Engine Control System (Service Information) (2AR-FE): Removal & Installation Toyota Camry XV50

INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Camshaft timing oil control valve assembly (for exhaust side) Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve. TEXT IN ILLUSTRATION *1 New O-ring Install the oil control valve with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) NOTE: Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with the cylinder head cover). Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve. Connect the oil control valve connector. Camshaft timing oil control valve assembly (for intake side) Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve. TEXT IN ILLUSTRATION *1 New O-ring Install the oil control valve with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) NOTE: Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover). Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve. Connect the oil control valve connector.
2. INSTALL ENGINE WIRE Install the engine wire with the 2 nuts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf)
3. INSPECT FOR OIL LEAK
4. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 68»(ref-507910-S17574886552012100900000)

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1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Install a new gasket to the intake manifold. Install the fuel tube bracket with the bolt. Torque: 13 N*m ( 132 kgf*cm, 10 ft.*lbf) Install the throttle with motor body assembly with the 4 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Connect the throttle body connector. Connect the fuel tube to the clamp. Connect the No. 2 water by-pass hose to the throttle with motor body assembly. Connect the water by-pass hose to the throttle with motor body assembly.
2. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Install the air cleaner cap sub-assembly with the 2 clamps. Install the air cleaner hose with the hose clamp. Connect the ventilation hose to the cylinder head cover. Install the fuel vapor feed hose to the air cleaner hose. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly. Connect the vacuum switching valve assembly to the air cleaner hose.
3. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-507914-S12836807282012100900000)
4. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-507939-S33180782162012100900000)
5. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 68»(ref-507910-S17574886552012100900000)
6. INSTALL ENGINE UNDER COVER RH
7. INSTALL ENGINE UNDER COVER LH
8. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
9. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
10. PERFORM INITIALIZATION NOTE: Be sure to perform this procedure after reassembling the throttle with motor body assembly or removing and reinstalling any throttle body component. 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 body is cleaned. Turn the ignition switch to ON without operating the accelerator pedal. NOTE: If the accelerator pedal is operated, perform the above step again. Connect the Techstream to the DLC3 and clear the DTCs . Refer to «DTC CHECK / CLEAR»(ref-507772-S40821088752012100900000) . Perform the "Inspection After Repair" . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) . 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 when the A/C is switched off. Standard Condition Engine Idle Speed A/C switched off 610 to 710 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 and ECT / 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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REMOVAL

Note. Perform the Vehicle Identification Number (VIN) registration when replacing the ECM . Refer to REGISTRATION .

HINT

When removing only the ECM, it is not necessary to remove the cool air intake duct seal and battery.

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1. 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»(ref-507751-S35488016672012100900000) .
2. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 1»(ref-507940-S15896872182012100900000)
3. REMOVE BATTERY . Refer to «REMOVAL - Step 23»(ref-507910-S10103231632012100900000)
4. REMOVE ECM Disconnect the 2 ECM connectors. Push in the locks on the 2 levers, 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 part of the connectors. Remove the nut. Remove the screw (A). Loosen the screw (B) and remove the ECM. Remove the screw (B). Remove the 2 screws and No. 2 ECM bracket.
5. REMOVE NO. 1 ECM BRACKET Remove the nut. Disconnect the wire harness clamp. Disconnect the wire harness clamp. Remove the nut and No. 1 ECM bracket.

1. INSTALL NO. 1 ECM BRACKET Install the No. 1 ECM bracket with the nut. Torque: 12 N*m ( 122 kgf*cm, 9 ft.*lbf) Connect the wire harness clamp. Connect the wire harness clamp. Install the nut. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf)
2. INSTALL ECM Install the No. 2 ECM bracket to the ECM with the 2 screws. Torque: 3.0 N*m ( 31 kgf*cm, 27 in.*lbf) Temporarily install the screw (B). Install the ECM with the nut. Torque: 12 N*m ( 122 kgf*cm, 9 ft.*lbf) Install the screw (A). Torque: 3.0 N*m ( 31 kgf*cm, 27 in.*lbf) Tighten the screw (B). Torque: 3.0 N*m ( 31 kgf*cm, 27 in.*lbf) 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 become stuck between the connectors and other part. Make sure that the 2 levers are securely locked. Connect the 2 wire harness clamps.
3. INSTALL BATTERY . Refer to «INSTALLATION - Step 49»(ref-507910-S17574886552012100900000)
4. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 4»(ref-507940-S04000309782012100900000)
5. 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»(ref-507751-S35488016672012100900000) .
6. PERFORM INITIALIZATION Refer to «PRECAUTION»(ref-507772-S15806334842012100900000)

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HINT

Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly . Refer to INITIALIZATION .

1. INSTALL MASS AIR FLOW METER SUB-ASSEMBLY Install the mass air flow meter sub-assembly with the 2 screws. NOTE: Make sure that the O-ring is not cracked or jammed when installing the mass air flow meter. HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) . Connect the mass air flow meter connector.

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1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 18»(ref-507910-S10103231632012100900000)
2. REMOVE CAMSHAFT POSITION SENSOR Camshaft position sensor (for Exhaust Side) Disconnect the sensor connector. Remove the bolt and sensor. Camshaft position sensor (for Intake Side) Disconnect the sensor connector. Remove the bolt and sensor.

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1. INSTALL CAMSHAFT POSITION SENSOR Camshaft position sensor (for Intake Side) Clean and degrease the threads of the bolt for the camshaft position sensor. Apply a light coat of engine oil to the O-ring of the sensor. NOTE: Make sure that the O-ring is not cracked or does not jump out of position during installation. Apply adhesive to 2 or 3 threads of the bolt. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Install the sensor with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Connect the sensor connector. Camshaft position sensor (for Exhaust Side) Clean and degrease the threads of the bolt for the camshaft position sensor. Apply a light coat of engine oil to the O-ring of the sensor. NOTE: Make sure that the O-ring is not cracked or does not jump out of position during installation. Apply adhesive to 2 or 3 threads of the bolt. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Install the sensor with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Connect the sensor connector.
2. INSPECT FOR OIL LEAK
3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 68»(ref-507910-S17574886552012100900000)

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1. REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor.

HINT

Perform "Inspection After Repair" after replacing the spark plug and ignition coil assembly . Refer to INITIALIZATION .

1. INSTALL SPARK PLUG Using a spark plug wrench, install the 4 spark plugs. Torque: 25 N*m ( 255 kgf*cm, 18 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the spark plug . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) .
2. INSTALL IGNITION COIL ASSEMBLY Install the 4 ignition coil assemblies with the 4 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the ignition coil assembly . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) . Connect the 4 ignition coil assembly connectors.
3. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 68»(ref-507910-S17574886552012100900000)

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1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 1»(ref-507914-S12836807282012100900000)
6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 18»(ref-507910-S10103231632012100900000)
7. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 1»(ref-507940-S15896872182012100900000)
8. REMOVE INLET AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 19»(ref-507910-S10103231632012100900000)
9. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the engine coolant temperature sensor connector. Remove the 2 bolts and disconnect the wire harness. Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor. TEXT IN ILLUSTRATION *1 Ball Joint Lock Nut Wrench *2 Gasket Remove the gasket from the engine coolant temperature sensor.

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1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR TEXT IN ILLUSTRATION *a Component without harness connected (Engine Coolant Temperature Sensor) *b Temperature °C (°F) *c Resistance ohms *d Acceptable Partially immerse the sensor in water and warm up the water. 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) 2.32 to 2.59 kohms 1 - 2 80°C (176°F) 0.310 to 0.326 kohms NOTE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. If the result is not as specified, replace the engine coolant temperature sensor.

HINT

Perform "Inspection After Repair" after replacing the engine coolant temperature sensor . Refer to INITIALIZATION .

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the engine coolant temperature sensor. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor. Torque: 20 N*m ( 204 kgf*cm, 15 ft.*lbf) NOTE: Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a ball joint lock nut wrench . Refer to «PRECAUTION»(ref-507751-S05084837522012100900000) . HINT: Perform "Inspection After Repair" after replacing the engine coolant temperature sensor . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) . Connect the engine coolant temperature sensor connector. Install the wire harness with the 2 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf)
2. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 53»(ref-507910-S17574886552012100900000)
3. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 4»(ref-507940-S04000309782012100900000)
4. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-507914-S12836807282012100900000)
5. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-507939-S33180782162012100900000)
6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 68»(ref-507910-S17574886552012100900000)
7. INSTALL ENGINE UNDER COVER RH
8. INSTALL ENGINE UNDER COVER LH
9. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
10. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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1. REMOVE INTAKE MANIFOLD Refer to «REMOVAL»(ref-507935-S15256544302012100900000)
2. REMOVE KNOCK CONTROL SENSOR Disconnect the sensor connector. Remove the bolt and knock control sensor.

Perform "Inspection After Repair" after replacing the knock control sensor . Refer to INITIALIZATION .

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1. INSTALL KNOCK CONTROL SENSOR Install the sensor with the bolt so that the sensor is angled as shown in the illustration. Torque: 20 N*m ( 204 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION *a Front of Engine *b Up *c 7° *d 10° NOTE: The acceptable installation angle of the sensor is between 7° upward and 10° downward from the horizontal position. HINT: Perform "Inspection After Repair" after replacing the knock control sensor . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) Connect the sensor connector.
2. INSTALL INTAKE MANIFOLD Refer to «INSTALLATION»(ref-507935-S04695264952012100900000)

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1. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to «REMOVAL - Step 8»(ref-507935-S11509010662012100900000)
2. REMOVE AIR FUEL RATIO SENSOR (except PZEV) Remove the hose clamp. Disconnect the air fuel ratio sensor connector. Using SST, remove the air fuel ratio sensor from the exhaust manifold. SST: 09224-00010
3. REMOVE AIR FUEL RATIO SENSOR (for PZEV) Disconnect the air fuel ratio sensor connector. Using SST, remove the air fuel ratio sensor from the exhaust manifold. SST: 09224-00010

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1. INSPECT AIR FUEL RATIO SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (HA1A) - 2 (+B) 20°C (68°F) 1.6 to 3.2 ohms 1 (HA1A) - 4 (A1A-) Always 10 kohms or higher TEXT IN ILLUSTRATION *a Component without harness connected: (Air Fuel Ratio Sensor) If the result is not as specified, replace the air fuel ratio sensor.

HINT

Perform "Inspection After Repair" after replacing the air fuel ratio sensor . Refer to INITIALIZATION .

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1. INSTALL AIR FUEL RATIO SENSOR (for PZEV) Using SST, install the air fuel ratio sensor to the exhaust manifold. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm *b Fulcrum Length 300 mm SST: 09224-00010 without SST Torque: 44 N*m ( 449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m ( 408 kgf*cm, 30 ft.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) . Refer to «PRECAUTION»(ref-507751-S05084837522012100900000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) . Connect the air fuel ratio sensor connector.
2. INSTALL AIR FUEL RATIO SENSOR (except PZEV) Using SST, install the air fuel ratio sensor to the exhaust manifold. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm *b Fulcrum Length 300 mm SST: 09224-00010 without SST Torque: 44 N*m ( 449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m ( 408 kgf*cm, 30 ft.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) . Refer to «PRECAUTION»(ref-507751-S05084837522012100900000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. HINT: Perform "Inspection After Repair" after replacing the air fuel ratio sensor . Refer to «INITIALIZATION»(ref-507772-S36366337852012100900000) . Connect the air fuel ratio sensor connector. Install the hose clamp.
3. INSPECT FOR EXHAUST GAS LEAK
4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV) . Refer to «INSTALLATION - Step 4»(ref-507935-S34452740642012100900000)

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1. REMOVE HEATED OXYGEN SENSOR Disconnect the heated oxygen sensor connector. Using SST, remove the heated oxygen sensor from the front exhaust pipe. SST: 09224-00010

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1. INSPECT OXYGEN SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (HT1B) - 2 (+B) 20°C (68°F) 11 to 16 ohms 1 (HT1B) - 4 (E2) Always 10 kohms or higher TEXT IN ILLUSTRATION *a Component without harness connected (Oxygen Sensor) If the result is not as specified, replace the oxygen sensor.

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1. INSTALL HEATED OXYGEN SENSOR Using SST, install the heated oxygen sensor to the front exhaust pipe. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm *b Fulcrum Length 300 mm SST: 09224-00010 without SST Torque: 44 N*m ( 449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m ( 408 kgf*cm, 30 ft.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) . Refer to «PRECAUTION»(ref-507751-S05084837522012100900000) The "with SST" torque value is effective when SST is parallel to the torque wrench. Connect the heated oxygen sensor connector.
2. INSPECT FOR EXHAUST GAS LEAK

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1. REMOVE NO. 1 RELAY BLOCK COVER
2. REMOVE NO. 1 INTEGRATION RELAY Disconnect the connector. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and disconnect the No. 1 integration relay. Disconnect the 4 connectors and remove the No. 1 integration relay.

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1. INSPECT NO. 1 INTEGRATION RELAY TEXT IN ILLUSTRATION *1 No. 1 Integration Relay - - EFI MAIN RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 1 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 1 integration relay 1B-1 - No. 1 integration relay 1A-8 Battery voltage is not applied between terminals 1C-7 and 1E-2 10 kohms or higher No. 1 integration relay 1B-1 - No. 1 integration relay 1A-8 Battery voltage is applied between terminals 1C-7 and 1E-2 Below 1 ohms No. 1 integration relay 1B-1 - No. 1 integration relay 1C-3 No. 1 integration relay 1B-1 - No. 1 integration relay 1C-4 No. 1 integration relay 1B-1 - No. 1 integration relay 1C-9 No. 1 integration relay 1B-1 - No. 1 integration relay 1C-10 If the resistance is not as specified, replace the No. 1 integration relay. EFI MAIN2 RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 1 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 1 integration relay 1A-6 - No. 1 integration relay 1D-1 Battery voltage is not applied between terminals 1A-8 and 1E-2 10 kohms or higher No. 1 integration relay 1A-6 - No. 1 integration relay 1D-1 Battery voltage is applied between terminals 1A-8 and 1E-2 Below 1 ohms No. 1 integration relay 1A-7 - No. 1 integration relay 1D-1 If the resistance is not as specified, replace the No. 1 integration relay. IG2 RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 1 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 1 integration relay 1A-1 - No. 1 integration relay 1D-3 Battery voltage is not applied between terminals 1C-8 and 1E-2 10 kohms or higher No. 1 integration relay 1A-1 - No. 1 integration relay 1D-3 Battery voltage is applied between terminals 1C-8 and 1E-2 Below 1 ohms No. 1 integration relay 1A-3 - No. 1 integration relay 1D-3 No. 1 integration relay 1C-1 - No. 1 integration relay 1D-3 No. 1 integration relay 1C-2 - No. 1 integration relay 1D-3 No. 1 integration relay 1C-5 - No. 1 integration relay 1D-3 If the resistance is not as specified, replace the No. 1 integration relay. C/OPN RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 1 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 1 integration relay 1A-6 - No. 1 integration relay 1D-1 Battery voltage is not applied between terminals 1A-1 and 1E-1 10 kohms or higher No. 1 integration relay 1A-6 - No. 1 integration relay 1D-1 Battery voltage is applied between terminals 1A-1 and 1E-1 Below 1 ohms No. 1 integration relay 1A-7 - No. 1 integration relay 1D-1 If the resistance is not as specified, replace the No. 1 integration relay.

1. INSTALL NO. 1 INTEGRATION RELAY Connect the 4 connectors. Attach the No. 1 integration relay to the engine room relay block. Connect the connector.
2. INSTALL NO. 1 RELAY BLOCK COVER