Electronic and computer controlled systems : Course 673 technician handbook

© 2009 Toyota Motor Sales, U.S.A., Inc.

All rights reserved. This book may not be reproduced or copied, in whole or in part by any means, without the written permission of

Toyota Motor Sales, U.S.A., Inc.

Revision Date: June 22, 2009

TOYOTA Technical Training

Electronic & Computer Controlled Systems

Course 673 Technician Handbook

Table of Contents

673 Electronic & Computer Controlled Systems

Technical Training i

Objectives Final Student Performances ................................................................ a

Section 1:

Diagnostic

Techniques and

Tools

Course Menu ....................................................................................... 3

Section 1 Topics .................................................................................. 5

Electronic Control Units ........................................................................ 6

How ECUs Work ................................................................................... 7

Logic Function .................................................................................. 7

Simple ECU Inputs ................................................................................ 8

Voltage ON/OFF (Switch) Input ........................................................ 9

Variable Voltage Input .................................................................... 10

Variable Resistance Input ............................................................... 11

Pulse Pattern Input ......................................................................... 12

Simple ECU Outputs ........................................................................... 13

Transistors as Switches .................................................................. 13

Pulse Width Modulation ...................................................................... 14

Duty Cycle ........................................................................................... 15

Power-Side Control ......................................................................... 16

Self Diagnosis ..................................................................................... 17

Differences in Self-Diagnosis .......................................................... 17

ECU Memory ...................................................................................... 19

Types of ECU Memory ................................................................... 19

Customization ..................................................................................... 20

Initialization ......................................................................................... 21

Why Initialize? ................................................................................. 21

Section 2:

Overview of

Multiplex

Communication

Section 2 Topics ................................................................................. 23

Why Use Multiplexing ......................................................................... 24

Applications of Multiplexing ............................................................ 24

Benefits of Multiplexing ................................................................... 24

Multiplexing ......................................................................................... 25

ECU Communication .......................................................................... 26

Signaling Between ECUs .................................................................... 27

Communication Protocols ................................................................... 28

Multiplex Topology .............................................................................. 29

Ring Topology ................................................................................. 30

Two Opens in a Ring Network ........................................................ 31

Open in a Star Network .................................................................. 32

Open in a Bus Network ................................................................... 33

Single Wire vs. Twisted-Pair ............................................................... 34

Advantage of Twisted-Pair Wiring .................................................. 35

Section 3:

Signals &

Waveforms

Section 3 Topics ................................................................................. 37

Electronic Communication .................................................................. 38

Types of Waveforms ....................................................................... 38

Waveform Measurements ................................................................... 39

Amplitude ........................................................................................ 39

Table of Contents

673 Electronic & Computer Controlled Systems

ii Technical Training

Frequency ....................................................................................... 40

Pulse Width ..................................................................................... 41

Duty Cycle ...................................................................................... 42

Section 4:

Measuring

Signals

Section 4 Topics ................................................................................. 43

The Oscilloscope ................................................................................ 44

PC Oscilloscopes ................................................................................ 45

Basic Operation .................................................................................. 46

Oscilloscope Scales ............................................................................ 47

Repair Manual Suggested Scales .................................................. 48

Repeating vs. Changing Patterns ....................................................... 49

Capturing Waveforms ......................................................................... 50

Scope Pattern Comparison ................................................................. 51

The Effect of Scale .............................................................................. 52

Trigger Function .................................................................................. 53

Other Trigger Uses ............................................................................. 54

Advanced DVOM Features ................................................................. 55

MIN/MAX Recording ....................................................................... 55

Peak MIN/MAX ............................................................................... 55

Relative Delta ................................................................................. 55

Frequency Measurement ................................................................ 56

Duty Cycle ...................................................................................... 56

Worksheet: DVOM Set-up & Advance Features ................................. 57

Instructor Demo: Using DVOM Resistance Setting ............................ 58

Section 5: Using

a PicoScope™

Section 5 Topics ................................................................................. 59

Introduction to PicoScope™ ................................................................ 60

Connecting the Leads ..................................................................... 60

PicoScope Features ........................................................................... 61

Auto Voltage Scale ......................................................................... 61

Auto Setup ...................................................................................... 61

Manual Voltage Scale Settings ....................................................... 62

Manual Time Scale Settings ........................................................... 62

Turning the Trigger On ................................................................... 63

Setting the Trigger .......................................................................... 64

Start and Stop Capturing ................................................................ 65

Horizontal Zoom ............................................................................. 66

Rulers ............................................................................................. 67

Sample Rate ................................................................................... 69

Displaying Two Channels ............................................................... 70

Separating the A-B Traces ............................................................. 71

Printing, Saving and Sending Patterns ........................................... 72

Worksheet: In-class PicoScope: Basic Set-up .................................... 73

Worksheet: Using DVOM & PicoScope .............................................. 74

Instructor Demo: PicoScope & Power Window Circuit ....................... 74

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673 Electronic & Computer Controlled Systems

Technical Training iii

Section 6: Using

an Inductive

Clamp

Section 6 Topics ................................................................................. 75

The Inductive Clamp ........................................................................... 76

Polarity ............................................................................................ 76

Current Rating ................................................................................ 77

Preparation for Use ......................................................................... 78

Converting Measurements to Amps ............................................... 79

Amp Clamp Applications ..................................................................... 80

Diagnosing Short Circuits and Parasitic Draw ................................ 80

Diagnosing Motor Faults with an Oscilloscope ............................... 81

Worksheet: Inductive Current Clamp I: Measurement & Conversion . 82

Worksheet: Inductive Current Clamp II: A/C Blower Motor ................. 82

Section 7:

Multiplex Circuit

Diagnosis

Section 7 Topics ................................................................................ 83

Additional Properties of MPX Protocols .............................................. 84

Communication Direction ................................................................ 85

Transmission Timing ....................................................................... 86

Collision Detection .......................................................................... 87

Data Casting ................................................................................... 88

Sleep Mode ..................................................................................... 89

Wakeup Function ............................................................................ 89

Body Electronics Area Network .......................................................... 90

Local Interconnect Network ................................................................ 91

LIN Characteristics ......................................................................... 91

LIN Replacing BEAN ...................................................................... 91

LIN Gateway Function .................................................................... 92

Controller Area Network ...................................................................... 93

Terminating Resistors ..................................................................... 93

Audio Visual Communication-Local Area Network ............................. 94

AVC-LAN Protocol .......................................................................... 95

Gateway ECU ..................................................................................... 96

CAN Gateway ECU ........................................................................ 96

Summary of Gateway ECU Functions ............................................ 97

CAN Gateway ECU Functions ........................................................ 98

Transmit/Receive Charts .................................................................... 99

BEAN Signal ..................................................................................... 100

BEAN Diagnosis ............................................................................... 101

Open Circuit .................................................................................. 102

Short Circuit .................................................................................. 103

Short Circuit Step 1........................................................................ 104

Short Circuit Step 2........................................................................ 105

Short Circuit Step 3........................................................................ 106

Short Circuit Step 4........................................................................ 107

Short Circuit Step 5........................................................................ 108

Short Circuit Step 6........................................................................ 109

Diagnosing a Large Network ........................................................ 110

Diagnosing with Techstream ........................................................ 111

Diagnosing a BEAN Open Circuit with an Oscilloscope ............... 112

Table of Contents

673 Electronic & Computer Controlled Systems

iv Technical Training

Worksheet: BEAN Network Diagnosis .............................................. 113

Instructor Demo: BEAN Operation and Diagnosis ............................ 113

LIN Signal ......................................................................................... 114

LIN Diagnosis .................................................................................... 115

Worksheet: A/C LIN Interface ........................................................... 116

CAN Signal ....................................................................................... 117

CAN Diagnosis ................................................................................. 118

Short Between CANH and CANL ................................................. 118

Short to B+ or Ground ................................................................... 118

Opens ........................................................................................... 119

CAN Bus Check ............................................................................ 120

Location of DLC3 .......................................................................... 120

Terminating Resistors ................................................................... 121

Resistance Tests on CAN Circuits ................................................ 122

Worksheet: CAN Diagnosis ............................................................. 124

Instructor Demo: CAN Resistance Test Precautions ........................ 124

Worksheet: CAN Main Bus Faults ................................................... 125

Worksheet: CAN Sub Bus Diagnosis ............................................... 125

AVC-LAN Signal ............................................................................... 126

AVC-LAN Diagnosis .......................................................................... 127

AVC-LAN DTCs ............................................................................ 128

Worksheet: AVC-LAN Inspection ...................................................... 129

Other Multiplex Circuits ..................................................................... 130

A/C Servo Motor Circuits .............................................................. 130

BUS Connectors ............................................................................... 131

Pulse-Type Servo Motors ................................................................. 132

Worksheet: A/C Bus Servo Motor Operation & Diagnosis ................ 133

Section 8:

Electronic

Systems

Section 8 Topics ............................................................................... 135

Engine Immobilizer Function ............................................................ 136

Engine Immobilizer Operation .......................................................... 137

Key Code Registration ...................................................................... 137

Master Keys and Sub Keys .............................................................. 138

Automatic Key Code Registration ..................................................... 139

Watch for Error Codes .................................................................. 139

Ending Automatic Registration ..................................................... 139

Configuration in Earlier Models ......................................................... 140

Configuration in Later Models ........................................................... 141

Immobilizer Reset ............................................................................. 142

Immobilizer Reset Support Chart ...................................................... 143

ECU Communication ID Registration ............................................... 144

Be Wary of Differences between Models .......................................... 145

Analyzing ECU Input and Outputs .................................................... 146

Transponder Signals ..................................................................... 147

Power and Ground Circuits ........................................................... 148

Terminal Values and Conditions ................................................... 149

Table of Contents

673 Electronic & Computer Controlled Systems

Technical Training v

Transponder Key Amplifier Terminal Values ................................. 150

ECM Terminal Values ................................................................... 151

Worksheet: Immobilizer .................................................................... 152

Power Distributor ............................................................................. 153

Protect Mode ............................................................................... 153

Mode Monitor Terminal ................................................................ 153

Smart Junction Box (MICON) ........................................................... 154

High Intensity Discharge (HID) Headlights ....................................... 155

Dynamic Laser Cruise Control Operation ......................................... 156

Laser Sensor ..................................................................................... 157

Indicators ......................................................................................... 158

Error/Cancellation Codes .................................................................. 158

Constant Speed Control .................................................................... 159

Decelerator Control............................................................................ 160

Follow-Up Control .............................................................................. 161

Accelerator Control ........................................................................... 162

System Diagram ............................................................................... 163

Distance Control ECU Waveforms .................................................... 164

Laser Radar Sensor Waveforms ....................................................... 165

Appendix Appendix ........................................................................................... 167

Transistors ........................................................................................ 168

Transistor Types ........................................................................... 169

How a Transistor Works ............................................................... 170

Transistor Switches ...................................................................... 171

Transistor Amplifiers ..................................................................... 172

Digital Circuits ............................................................................... 173

Analog-to-Digital Converter .......................................................... 174

Logic Gates ....................................................................................... 175

Normal CAN Signal ........................................................................... 176

CAN Shorts and Opens .................................................................... 177

Short CANH to CANL ................................................................... 177

Short CANH to B+ ......................................................................... 178

Short CANL to B+ ......................................................................... 178

Short CANH to Ground ................................................................. 179

Short CANL to Ground .................................................................. 179

Open in CANH or CANL (Main Bus) ............................................. 180

Open in CANH and CANL (Main Bus) .......................................... 181

BEAN Signals ................................................................................... 182

BEAN Short to Ground ................................................................. 183

Normal BEAN, Dual Trace ................................................................ 184

BEAN Open Circuit, Dual Trace ................................................... 185

Worksheets

Table of Contents

673 Electronic & Computer Controlled Systems

vi Technical Training

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Objectives

673 Electronic & Computer Controlled Systems

Technical Training a

Course 673 Electronic & Computer Controlled Systems

Final Student Performances

Terminal Objective (Terminal FSP)

Given all of the applicable tools, equipment, and appropriate vehicles, the technician will be

able to apply a number of diagnostic techniques to monitor and repair faults in advanced

computer and electronic circuits.

Technician Objectives (FSPs)

The technician will be able to:

1. Research information related to:

• The purpose and function of ECU terminals

• Inputs & Outputs

• Terminals of the ECU

• Power & Ground points

2. Identify inputs and outputs and determine how they affect ECU operation.

3. Differentiate between:

• Pulse width & duty cycle

• Frequency & duty cycle

4. Identify the consequences of the following to the diagnostic process:

• Initialization (Memory Loss)

• Customization (CBEST)

• Sleep mode vs. normal operation

5. Demonstrate proficient use of the advanced DVOM features.

• MIN/MAX function

• Peak MIN/MAX function

• Measure frequency

• Measure duty cycle

6. Apply advanced DVOM functions for quick diagnostic evaluations.

7. Practice using an Inductive Current Clamp with a DVOM to provide the ability to take

current readings without breaking into a circuit.

8. Utilize an inductive Current Clamp to evaluate system operation & determine

diagnostic strategy.

9. Practice conversion of voltage and amperage values to apply to inductive clamps that use

conversion factors for sensitivity.

10. Monitor AC blower motor current using a DVOM equipped with an inductive current

clamp, and monitor current using an oscilloscope and inductive clamp.

Objectives

673 Electronic & Computer Controlled Systems

b Technical Training

11. Properly set-up an oscilloscope

• Auto features

• Voltage & Time Scale Settings

• Horizontal & vertical rulers

• Trigger point

• Horizontal & vertical zoom features

12. Apply the basic features of the oscilloscope used in combination with the

Techstream Unit.

13. Locate and back probe a dimmer-controlled interior lamp or LED, practice measuring

Voltage (V), Hertz (Hz), and percentage values (%) using a DVOM, and use an

oscilloscope to display the signal pattern.

14. Set oscilloscope voltage and time settings appropriate to the circuit measured.

15. Utilize oscilloscope patterns derived from a known good vehicle to verify normal

system operation.

16. Differentiate between different oscilloscope patterns.

17. Use an oscilloscope to confirm proper operation vs. a faulty circuit

• Duty cycle

• Frequency

• Amplitude

18. Use an oscilloscope to identify intermittent faults.

19. Capture, record, save and send oscilloscope waveforms.

20. Identify Body Electronics Area Network topology and network operation.

21. Perform fault diagnostics on a BEAN network.

22. Identify Local Area Network topology and network operation.

23. Monitor and diagnose the AC Control Assembly operation and LIN communication using

Techstream, an oscilloscope and TIS.

24. Identify Controller Area Network topology and network operation.

25. Use an ohmmeter and an oscilloscope to observe CAN High and CAN Low; diagnose a

short to ground and an open circuit on CAN High and CAN Low; and short CAN High to

CAN Low to observe the results.

26. Develop a strategy to diagnose a CAN Network fault using the EWD, a Techstream CAN

Bus Check, and the information provided.

27. Identify Audio Visual Communication-Local Area Network topology and network operation.

28. Create, monitor and diagnose an AVC-LAN System amplifier malfunction using

Techstream and an oscilloscope.

29. Monitor AC bus and servo motor operation using Techstream DATA LIST and an

oscilloscope to deduce communication problems with the AC System.

30. Reference service literature to determine if immobilizer reset is supported on a vehicle.

31. Use Techstream Data List to make determinations related to the ID Code of the

transponder chip embedded in the ignition key of the Immobilizer System.

32. Use an oscilloscope to observe Immobilizer System waveforms under varying conditions

and compare them to those found in the Repair Manual.

673 Electronic & Computer Controlled Systems Technician Handbook

673 Electronic & Computer Controlled Systems

Welcome Toyota Technicians

Technical Training 1

673 Electronic & Computer Controlled Systems Technician Handbook

2 Technical Training

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673 Electronic & Computer Controlled Systems Technician Handbook

Course Menu

• Electronic Control Units

• Overview of Multiplex Communication

• Signals & Waveforms

• Measuring Signals

• Using a PicoScope™

• Using an Inductive Clamp

• Multiplex Circuit Diagnosis

• Electronic Systems

Electronic & Computer Controlled Systems

• Transistors

• CAN Waveforms A

• BEAN Waveforms

Appendix

Technical Training 3

673 Electronic & Computer Controlled Systems Technician Handbook

4 Technical Training

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673 Electronic & Computer Controlled Systems Technician Handbook

Technical Training 5

• Electronic Control Units

• Logic Function

• Simple ECU Inputs

• Simple ECU Outputs

• Self-Diagnosis

• Memory

• Customization

• Initialization

Section 1 Topics

Electronic Control Units