Engine Control System (Service Information): Diagnosis Lexus ES XV60

ON-VEHICLE INSPECTION [06/2012 - ]

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Connect the Techstream to the DLC3. Start the engine. Turn the Techstream on. Turn the A/C switch on. Inspect the camshaft timing oil control valve assembly (for intake camshaft). Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Linear (Bank 1). Check the engine speed when the camshaft timing oil control valve assembly is operated using the Techstream with the engine coolant temperature at 50°C (122°F) or less. HINT: When performing the Active Test, the air conditioning should be on. Engine coolant temperature when the engine is started should be 30°C (86°F) or less. Standard Condition Control Range Specified Condition 0% Normal engine speed 100% Engine idles roughly or stalls If the operation is not as specified, check the camshaft timing oil control valve assembly, wire harness and ECM. Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Linear (Bank 2). Check the engine speed when the camshaft timing oil control valve assembly is operated using the Techstream with the engine coolant temperature at 50°C (122°F) or less. HINT: When performing the Active Test, the air conditioning should be on. Engine coolant temperature when the engine is started should be 30°C (86°F) or less. Standard Condition Control Range Specified Condition 0% Normal engine speed 100% Engine idles roughly or stalls If the operation is not as specified, check the camshaft timing oil control valve assembly, wire harness and ECM. Inspect the camshaft timing oil control valve assembly (for exhaust camshaft). Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Exhaust Linear (Bank 1). Check the engine speed when the camshaft timing oil control valve assembly is operated using the Techstream with the engine coolant temperature at 50°C (122°F) or less. HINT: When performing the Active Test, the air conditioning should be on. Engine coolant temperature when the engine is started should be 30°C (86°F) or less. Standard Condition Control Range Specified Condition 0% Normal engine speed 100% Engine idles roughly or stalls If the operation is not as specified, check the camshaft timing oil control valve assembly, wire harness and ECM. Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Exhaust Linear (Bank 2). Check the engine speed when the camshaft timing oil control valve assembly is operated using the Techstream with the engine coolant temperature at 50°C (122°F) or less. HINT: When performing the Active Test, the air conditioning should be on. Engine coolant temperature when the engine is started should be 30°C (86°F) or less. Standard Condition Control Range Specified Condition 0% Normal engine speed 100% Engine idles roughly or stalls If the operation is not as specified, check the camshaft timing oil control valve assembly, wire harness and ECM.

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1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to «REMOVAL [06/2012 - ]»(ref-598608-S29092353242014021400000) .
2. DISCONNECT ENGINE WIRE Disconnect the 3 wire harness clamps. TEXT IN ILLUSTRATION *a for Bank 2 *b for Bank 1 Remove the 2 bolts and 2 wire harness brackets.
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Disconnect the 4 camshaft timing oil control valve assembly connectors. Remove the 4 bolts and 4 camshaft timing oil control valve assemblies. TEXT IN ILLUSTRATION *a for Intake Side *b for Exhaust Side *c for Bank 2 *d for Bank 1 Remove the O-ring from each camshaft oil control valve assembly. TEXT IN ILLUSTRATION *1 O-ring

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1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Specified Condition 1 - 2 6.9 to 7.9 ohms at 20°C (68°F) If the result is not as specified, replace the camshaft timing oil control valve assembly. Check the operation. TEXT IN ILLUSTRATION *1 Spool Valve *2 Battery Connect a battery positive (+) lead to terminal 1 and negative (-) lead to terminal 2, and check the movement of the spool valve. OK Condition Specified Condition Battery voltage is applied Valve moves in black arrow direction shown in illustration Battery voltage is not applied Valve moves in white arrow direction shown in illustration If the result is not as specified, replace the camshaft timing oil control valve assembly. NOTE: Accumulation of foreign matter can cause minor pressure leaks. Minor pressure leaks in the intake side oil control valve will cause the intake camshaft to advance. Minor pressure leaks in the exhaust side oil control valve will cause the exhaust camshaft to retard. The inappropriate camshaft timing that results from these leaks will cause a DTC to be set.

1. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY Check the throttle control motor operating sound. Turn the engine switch on (IG). When depressing the accelerator pedal, check the operating sound of the throttle control motor. Make sure that no friction noises are emitted from the throttle control motor. If friction noise exists, replace the throttle with motor body assembly. Check the throttle position sensor. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Data List / All Data / Throttle Sensor Position. Depress the accelerator pedal. When the throttle valve is fully open, check that the Throttle Sensor Position value is within specification. Standard Throttle Valve Opening Percentage Tester Display Specified Condition Throttle Sensor Position 60% or more NOTE: When checking the throttle valve opening percentage, the shift lever should be in N. Fully depress the accelerator pedal. If the percentage is less than 60%, replace the throttle with motor body assembly.

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1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
4. REMOVE ENGINE UNDER COVER LH
5. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT [06/2012 - ] - Step 1»(ref-598590-S28562218122014021400000)
6. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 17»(ref-598588-S29832633602014021400000)
7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Disconnect the mass air flow meter connector and wire harness clamp. Disconnect the 3 hoses. Disconnect the ventilation hose from the air cleaner cap sub-assembly. Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly. Release the 2 clamps and remove the air cleaner cap sub-assembly.
8. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY Disconnect the 2 water by-pass hoses from the throttle with motor body assembly. Disconnect the throttle with motor body assembly connector and wire harness clamp. Remove the 4 bolts, throttle with motor body assembly and wire harness clamp stay. Remove the gasket from the intake air surge tank assembly.

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1. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (M-) - 2 (M+) 20°C (68°F) 0.3 to 100 ohms TEXT IN ILLUSTRATION *a Component without harness connected (Throttle with motor body assembly) If the result is not as specified, replace the throttle with motor body assembly.

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1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Install a new gasket to the intake air surge tank assembly. Install the throttle with motor body assembly and wire harness clamp stay to the intake air surge tank assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the throttle with motor body assembly connector and wire harness clamp. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
2. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Connect the air cleaner cap sub-assembly to the throttle with motor body assembly with the hose clamp. Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps. Connect the 3 hoses. Connect the ventilation hose. Connect the mass air flow meter connector and wire harness clamp.
3. ADD ENGINE COOLANT . Refer to «REPLACEMENT [06/2012 - ] - Step 2»(ref-598590-S28562218122014021400000)
4. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [06/2012 - ] - Step 1»(ref-598616-S28605636602014021400000)
5. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 82»(ref-598588-S26055333012014021400000)
6. INSTALL ENGINE UNDER COVER RH
7. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
8. INSTALL ENGINE UNDER COVER LH
9. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
10. PERFORM INITIALIZATION NOTE: Be sure to perform this procedure after removing and reinstalling the throttle with motor body assembly or any throttle with motor body components. Perform the following procedure after replacing the throttle with motor body assembly or any throttle body components. The following procedure should also be performed if the throttle with motor body assembly is cleaned. Turn the engine switch on (IG) without operating the accelerator pedal. NOTE: If the accelerator pedal is operated, perform the above steps again. Connect the Techstream to the DLC3 and clear the DTCs. Refer to «DTC CHECK / CLEAR [06/2012 - ]»(ref-598472-S02009234142014021400000) . Perform "Inspection After Repair". Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) . Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range with the A/C switch off. Standard Condition Engine Idle Speed A/C switch off 600 to 700 rpm NOTE: Be sure to perform this step with all accessories off. Make sure that the shift lever is in N. Enter the following menus: Powertrain / Engine / Data List / Gas Throttle / Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more. Perform a road test and confirm that there are no abnormalities.

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1. PRECAUTION NOTE: After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to «PRECAUTION [06/2012 - ]»(ref-598449-S42461431542014021400000) .
2. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
5. REMOVE ENGINE UNDER COVER LH
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [06/2012 - ]»(ref-598449-S08309221792014021400000) .
7. REMOVE DUTY VACUUM SWITCHING VALVE Disconnect the 2 vacuum hoses from the duty vacuum switching valve. Disconnect the hose. Disconnect the vacuum hose and duty vacuum switching valve connector. Remove the bolt and duty vacuum switching valve.

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1. INSPECT DUTY VACUUM SWITCHING VALVE (OPERATION) Check the operation of the duty vacuum switching valve when positive battery voltage is applied to its terminals. Standard Condition Condition Specified Condition Battery voltage is not applied The air applied to pipe G flows out of pipes E and H. Battery voltage is applied The air applied to pipe F flows out of pipes E and H. If the result is not as specified, replace the duty vacuum switching valve.
2. INSPECT DUTY VACUUM SWITCHING VALVE (RESISTANCE) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 19 to 21 ohms If the resistance is not as specified, replace the duty vacuum switching valve.

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1. INSTALL DUTY VACUUM SWITCHING VALVE Connect the vacuum hose and duty vacuum switching valve connector. Install the duty vacuum switching valve with the bolt. HINT: Hose A: Large hose Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Connect the 2 vacuum hoses to the duty vacuum switching valve. HINT: Hose B: Dummy hose (not used for ventilation, the other end is plugged) Connect the hose.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [06/2012 - ]»(ref-598449-S08309221792014021400000) .
3. INSTALL ENGINE UNDER COVER LH
4. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
5. INSTALL ENGINE UNDER COVER RH
6. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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1. INSPECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Check the operation. Connect the Techstream to the DLC3. Start the engine and turn the Techstream on. Enter the following menus: Powertrain / Engine / Active Test / Control the ACM Inhibit. Tester Display Test Part Control Range Diagnostic Note Control the ACM Inhibit ACM ON / OFF Test is possible while engine is idling Check if the front engine mounting insulator assembly operates in accordance with tester operation. Result Condition Specified Condition "Control the ACM Inhibit" is OFF The engine does not move (insulator operation is normal). "Control the ACM Inhibit" is ON The engine moves in accordance with insulator operation. HINT: While "Control the ACM Inhibit" is ON, the front engine mounting insulator assembly operates repeatedly. Inspect for vacuum leaks. Disconnect the vacuum hose from the front engine mounting insulator assembly. Using a vacuum pump, apply vacuum of 80 kPa (600 mmHg, 25 in.Hg) and wait for 1 minute. Check that there is no change in the needle movement of the vacuum pump gauge. OK Vacuum pressure holds. Check that there is no fluid leakage caused by a break in the diaphragm. Reconnect the vacuum hose.

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1. REMOVE RADIATOR ASSEMBLY Refer to «REMOVAL [06/2012 - ]»(ref-598590-S37983240142014021400000) .
2. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET HINT: Securely support the automatic transaxle using a jack. Remove the 2 bolts and separate the transmission oil cooler. Remove the 4 bolts and transverse engine mounting bracket.
3. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Disconnect the duty vacuum switching valve connector and 2 clamps. Remove the hole plug. Remove the 3 nuts and front engine mounting insulator assembly.

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1. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Install the front engine mounting insulator assembly with the 3 nuts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Install the hole plug. Connect the duty vacuum switching valve connector and 2 clamps.
2. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET Install the transverse engine mounting bracket with the 4 bolts. TEXT IN ILLUSTRATION *1 Bolt A *2 Bolt B Bolt A Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Bolt B Torque: 64 N*m (652 kgf*cm, 47 ft.*lbf) Install the transmission oil cooler with the 2 bolts. Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf)
3. INSTALL RADIATOR ASSEMBLY Refer to «INSTALLATION [06/2012 - ]»(ref-598590-S42617498162014021400000) .

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1. INSPECT ACCELERATOR PEDAL SENSOR ASSEMBLY Measure the voltage. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Gas Throttle / All Data / Accel Sensor Out No. 1 and Accel Sensor Out No. 2. Read the values displayed on the Techstream. Standard Voltage Accelerator Pedal Operation Accel Sensor Out No. 1 Accel Sensor Out No. 2 Fully Released 0.5 to 1.1 V 1.2 to 2.0 V Fully Depressed 2.6 to 4.5 V 3.4 to 4.98 V If the result is not as specified, check the accelerator pedal sensor assembly, wire harness or ECM.

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1. REMOVE ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE: Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly. This accelerator pedal does not require lubrication. Do not apply oil or other lubrication to the accelerator pedal sensor assembly. If applied, the accelerator pedal sensor assembly must be replaced. Disconnect the accelerator pedal sensor assembly connector. Remove the 2 bolts and accelerator pedal sensor assembly.

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1. INSTALL ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE: Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly. This accelerator pedal does not require lubrication. Do not apply oil or other lubrication to the accelerator pedal sensor assembly. If applied, the accelerator pedal sensor assembly must be replaced. Temporarily install the accelerator pedal sensor assembly with the 2 bolts. Tighten the 2 bolts in the order shown in the illustration. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the accelerator pedal sensor assembly connector.

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Note. Perform the mass air flow meter sub-assembly inspection according to the following procedure. Only replace the mass air flow meter sub-assembly when the mass air flow meter sub-assembly value in the Data List (with the engine stopped) is not within the normal operating range or there is foreign matter on the mass air flow meter sub-assembly platinum hot wire (heater).

HINT

Perform "Inspection After Repairs" after replacing the mass air flow meter. Refer to INITIALIZATION [06/2012 - ] .

1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY Read the values using the Techstream (MAF). NOTE: Perform the inspection with the vehicle indoors and on a level surface. Perform the inspection of the mass air flow meter sub-assembly while it is installed to the air cleaner cap sub-assembly (installed to the vehicle). During the test, do not use an exhaust air duct on the exhaust pipe. Connect the Techstream to the DLC3. Turn the engine switch on (IG) (do not start the engine). Enter the following menus: Powertrain / Engine / Data List / MAF. Wait for 30 seconds, and read the values on the Techstream. Standard Condition Tester Display Condition Specified Condition MAF Engine not running 30 seconds after engine switch turned on (IG) 0.49 g/sec. or less If the result is not as specified, replace the mass air flow meter sub-assembly. If the result is within the specified range, remove and inspect the mass air flow meter sub-assembly See step 1 .

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1. REMOVE MASS AIR FLOW METER SUB-ASSEMBLY Disconnect the mass air flow meter sub-assembly connector. Remove the 2 screws and mass air flow meter sub-assembly.

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1. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter sub-assembly shown in the illustration. TEXT IN ILLUSTRATION *a Platinum Hot Wire (Heater) OK There is no foreign matter. If the result is not as specified, replace the mass air flow meter sub-assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (THA) - 2 (E2) -20°C (-4°F) 13.6 to 18.4 kohms 1 (THA) - 2 (E2) 20°C (68°F) 2.21 to 2.69 kohms 1 (THA) - 2 (E2) 60°C (140°F) 0.49 to 0.67 kohms TEXT IN ILLUSTRATION *a Component without harness connected (Mass Air Flow Meter Sub-assembly) If the result is not as specified, replace the mass air flow meter sub-assembly.

INSPECTION [06/2012 - ]

1. INSPECT CRANK POSITION SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Temperature Specified Condition Cold 1630 to 2740 ohms Hot 2065 to 3225 ohms HINT: "Cold" and "Hot" mean the temperature of the coils themselves. "Cold" is from -10 to 50°C (14 to 122 °F) and "Hot" is from 50 to 100°C (122 to 212°F). If the resistance is not as specified, replace the crank position sensor.

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1. INSTALL CRANK POSITION SENSOR Clean and degrease the threads of the bolt for the crank position sensor. Apply a light coat of engine oil to the O-ring on the crank position sensor. TEXT IN ILLUSTRATION *1 O-ring Install the crank position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Make sure that the O-ring is not cracked or does not move out of place during installation. Connect the crank position sensor connector.
2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Install the compressor and magnetic clutch. Refer to «INSTALLATION [06/2012 - ]»(ref-598598-S14438151422014021400000) .

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1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to «REMOVAL [06/2012 - ]»(ref-598608-S29092353242014021400000) .
2. REMOVE NO. 1 SURGE TANK STAY . Refer to «REMOVAL [06/2012 - ] - Step 3»(ref-598588-S03468553012014021400000)
3. REMOVE IGNITION COIL ASSEMBLY Remove the nut. Disconnect the 2 harness clamps. Disconnect the 6 ignition coil assembly connectors. Remove the 6 bolts and 6 ignition coil assemblies.
4. REMOVE SPARK PLUG Remove the 6 spark plugs.