Engine Control System (Service Information): Removal & Installation Toyota Yaris II рестайлинг

INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Apply a light coat of engine oil to a new O-ring and install it onto the camshaft timing oil control valve assembly. NOTE: Do not twist the O-ring. Install the camshaft timing oil control valve assembly with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the camshaft timing oil control valve assembly connector.
2. INSTALL FAN BELT ADJUSTING BAR Provisionally install the fan belt adjusting bar with the bolt and nut. Tighten the nut to the specified torque. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf)
3. INSTALL FAN & GENERATOR V BELT . Refer to «INSTALLATION - Step 1»(ref-394510-S39196493552011040800000)
4. ADJUST FAN & GENERATOR V BELT . Refer to «INSTALLATION - Step 2»(ref-394510-S39196493552011040800000)
5. INSPECT FAN & GENERATOR V BELT . Refer to «INSTALLATION - Step 3»(ref-394510-S39196493552011040800000)
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
7. CHECK FOR ENGINE OIL LEAKAGE
8. INSTALL CYLINDER HEAD COVER NO. 2 . Refer to «INSTALLATION - Step 3»(ref-394534-S22575920652011040800000)
9. INSTALL ENGINE UNDER COVER RH

Scheme 30

Scheme 31

1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Install a new gasket onto the intake manifold. Install the throttle with motor body assembly using the bolt and 3 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Install the water filler sub-assembly with hose using the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Install the wire harness with bracket using the nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Connect the throttle with motor body assembly connector.
2. CONNECT WATER BY-PASS HOSE NO. 2 Connect water by-pass hose No. 2.
3. CONNECT WATER BY-PASS HOSE Connect the water by-pass hose.
4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 Install air cleaner cap sub-assembly with air cleaner hose No. 1. Tighten the hose clamp to the specified torque. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) Connect the wire harness clamp and mass air flow meter connector. Connect ventilation hose No. 2. Connect the vacuum switching valve assembly connector and wire harness clamp. Connect fuel vapor feed hose No. 1 and fuel vapor feed hose No. 2 to the vacuum switching valve assembly.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
6. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-394508-S16829671782011040800000)
7. CHECK FOR ENGINE COOLANT LEAKAGE . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-394535-S31369130882011040800000)
8. INSTALL CYLINDER HEAD COVER NO. 2 . Refer to «INSTALLATION - Step 3»(ref-394534-S22575920652011040800000)
9. PERFORM INITIALIZATION NOTE: Perform the following procedure after replacing the ECM, throttle body assembly or any throttle body components. The following procedure should also be performed if the throttle body is cleaned. Disconnect the cable from the negative (-) battery terminal. Wait at least 60 seconds and reconnect the cable. Turn the ignition switch to ON without operating the accelerator pedal. NOTE: If the accelerator pedal is operated, perform the above steps again. Connect the Techstream to the DLC3 and clear the DTCs. Refer to «DTC CHECK / CLEAR»(ref-394513-S17742279252011040800000) . Start the engine and check that the MIL is not illuminated and that the idle speed is within the specified range when the A/C is switched off after the engine is warmed up. Standard (for Automatic Transaxle) Condition Engine Idle Speed A/C switched off 650 to 750 rpm Standard (for Manual Transaxle) Condition Engine Idle Speed A/C switched off 550 to 650 rpm HINT: Be sure to perform this step with all accessories off. Make sure that the shift lever is in neutral. Enter the following menus: Powertrain / Engine and ECT / Data List / Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more. Perform a road test and confirm that there are no abnormalities.

Scheme 32

Scheme 33

Scheme 34

REMOVAL

Note. Replace the ECM with a new one if necessary.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT WIPER ARM HEAD CAP (for Hatchback) . Refer to «REMOVAL - Step 2»(ref-394536-S25637269482011040800000)
3. REMOVE FRONT WIPER ARM HEAD CAP (for Sedan) . Refer to «REMOVAL - Step 2»(ref-394536-S14114603472011040800000)
4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) . Refer to «REMOVAL - Step 3»(ref-394536-S25637269482011040800000)
5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) . Refer to «REMOVAL - Step 3»(ref-394536-S14114603472011040800000)
6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) . Refer to «REMOVAL - Step 4»(ref-394536-S25637269482011040800000)
7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) . Refer to «REMOVAL - Step 4»(ref-394536-S14114603472011040800000)
8. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) . Refer to «REMOVAL - Step 5»(ref-394536-S25637269482011040800000)
9. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) . Refer to «REMOVAL - Step 5»(ref-394536-S14114603472011040800000)
10. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) . Refer to «REMOVAL - Step 6»(ref-394536-S14114603472011040800000)
11. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) . Refer to «REMOVAL - Step 7»(ref-394536-S25637269482011040800000)
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) . Refer to «REMOVAL - Step 6»(ref-394536-S25637269482011040800000)
13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan LHD) . Refer to «REMOVAL - Step 7»(ref-394536-S14114603472011040800000)
14. REMOVE WINDSHIELD WIPER MOTOR AND LINK (for Hatchback) . Refer to «REMOVAL - Step 8»(ref-394536-S25637269482011040800000)
15. REMOVE WINDSHIELD WIPER MOTOR AND LINK (for Sedan) . Refer to «REMOVAL - Step 8»(ref-394536-S14114603472011040800000)
16. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback) . Refer to «REMOVAL - Step 20»(ref-394510-S14292004792011040800000)
17. REMOVE FRONT AIR SHUTTER SEAL (for Sedan) Disengage the 3 claws and remove the front air shutter seal.
18. REMOVE COWL TOP PANEL OUTER (for Hatchback) . Refer to «REMOVAL - Step 22»(ref-394510-S14292004792011040800000)
19. REMOVE COWL TOP PANEL OUTER (for Sedan) Disengage the claw and disconnect the wire harness. Remove the 2 bolts and remove the cowl top panel outer center bracket. Remove the 8 bolts and remove the cowl top panel outer.
20. REMOVE ECM Remove the 2 lock knobs and harness clamp. Disconnect the 2 ECM connectors. Remove the bolt and 2 nuts and remove the ECM.
21. REMOVE ECM BRACKET Remove the 2 screws and the ECM bracket.
22. REMOVE ECM BRACKET NO. 2 Remove the 2 screws and ECM bracket No. 2.

Scheme 43

1. INSTALL ECM BRACKET NO. 2 Install ECM bracket No. 2 with the 2 screws.
2. INSTALL ECM BRACKET Install the ECM bracket with the 2 screws.
3. INSTALL ECM Install the ECM with the bolt and 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 2 ECM connectors. Install the 2 lock knobs and harness clamp.
4. INSTALL COWL TOP PANEL OUTER (for Hatchback) . Refer to «INSTALLATION - Step 82»(ref-394510-S30457922992011040800000)
5. INSTALL COWL TOP PANEL OUTER (for Sedan) Install the cowl top panel outer and install the 8 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) Install the cowl top panel outer center bracket and install the 2 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) Connect the wire harness and engage the claw.
6. INSTALL FRONT AIR SHUTTER SEAL (for Sedan) Install the front air shutter seal and engage the 3 claws.
7. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback) . Refer to «INSTALLATION - Step 84»(ref-394510-S30457922992011040800000)
8. INSTALL WINDSHIELD WIPER MOTOR AND LINK (for Hatchback) . Refer to «INSTALLATION - Step 2»(ref-394536-S11422519412011040800000)
9. INSTALL WINDSHIELD WIPER MOTOR AND LINK (for Sedan) . Refer to «INSTALLATION - Step 2»(ref-394536-S37693798292011040800000)
10. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) . Refer to «INSTALLATION - Step 3»(ref-394536-S11422519412011040800000)
11. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) . Refer to «INSTALLATION - Step 4»(ref-394536-S11422519412011040800000)
12. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan) . Refer to «INSTALLATION - Step 3»(ref-394536-S37693798292011040800000)
13. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) . Refer to «INSTALLATION - Step 5»(ref-394536-S11422519412011040800000)
14. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) . Refer to «INSTALLATION - Step 4»(ref-394536-S37693798292011040800000)
15. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) . Refer to «INSTALLATION - Step 5»(ref-394536-S37693798292011040800000)
16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) . Refer to «INSTALLATION - Step 6»(ref-394536-S11422519412011040800000)
17. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) . Refer to «INSTALLATION - Step 6»(ref-394536-S37693798292011040800000)
18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) . Refer to «INSTALLATION - Step 7»(ref-394536-S11422519412011040800000)
19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) . Refer to «INSTALLATION - Step 7»(ref-394536-S37693798292011040800000)
20. INSTALL FRONT WIPER ARM HEAD CAP (for Hatchback) . Refer to «INSTALLATION - Step 8»(ref-394536-S11422519412011040800000)
21. INSTALL FRONT WIPER ARM HEAD CAP (for Sedan) . Refer to «INSTALLATION - Step 8»(ref-394536-S37693798292011040800000)
22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Scheme 44

Note. Avoid any physical shock to the accelerator pedal. Do not disassemble the accelerator pedal.

1. INSTALL ACCELERATOR PEDAL ASSEMBLY Install the accelerator pedal with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Connect the accelerator pedal connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Scheme 45

1. INSTALL MASS AIR FLOW METER Install a new O-ring onto the mass air flow meter. Install the mass air flow meter with the 2 screws. Connect the wire harness clamp and mass air flow meter connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Scheme 46

Scheme 47

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. Remove the bolt and remove the camshaft position sensor.

Scheme 48

1. INSPECT CAMSHAFT POSITION SENSOR Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Temperature Specified Condition Cold 1,630 to 2,740 ohms Hot 2,065 to 3,225 ohms HINT: In the table above, the terms Cold and Hot refer to the temperature of the coils. Cold means approximately -10 to 50 °C (14 to 122 °F). Hot means approximately 50 to 100 °C (122 to 212 °F). If the resistance is not as specified, replace the camshaft position sensor.

1. INSTALL CAMSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring on the camshaft position sensor. Install the camshaft position sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE: Do not twist the O-ring. Connect the camshaft position sensor connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
3. CHECK FOR ENGINE OIL LEAKAGE

Scheme 49

Scheme 50

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE CRANKSHAFT POSITION SENSOR Disconnect the crankshaft position sensor connector. Remove the bolt and remove the crankshaft position sensor.

Scheme 51

1. INSPECT CRANKSHAFT POSITION SENSOR Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Temperature Specified Condition Cold 985 to 1,600 ohms Hot 1,265 to 1,890 ohms HINT: In the table above, the terms Cold and Hot refer to the temperature of the coils. Cold means approximately -10 to 50 °C (14 to 122 °F). Hot means approximately 50 to 100 °C (122 to 212 °F). If the resistance is not as specified, replace the crankshaft position sensor.

1. INSTALL CRANKSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring on the crankshaft position sensor. Install the crankshaft position sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTE: Do not twist the O-ring. Connect the crankshaft position sensor connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
3. CHECK FOR ENGINE OIL LEAKAGE
4. INSTALL ENGINE UNDER COVER RH

Scheme 52

Scheme 53

Scheme 54

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 1»(ref-394508-S16829671782011040800000)
3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the engine coolant temperature sensor connector. Using SST, remove the engine coolant temperature sensor. SST: 09817-33190

Scheme 55

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Condition Specified Condition Approximately 20°C (68°F) 2.32 to 2.59 kohms Approximately 80°C (176°F) 0.310 to 0.326 kohms NOTE: When checking the engine coolant temperature sensor in water, keep the terminals dry. After the check, wipe the sensor dry. If the resistance is not as specified, replace the engine coolant temperature sensor.

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Provisionally install the engine coolant temperature sensor through a new gasket. Using SST, tighten the engine coolant temperature sensor. SST: 09817-33190 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Connect the engine coolant temperature sensor connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
3. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-394508-S16829671782011040800000)
4. CHECK FOR ENGINE COOLANT LEAKAGE . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-394535-S31369130882011040800000)

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 1»(ref-394508-S16829671782011040800000)
3. REMOVE CYLINDER HEAD COVER NO. 2 . Refer to «REMOVAL - Step 2»(ref-394534-S35282352712011040800000)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 See step 4
5. DISCONNECT WATER BY-PASS HOSE See step 5
6. DISCONNECT WATER BY-PASS HOSE NO. 2 See step 6
7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY See step 7
8. REMOVE INTAKE MANIFOLD Separate the engine wire harness from the intake manifold. Separate water by-pass hose No. 2. Disconnect the ventilation hose. Disconnect the union to connector tube hose. Remove the 3 bolts and 2 nuts and remove the intake manifold. Remove the gasket from the intake manifold.
9. REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut and remove the knock sensor.

Scheme 64

1. INSPECT KNOCK SENSOR Check the resistance. Using an ohmmeter, measure the resistance between the terminals. Standard resistance 120 to 280 kohms at 20°C (68°F) If the result is not as specified, replace the knock sensor.

Scheme 65

1. INSTALL KNOCK SENSOR Install the knock sensor with the nut as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Connect the knock sensor connector.
2. INSTALL INTAKE MANIFOLD Install a new gasket onto the intake manifold. Install the intake manifold with the 3 bolts and 2 nuts. Torque: 30 N*m (304 kgf*cm, 22 ft.*lbf) Connect the union to connector tube hose. Connect the ventilation hose. Install water by-pass hose No. 2. Install the engine wire harness onto the intake manifold.
3. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY See step 1
4. CONNECT WATER BY-PASS HOSE NO. 2 See step 2
5. CONNECT WATER BY-PASS HOSE See step 3
6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 See step 4
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
8. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-394508-S16829671782011040800000)
9. CHECK FOR ENGINE COOLANT LEAKAGE . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-394535-S31369130882011040800000)
10. INSTALL CYLINDER HEAD COVER NO. 2 . Refer to «INSTALLATION - Step 3»(ref-394534-S22575920652011040800000)

Scheme 66

Scheme 67

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE RELAY BLOCK COVER NO. 1
3. REMOVE INTEGRATION NO. 1 RELAY Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and disconnect the integration relay. Disconnect the 3 connectors.

Scheme 68

Scheme 69

Scheme 70

1. INSPECT INTEGRATION NO. 1 RELAY Inspect the EFI fuse. Disconnect the fuse. TEXT IN ILLUSTRATION *1 Fuse Side *2 EFI fuse Measure the resistance of the fuse. Standard Resistance Tester Connection Condition Specified Condition EFI fuse Always Below 1 ohms Inspect the EFI relay. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Component without harness connected (Integration Relay) Standard Resistance Tester Connection Condition Specified Condition C1 - A4 Battery voltage not applied 10 kohms or higher Battery voltage applied to terminals A2 and A3 Below 1 ohms C1 - A1 Always Below 1 ohms NOTE: While using the battery for the inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. If the result is not as specified, replace the integration relay. Inspect the FAN NO. 1 relay. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Component without harness connected (Integration Relay) Standard Resistance Tester Connection Condition Resistance B5 - B8 Battery voltage not applied 10 kohms or higher Battery voltage applied to terminals B6 and B7 Below 1 ohms NOTE: While using the battery for the inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. If the result is not as specified, replace the integration relay. Inspect the AM2 fuse. Disconnect the fuse. TEXT IN ILLUSTRATION *1 Fuse Side *2 AM2 fuse Measure the resistance of the fuse. Standard Resistance Tester Connection Condition Specified Condition AM2 fuse Always Below 1 ohms Inspect the IG2 relay. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Component without harness connected (Integration Relay) Standard Resistance Tester Connection Condition Resistance C1 - B4 Battery voltage not applied 10 kohms or higher Battery voltage applied to terminals B2 and B3 Below 1 ohms C1 - B1 Always Below 1 ohms If the result is not as specified, replace the integration relay.

1. INSTALL INTEGRATION NO. 1 RELAY Connect the 3 connectors. Attach the integration relay to the engine room relay block.
2. INSTALL RELAY BLOCK COVER NO. 1
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)