECTION EXAMPLES

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HINT

1. Obtaining a normal judgment and performing a universal trip driving pattern can be done in the same driving cycle or in different driving cycles.
2. It is unnecessary to obtain a normal judgment if the DTCs are misfire or fuel system DTCs.

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1. CHECK DTC Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. Check the DTC(s) and freeze frame data, and then write them down. Check the details of the DTC(s). Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-553305-S14271064972013051700000) .
2. CLEAR DTC (Pending and Current DTC) Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. Clear the DTCs.
3. CLEAR DTC (Pending and Current DTC without using Techstream) Perform either of the following operations: NOTE: After turning power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to «PRECAUTION»(ref-553290-S20522462032013051700000) . Disconnect the cable from the negative (-) auxiliary battery terminal for more than 1 minute. Remove the EFI MAIN and ETCS fuses from the engine room relay block and junction block assembly located inside the engine compartment for more than 1 minute.
4. CLEAR PERMANENT DTC HINT: Even if the following procedure is not performed, permanent DTCs are cleared by obtaining a normal judgment during 3 consecutive driving cycles. Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. Check if permanent DTCs are stored. HINT: If permanent DTCs are not output, it is not necessary to continue this procedure. Clear the DTCs. Perform the respective confirmation driving patterns in order to obtain a normal judgment for the output DTCs. HINT: Confirmation driving patterns do not need to be performed for misfire and fuel system DTCs. For the confirmation driving pattern, refer to the procedures for the relevant DTC. Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-553305-S14271064972013051700000) . Perform the universal trip. WARNING: When performing the confirmation driving pattern, obey all speed limits and traffic laws. HINT: The driving pattern to obtain a normal judgment and the universal trip driving can be performed consecutively in the same driving cycle. Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(ref-553290-S22500871302013051700000) . Idle the engine for 30 seconds or more. Drive the vehicle at 40 km/h (25 mph) or more for a total of 5 minutes or more. HINT: It is possible to complete the drive pattern even if the vehicle decelerates to less than 40 km/h (25 mph) during the driving cycle provided that the vehicle is driven at 40 km/h (25 mph) or more for a total of 5 minutes. Allow 10 minutes or more to elapse from the time the engine is started. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. Check that the permanent DTCs have been cleared. HINT: The permanent DTCs are cleared when the universal trip is completed.

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1. DESCRIPTION The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was moving or stationary, whether the engine was warmed up or not, whether the air fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. HINT: If it is impossible to replicate the problem even though a DTC is detected, confirm the freeze frame data. The ECM records engine conditions in the form of freeze frame data every 0.5 seconds. Using the Techstream, 5 separate sets of freeze frame data can be checked. 3 data sets before the DTC was stored. 1 data set when the DTC was stored. 1 data set after the DTC was stored. These data sets can be used to simulate the condition of the vehicle around the time of the occurrence the malfunction. The data may assist in identifying the cause of the malfunction, and judging whether it was temporary or not.
2. PENDING FREEZE FRAME DATA HINT: Pending freeze frame data is stored when a 2 trip DTC is first detected during the first trip. Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. Select a DTC in order to display its pending freeze frame data. HINT: Pending freeze frame data is cleared when any of the following occurs. Using the Techstream, the DTCs cleared. The cable is disconnected from the negative (-) auxiliary battery terminal. 40 trips with the engine fully warmed up have been performed after returning to normal. (Pending freeze frame data will not be cleared by only returning the system to normal.) With previous pending freeze frame data stored, if pending freeze frame data is newly stored when a 2 trip DTC is detected in the first trip, the old freeze frame data will be replaced with the new one of the newly detected DTC in the next trip.
3. LIST OF FREEZE FRAME DATA Refer to "Data List / Active Test". Refer to «DATA LIST / ACTIVE TEST»(ref-553305-S02986196612013051700000) .

DIAGNOSTIC TROUBLE CODE CHART

HINT

Factors such as instrument type may cause readings to differ slightly from the stated values. If any DTCs are output during a check mode DTC check, check the trouble area for the DTCs listed in the table below. For details of each DTC, refer to the "Table" below.

SFI SYSTEM

*: The MIL flashes when catalyst-damaging misfire is detected.