No.

: OB- 1007
SERVICE
TRAINING AND PUBLICATION 010
Date : 2011/1/13

BULLETIN TRAINING
PUBLICATION
APPLICABLE COUNTRIES: INFORMATION
ALL COUNTRIES N. AMERICA GENERAL COUNTRIES, EUROPE ADVANCE ORDER
Other OTHERS

To: Service Manager

CORRECTION TO x REPAIR MANUAL

REPAIR MANUAL SUPPLEMENT
ELECTRICAL WIRING DIAGRAM
NEW CAR FEATURES
BODY REPAIR MANUAL
SERVICE DATA SHEET

Errors have been found in the following manual:

Pub. No.: RM12W3E Pub. Name: YARIS Repair Manual

Section Title Paragraph

2SZ-FE
SFI SYSTEM P0016
ENGINE CONTROL SYSTEM
2SZ-FE
TIMING CHAIN INSPECTION
ENGINE MECHANICAL
2SZ-FE
ENGINE UNIT INSPECTION
ENGINE MECHANICAL

The revised pages listed above are attached.

(The corrected parts are indicated by arrows.)

Please attach the accompanying revised pages to the applicable pages in the manual above.

This bulletin is also available on the OASIS Global Service Information Center.
Inquiries : BM_correction_information@mta.mx.toyota.co.jp

KEEP IN BINDER TOGETHER WITH SERVICE PUBLICATIONS GUIDE

TECHNICAL INFORMATION DEVELOPMENT

GROUP SERVICE INFORMATION DEPARTMENT
TECHNICAL SERVICE DIVISION
 2SZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–51

Crankshaft Position - Camshaft Position

DTC P0016
Correlation (Bank 1 Sensor A)
DESCRIPTION
In the VVT (Variable Valve Timing) system, the appropriate intake valve open and close timing is
controlled by the ECM. The ECM performs intake valve control by performing the following: 1) controlling
the camshaft and camshaft timing oil control valve, and operating the camshaft timing gear; and 2)
changing the relative positions of the gaps between the camshaft and crankshaft. [Corrected]
DTC No. DTC Detection Conditions Trouble Areas
• Valve timing
• Camshaft timing oil control valve assembly
Deviation in crankshaft and camshaft position sensor signals
P0016 • Camshaft timing sprocket assembly
(2 trip detection logic)
• Oil control valve filter
• ECM

CONFIRMATION DRIVING PATTERN ES

There is no designated
vehicle speed
Vehicle Speed
[E]

[B] [C] [F]

Idling
Ignition Switch [A]
ON

Warming up 5 minutes or more 2 to 3 minutes 5 minutes or more

the engine

[D] [G]

A197314E20

1. Connect the intelligent tester to the DLC3.

2. Turn the ignition switch to ON and turn the tester on.
3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC operation).
4. Turn the ignition switch off and wait for at least 30 seconds.
5. Turn the ignition switch to ON and turn the tester on [A].
6. Start the engine and warm it up until the ECT reaches 75°C (167°F) or higher [B].
7. Idle the engine for 5 minutes or more [C].
8. Enter the following menus: Powertrain / Engine and ECT / DTC [D].
9. Read the pending DTCs.
HINT:
• If a pending DTC is output, the system is malfunctioning.
• If a pending DTC is not output, perform the following procedure.
10.Enter the following menus: Powertrain / Engine and ECT / Utility / All Readiness.
11.Input the DTC: P0016.

[Added]
Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 1/8
 [All Corrected]
ES–52 2SZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

12.Check the DTC judgment result.

Tester Display Description
• DTC judgment completed
NORMAL
• System normal
• DTC judgment completed
ABNORMAL
• System abnormal
• DTC judgment not completed
INCOMPLETE
• Perform driving pattern after confirming DTC enabling conditions
• Unable to perform DTC judgment
UNKNOWN
• Number of DTCs which do not fulfill DTC preconditions has reached ECU memory limit

HINT:
• If the judgment result shows NORMAL, the system is normal.
• If the judgment result shows ABNORMAL, the system has a malfunction.
• If the judgment result shows INCOMPLETE or UNKNOWN, perform steps [E] through [G].
13.Drive the vehicle for 2 to 3 minutes [E].
CAUTION:
ES When performing the confirmation driving pattern, obey all speed limits and traffic laws.
14.Idle the engine for 5 minutes or more [F].
15.Enter the following menus: Powertrain / Engine and ECT / DTC [G].
16.Read the pending DTCs.
HINT:
• If a pending DTC is output, the system is malfunctioning.
• If a pending DTC is not output, perform the following procedure.
17.Check the DTC judgment result.
HINT:
• If the judgment result shows NORMAL, the system is normal.
• If the judgment result shows ABNORMAL, the system has a malfunction.

WIRING DIAGRAM
Refer to DTC P0335 (See page ).
See:
INSPECTION PROCEDURE 2SZ-FE ENGINE CONTROL SYSTEM - SFI SYSTEM - P0335
HINT:
• The monitor for this DTC detects when the timing chain is shifted by one tooth or more.
• Read freeze frame data using an intelligent tester. Freeze frame data record the engine condition when
malfunctions are detected. 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 P0016)

(a) Connect the intelligent tester to the DLC3.

(b) Turn the ignition switch to ON.
(c) Turn the tester on.
(d) Enter the following menus: Powertrain / Engine and ECT
/ DTC.
(e) Read the DTCs.
Result
Result Proceed to
DTC P0016 is output A
DTC P0016 and other DTCs are output B

Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 2/8

 [Page Added]
2SZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–53

HINT:
If any DTCs other than P0016 are output, perform
troubleshooting for those DTCs first.
B GO TO DTC CHART See*1

2 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE CAMSHAFT TIMING

OIL CONTROL VALVE ASSEMBLY)

HINT:
If the VVT system can be operated through the Active Test, it
can be assumed that the VVT system is operating normally.
(a) Connect the intelligent tester to the DLC3.
(b) Start the engine.
(c) Turn the A/C on.
(d) Turn the tester on. ES
(e) Enter the following menus: Powertrain / Engine and ECT
/ Active Test / Control the VVT Linear (Bank 1) / VVT
Change Angle (Bank 1).
(f) Perform the Active Test. Check that the displacement
angle varies.
OK:
Displacement angle varies.
NG Go to step 4

OK

3 ADJUST VALVE TIMING

(a) Adjust the valve timing (See

See*2 p.
HINT:
Inspect the timing chain when adjusting the valve timing
(See .
See*3

NEXT Go to step 7

4 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Inspect the camshaft timing oil control valve assembly

(See
See*4 p.

NG REPLACE CAMSHAFT TIMING OIL

CONTROL VALVE ASSEMBLY See*5

OK

5 INSPECT OIL CONTROL VALVE FILTER

(a) Inspect the oil control valve filter (See

See*6 p.

See*1: 2SZ-FE ENGINE CONTROL SYSTEM - SFI SYSTEM - DIAGNOSTIC TROUBLE CODE CHART
See*2: 2SZ-FE ENGINE MECHANICAL - CYLINDER HEAD - REMOVAL
See*3: 2SZ-FE ENGINE MECHANICAL - TIMING CHAIN - INSPECTION
See*4: 2SZ-FE ENGINE CONTROL SYSTEM - CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY - INSPECTION
See*5: 2SZ-FE ENGINE CONTROL SYSTEM - CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY - REMOVAL
See*6: 2SZ-FE ENGINE CONROL SYSTEM - SFI SYSTEM - P0011 Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 3/8
 [Page Added]
ES–54 2SZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

NG CLEAN OR REPLACE OIL CONTROL VALVE

FILTER

OK

6 INSPECT CAMSHAFT TIMING SPROCKET ASSEMBLY

(a) Inspect the camshaft timing sprocket assembly (See

page
See*1 .

NG REPLACE CAMSHAFT TIMING SPROCKET

ASSEMBLY See*2

OK

ES 7 CHECK WHETHER DTC OUTPUT RECURS (DTC P0016)

(a) Connect the intelligent tester to the DLC3.

(b) Turn the ignition switch to ON.
(c) Turn the tester on.
(d) Clear DTCs (SeeSee*3 p.
(e) Turn the ignition switch to off and wait for at least 30
seconds.
(f) Turn the ignition switch to ON.
(g) Turn the tester on.
(h) Start the engine and warm it up.
(i) Drive the vehicle in accordance with the driving pattern
described in Confirmation Driving Pattern.
(j) Enter the following menus: Powertrain / Engine and ECT
/ DTC.
(k) Read pending DTCs.
Result
Result Proceed to
DTC is not output A
DTC P0016 is output B

B REPLACE ECM See*4

END

See*1: 2SZ-FE ENGINE MECHANICAL - CAMSHAFT - INSPECTION

See*2: 2SZ-FE ENGINE MECHANICAL - CAMSHAFT - REMOVAL
See*3: 2SZ-FE ENGINE CONTROL SYSTEM - SFI SYSTEM - DTC CHECK / CLEAR
See*4: 2SZ-FE ENGINE CONTROL SYSTEM - ECM - REMOVAL

Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 4/8

 EM–18 2SZ-FE ENGINE MECHANICAL – TIMING CHAIN

(d) Insert a 3mm diameter bar into the holes in the

stopper plate and the chain tensioner plunger.
(e) Remove the bolt and the nut and remove the chain
tensioner plunger.

A129133

46. REMOVE TIMING CHAIN TENSION ARM

(a) Remove the bolt and remove the timing chain
tension arm.

A129134

47. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 bolts and remove the timing chain
guide.
EM

A129135

48. REMOVE NO. 2 TIMING CHAIN GUIDE

(a) Remove the 2 bolts and remove the No. 2 timing
chain guide.
49. REMOVE CHAIN SUB-ASSEMBLY

A129136

INSPECTION
1. INSPECT CHAIN SUB-ASSEMBLY
(a) Visually check the timing chain for wear and cracks.
HINT:
If the timing chain is not normal, replace the timing
chain and check the sprocket.

[Corrected]
A104129

Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 5/8

 2SZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–19

(b) Pull the timing chain with a force of 225 N (23 kgf,
51 lbf) as shown in the illustration.
(c) Using a vernier caliper, measure the length of 15
links.
[Added] Maximum chain elongation:
Measuring Area 93.1 mm (3.665 in.)
HINT:
Perform the measurement at 3 random places. Use
01 23 45 14 15 the average of the measurements.
A162995E11 If the average elongation is greater than the
maximum, replace the timing chain.
INSTALLATION
[Added]
1. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the matchmarks of the crankshaft sprocket
and the timing chain and install the timing chain.

Matchmark

EM

Mark Plate

A129137E01

(b) Align the matchmarks of the camshaft timing

Mark Plate
sprocket and the camshaft timing gear or sprocket
with the timing marks of the timing chain and install
the timing chain.

Matchmark

A129139E01

2. INSTALL NO. 2 TIMING CHAIN GUIDE

(a) Install the No. 2 timing chain guide with the 2 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

A129136

Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 6/8

 [INSPECTION]
EM–34 2SZ-FE ENGINE MECHANICAL – ENGINE UNIT

(3) Apply air at about 100 kPa (1.0 kgf*cm2)

pressure to the 2 broken paths (the advance
Retard Advance side path and the retard side path).
Side Path Side Path
NOTICE:
Cover the paths with a shop rag or piece of
cloth to prevent oil splashes.

A131398E01

(4) Confirm that the camshaft timing gear

assembly revolves in the timing advance
direction when the air pressure on the timing
retard path is reduced.
HINT:
Retard Adavance The lock pin is released and the camshaft
Side Path Side Path timing gear revolves in the advance direction.
(5) When the camshaft timing gear reaches the
most advanced position, release the air
pressure on the timing retard side path, and
then release the air pressure on the timing
advance side path.
Decompress Hold Pressure NOTICE:
Camshaft timing gear assembly
EM A131399E01
occasionally shifts to the retard side
abruptly if the air pressure on the advance
side path is released first. This often results
in breakage of the lock pin.
(c) Check the revolution.
(1) Rotate the valve timing assembly back and
forth several times, except where the lock pin
meets it at the most retarded angle. Check the
movable range and that it rotates smoothly.
Standard:
Smooth movable range is about 30°.
NOTICE:
Perform this check by hand, instead of
using air pressure.
(d) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear
assembly is locked in the most retarded
position.
2. INSPECT CHAIN SUB-ASSEMBLY
(a) Visually check the timing chain for wear and cracks.
HINT:
If the timing chain is not normal, replace the timing
chain and check the sprocket.

[Corrected]

A104129

Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 7/8

 [INSPECTION]
2SZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–35
[Added]

(b) Pull the timing chain with a force of 225 N (23 kgf,
51 lbf) as shown in the illustration.
(c) Using a vernier caliper, measure the length of 15
links.
[Added] Maximum chain elongation:
Measuring Area 93.1 mm (3.665 in.)
HINT:
Perform the measurement at 3 random places. Use
01 23 45 14 15 the average of the measurements.
A162995E11 If the average elongation is greater than the
maximum, replace the timing chain.
3. INSPECT CHAIN TENSIONER PLUNGER
(a) Check that the plunger moves smoothly when the
ratchet pawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger
is locked in place by the ratchet pawl and does not
move when pushed with your finger.

A129199

4. INSPECT CAMSHAFT TIMING SPROCKET

ASSEMBLY
(a) Wrap the chain around the timing sprocket.
(b) Using vernier calipers, measure the diameter of the EM
timing gear with the chain.
Minimum gear diameter (with chain):
90.2 mm (3.551 in.)
If the diameter is less the than the minimum, replace
the camshaft timing sprocket.
A129201 NOTICE:
Make sure that the vernier calipers are in
contact with the chain link when measuring.
5. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using vernier calipers, measure the diameter of the
timing gear with the chain.
Minimum gear diameter (with chain):
90.2 mm (3.551 in.)
If the diameter is less than the minimum, replace the
camshaft timing gear.
NOTICE:
A129200 Make sure that the vernier calipers are in
contact with the chain link when measuring.

Correction to Pub. No. RM12W3E (Bulletin No. OB-1007) 8/8