ESP TOYOTA CAMRY V20 1986 Service Information

Disconnect solenoid wire connector and road test.
Does the transaxle operate in the respective gear
when in the following ranges while driving?
D range .... Overdrive
2 range .... Overdrive
L range .... 1 st gear
TROUBLESHOOTING FLOW±CHART (A540E)
Trouble No. 1 No Shifting
Is voltage between Engine and ECT ECU
terminals BK and E1 as follows?
0V: Brake pedal released
10 ± 14V: Brake pedal depressed
Connect solenoid wire connector and road test.
Does Tt terminal voltage rise from 0V to
7V in sequence?Warm up engine
Coolant temp.: 176°F (80°C)
ATF temp.: 122 ± 176°F (50 ± 80°C)
Connect a voltmeter to terminals Tt and E1.
Does Tt terminal voltage vary with changes in
throttle opening? (See page AT±215)
wECU power source and ground faulty
wThrottle position signal faulty
wTt terminal wire open or short
Are there 10 ± 14V between
Engine and ECT ECU terminals 2 ± E
when in the D range?
Are there 10 ± 14V between Engine and ECT
ECU terminals L ± Ex when in the D range?
wNeutral start switch circuit faulty
wNeutral start switch faultyProceed to trouble No. 3
(See page AT±209)
Try another Engine and ECT ECUw Transaxle faulty
wSolenoid faultyBrake signal faulty
Transaxle faulty
Ye s
Ye s
Ye s
Ye s Ye s
± AUTOMATIC TRANSAXLETroubleshooting (Electronic Control System) (A540E and
A540H)AT±207

Disconnect solenoid wire connector and road test.
Does the transaxle operate in the respective gear
when in the following ranges white driving?
D range .... Overdrive
2 range .... Overdrive
L range .... 1 st gear
TROUBLESHOOTING FLOW±CHART (A540H)
Trouble No. 1 No Shifting
Is voltage between ECT ECU terminals BK
and GND as follows?
0V: Brake pedal released
10 ± 14V: Brake pedal depressed
Connect solenoid wire connector and road test.
Does Tt terminal voltage rise from OV to 7V in se-
quence?Warm up engine
Coolant temp.: 176°F (80°C)
ATF temp.: 122 ± 176°F (50 ± 80°)
Connect a voltmeter to terminals Tt and E1.
Does Tt terminal voltage vary with changes in
throttle opening? (See page AT±215)
wECU power source and ground faulty
wThrottle position signal faulty
wTt terminal wire open or short
Are there 10 ± 14V between ECT
ECU terminals 2L ± GND when in the
D range?
Are there 10 ± 14V between ECT ECU
terminals LL ± GND when in the D range?
wNeutral start switch circuit faulty
wNeutral start switch faultyProceed to trouble No. 3
(See page AT±227) Transaxle faulty
Solenoid faulty
Try another ECT ECUBrake signal
faulty
Transaxle faulty
Ye s
Ye s
Ye s Ye s
Ye s
± AUTOMATIC TRANSAXLETroubleshooting (Electronic Control System) (A540E and
A540H)AT±211

3. INSPECT EACH UP±SHIFT POSITION
(a) Warm up the engine.
Coolant temperature: 176
°F (80°)
(b) Turn the O/D switch to ºONº.
(c) Place the pattern select switch in ºNormalº and the shift
lever into the D range.
(d) During a road test (above 10 km/h or 6 mph) check that volt-
age at the Tt terminal is as indicated below for each up±
shift position.
If the voltage rises from 0V to 7V in the sequence shown,
the control system is okay.
The chart on the left shows the voltmeter reading and cor-
responding gears.
HINT: Determine the gear position by a fight shock or
change in engine rpm when shifting. The lock±up clutch will
turn ON only infrequently during normal 2nd and 3rd gear
operation. To trigger this action, press the accelerator pedal
to 50% or more of its stroke. At less than 50%, the voltage
may change in the sequence 2v ± 4V ± 6V ± 7V. 2. INSPECT BRAKE SIGNAL
(a) Depress the accelerator pedal until the Tt terminal indi-
cates 8V.
(b) Depress the brake pedal and check the voltage read-
ing from the Tt terminal.
Brake pedal depressed ...... 0V
Brake pedal released . . . . . . . . 8V
If not as indicated, there is a malfunction in either the
stop light switch or circuit.
INSPECTION OF ECT OR Tt TERMINAL
VOLTAGE
1. INSPECT THROTTLE POSITION SENSOR SIGNAL
(a) Turn the ignition switch to ON. Do not start the engine.
(b) Connect a voltmeter to terminals Tt and E1.
(c)while slowly depressing the accelerator pedal, check
that Tt terminal voltage rises in sequence.
If the voltage does not change in proportion to the
throttle opening angle, there is a malfunction in the
throttle position sensor or circuit.
± AUTOMATIC TRANSAXLETroubleshooting (Electronic Control System) (A540E and
A540H)AT±215

INSTALLATION OF THROTTLE CABLE
1. INSTALL CABLE INTO TRANSMISSION CASE
2. INSTALL VALVE BODY
3. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR
PAINT MARK ON INNER CABLE
HINT: New cable do not have a cable stopper staked.
(a) Bend the cable so there is a radius of about 200 mm(7.87 in.).
(b) Pull the inner cable lightly until a slight resistance is felt, and hold
it.
(e) Stake the stopper, 0.8 ± 1.5 mm (0.031 ± 0.059 in.)
from the end of outer cable.
4. CONNECT THROTTLE CABLE TO ENGINE
5. ADJUST THROTTLE CABLE (See page AT±201)
6. INSTALL AND ADJUST NEUTRAL START SWITCH
7. TEST DRIVE VEHICLE
Throttle Cable
REMOVAL OF THROTTLE CABLE
1. DISCONNECT THROTTLE CABLE FROM ENGINE
2. REMOVE NEUTRAL START SWITCH
3. REMOVE VALVE BODY
4. REMOVE THROTTLE CABLE
ON±VEHICLE REPAIR
HINT: The components mentioned below can be replaced on the vehicle without any necessity for
removal of the transaxle. For the respective operating procedures refer to the following pages:
Speedometer driven gear oil
seal
Extension housing oil
seal Side gear
shaft oil sealAT±232 and AT±233 AT±242 to AT±244
Throttle cable
Only A540H Components
Valve bodyInstallation
RemovalRemarks
AT±231AT±231
AT±233AT±232
AT±233AT±232
AT±232
± AUTOMATIC TRANSAXLEOn±Vehicle Repair (A540E and A540H)AT±231

COMPONENT PARTS
General Notes
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar±looking parts of different subassemblies being on your
workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next
component group. If a component group can not be assembled because parts are being ordered,
be sure to
keep all parts of that group in a separate container while proceeding with disassembly, inspection,
repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: A540E ATF DEXRON
II
A540H ATF Type T or equivalent
Recommended oil for the transfer: Transaxle oil E50, API GL5, SAE 75W±90 or equivalent
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean, with any fluid passages and holes blown through with
compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying
automatic transaxle fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection, repairs, and reas-
sembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least
fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O±rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the
groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
± AUTOMATIC TRANSAXLEComponent Parts (General Notes) (A540E and A540H)AT±262

Setting speed does not cancel when shifted to ºNº
range (A/T only).Setting speed does not cancel when parking brake
pulled up.Vehicle speed does not decrease when coast switch
turned on.
Setting speed does not cancel when clutch pedal
depressed (M/T only).Vehicle speed does not return to memorized speed
when resume switch turned on.
Setting speed does not cancel when brake pedal
depressed.Vehicle speed fluctuates when set switch turned on.
Cruise control will not disengage even about
40 km/h (25 mph).Vehicle speed does not accelerate when accel
switch turned on.
A short period after the O/D cut, (Approx.
within 14 seconds) the O/D wilt resume. Speed can be set below about 40 km/h (25 mph).Inspect No.5 of type A code.
Inspect No.6 of type A code. Return and acceleration response is sluggish.
Troubleshooting
Setting speed deviates on high side.
Setting speed deviates on low side.
Inspect No.4 of type A code. Cruise control does not operate.
Inspect No.4 of type A code.Inspect No. 1 of type A code.
Inspect No.4 of type A code.
Inspect No.4 of type A code.Inspect No.3 of type A code.Inspect No.2 of type A code.(a) Inspect type A
codes.
(e) All codes are normal.(b) Inspect type6 codes.Inspection item
ProblemNo.
± BODY ELECTRICAL SYSTEMCruse Control SystemBE±73

Cruise Control Computer Circuit
INSPECTION OF COMPUTER CIRCUIT
Disconnect the computer and inspect the connector on
wire harness side as shown in the below.
Remove CHARGE fuse and
ignition switch turned on with
parking brake lever released. Clutch pedal released or shifted
into only range except
ºNº and ºPº range
Remove CHARGE fuse and
ignition switch turned on with
parking brake lever pulled up.
Apply vacuum approx. 170
mmHg (fi.69 in.Hg, 22.7 kPa)Turn ignition switch and main
switch on
Turn ignition switch and main
switch off
Turn ignition switch and main
switch off Turn ignition switch and main
switch on
Clutch pedal depressed or
shifted into ºNº range Clutch Switch
(M/T) or Neutral
Start Switch (A/T)1 pulse each 44 cm
(15.75 in.) Stop Light Switch
and Release Valve
Turn resume/accel switch offTurn resume/accel switch on Control Switch
(indicator circuit)
Connection or
measure rtem
Turn set/coast switch off Turn set/coast switch on
Control Switch
(resunne/accel)Control Switch
(set/coast)
Vehicle moving slowlyBrake pedal depressed
Parking Brake
SwitchBrake pedal releasedBrake pedal released
10 ± Body ground
13 ± Body ground16 ± Body ground
17 ± Body ground
12 ± Body ground11 ± Body ground15 ± Body ground Tester connection
Stop Light Switch
3 ± Body ground
5 ± Body ground
7 ± Body ground
1 ± Body ground 9 ± Body groundBattery voltageSpecified value
Battery voltage
Battery voltageBattery voltage
Battery voltage No continuity
Vacuum SwitchControl Switch
Vacuum PumpNo continuity Approx. 68

Speed Sensor
No continuity Approx. 30

No continuity
Body GroundControl Valve
No voltageNo voltage
Continuity
Continuity ContinuityContinuity Resistance
ContinuityContinuity
Continuity Continuity
ContinuityNo voltage
No vacuum
ContinuityContinuityContinuity
ContinuityNo vohage
Condition
Resistance Stop FuseCheck for
VoltageVoltage Voltage
Voltage
Voltage4±142±14
± BODY ELECTRICAL SYSTEMCruise Control SystemBE±88

INITIAL CHECK
CHECK ACTUATOR OPERATION NOISE
(a) Start the engine and drive at a speed over 6 km/h
(4 mph).
(b) Check that the actuator operation noise is heard.
HINT: A initial check is carried out once each time after the
engine has been started and initial speed exceeds 6
km/h (4 mph). The respective functions, in order, of the 3
position solenoid and pump motor in the actuator are
checked. However, if the brake pedal is depressed, the ini-
tial check is not carried out, but is started after the pedal
has been released.
INSPECTION OF DIAGNOSIS SYSTEM
1. INSPECT BATTERY VOLTAGE
Inspect that the battery voltage is about 12 V.
2. CHECK THAT WARNING LIGHT TURNS ON
(a) Turn the ignition switch on.
(b) Check that the ºANTILOCKº warning light turns on for
3 seconds.
If not, inspect and repair or replace the fuse, bulb and wire
harness.
Diagnosis System
DESCRIPTION
If a malfunction occurs, the system will identify the prob-
lem and the computer will store the codes for the trouble
items.
At the same time, the system informs the driver of a mal-
function via the ºANTILOCKº warning light in the combina-
tion meter.
By turning on the ignition switch and disconnecting the
check connector, the trouble can be identified by the
number of blinks (diagnostic code) of the warning light.
In the event of two codes, that having the smallest num-
ber (code) will be identified first.
HINT: The warning light does not show the diagnostic
codes while the vehicle is running.
± BRAKE SYSTEMAnti±lock Brake System (A.B.S.)BR±67

The ER system is composed of there basic sub±systems: Fuel, Air Induction and Electronic Control Systems.
FUEL SYSTEM
Fuel is supplied under constant pressure to the EFI injectors by an electric fuel pump. The injectors inject a
metered quantity of fuel into the intake manifold in a accordance with signals from the ECU (Electronic Control
Unit).
AIR INDUCTION SYSTEM
The air induction system provides sufficient air for engine operation.
ELECTRONIC CONTROL SYSTEM
The Camry 3S±FE and 2V1±FE engines are equipped with a Toyota Computer Control System (TCCS) which
centrally controls the EFI, ESA, ISC, Diagnosis systems etc. by means of an Electronic Control Unit (ECU±
formerly ER computer) employing a microcomputer.
By means of the ECU, the TCCS controls the following functions:
1. Electronic Fuel Injection (EFI)
The ECU receives signals from various sensors indicating changing engine operation conditions such as:
Intake air volume
Intake air temperature
Coolant temperature
Engine rpm
Acceleration/deceleration
Exhaust oxygen content etc.
The signals are utilized by the ECU to determine the injection duration necessary for an optimum air±fuel ratio.
2. Electronic Spark Advance (ESA)
The ECU is programmed with data for optimum ignition timing under any and all operating conditions.
Using data provided by sensors which monitor various engine functions (rpm, coolant temperature, etc.), the
microcomputer (ECU) triggers the spark at precisely the right instant. (See IG section)
3. Idle Speed Control (ISC)
The ECU is programmed with target idling speed values to respond to different engine conditions (coolant
temperature, air conditioner ON/OFF, etc.). Sensors transmit signals to the ECU which control the flow of air
through the by±pass of the throttle valve and adjust idle speed to the target value. (See page FI±45,115
or 62, 117)
4. Diagnosis
The ECU detects any malfunctions or abnormalities in the sensor network and lights a ºCHECKº engine warn-
ing light on the instrument panel. At the same time, the trouble is identified and a diagnosis code is recorded
by the ECU. The diagnosis code can be read by the number of blinks of the ºCHECKº engine warning light
when terminals TE1 and E1 are connected. The diagnostic codes are refer to the later page.
(See page FI±25 or 27)
5. Fail±safe Function
In the event of the sensor malfunctioning, a back±up circuit will take over to provide minimal drivability, and
the ºCHECKº engine warning light.
± EFI SYSTEMSystem DescriptionFI±4

PRECAUTIONS
1. Before working the fuel system, disconnect the cable
from negative (±) terminal of the battery.
HINT: Any diagnostic code retained by the computer will be erased
when the battery terminal is removed. Therefore, if necessary, read
the diagnosis before removing the battery terminal.
2. Do not smoke or work open flame when working the fuel system.
3. Keep gasoline off rubber or leather parts.
INSPECTION PRECAUTIONS
MAINTENANCE PRECAUTIONS
1. CHECK CORRECT ENGINE TUNE±UP
(See page EM±8)
2. PRECAUTIONS WHEN CONNECTING GAUGE
(a) Use the battery as the power source for the timing light, tachome-
ter, etc.
(b) (3S±FE)
Connect the test probe of a tachometer to the service
connector of the distributor.
(c) (2VZ±FE)
Connect the test probe of a tachometer to the terminal
IG ± of the check connector.
3. IN EVENT OF ENGINE MISFIRE FOLLOWING
PRECAUTIONS SHOULD BE TAKEN
(a) Check proper connection of battery terminals, etc.
(b) Handle high±tension cords carefully.
(c) After repair work, check that the ignition coil terminals and
all other ignition system lines are reconnected securely.
(d) When cleaning the engine compartment, be especially
careful to protect the electrical system from water.
4. PRECAUTIONS WHEN HANDLING OXYGEN
SENSOR(S)
(a) Do not allow the oxygen sensor to drop or hit against an ob-
ject.
(b) Do not allow the sensor to come into contact with water.
± EFI SYSTEMPrecautionsFI±5