05−323

DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

05743−01

PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description for Euro−OBD
S When troubleshooting Euro−OBD vehicles, the
only difference from the usual troubleshooting pro-
cedure is that you connect the vehicle to the OBD
scan tool complying with ISO 15031−4 or hand−
held tester, and read off various data output from
the vehicle’s ECM.
S Euro−OBD regulations require that the vehicle’s
on−board computer lights up the Check Engine
Warning Light (Malfunction Indicator Lamp)/CHK
ENG (MIL) on the instrument panel when the com-
puter detects a malfunction in the emission control
system/components or in the powertrain control
components which affect vehicle emissions, or a
malfunction in the computer. In addition to CHK
ENG (MIL) lighting up when a malfunction is de-
tected, the applicable Diagnostic Trouble Codes
(DTCs) prescribed by ISO15031−6 are recorded in
the ECM memory (See page 05−332).
If the malfunction code is not detected in 3 consecutive trips,
CHK ENG (MIL) goes off automatically but the DTCs remain re-
corded in the ECM memory.
S To check the DTCs, connect the OBD scan tool or
hand−held tester to the Data Link Connector 3
(DLC3) on the vehicle. The OBD scan tool or hand−
held tester also enables you to erase the DTCs and
check freezed frame data and various forms of en-
gine data (For operating instructions, see the OBD
scan tool’s instruction book.).
S DTCs include ISO controlled codes and manufac-
turer controlled codes. ISO controlled codes must
be set as prescribed by the ISO, while manufacturer
controlled codes can be set freely by the manufac-
turer within the prescribed limits (See DTC chart on
page 05−332).
S The diagnosis system operates in normal mode
during normal vehicle use. It also has a check mode
for technicians to simulate malfunction symptoms
and troubleshoot. Most DTCs use 2 trip detection
logic* to prevent erroneous detection, and ensure
thorough malfunction detection. By switching the
ECM to check mode when troubleshooting, the
technician can cause the CHK ENG (MIL) to light up
for a malfunction that is only detected once or mo-
mentarily (Hand−held tester only) (See step 2).

COROLLA REPAIR MANUAL (RM925E)

05−324
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

S *2 trip detection logic:

When a malfunction is first detected, the malfunc-
tion code is temporarily stored in the ECM memory
(1st trip). If the same malfunction is detected again
during the second drive test, this second detection
causes the CHK ENG (MIL) to light up (2nd trip)
(However, the ignition switch must be turned OFF
between the 1st trip and the 2nd trip.).
S Freeze frame data:
Freeze frame data records the engine condition
when a misfire (DTCs P0300 − P0304) or fuel trim
malfunction (DTCs P0170) or other malfunction
(first malfunction only), is detected.
Because freeze frame data records the engine
conditions (fuel system, calculated load, engine
coolant temperature, fuel trim, engine speed, ve-
hicle speed, etc.) when the malfunction is detected.
When troubleshooting, it is useful to determine
whether the vehicle was running or stopped, the en-
gine was warmed up or not, the air−fuel ratio was
lean or rich, etc. at the time of the malfunction.
Priorities for troubleshooting. If troubleshooting priorities for
multiple DTCs are given in the applicable DTC chart, these
should be followed.
If no instructions are given, troubleshoot DTCs according to the
following priorities.
(1) DTCs ot her t han f uel t r im m alf unct ion ( DTCs
P0170) and misfire (DTCs P0300 − P0304).
(2) Fuel trim malfunction (DTCs P0170).
(3) Misfire (DTCs P0300 − P0304).
(b) Description for M−OBD
S When troubleshoot Multiplex OBD (M−OBD) ve-
hicles, the only difference from the usual trouble-
shooting procedure is that you connect the vehicle
to the hand−held tester, and read off various data
output from the vehicle’s ECM.
S The vehicle’s on−board computer indicates the
check engine light (CHK ENG) on the instrument
panel when the computer detects a malfunction in
the computer itself or in drive system components.
In addition to an indication of the CHK ENG when
a malfunction is detected, the applicable Diagnostic
Trouble Codes (DTCs) are recorded in the ECM
memory (See page 05−332). When the malfunction
does not reoccur, the CHK ENG is indicated until the
ignition switch is turned off, and then the CHK ENG
is not indicated when the ignition switch is turned on
but the DTCs remain recorded in the ECU memory.

COROLLA REPAIR MANUAL (RM925E)

 05−325
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

S To check the DTCs, connect the hand−held tester

to Data Link Connector 3 (DLC3) on the vehicle or
read the DTC which is indicated on the multi in-
formation display when TC and CG terminals on the
DLC3 are connected. The hand−held tester also
enables you to erase the DTCs and check freezed
frame data and various forms of engine data. (For
operating instructions, see the instruction book.)
S The diagnosis system operates in the normal mode
during normal vehicle use. It also has a check (test)
mode for technicians to simulate malfunction symp-
toms and troubleshoot. Most DTCs use 2 trip detec-
tion logic* to prevent erroneous detection, and en-
sure thorough malfunction detection. By switching
the ECM to the check (test) mode using hand−held
tester when troubleshooting, the technician can
cause the CHK ENG on the light up for a malfunc-
tion that is only detected once or momentarily
(Hand−held tester only) (See step 2).
S * 2 trip detection logic
When a logic malfunction is fist detected, the mal-
function is temporally stored in the ECM memory. If
the same malfunction is detected again during the
second drive test, this second detection cases the
CHK ENG to light up.
The 2 trip repeats the same mode for 2 times (How-
ever, the ignition switch must be turned OFF be-
tween the 1st trip and 2nd trip).
S Freeze frame data:
Freeze frame data records the engine condition
when malfunction is detected.
Because freeze frame data records the engine
conditions (fuel system, calculator load, water tem-
perature, fuel trim, engine speed, vehicle speed,
etc.) when the malfunction is detected. When trou-
bleshooting, it is useful for determining whether the
vehicle was running or stopped, the engine was
warmed up or not, the air−fuel ratio was lean or rich,
etc. at the time of the malfunction.

(c) Check the DLC3.

The vehicle’s engine ECU uses the ISO 14230(M−OBD)
communication protocol. The terminal arrangement of
1 23 4 5 6 78 DLC3 complies with ISO 15031−03 and matches the ISO
14230 format.
9 10111213141516

DLC3

A04550

COROLLA REPAIR MANUAL (RM925E)

05−326
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

Terminal No. Connection / Voltage or Residence Condition

7 Bus + Line / Pulse generation+ During transmission
4 Chassis Ground « Body Ground / 1 W or less Always
16 Battery Positive « Body Ground / 9 − 14 V Always
HINT:
If the display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of the OBD scan tool or
hand−held tester to DLC3, turned the ignition switch ON and
operated the hand−held tester, there is a problem on the vehicle
side or tool side.
S If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
S If communication is still not possible is when the tool is
connected to another vehicle, the problem is probably in
the tool itself, so consult the Service Debarment listed in
the tool,s instruction manual.

2. INSPECT DIAGNOSIS (Normal Mode)

(a) Check the check engine warning light.
(1) The check engine warning (CHK ENG) comes on
when the ignition switch is turned ON and the en-
gine is not running.
HINT:
If the check engine warning (CHK ENG) does not light up, trou-
bleshoot the combination meter.
FI2547 (2) When the engine is started, the check engine warn-
ing light should go off. If the lamp remains on, the
diagnosis system has detected a malfunction or ab-
normality in the system.
(b) Check the DTC, using hand−held tester.
NOTICE:
When the diagnosis system is switched from normal mode
to check (test) mode, it erases all DTCs and freezed frame
data recorded in normal mode. So before switching modes,
always check the DTCs and freezed frame data, and note
them down.
(1) Prepare the hand−held tester.
(2) Connect the hand−held tester to DLC3.
(3) Turn the ignition switch ON and switch the hand−
held tester main switch ON.
(4) Use the hand−held tester to check the DTCs and
freezed frame data; note them down. (For operating
instructions, see the hand−held tester’s instruction
book.)
(5) See page 05−332 to confirm the details of the
DTCs.

COROLLA REPAIR MANUAL (RM925E)

 05−327
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

NOTICE:
S When simulating symptoms without a hand−held tes-
ter to check the DTCs, use normal mode. For codes
on the DTCs, chart subject to ”2 trip detection logic”,
turn the ignition switch OFF after the symptom is sim-
ulated the first time. Then repeat the simulation pro-
cess again. When the problem has been simulated
twice, the check engine warning light Iights up and
the DTCs, are recorded in the engine ECU.
S Check the 1st trip DTC using Mode7 for ISO 15031.
(Continuous Test Results of Euro−OBD function in
hand−held tester)
3. INSPECT DIAGNOSIS (Check (Test) Mode)
HINT:
Hand−held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check (test) mode.
(a) Check the DTC.
(1) Initial conditions
S Battery positive voltage 11V or more.
S Throttle valve fully closed.
S Transmission in ”P” or ”N” position.
S Air conditioning switched OFF.
(2) Turn ignition switch OFF.
(3) Prepare the hand−held tester.
(4) Connect the hand−held tester to DLC3 on the at the
lower left of the instrument panel.
(5) Turn the ignition switch ON and switch the push the
hand−held tester ON.

(6) Switch the hand−held tester normal mode to check

(test) mode. (Check that the check engine warning
light (CHK ENG) flashes.)
Flashing (7) Start the engine. (The check engine warning (CHK
ON ENG) light goes out after the engine start.)
OFF (8) Simulate the conditions of the malfunction de-
scribed by the customer.
0.13 Second NOTICE:
FI3605 Leave the ignition switch ON until you have checked the
DTC, etc.
(9) After simulating the malfunction conditions, use the
hand−held tester diagnosis selector to check the
DTCs and freezed frame data, etc.

COROLLA REPAIR MANUAL (RM925E)

05−328
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

HINT:
Be careful not to turn the ignition switch OFF. When turning the
ignition switch OFF, the diagnosis system converts from check
(test) mode to normal mode. All DTCs, etc. are erased at this
condition.
(10) After checking the DTCs, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTCs and freezed
frame data.
S Operating the hand−held tester to erase the
codes. (See the hand−held tester ’s instruc-
tion book for operating instructions.)
S Disconnecting the battery terminals or EFI
fuse.
NOTICE:
If the hand−held tester switches the engine ECU from nor-
mal mode to check mode or vice−versa, or if the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTCs and freezed frame data will be erased.
4. FAIL−SAFE CHART
If any of the following codes is recorded, the engine ECU enters fail−safe mode.
DTC No. Fail−Safe Operation Fail−Safe Deactivation Conditions
P0102
Ignition timing fixed at 5˚ BTDC Returned to normal condition
P0103
P0112
Intake air temp. is fixed at 20˚C (68˚F) Returned to normal condition
P0113
P0116
P0117 Water temp. is fixed at 80˚C(176˚F) Returned to normal condition
P0118
The following condition must be repeated at least 2 times
P0122 consecutively
VTA is fixed at 0˚
P0123 When closed throttle position switch is ON:
VTA  0.1 V and % 0.95 V
P0135 The heater circuit in which an abnormality is detected is
IG switch OFF
P0141 turned off
P0135 Max. timing retardation IG switch OFF
5. CHECK FOR INTERMITTENT PROBLEMS
HAND−HELD TESTER only:
By putting the vehicle’s engine ECU in check (test) mode, 1 trip detection logic is possible instead of 2 trip
detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent
problems.
(a) Clear the DTC. (See step 3.)
(b) Set the check (test) mode (See step 3.)
(c) Perform a simulation test. (See page 01−20)
(d) Check the connector and terminal. (See page 01−30)
(e) Handle the connector. (See page 01−30)

COROLLA REPAIR MANUAL (RM925E)

 05−329
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

6. ENGINE OPERATING CONDITION

NOTICE:
The values given below for ”Normal Condition” are representative values, so a vehicle may still be
normal even if its value from those listed here. So do not decide whether a part is faulty or not solely
according to the ”Normal Condition” here.
Hand−held tester display Measurement Item Normal Condition*1
Fuel System Bank 1
FUEL SYS #1 OPEN: Air−fuel ratio feedback stopped Idling after warming up: CLOSED
CLOSED: Air−fuel ratio feedback operating
Calculator Load:
Idling: 27.5 − 46.4 %
CALC LOAD Current intake air volume as a proportion of max.
Racing without load (2,500rpm): 19.7 − 40.5 %
intake air volume
COOLANT TEMP./WATER TEMP. Water Temp. Sensor Value After warming up: 80 − 95˚C (176 − 203˚F)
SHORT FT #1 Short−term Fuel Trim Bank 1 0 ± 20%
LONG FT #1 Long−term Fuel Trim Bank 1 0 ± 20%
Idling:
ENGINE SPD Engine Speed
600 − 700 rpm
VEHICLE SPD Vehicle Speed Vehicle Stopped: 0 km/h (0 mph)
Ignition Advance: Idling:
IGN ADVANCE
Ignition Timing of Cylinder No. 1 BTDC 3 − 13˚
INTAKE AIR Intake Air Temp. Sensor Value Equivalent to Ambient Temp.
Voltage Output of Throttle Position Sensor
Throttle Fully Closed: 8 − 20 %
THROTTLE POS Calculated as a percentage:
Throttle Fully Open: 64 − 96 %
0 V ® 0%, 5 V ® 100%
Voltage Output of Oxygen Sensor
O2S B1, S1 Idling: 0.1 − 0.9 V
Bank 1, Sensor 1
Voltage Output of Oxygen Sensor Bank 1 Sensor
O2S B1, S2 Driving 50 km/h (31 mph): 0.1 − 0.9 V
2
Oxygen Sensor Fuel Trim Bank 1, Sensor 1
O2FT B1, S1 0 ± 20 %
(Same as SHORT FT #1)
Distance since activation of check engine warn-
MIL ON RUN DIST When there is no DTC: 0 km (0 mph)
ing light
INJECTOR Fuel injection time for cylinder No.1 Idling: 1.92 − 3.37 ms
MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm
MISFIRE LOAD Engine LOAD for first misfire range Misfire 0: 0 g/r
STARTER SIG Starter Signal Cranking: ON
A/C SIG A/C Switch Signal A/C ON: ON
PNP SW/NSW *2 Neutral start switch signal P or N position: ON
ELECTRCL LOAD SIG Electrical Load Signal Defogger switch ON: ON
CTP SW Closed Throttle Position Switch Signal Throttle Fully Closed: ON
STOP LIGHT SW Stop Light Switch Signal Stop light switch ON: ON
PS OIL PRESS SW Power Steering Oli Pressure Switch Signal Turn steering wheel: ON
Fuel Cut Idle: Fuel cut when throttle valve fully
FC IDL Fuel cut operating: ON
closed, during deceleration
FC TAU Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON
CYL#1, CYL#2, CYL#3, CYL#4 Abnormal revolution variation for each cylinder 0%
Total number of ignition for every 1,000 revolu-
IGNITION 0 − 300
tions
INTAKE CTRL VSV Intake Air Control Valve VSV Signal VSV operating: ON
A/C CUT SIG A/C Cut Signal A/C S/W OFF: ON
FUEL PUMP Fuel Pump Signal Idling: ON
EVAP (PURGE) VSV EVAP VSV Signal VSV operating: ON
Total Fuel Trim Bank 1: Average value for fuel
TOTAL FT B1 Idling: 0.5 − 1.4
trim system of bank 1

COROLLA REPAIR MANUAL (RM925E)

05−330
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

Oxygen Sensor Lean Rich Bank 1 Sensor 1:

O2 LR B1 S1 Response time for oxygen sensor output to Idling after warming up: 0 − 1,000 msec.
switch from lean to rich
Oxygen Sensor Rich Lean Bank 1 Sensor 1:
O2 RL B1 S1 Response time for oxygen sensor output to Idling after warming up: 0 − 1,000 msec.
switch from rich to lean
*1: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C
switch is OFF and all accessory switches are OFF.
*2: A/T only

BASIC INSPECTION

When the malfunction code is not confirmed in the DTC check, troubleshooting should be carried out in the
order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying
out the basic engine check shown in the following flow chart, the location causing the problem can be found
quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting.
1 CHECK BATTERY VOLTAGE

NOTICE:
Carry out this check in engine stoppage condition.
REFERENCE:
OK NG
VOLTAGE 11V OR MORE LESS THAN 11V

NG CHARGE OR REPLACE BATTERY

OK

2 CHECK IF ENGINE IS CRANKED

NG PROCEED TO PROBLEM TABLE

(See page 05−340)

OK

3 CHECK IF ENGINE STARTS

NG GO TO STEP 7

OK

COROLLA REPAIR MANUAL (RM925E)

 05−331
DIAGNOSTICS − EFI SYSTEM (4ZZ−FE)

4 CHECK AIR FILER

(a) Visually check that the air filter is not excessively dirty or oily.
HINT:
If necessary, clean the filter with compressed air. First blow from inside thoroughly, then blow from outside
of filter.
NG REPAIR OR REPLACE

OK

5 CHECK IDLE SPEED (See page 14−82)

NG PROCEED TO PROBLEM SYMPTOM TABLE

(See page 05−180)

OK

6 CHECK IGNITION TIMING (See page 18−5)

NG PROCEED TO PAGE 18−5 AND CONTINUE TO

TROUBLESHOOT

OK

7 CHECK FUEL PRESSURE (See page 11−5,11−15)

NG PROCEED TO PAGE 11−5,11−15 AND CON-

TINUE TO TROUBLESHOOT

OK

8 CHECK FOR SPARK (See page 18−5)

NG PROCEED TO PAGE 18−5 AND CONTINUE TO

TROUBLESHOOT

OK

PROCEED TO PROBLEM SYMPTOMS TABLE (See page 05−180)

COROLLA REPAIR MANUAL (RM925E)