Engine Control System (2ZR-FE) (Service Information): Removal & Installation Toyota Matrix E140

INSTALLATION

1. INSTALL ACCELERATOR PEDAL ASSEMBLY Install the accelerator pedal assembly with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Connect the accelerator pedal assembly connector.

Scheme 468

1. INSTALL MASS AIR FLOW METER Install the mass air flow meter with the 2 screws. Torque: 1.0 N*m (10 kgf*cm, 9 in.*lbf) 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.

Scheme 469

REMOVAL

HINT

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

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 10»(ref-427476-S27401153472011101200000)
2. REMOVE NO. 1 CRANK POSITION SENSOR Exhaust camshaft side: Disconnect the duty vacuum switching valve connector and 3 engine wire harness clamps. Disconnect the No. 1 crank position sensor connector. Remove the bolt and No. 1 crank position sensor. Intake camshaft side: 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 sensors, this procedure is for the camshaft position sensors.

Scheme 475

1. INSTALL NO. 1 CRANK POSITION SENSOR Apply a light coat of engine oil to the O-rings on the No. 1 crank position sensors. Intake camshaft side: 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. Exhaust camshaft side: 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. Connect the 3 engine wire harness clamps and duty vacuum switching connector.
2. INSPECT FOR OIL LEAK
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 85»(ref-427476-S41994840882011101200000)

Scheme 476

Scheme 477

1. REMOVE ENGINE UNDER COVER RH
2. REMOVE CRANK POSITION SENSOR Disconnect the crank position sensor connector. Remove the bolt and crank position sensor.

Scheme 478

1. INSPECT CRANK POSITION SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Cold 1630 to 2740 ohms Hot 2065 to 3225 ohms HINT: In the table above, the terms Cold and Hot refer to the temperature of the coils. Cold means approximately -10 to 50°C (14 to 122°F). Hot means approximately 50 to 100°C (122 to 212°F). If the resistance is not as specified, replace the crank position sensor.

Scheme 479

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, 7.4 ft.*lbf) Connect the crank position sensor connector.
2. INSPECT FOR OIL LEAK
3. INSTALL ENGINE UNDER COVER RH

Scheme 480

Scheme 481

Scheme 482

Scheme 483

1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 10»(ref-427476-S27401153472011101200000)
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, 7.4 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 85»(ref-427476-S41994840882011101200000)

Scheme 484

Scheme 485

Scheme 486

1. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 1»(ref-427482-S20059146522011101200000)
2. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 10»(ref-427476-S27401153472011101200000)
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE See step 3
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the engine coolant temperature sensor connector. Remove the engine coolant temperature sensor and gasket.

Scheme 487

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.

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install the engine coolant temperature sensor through a new gasket. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) Connect the engine coolant temperature sensor connector.
2. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-427482-S20059146522011101200000)
3. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-427483-S29281529002011101200000)
4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE See step 2
5. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 85»(ref-427476-S41994840882011101200000)

Scheme 488

Scheme 489

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 1»(ref-427482-S20059146522011101200000)
3. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 10»(ref-427476-S27401153472011101200000)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE See step 3
5. REMOVE INTAKE MANIFOLD Disconnect the throttle body connector and the 2 water by-pass hoses. Separate the wire harness clamp and remove the bolt and wire harness bracket. Separate the 2 hoses. Separate the ventilation hose. Separate the 2 wire harness clamps. Separate the 2 wire harness clamps. Remove the 4 bolts and 2 nuts and remove the intake manifold stay and intake manifold with throttle body. Remove the gasket from the intake manifold.
6. REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the bolt and remove the knock sensor.

Scheme 498

1. INSPECT KNOCK SENSOR 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) 120 to 280 kohms If the result is not as specified, replace the knock sensor.

Scheme 499

Scheme 500

Scheme 501

Scheme 502

1. INSTALL KNOCK SENSOR Install the knock sensor with the bolt as shown in the illustration. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) Connect the knock sensor connector.
2. INSTALL INTAKE MANIFOLD Install a new gasket to the intake manifold. Install the intake manifold and intake manifold stay with the 4 bolts and 2 nuts. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) Connect the 2 wire harness clamps. Connect the 2 wire harness clamps. Connect the ventilation hose. Connect the 2 hoses. Connect the wire harness clamp and install the wire harness bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 89 in.*lbf) Connect the 2 water by-pass hoses and the throttle body connector.
3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE See step 2
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 2»(ref-427482-S20059146522011101200000)
6. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-427483-S29281529002011101200000)
7. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 85»(ref-427476-S41994840882011101200000)

Scheme 503

Scheme 504

Scheme 505

Scheme 506

1. REMOVE FRONT WIPER ARM HEAD CAP . Refer to «REMOVAL - Step 1»(ref-427470-S04472184662011101200000)
2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to «REMOVAL - Step 2»(ref-427470-S04472184662011101200000)
3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to «REMOVAL - Step 3»(ref-427470-S04472184662011101200000)
4. REMOVE HOOD TO COWL TOP SEAL . Refer to «REMOVAL - Step 4»(ref-427470-S04472184662011101200000)
5. REMOVE COWL TOP VENTILATOR LOUVER RH . Refer to «REMOVAL - Step 5»(ref-427470-S04472184662011101200000)
6. REMOVE COWL TOP VENTILATOR LOUVER LH . Refer to «REMOVAL - Step 6»(ref-427470-S04472184662011101200000)
7. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to «REMOVAL - Step 7»(ref-427470-S04472184662011101200000)
8. REMOVE OUTER COWL TOP PANEL . Refer to «REMOVAL - Step 8»(ref-427466-S18184728202011101200000)
9. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 10»(ref-427476-S27401153472011101200000)
10. REMOVE AIR FUEL RATIO SENSOR Disconnect the air fuel ratio sensor connector and clamp. Using SST, remove the air fuel ratio sensor. SST: 09224-00010

Scheme 507

1. INSPECT AIR FUEL RATIO SENSOR Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *a Component without harness connected (Air Fuel Ratio Sensor) 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 If the result is not as specified, replace the air fuel ratio sensor.

Scheme 508

1. INSTALL AIR FUEL RATIO SENSOR Using SST, install the air fuel ratio sensor. 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 SST is parallel to the torque wrench. The "with SST" torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and SST with a measurement of 30 mm (1.18 in.). Refer to «PRECAUTION»(ref-427305-S14224765222011101200000) . Connect the air fuel ratio sensor connector and clamp.
2. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 85»(ref-427476-S41994840882011101200000)
3. INSTALL OUTER COWL TOP PANEL . Refer to «INSTALLATION - Step 19»(ref-427466-S28270894352011101200000)
4. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-427470-S00235964302011101200000)
5. INSTALL COWL TOP VENTILATOR LOUVER LH . Refer to «INSTALLATION - Step 4»(ref-427470-S00235964302011101200000)
6. INSTALL COWL TOP VENTILATOR LOUVER RH . Refer to «INSTALLATION - Step 5»(ref-427470-S00235964302011101200000)
7. INSTALL HOOD TO COWL TOP SEAL . Refer to «INSTALLATION - Step 6»(ref-427470-S00235964302011101200000)
8. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to «INSTALLATION - Step 7»(ref-427470-S00235964302011101200000)
9. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to «INSTALLATION - Step 8»(ref-427470-S00235964302011101200000)
10. INSTALL FRONT WIPER ARM HEAD CAP . Refer to «INSTALLATION - Step 9»(ref-427470-S00235964302011101200000)
11. INSPECT FOR EXHAUST GAS LEAK

Scheme 509

Scheme 510

Scheme 511

1. REMOVE HEATED OXYGEN SENSOR Disconnect the heated oxygen sensor connector. Remove the grommet and pull the sensor connector out of the cabin through the floor panel. Remove the wire harness clamp bracket and disconnect the wire harness clamp. Using SST, remove the heated oxygen sensor. SST: 09224-00010

Scheme 512

1. INSPECT HEATED OXYGEN SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 2 (HT1B) - 1 (+B) 20°C (68°F) 11 to 16 ohms 2 (HT1B) - 3 (E2) Always 10 kohms or higher If the result is not as specified, replace the heated oxygen sensor.

Scheme 513

1. INSTALL HEATED OXYGEN SENSOR Using SST, install the heated oxygen sensor onto the front exhaust pipe. 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: This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with measurement of 30 mm (1.18 in.). Refer to «PRECAUTION»(ref-427305-S14224765222011101200000) . This torque value is effective when SST is parallel to the torque wrench. Install the wire harness clamp bracket and connect the wire harness clamp. Pass the sensor connector through the floor panel and install the grommet. Connect the heated oxygen sensor connector.
2. INSPECT FOR EXHAUST GAS LEAK

Scheme 514

Scheme 515

Scheme 516

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE INTEGRATION NO. 1 RELAY Remove the No. 1 relay block cover. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and then pull the integration relay out of the No. 1 relay block. Disconnect the 3 connectors and remove the integration relay.

Scheme 517

Scheme 518

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

Scheme 519

1. INSTALL INTEGRATION NO. 1 RELAY Connect the 3 connectors. Push the integration relay into the engine room relay block. Install the No. 1 relay block cover.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 520

Scheme 521

1. INSPECT CIRCUIT OPENING RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 2A-8 - 2B-11 Battery voltage is not applied between terminals 2B-10 and 2B-9 10 kohms or higher 2A-8 - 2B-11 Battery voltage is applied between terminals 2B-10 and 2B-9 Below 1 ohms If the resistance is not as specified, replace the instrument panel junction block.