Inspection Procedure

HINT:

Read freeze frame data using Techstream. The ECM (included in the hybrid vehicle control ECU) records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.

1. CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0420) 
   1. Connect Techstream to the DLC3.
   2. Turn the power switch on (IG) and turn the tester on.
   3. Select the following menu items: Powertrain / Engine / Trouble Code.
   4. Read the DTCs.

      Result 

      RESULT CHART
      
      

      Display (DTC Output)	Proceed to
      P0420	A
      P0420 and other DTCs	B

      HINT:

      If any DTCs other than P0420 are output, troubleshoot those DTCs first.

   B:  Go to DTC CHART 

   A: Go to next step 

2. PERFORM ACTIVE TEST USING TECHSTREAM (A/F CONTROL) 
   1. Connect Techstream to the DLC3.
   2. Put the engine in inspection mode (See INSPECTION MODE PROCEDURE ).
   3. Turn the tester on.
   4. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds.
   5. On the tester, select the following menu items: Powertrain / Engine / Active Test / Control the Injection Volume for A/F sensor.
   6. Perform the Control the Injection Volume for A/F sensor operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume).
   7. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1 S1 and O2S B1 S2) displayed on the tester.

      Result: 

      A/F sensor reacts in accordance with increases and decreases in fuel injection volume: 

      +25% = Rich output: 

      Less than 3.0 V 

      -12.5% = Lean output: 

      More than 3.35 V 

      NOTE: The A/F sensor has an output delay of a few seconds and the HO2 sensor has a maximum output delay of approximately 20 seconds.
   HO2 SENSOR VOLTAGE CHART
   
   

   Case	A/F Sensor (Sensor 1) Output Voltage		HO2 Sensor (Sensor 2) Output Voltage		Main Suspected Trouble Area
   1	Injection Volume +025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Injection Volume 025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Catalyst Exhaust gas leakage
   	Output Voltage More than 3.35 V Less than 3.0 V	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Output Voltage More than 0.5 V Less than 0.4 V	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2	Injection Volume +025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Injection Volume 025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	A/F sensor A/F sensor heater A/F sensor circuit
   	Output Voltage Almost no reaction	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Output Voltage More than 0.5 V Less than 0.4 V	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3	Injection Volume +025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Injection Volume 025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HO2 sensor HO2 sensor heater HO2 sensor circuit
   	Output Voltage More than 3.35 V Less than 3.0 V	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Output Voltage Almost no reaction	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4	Injection Volume +025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Injection Volume 025% -12.5%	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Extremely rich or lean actual air-fuel ratio Injector Fuel pressure Gas leakage from exhaust system
   	Output Voltage Almost no reaction	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Output Voltage Almost no reaction	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Following the Control the Injection Volume for A/F sensor procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. To display the graph, select the following menu items on the tester: Powertrain / Engine / Active Test / Control the Injection Volume for A/F Sensor / A/F Control System / AFS B1 S1 and O2S B1 S2 then press the graph button on the Data List view.

   Result 

   RESULT CHART
   
   

   Result	Proceed to
   Case 1	A
   Case 2	B
   Case 3	C
   Case 4	D

   B: REPLACE AIR-FUEL RATIO SENSOR 

   C:  Go to step  5

   D: CHECK CAUSE OF EXTREMELY RICH OR LEAN ACTUAL AIR-FUEL RATIO, REPLACE FAULTY AREA AND GO TO NEXT STEP 

   A: Go to next step 

3. INSPECT FOR EXHAUST GAS LEAK 

   OK: 

   No gas leakage. 

   NG: REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT 

   OK: Go to next step 

4. REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
   1. Replace exhaust manifold converter sub-assembly (See REMOVAL ).

   NEXT: REPLACE FRONT EXHAUST PIPE ASSEMBLY  (See EXHAUST PIPE )

5. INSPECT FOR EXHAUST GAS LEAK 

   OK: 

   No gas leakage. 

   NG: REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT 

   OK: REPLACE HEATED OXYGEN SENSOR