Engine Control System (2ZR-FXE) (Service Information): Removal & Installation Lexus CT I

INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Apply a light coat of engine oil to a new O-ring and install it onto the camshaft timing oil control valve assembly. NOTE: Do not twist the O-ring. Install the camshaft timing oil control valve assembly with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the camshaft timing oil control valve assembly connector.
2. INSPECT FOR OIL LEAK . Refer to «REPLACEMENT - Step 6»(ref-568748-S36548039812013072300000)
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 98»(ref-568735-S28791889062013072300000)

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1. INSTALL THROTTLE BODY ASSEMBLY Install a new gasket onto the intake manifold. Install the throttle body assembly with the 2 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 2 water by-pass hoses and throttle body connector.
2. INSTALL AIR CLEANER HOSE ASSEMBLY Install the air cleaner hose assembly and lock the hose clamp. Connect the ventilation hose.
3. INSTALL AIR CLEANER CASE Install the air cleaner case with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Install the water hose to the hose clamp. Install the air cleaner filter element.
4. INSTALL INLET AIR CLEANER ASSEMBLY Install the inlet air cleaner assembly to the air cleaner case. Install the inlet air cleaner assembly with the 2 bolts and 2 clips. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Connect the wire harness clamp to the inlet air cleaner assembly. Install the water hose to the hose clamp.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Install the air cleaner cap sub-assembly with the 2 clamps. Tighten the hose clamp. Connect the mass air flow meter connector. Connect the wire harness clamp.
6. ADD ENGINE COOLANT (for Engine) . Refer to «REPLACEMENT - Step 2»(ref-568743-S28061158612013072300000)
7. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-568726-S04853020212013072300000)
8. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 98»(ref-568735-S28791889062013072300000)
9. INSTALL RADIATOR SUPPORT OPENING COVER . Refer to «INSTALLATION - Step 3»(ref-568749-S42200779382013072300000)
10. PERFORM INITIALIZATION NOTE: Be sure to perform this procedure after reassembling the throttle body assembly, removing and reinstalling any throttle body component or replacing the ECM. Disconnect the cable from the negative (-) auxiliary battery terminal. Wait at least 60 seconds and reconnect the cable. Connect the Techstream to the DLC3 and clear the DTCs. Refer to «DTC CHECK / CLEAR»(ref-568607-S14015113742013072300000) . Set the vehicle to inspection mode. Refer to «INSPECTION MODE PROCEDURE»(ref-568589-S23460353802013072300000) . Start the engine without operating the accelerator pedal and check that the MIL is not illuminated and that the idle speed is within the specified range when the air conditioning is switched off after the engine is warmed up. Standard Condition Engine Idle Speed A/C switched off 950 to 1050 RPM NOTE: If the accelerator pedal is operated, perform the above steps again. Be sure to perform this step with all accessories off. Make sure that park (P) is selected. Perform a road test and confirm that there are no abnormalities.

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1. PRECAUTION NOTE: After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to «PRECAUTION»(ref-568589-S04857946582013072300000) .
2. REMOVE REAR NO. 2 FLOOR BOARD . Refer to «REMOVAL - Step 1»(ref-568750-S13952416472013072300000)
3. REMOVE REAR DECK FLOOR BOX . Refer to «REMOVAL - Step 2»(ref-568750-S13952416472013072300000)
4. REMOVE REAR NO. 3 FLOOR BOARD . Refer to «REMOVAL - Step 3»(ref-568750-S13952416472013072300000)
5. REMOVE DECK FLOOR BOX RH . Refer to «REMOVAL - Step 4»(ref-568750-S13952416472013072300000)
6. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE . Refer to «REMOVAL - Step 5»(ref-568750-S13952416472013072300000)
7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL
8. REMOVE INVERTER WITH CONVERTER ASSEMBLY Refer to «REMOVAL»(ref-568590-S11950336722013072300000)
9. SEPARATE INVERTER RESERVE TANK ASSEMBLY Remove the 2 bolts and separate the inverter reserve tank assembly.
10. REMOVE ECM Separate the wire harness clamp. Disconnect the 2 ECM connectors. Disconnect the wire harness clamp. Push the locks on the 2 levers, then raise the levers, and disconnect the 2 ECM connectors. NOTE: After disconnecting the connectors, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connectors. Remove the 2 bolts and ECM. Remove the 4 screws and 2 ECM brackets.

Scheme 245

1. INSTALL ECM Install the 2 ECM brackets to the ECM with the 4 screws. Install the ECM with the 2 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Connect the 2 ECM connectors. Connect the 2 ECM connectors and lower the 2 levers. NOTE: When connecting the connectors, make sure that dirt, water or other foreign matter does not get caught between the connectors and other parts. Make sure that the 2 levers are securely locked. Install the wire harness clamp.
2. INSTALL INVERTER RESERVE TANK ASSEMBLY Install the inverter reserve tank assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to «INSTALLATION»(ref-568590-S06603627362013072300000)
4. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
5. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE . Refer to «INSTALLATION - Step 70»(ref-568750-S15440718192013072300000)
6. INSTALL DECK FLOOR BOX RH . Refer to «INSTALLATION - Step 71»(ref-568750-S15440718192013072300000)
7. INSTALL REAR NO. 3 FLOOR BOARD . Refer to «INSTALLATION - Step 72»(ref-568750-S15440718192013072300000)
8. INSTALL REAR DECK FLOOR BOX . Refer to «INSTALLATION - Step 73»(ref-568750-S15440718192013072300000)
9. INSTALL REAR NO. 2 FLOOR BOARD . Refer to «INSTALLATION - Step 74»(ref-568750-S15440718192013072300000)
10. PERFORM REGISTRATION NOTE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. Refer to «REGISTRATION»(ref-568607-S16834217972013072300000) .
11. PERFORM INITIALIZATION NOTE: Perform Initialization when replacing the ECM See step 10 . When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-568589-S03492911652013072300000) .

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1. INSTALL MASS AIR FLOW METER Install the mass air flow meter with the 2 screws. NOTE: Make sure that the O-ring is not cracked or does not jump out of position during installation. Connect the mass air flow meter connector.

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REMOVAL

HINT

Although the part name refers to the No. 1 crank position sensor, this procedure is for the camshaft position sensor.

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1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 20»(ref-568735-S42395500822013072300000)
2. REMOVE NO. 1 CRANK POSITION SENSOR Disconnect the No. 1 crank position sensor connector. Remove the bolt and No. 1 crank position sensor.

HINT

Although the part name refers to the No. 1 crank position sensor, this procedure is for the camshaft position sensor.

Scheme 249

1. INSTALL NO. 1 CRANK POSITION SENSOR Apply a light coat of engine oil to the O-ring on the No. 1 crank position sensor. Install the No. 1 crank position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 1 crank position sensor connector.
2. INSPECT FOR OIL LEAK . Refer to «REPLACEMENT - Step 6»(ref-568748-S36548039812013072300000)
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 98»(ref-568735-S28791889062013072300000)

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1. REMOVE REAR ENGINE UNDER COVER RH
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE CRANK POSITION SENSOR Disconnect the crank position sensor connector. Remove the bolt and crank position sensor.

Scheme 254

1. INSPECT CRANK POSITION SENSOR Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Ohmmeter Standard Resistance Tester Connection Condition Specified Condition 1 - 2 -10 to 50°C (14 to 122°F) 1630 to 2740 ohms 50 to 100°C (122 to 212°F) 2065 to 3225 ohms

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1. INSTALL CRANK POSITION SENSOR Apply a light coat of engine oil to the O-ring on the crank position sensor. Install the crank position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the crank position sensor connector.
2. INSPECT FOR OIL LEAK
3. INSTALL NO. 1 ENGINE UNDER COVER
4. INSTALL REAR ENGINE UNDER COVER RH

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1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 20»(ref-568735-S42395500822013072300000)
2. REMOVE IGNITION COIL ASSEMBLY Disconnect the 4 ignition coil connectors. Remove the 4 bolts and 4 ignition coils. NOTE: When removing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.
3. REMOVE SPARK PLUG Using a 14 mm spark plug wrench, remove the 4 spark plugs.

1. INSTALL SPARK PLUG Using a 14 mm spark plug wrench, install the 4 spark plugs. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
2. INSTALL IGNITION COIL ASSEMBLY Install the 4 ignition coils with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: When installing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube. Connect the 4 ignition coil connectors.
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 98»(ref-568735-S28791889062013072300000)

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1. DISCHARGE FUEL SYSTEM PRESSURE Refer to «REMOVAL - Step 2»(ref-568741-S34778848562013072300000)
2. REMOVE FUEL INJECTOR ASSEMBLY Refer to «REMOVAL»(ref-568741-S26257196172013072300000)
3. SEPARATE INVERTER RESERVE TANK ASSEMBLY See step 9
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the engine coolant temperature sensor connector. Using SST, remove the engine coolant temperature sensor and gasket. SST: 09205-76030

Scheme 261

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Condition Specified Condition Approximately 20°C (68°F) 2.32 to 2.59 kohms Approximately 80°C (176°F) 0.310 to 0.326 kohms NOTE: When checking the engine coolant temperature sensor in water, keep the terminals dry. After the check, dry the sensor. If the resistance is not as specified, replace the engine coolant temperature sensor.

Scheme 262

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install the engine coolant temperature sensor through a new gasket. TEXT IN ILLUSTRATION *a Fulcrum Length 25 mm *b Fulcrum Length 180 mm SST: 09205-76030 without SST Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) with SST Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 25 mm (0.984 in.) and a torque wrench with a fulcrum length of 180 mm (7.09 in.). Refer to «PRECAUTION»(ref-568589-S04857946582013072300000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. Connect the engine coolant temperature sensor connector.
2. INSTALL INVERTER RESERVE TANK ASSEMBLY See step 2
3. INSTALL FUEL INJECTOR ASSEMBLY Refer to «INSTALLATION»(ref-568741-S15999084482013072300000)

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1. REMOVE INTAKE MANIFOLD Refer to «REMOVAL - Step 5»(ref-568745-S37180711792013072300000)
2. REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the bolt and knock sensor.