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

INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Apply a light coat of engine oil to 4 new O-rings and install them to the 4 camshaft timing oil control valve assemblies. TEXT IN ILLUSTRATION *1 New O-ring Install the 4 oil control valves with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Make sure that each O-ring is not cracked or does not jump out of position during installation. Connect the 4 oil control valve connectors.
2. CONNECT ENGINE WIRE Install the 2 wire harness brackets with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 3 wire harness clamps.
3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to «INSTALLATION»(ref-507949-S19673923252012100900000) .

Scheme 612

Scheme 613

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.

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

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 22»(ref-507911-S14997345162012100900000)
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 2 wire harness clamps. 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.
3. INSTALL BATTERY . Refer to «INSTALLATION - Step 55»(ref-507911-S02874458522012100900000)
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-507773-S32828854172012100900000) .

Scheme 620

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 with the 2 screws. NOTE: Make sure that the O-ring is not cracked or does not jump out of position during installation. HINT: Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly. Refer to «INITIALIZATION»(ref-507773-S30241089062012100900000) . Connect the mass air flow meter connector.

Scheme 621

Scheme 622

Scheme 623

1. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to «REMOVAL»(ref-507949-S05965159782012100900000) .
2. REMOVE VVT SENSOR Disconnect the 4 sensor connectors. Remove the 4 bolts and 4 sensors. TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 *c for Intake Side *d for Exhaust Side

1. INSTALL VVT SENSOR Install the 4 sensors with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 4 sensor connectors.
2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to «INSTALLATION»(ref-507949-S19673923252012100900000) .

Scheme 624

Scheme 625

1. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Remove the compressor and magnetic clutch. Refer to «REMOVAL»(ref-507925-S34271215012012100900000) .
2. REMOVE CRANK POSITION SENSOR Disconnect the crank position sensor connector. Remove the bolt and crank position sensor.

HINT

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

Scheme 626

1. INSTALL SPARK PLUG Install the 6 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the spark plug. Refer to «INITIALIZATION»(ref-507773-S30241089062012100900000) .
2. INSTALL IGNITION COIL ASSEMBLY Install the 6 ignition coils with the 6 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-507773-S30241089062012100900000) . Connect the 6 ignition coil connectors. Connect the 2 wire harness clamps. Install the nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
3. INSTALL NO. 1 SURGE TANK STAY . Refer to «INSTALLATION - Step 18»(ref-507911-S22307426712012100900000)
4. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to «INSTALLATION»(ref-507949-S19673923252012100900000) .

Scheme 627

Scheme 628

Scheme 629

Scheme 630

1. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
4. REMOVE ENGINE UNDER COVER RH
5. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 1»(ref-507915-S40057139762012100900000)
6. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 1»(ref-507940-S15896872182012100900000)
7. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 17»(ref-507911-S14997345162012100900000)
8. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the 2 engine wire clamps. Disconnect the engine coolant temperature sensor connector. 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.

Scheme 631

1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (E2) - 2 (THW) 20°C (68°F) 2.32 to 2.59 kohms 1 (E2) - 2 (THW) 80°C (176°F) 0.310 to 0.326 kohms NOTE: If checking the sensor in water, be careful not to allow water to contact the terminals. After checking, wipe the water off the sensor. 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 onto the engine coolant temperature sensor. 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-507773-S30241089062012100900000) . Connect the engine coolant temperature sensor connector. Connect the 2 engine wire clamps.
2. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-507915-S40057139762012100900000)
3. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-507955-S28178885252012100900000)
4. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 4»(ref-507940-S04000309782012100900000)
5. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 82»(ref-507911-S02874458522012100900000)
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

Scheme 632

Scheme 633

1. REMOVE INTAKE MANIFOLD Refer to «REMOVAL»(ref-507949-S05965159782012100900000) .
2. REMOVE KNOCK CONTROL SENSOR Disconnect the 2 knock control sensor connectors. Remove the 2 bolts and 2 knock control sensors.

Scheme 634

1. INSPECT KNOCK CONTROL SENSOR Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *a Component without harness connected (Knock Control Sensor) Standard Resistance Tester Connection Condition Specified Condition 1 (Ground) - 2 (Output) 20°C (68°F) 120 to 280 kohms If the result is not as specified, replace the knock control sensor.

Scheme 635

1. INSTALL KNOCK CONTROL SENSOR Install the 2 knock control sensors with the 2 bolts as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 *c Front of Vehicle NOTE: Make sure that each knock control sensor is in the correct position. Connect the 2 knock control sensor connectors.
2. INSTALL INTAKE MANIFOLD Refer to «INSTALLATION»(ref-507949-S19673923252012100900000) .

Scheme 636

Scheme 637

Scheme 638

Scheme 639

Scheme 640

Scheme 641

1. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 1»(ref-507940-S15896872182012100900000)
2. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 17»(ref-507911-S14997345162012100900000)
3. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) Disconnect the air fuel ratio sensor connector. Separate the wire harness clamp. Using SST, remove the air fuel ratio sensor from the exhaust manifold LH. SST: 09224-00010
4. REMOVE FRONT EXHAUST PIPE ASSEMBLY Refer to «REMOVAL»(ref-507949-S16776240672012100900000) .
5. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) Disconnect the air fuel ratio sensor connector. Disconnect the harness clamp. Using SST, remove the air fuel ratio sensor from the exhaust manifold RH. SST: 09224-00010

Scheme 642

Scheme 643

1. INSPECT AIR FUEL RATIO SENSOR (for Bank 1) 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-) - 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.
2. INSPECT AIR FUEL RATIO SENSOR (for Bank 2) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (HA2A) - 2 (+B) 20°C (68°F) 1.6 to 3.2 ohms 1 (HA2A) - 4 (A2A-) - 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 .

Scheme 644

Scheme 645

1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) Using SST, install the air fuel ratio sensor to the exhaust manifold RH. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm (1.18 in.) *b Fulcrum Length 180 mm (7.09 in.) SST: 09224-00010 without SST Torque: 44 N*m (449 kgf*cm, 33 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 180 mm (7.09 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-507773-S30241089062012100900000) . Connect the harness clamp. Connect the air fuel ratio sensor connector.
2. INSTALL FRONT EXHAUST PIPE ASSEMBLY Refer to «INSTALLATION»(ref-507949-S11431538732012100900000) .
3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) Using SST, install the air fuel ratio sensor to the exhaust manifold LH. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm (1.18 in.) *b Fulcrum Length 180 mm (7.09 in.) SST: 09224-00010 without SST Torque: 44 N*m (449 kgf*cm, 33 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 180 mm (7.09 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-507773-S30241089062012100900000) . Connect the air fuel ratio sensor connector. Install the wire harness clamp.
4. INSPECT FOR EXHAUST GAS LEAK
5. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 82»(ref-507911-S02874458522012100900000)
6. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 4»(ref-507940-S04000309782012100900000)

Scheme 646

Scheme 647

Scheme 648

1. REMOVE FRONT EXHAUST PIPE ASSEMBLY Refer to «REMOVAL»(ref-507949-S16776240672012100900000) .
2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) Using SST, remove the heated oxygen sensor from the front exhaust pipe sub-assembly. SST: 09224-00010
3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) Using SST, remove the heated oxygen sensor from the front exhaust pipe assembly. SST: 09224-00010

Scheme 649

Scheme 650

1. INSPECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) 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) - 10 kohms or higher TEXT IN ILLUSTRATION *a Component without harness connected (Heated Oxygen Sensor) If the resistance is not as specified, replace the heated oxygen sensor.
2. INSPECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (HT2B) - 2 (+B) 20°C (68°F) 11 to 16 ohms 1 (HT2B) - 4 (E2) - 10 kohms or higher TEXT IN ILLUSTRATION *a Component without harness connected (Heated Oxygen Sensor) If the resistance is not as specified, replace the heated oxygen sensor.

Scheme 651

Scheme 652

1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) Using SST, install the heated oxygen sensor to the front exhaust pipe assembly. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm (1.18 in.) *b Fulcrum Length 180 mm (7.09 in.) SST: 09224-00010 without SST Torque: 44 N*m (449 kgf*cm, 33 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 180 mm (7.09 in.). Refer to «PRECAUTION»(ref-507751-S05084837522012100900000) . The "with SST" torque value is effective when SST is parallel to the torque wrench.
2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) Using SST, install the heated oxygen sensor to the center exhaust pipe assembly. TEXT IN ILLUSTRATION *a Fulcrum Length 30 mm (1.18 in.) *b Fulcrum Length 180 mm (7.09 in.) SST: 09224-00010 without SST Torque: 44 N*m (449 kgf*cm, 33 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 180 mm (7.09 in.). Refer to «PRECAUTION»(ref-507751-S05084837522012100900000) . The "with SST" torque value is effective when SST is parallel to the torque wrench.
3. INSTALL FRONT EXHAUST PIPE ASSEMBLY Refer to «INSTALLATION»(ref-507949-S11431538732012100900000) .

Scheme 653

Scheme 654

Scheme 655

Scheme 656

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.

Scheme 657

Scheme 658

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. 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-6 No. 1 integration relay 1B-1 - No. 1 integration relay 1C-9 No. 1 integration relay 1B-1 - No. 1 integration relay 1C-10 TEXT IN ILLUSTRATION *1 No. 1 Integration Relay If the resistance is not as specified, replace the No. 1 integration relay. A/F HTR RELAY: Measure the resistance according to the value(s) in the table below. 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 TEXT IN ILLUSTRATION *1 No. 1 Integration Relay 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. 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 1A-5 - 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 TEXT IN ILLUSTRATION *1 No. 1 Integration Relay If the resistance is not as specified, replace the No. 1 integration relay.

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