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Intelligent Tester
CAN VIM
DLC3
2GR-FE ENGINE MECHANICAL – ENGINE

ENGINE

ON-VEHICLE INSPECTION

1.
INSPECT ENGINE COOLANT
(a) Inspect the engine coolant (See page CO-1).
2.
INSPECT ENGINE OIL
(a) Inspect the engine oil (See page LU-1).
3.
INSPECT BATTERY
(a) Inspect the battery (See page CH-4).
4.
INSPECT SPARK PLUGS
(a) Inspect the spark plugs (See page IG-5).
5.
INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, and/or
damage to the air cleaner filter element.
HINT:
• If there is any dirt or a blockage in the air cleaner
• If any dirt or a blockage remains even after
6.
INSPECT VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the
inspection above, perform lash adjuster inspection
(See page EM-87).
7.
INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
C110200E02
filter element, clean it with compressed air.
cleaning the air cleaner filter element with
compressed air, replace it.
tester.
Ignition timing:
8 to 12° BTDC at idle
HINT:
Refer to the intelligent tester operator's manual
for help when selecting the DATA LIST.
EM–1
EM

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Summary of Contents for Toyota 2GR-FE

  • Page 1 EM–1 2GR-FE ENGINE MECHANICAL – ENGINE ENGINE ON-VEHICLE INSPECTION INSPECT ENGINE COOLANT (a) Inspect the engine coolant (See page CO-1). INSPECT ENGINE OIL (a) Inspect the engine oil (See page LU-1). INSPECT BATTERY (a) Inspect the battery (See page CH-4).
  • Page 2 EM–2 2GR-FE ENGINE MECHANICAL – ENGINE (c) When not using the intelligent tester: Check the ignition timing. DLC3 (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. 09843-18040 NOTICE: 2 3 4 5 6 7 8 •...
  • Page 3 EM–3 2GR-FE ENGINE MECHANICAL – ENGINE • Switch off all accessories and air conditioning before connecting the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. (c) When not using the intelligent tester: Check the idle speed.
  • Page 4 EM–4 2GR-FE ENGINE MECHANICAL – ENGINE (h) Install the 6 ignition coils. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the intake air surge tank. (See page FU-17). 10. INSPECT CO/HC (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds.
  • Page 5: Drive Belt

    EM–5 2GR-FE ENGINE MECHANICAL – DRIVE BELT DRIVE BELT ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS V-BANK COVER SUB-ASSEMBLY FRONT FENDER APRON SEAL RH V-RIBBED BELT A134931E01...
  • Page 6 EM–6 2GR-FE ENGINE MECHANICAL – DRIVE BELT REMOVAL REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE V-RIBBED BELT (a) Using SST, release the belt tension by turning the belt tensioner counterclockwise, and remove the V- ribbed belt from the belt tensioner.
  • Page 7 EM–7 2GR-FE ENGINE MECHANICAL – DRIVE BELT INSPECTION REPLACE INSPECT V-RIBBED BELT (a) Visually check the V-ribbed belt for excessive wear, frayed cords, etc. If any defect has been found, replace the V-ribbed belt. HINT: Cracks on the rib side of a V-ribbed belt are considered acceptable.
  • Page 8 EM–8 2GR-FE ENGINE MECHANICAL – DRIVE BELT INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
  • Page 9 EM–8 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL ENGINE FRONT OIL SEAL ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS TIMING CHAIN CASE OIL SEAL 250 (2,550, 184) V-BANK COVER SUB-ASSEMBLY CRANKSHAFT PULLEY V-RIBBED BELT FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 10 EM–9 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL REMOVAL REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE V-RIBBED BELT (See page EM-6) REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the crankshaft pulley bolt.
  • Page 11 EM–10 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL INSTALLATION Chain Cover INSTALL TIMING CHAIN CASE OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.
  • Page 12 EM–11 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL ENGINE REAR OIL SEAL ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS ENGINE REAR OIL SEAL FRONT SPACER 83 (850, 61) REAR SPACER DRIVE PLATE AND RING GEAR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 13 EM–12 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL REMOVAL REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-207. REMOVE DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (a) Using SST, hold the crankshaft. 09213-70011 (09213-70020), 09330-00021 A129631E01 (b) Remove the 8 bolts, front spacer, drive plate and rear spacer.
  • Page 14 EM–13 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL INSTALL DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (a) Using SST, hold the crankshaft. 09213-70011 (09213-70020), 09330-00021 A129631E01 (b) Apply adhesive to 2 or 3 threads of the mounting bolt end.
  • Page 15: Engine Assembly

    EM–14 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE ASSEMBLY ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS FRONT WIPER ARM AND 20 (204, 15) BLADE ASSEMBLY RH FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND COWL TOP VENTILATOR BLADE ASSEMBLY LH...
  • Page 16 EM–15 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE RELAY BLOCK...
  • Page 17 EM–16 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 38 (388, 28) FRONT FENDER APRON SEAL RH V-RIBBED BELT 23 (235, 17) ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 ENGINE MOUNTING STAY RH 43 (438, 32) NO. 1 FUEL VAPOR FEED HOSE...
  • Page 18 EM–17 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY STEERING SLIDING YOKE FRONT STABILIZER LINK ASSEMBLY LH 35 (360, 26) TIE ROD ASSEMBLY LH 74 (755, 55) 49 (500, 36) COTTER PIN FRONT SPEED SENSOR LH 8.0 (85, 71 in.*lbf) 294 (3,000, 217)
  • Page 19 EM–18 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 87 (887, 64) ENGINE ASSEMBLY ENGINE WIRE WITH TRANSAXLE 95 (969, 70) 95 (969, 70) VANE PUMP ASSEMBLY NO. 2 FUEL PIPE CLAMP FUEL TUBE SUB-ASSEMBLY STARTER ASSEMBLY 43 (439, 32) 37 (380, 26)
  • Page 20 EM–19 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 54 (551, 40) ENGINE MOUNTING BRACKET RH DRIVE SHAFT BEARING BRACKET HOLE SNAP RING FRONT DRIVE SHAFT DRIVE SHAFT BEARING BRACKET ASSEMBLY RH 64 (650, 47) 32 (334, 30) FRONT DRIVE SHAFT INNER NO.
  • Page 21 EM–20 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY UNION TO CHECK VALVE HOSE 21 (214, 15) 5.4 (55, 48 in.*lbf) VACUUM HOSE CLAMP 21 (214, 15) THROTTLE BODY BRACKET VENTILATION HOSE 21 (214, 15) NO. 1 SURGE TANK STAY 16 (163, 12) NO.
  • Page 22 EM–21 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 8.5 (87, 75 in.*lbf) EXHAUST MANIFOLD TO HEAD GASKET NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 21 (214, 15) EXHAUST MANIFOLD TO 8.5 (87, 75 in.*lbf) HEAD LH GASKET IGNITION COIL ASSEMBLY 10 (102, 7)
  • Page 23 EM–22 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 21 (214, 15) INTAKE MANIFOLD NO. 2 ENGINE MOUNTING NO. 2 INTAKE MANIFOLD STAY RH TO HEAD GASKET 20 (200, 14) ENGINE COOLANT NO. 1 INTAKE MANIFOLD TEMPERATURE TO HEAD GASKET SENSOR RADIO SETTING...
  • Page 24 EM–23 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY REMOVAL DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH...
  • Page 25 EM–24 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 16. REMOVE AIR CLEANER INLET ASSEMBLY (a) Remove the 2 bolts, clamp and air cleaner inlet. 17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503) A132969 18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (a) Disconnect the vacuum hose and hose clamp.
  • Page 26 EM–25 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 21. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY (a) Remove the clip, bolt and intake air resonator. A133928 22. REMOVE NO. 2 ENGINE MOUNTING STAY RH (a) Remove the bolt, 2 nuts, and No. 2 mounting stay A132985 23.
  • Page 27 EM–26 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 26. REMOVE RADIATOR HOSE INLET (a) Remove the clamp and disconnect the radiator hose inlet. A132979 27. REMOVE RADIATOR HOSE OUTLET (a) Remove the clamp and disconnect the radiator hose outlet. A132980 28. DISCONNECT NO. 1 OIL COOLER INLET HOSE (a) Remove the clamp and disconnect the oil cooler inlet hose.
  • Page 28 EM–27 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 34. DISCONNECT ENGINE WIRE (a) Disconnect the engine wire from the engine room junction block. (1) Remove the nut and separate the wire harness. (2) Using a screwdriver, unlock the engine room J/ B.
  • Page 29 EM–28 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 36. SEPARATE FUEL TUBE SUB-ASSEMBLY (a) Remove the No. 1 fuel pipe clamp. A129626 (b) Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration.
  • Page 30 EM–29 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY HINT: Use the same procedures described for the LH side. 45. DISCONNECT FRONT SPEED SENSOR LH (See page DS-7) 46. DISCONNECT FRONT SPEED SENSOR RH HINT: Use the same procedures described for the LH side.
  • Page 31 EM–30 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (b) Remove the 4 bolts, 2 nuts, and frame side rail plates RH and LH. (c) Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH. (d) Operate the engine lifter, then remove the engine assembly from the vehicle.
  • Page 32 EM–31 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (b) Disconnect the 2 clamps. A132989 (c) Remove the 2 nuts and disconnect the engine RH Side: LH Side: mounting insulators RH and LH. A078403E05 (d) Remove the bolt and disconnect the engine mounting insulator FR.
  • Page 33 EM–32 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (e) Remove the bolt and vacuum hose clamp. A129466 Disconnect the connector. (g) Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket. A129467 (h) Using a 5 mm socket hexagon wrench, remove the 4 bolts.
  • Page 34 EM–33 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 74. REMOVE OIL LEVEL GAUGE GUIDE SUB- ASSEMBLY (a) Remove the oil level gauge. (b) Remove the 2 bolts, oil level gauge guides No. 1 and No. 2. (c) Remove the O-rings from the oil level gauge guide.
  • Page 35 EM–34 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 79. REMOVE DRIVE SHAFT BEARING BRACKET (a) Remove the 3 bolts and drive shaft bearing bracket. A129643 80. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the 5 bolts and V-ribbed belt tensioner assembly.
  • Page 36 EM–35 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 84. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (a) Remove the 6 bolts and No. 1 engine mounting bracket front LH. A129646 85. REMOVE RADIO SETTING CONDENSER (a) Remove the 2 bolts and 2 radio setting condensers.
  • Page 37 EM–36 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 89. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket. A129648 INSPECTION INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
  • Page 38 EM–37 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY INSPECT INTAKE MANIFOLD Cylinder head side: (a) Cylinder head side: (1) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.1 mm (0.003 in.) If the warpage is greater than the maximum, replace the intake manifold.
  • Page 39 EM–38 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (a) Install the bolt and No. 1 vacuum switching valve. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A132992 INSTALL RADIO SETTING CONDENSER (a) Install the 2 bolts and 2 radio setting condensers.
  • Page 40 EM–39 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY FR Side: (a) Install the No. 2 idler pulley sub-assembly and cover plate with the bolt. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) RR Side: A129645E01 INSTALL NO. 2 TIMING GEAR COVER (a) Install the No.
  • Page 41 EM–40 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 11. INSTALL DRIVE SHAFT BEARING BRACKET (a) Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) A129643 12. INSTALL ENGINE MOUNTING BRACKET RH (a) Install the engine mounting bracket RH with the 3 bolts.
  • Page 42 EM–41 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 15. INSTALL NO. 2 MANIFOLD STAY (a) Install the No. 2 manifold stay with the 2 bolts. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) A129639 16. INSTALL OIL LEVEL GAUGE GUIDE SUB- ASSEMBLY (a) Install 2 new O-rings to the oil level gauge guide.
  • Page 43 EM–42 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 19. INSTALL NO. 2 ENGINE MOUNTING STAY RH (a) Install the No. 2 mounting stay RH with the bolt.
  • Page 44 EM–43 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (e) Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the No. 1 ventilation hose. A129466 (g) Install the clamp and connect the throttle with motor body assembly connector.
  • Page 45 EM–44 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Connect the connector and clamp. A132990 (d) Connect the 2 clamps. A132989 30. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump with the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) (b) Install the pressure feed tube clamp bolt.
  • Page 46 EM–45 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 32. INSTALL COOLER COMPRESSOR ASSEMBLY (a) Temporarily install the cooler compressor with the 4 bolts. (b) Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.
  • Page 47 EM–46 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 49. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See page EX-4) 50. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EX-4) 51. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Connect the No. 1 oil reservoir to pump hose.
  • Page 48 EM–47 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 55. CONNECT ENGINE WIRE (a) Install the bolt and clamp to the bracket. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) A132981 (b) Install the 2 bolts and 2 clamps to the body. Torque: Bolt A 12 N*m (123 kgf*cm, 9 ft.*lbf)
  • Page 49 EM–48 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 60. CONNECT NO. 1 OIL COOLER INLET HOSE (a) Install the clamp and connect the oil cooler inlet hose. 61. CONNECT NO. 1 OIL COOLER OUTLET HOSE (a) Install the clamp and connect the oil cooler outlet hose.
  • Page 50 EM–49 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 66. INSTALL ENGINE MOVING CONTROL ROD SUB- ASSEMBLY (a) Temporarily install the engine moving control rod with the 4 bolts. (b) First install the bolts A, and then the remaining bolt Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf) A132986E01 67.
  • Page 51 EM–50 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 71. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the vacuum hose and hose clamp. 72. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See...
  • Page 52 EM–51 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 74. CONNECT VACUUM HOSES Vacuum Hose Routing Diagram : Throttle Body Intake Air Surge Tank Vacuum Tank From Canister Air Cleaner Actuator Engine Mounting Insulator FR VSV for Active Control Engine Mount (ACM) A132993E01 75.
  • Page 53 EM–52 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 84. BLEED POWER STEERING FLUID (See page PS-7) 85. CHECK FOR FUEL LEAKS (See page FU-8) 86. CHECK FOR ENGINE OIL LEAKS 87. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 88. CHECK FOR EXHAUST GAS LEAKS 89.
  • Page 54 EM–53 2GR-FE ENGINE MECHANICAL – ENGINE UNIT ENGINE UNIT ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS RH SIDE: CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 10 (102, 7) 10 (102, 7) 18 (184, 13) SPARK PLUG O-RING SEAL WASHER 10 (102, 7) 10 (102, 7)
  • Page 55 EM–54 2GR-FE ENGINE MECHANICAL – ENGINE UNIT LH SIDE: CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 18 (184, 13) SPARK PLUG O-RING 10 (102, 7) 10 (102, 7) OIL FILLER CAP CAMSHAFT POSITION SUB-ASSEMBLY SENSOR 10 (102, 7) OIL FILLER CAP GASKET...
  • Page 56 EM–55 2GR-FE ENGINE MECHANICAL – ENGINE UNIT O-RING 10 (102, 7) FRONT ENGINE MOUNTING BRACKET NO. 1 LH 10 (103, 7) 10 (102, 7) WATER OUTLET GASKET 13 (130, 9) CYLINDER BLOCK WATER DRAIN COCK PLUG 54 (551, 40) 25 (255, 18)
  • Page 57 EM–56 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 10 (102, 7) 10 (102, 7) 4.0 (41, 35 in.*lbf) GASKET OIL PAN BAFFLE PLATE OIL STRAINER SUB-ASSEMBLY 10 (102, 7) 10 (102, 7) 10 (102, 7) 21 (214, 15) O-RING OIL PAN SUB-ASSEMBLY 4.0 (41, 35 in.*lbf)
  • Page 58 EM–57 2GR-FE ENGINE MECHANICAL – ENGINE UNIT CHAIN COVER PLATE 9.1 (93, 81 in.*lbf) 21 (214, 15) CHAIN COVER PLATE GASKET 43 (438, 32) TIMING CHAIN COVER SUB-ASSEMBLY TIMING CHAIN 250 (2,550, 184) CASE OIL SEAL 21 (214, 15) CRANKSHAFT PULLEY 9.1 (93, 81 in.*lbf)
  • Page 59 EM–58 2GR-FE ENGINE MECHANICAL – ENGINE UNIT NO. 1 CHAIN TENSIONER ASSEMBLY NO. 2 CHAIN VIBRATION DAMPER 10 (102, 7) CHAIN TENSIONER SLIPPER 60 (612, 44) NO. 2 IDLE GEAR SHAFT NO. 1 IDLE GEAR SHAFT IDLE SPROCKET ASSEMBLY GASKET...
  • Page 60 EM–59 2GR-FE ENGINE MECHANICAL – ENGINE UNIT RH SIDE: 1st: 10 (102, 7) 2nd: 16 (163, 12) CAMSHAFT GASKET NO. 2 CHAIN SUB-ASSEMBLY GASKET 28 (286, 21) CAMSHAFT TIMING GEAR ASSEMBLY CAMSHAFT BEARING CAP 100 (1,020, 74) NO. 2 CAMSHAFT...
  • Page 61 EM–60 2GR-FE ENGINE MECHANICAL – ENGINE UNIT LH SIDE: NO. 3 CAMSHAFT 1st: 10 (102, 7) 2nd: 16 (163, 12) NO. 2 CHAIN GASKET SUB-ASSEMBLY GASKET 28 (286, 21) CAMSHAFT TIMING GEAR ASSEMBLY 100 (1,020, 74) CAMSHAFT BEARING CAP CAMSHAFT TIMING EXHAUST...
  • Page 62 EM–61 2GR-FE ENGINE MECHANICAL – ENGINE UNIT CYLINDER HEAD SUB-ASSEMBLY RH 1st: 36 (367, 27) 2nd: Turn 90° 3rd: Turn 90° 1st: 36 (367, 27) PLATE WASHER 2nd: Turn 90° 3rd: Turn 90° 30 (306, 22) PLATE WASHER CYLINDER HEAD...
  • Page 63 EM–62 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 44 (449, 32) NO. 1 STRAIGHT SCREW PLUG VALVE STEM CAP VALVE SPRING RETAINER LOCK VALVE STEM CAP VALVE SPRING RETAINER VALVE SPRING INNER COMPRESSION SPRING RETAINER LOCK VALVE STEM OIL SEAL VALVE SPRING...
  • Page 64 EM–63 2GR-FE ENGINE MECHANICAL – ENGINE UNIT PISTON RING SET PISTON PIN HOLE SNAP RING PISTON PISTON PIN PISTON PIN HOLE SNAP RING CONNECTING ROD SUB-ASSEMBLY CONNECTING ROD BEARING CONNECTING ROD CAP STRAIGHT PIN 1st: 25 (255, 18) 2nd: Turn 90°...
  • Page 65 EM–64 2GR-FE ENGINE MECHANICAL – ENGINE UNIT DISASSEMBLY REMOVE OIL FILLER CAP SUB-ASSEMBLY (a) Remove the oil filler cap and gasket. REMOVE SPARK PLUG (a) Remove the spark plugs. REMOVE OIL PAN DRAIN PLUG (a) Remove the drain plug and gasket.
  • Page 66 EM–65 2GR-FE ENGINE MECHANICAL – ENGINE UNIT REMOVE CAMSHAFT TIMING OIL CONTROL VALVE LH Bank: ASSEMBLY (a) Remove the 4 bolts and 4 oil control valves. RH Bank: A129662E01 REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and sensor. A129663 REMOVE NO.
  • Page 67 EM–66 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 10. REMOVE CYLINDER BLOCK WATER DRAIN COCK RH Side: SUB-ASSEMBLY (a) Remove the water drain cocks from the cylinder block. (b) Remove the water drain cock plugs from the water drain cocks. LH Side: A135829E01 11.
  • Page 68 EM–67 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (e) Using SST, remove the oil filter cap. 09228-06501 A129668E01 Remove the oil filter element and O-ring from the oil filter cap. Oil Filter NOTICE: Element Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
  • Page 69 EM–68 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 13. REMOVE FRONT ENGINE MOUNTING BRACKET NO. 1 LH (a) Remove the 6 bolts and engine mounting bracket. (b) Using "Torx" socket wrench E8, remove the 2 stud bolts. A129672 14. REMOVE WATER INLET HOUSING (a) Remove the 2 nuts, water inlet and thermostat.
  • Page 70 EM–69 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the 2 gaskets and O-ring. A129677 16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) (a) Remove the 12 bolts, seal washer, head cover and gasket. A129679 (b) Remove the 3 gaskets.
  • Page 71 EM–70 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 18. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove the 16 bolts and 2 nuts. A129680E01 (b) Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
  • Page 72 EM–71 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. Protective Tape NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
  • Page 73 EM–72 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a screwdriver, pry out the oil seal retainer. NOTICE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use. A129687E01 23. REMOVE ENGINE REAR OIL SEAL Wooden (a) Place the oil seal retainer on wooden blocks.
  • Page 74 EM–73 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.
  • Page 75 EM–74 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
  • Page 76 EM–75 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 30. REMOVE CHAIN SUB-ASSEMBLY Center Line (a) Turn the crankshaft counterclockwise 10° to loosen 10° the chain of the crankshaft timing sprocket. (b) Remove the pulley set bolt. Timing Mark Sensor Plate A134897E01 (c) Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
  • Page 77 EM–76 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 34. REMOVE CRANKSHAFT TIMING SPROCKET (a) Remove the crankshaft timing sprocket from the crankshaft. (b) Remove the 2 pulley set keys from the crankshaft. A109720 35. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) (a) While raising the No.
  • Page 78 EM–77 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 37. REMOVE CAMSHAFT BEARING CAP (for Bank 1) (a) Check that the camshafts are positioned as shown in the illustration. Front View 45° Knock Pin A129700E01 (b) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  • Page 79 EM–78 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH (a) Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  • Page 80 EM–79 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 42. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 3 chain tensioner. A109722 43. REMOVE CAMSHAFT BEARING CAP (for Bank 2) (a) Check that the camshafts are positioned as shown in the illustration.
  • Page 81 EM–80 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH (a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  • Page 82 EM–81 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE: • Be careful not to drop washers into the cylinder head.
  • Page 83 EM–82 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 55. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seals. A120701E01 56. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
  • Page 84 EM–83 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 58. REMOVE NO. 2 STRAIGHT SCREW PLUG (a) Using a 14 mm hexagon wrench, remove the screw LH Bank: plugs and gaskets. NOTICE: If water leaks from the straight screw plug or the plug corrodes, replace it.
  • Page 85 EM–84 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the 2 connecting rod cap bolts. Engine Front A129760E01 (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
  • Page 86 EM–85 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Uniformly loosen the 16 bearing cap bolts, in several steps and in the sequence shown in the illustration. A134892E01 (c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.
  • Page 87 EM–86 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 69. REMOVE PISTON SUB-ASSEMBLY WITH PIN (a) Check the fitting condition between the piston and piston pin. (1) Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
  • Page 88 EM–87 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Using a groove cleaning tool or broken ring, clean the piston ring grooves. A129730 (e) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. A129731 70.
  • Page 89 EM–88 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger. CORRECT INCORRECT 09276-75010 (c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
  • Page 90 EM–89 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (c) Using a micrometer, measure the journal diameter. Standard journal diameter Item Specification No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25. 975 mm (1.0220 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
  • Page 91 EM–90 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (g) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: Advance Side 2 advance side paths are provided in the...
  • Page 92 EM–91 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (h) Check for smooth rotation. (1) Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
  • Page 93 EM–92 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (g) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: Retard Side Advance Side 4 oil paths are provided in the groove. Plug 2...
  • Page 94 EM–93 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (h) Check for smooth rotation. (1) Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
  • Page 95 EM–94 2GR-FE ENGINE MECHANICAL – ENGINE UNIT INSPECT CHAIN SUB-ASSEMBLY (a) Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration. (b) Using vernier calipers, measure the length of 15 links. Maximum chain elongation: Measuring Area 136.9 mm (5.390 in.)
  • Page 96 EM–95 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE (a) Using a micrometer, measure the idle gear shaft diameter. Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.) A109648 (b) Using a caliper gauge, measure the inside diameter of the idle gear.
  • Page 97 EM–96 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY (a) Check that the plunger moves smoothly. (b) Measure the worn depth of the chain tensioner. Maximum depth: Depth 0.9 mm (0.035 in.) If the depth is greater than the maximum, replace the chain tensioner assembly.
  • Page 98 EM–97 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 18. INSPECT CYLINDER HEAD ASSEMBLY (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds. Standard warpage Item Warpage Cylinder head lower 0.05 mm (0.0020 in.)
  • Page 99 EM–98 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.03937 in.) Minimum margin thickness: 0.5 mm (0.0197 in.) Margin Thickness If the margin thickness is less than the minimum, replace the intake valve.
  • Page 100 EM–99 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Lightly press the valve face against the valve seat. (c) Check the valve face and valve seat by using the following procedure. (1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
  • Page 101 EM–100 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 24. REPAIR EXHAUST VALVE SEAT NOTICE: • Repair the seat while checking the seating position. • Keep the lip free of foreign matter. (a) Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.
  • Page 102 EM–101 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 26. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
  • Page 103 EM–102 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 28. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps, camshaft housing and camshaft journals. (b) Place the camshafts on the camshaft housing. (c) Lay a strip of Plastigage across each of the camshaft journals.
  • Page 104 EM–103 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Measure the Plastigage at its widest point. Plastigage Standard oil clearance Item Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.)
  • Page 105 EM–104 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Check that the front mark of the connecting rod cap Engine Front is facing forward. (e) Install the connecting rod cap (See page EM-113). NOTICE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap (See page EM-64).
  • Page 106 EM–105 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.)
  • Page 107 EM–106 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter: 94.200 mm (3.7087 in.)
  • Page 108 EM–107 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 36. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance Item Clearance No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No.
  • Page 109 EM–108 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter Mark Diameter 21.997 to 22.000 mm (0.8660 to 0.8661 in.) 22.000 to 22.003 mm (0.8661 to 0.8663 in.) 22.003 to 22.006 mm (0.8663 to 0.8664 in.) 5 mm (0.20 in.)
  • Page 110 EM–109 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 39. INSPECT CONNECTING ROD (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod assembly.
  • Page 111 EM–110 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Inspect the main journals. (1) Using a micrometer, measure the diameter of each main journal. Standard journal diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance.
  • Page 112 EM–111 2GR-FE ENGINE MECHANICAL – ENGINE UNIT If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot No. 1 be determined, select the correct bearing by adding together the numbers imprinted on the cylinder No.
  • Page 113 EM–112 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Standard upper bearing center wall thickness (No. 2 and No. 3 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.) "2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) "3"...
  • Page 114 EM–113 2GR-FE ENGINE MECHANICAL – ENGINE UNIT REASSEMBLY INSTALL STRAIGHT PIN (a) Using a plastic hammer, tap in new straight pins to the cylinder block. Front Cylinder Block: Rear Cylinder Block: Upper Cylinder Block: Lower Cylinder Block: Cylinder Block RH Side:...
  • Page 115 EM–114 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Item Protrusion Pin D 9 mm (0.354 in.) INSTALL STUD BOLT (a) Using E8 and E10 "torx" sockets, install the stud bolts. Front Cylinder Block: LH Side: 12 mm (0.472 in.) 23 mm (0.906 in.)
  • Page 116 EM–115 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Gradually heat the piston to approximately 80°C 80°C (176°F) (176°F). (c) Coat the piston pin with engine oil. A125895E02 (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
  • Page 117 EM–116 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a piston ring expander, install the oil ring rail as shown in the illustration. Piston Ring Expander Side Rail Upper Oil Ring No. 1 Ring No. 2 Ring Oil Ring Expander...
  • Page 118 EM–117 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Install the upper bearing. (1) Install the upper bearings to the cylinder block as shown in the illustration. NOTICE: • Do not apply engine oil to the bearings and the contact surfaces.
  • Page 119 EM–118 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Confirm the projection and numbers of the main bearing caps and install the bearing caps on the Projection cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position.
  • Page 120 EM–119 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (h) Install the 8 main bearing cap bolts to the outside positions. Install the crankshaft bearing cap bolts. HINT: The main bearing cap bolts are tightened in 2 progressive steps. Bolt Length 105.5 to 107.5 mm (4.15 to 4.23 in.)
  • Page 121 EM–120 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (n) Check the crankshaft thrust clearance (See page EM-104). INSTALL CONNECTING ROD BEARING (a) Install the connecting rod bearing to the connecting rod and bearing cap. (b) Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
  • Page 122 EM–121 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod.
  • Page 123 EM–122 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 11. INSTALL INTAKE VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05)
  • Page 124 EM–123 2GR-FE ENGINE MECHANICAL – ENGINE UNIT If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.
  • Page 125 EM–124 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 14. INSTALL NO. 1 STRAIGHT SCREW PLUG RH Bank: (a) Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) LH Bank: A129718E01 15.
  • Page 126 EM–125 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (a) Using E6 and E8 "torx" sockets, install the stud bolts. Rear Side RH: Intake Side RH: Intake Side LH: Exhaust Side RH: Exhaust Side LH: Rear Side LH: 20 mm 16 mm 16 mm (0.79 in.)
  • Page 127 EM–126 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 17. INSTALL STRAIGHT PIN (a) Using a plastic hammer, tap in new straight pins as shown in the illustration. LH Bank: RH Bank: 17.5 to 19.5 mm 34 mm (0.69 to 0.77 in.) (1.34 in.)
  • Page 128 EM–127 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 20. INSTALL EXHAUST VALVE (a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. (b) Install the valve, compression spring and spring retainer to the cylinder head.
  • Page 129 EM–128 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the retainer. 22. INSTALL VALVE STEM CAP (a) Apply a light coat of engine oil to the valve stem caps.
  • Page 130 EM–129 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 25. INSTALL WATER INLET PIPE (a) Install the water inlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Install the water by-pass hose No. 1. A120668 26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Lot No.
  • Page 131 EM–130 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Engine Front (a) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE: • Be careful of the installation direction.
  • Page 132 EM–131 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger. CORRECT INCORRECT 09276-75010 (c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
  • Page 133 EM–132 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A131903E01 31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH (a) Make sure that the valve rocker arm is installed as Valve Rocker Arm shown in the illustration.
  • Page 134 EM–133 2GR-FE ENGINE MECHANICAL – ENGINE UNIT • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. (d) Tighten the 8 bolts in the order shown in the illustration.
  • Page 135 EM–134 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Apply seal packing in a continuous line as shown in the illustration. 3.5 to 4.5 (0.138 to 0.177) Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
  • Page 136 EM–135 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (a) Install the No. 2 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (b) While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it.
  • Page 137 EM–136 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) Install the chain tensioner with the bolt. Plunger Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (b) While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to hold it.
  • Page 138 EM–137 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 40. INSTALL CRANKSHAFT TIMING SPROCKET (a) Install the 2 timing gear set keys and timing sprocket as shown in the illustration. A109720 41. INSTALL IDLE SPROCKET ASSEMBLY (a) Apply a light coat of engine oil to the rotating surface of the No.
  • Page 139 EM–138 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Do not pass the chain over the crankshaft, just put it on it. A134890 (c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between Turn the banks.
  • Page 140 EM–139 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Turn the crankshaft clockwise to set it to the RH Center Line block bore center line (TDC / compression). 43. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper. Timing Marks A129691E02 44.
  • Page 141 EM–140 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Remove the hexagon wrench of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression. (e) Remove the pulley set bolt. Timing Marks Timing Marks...
  • Page 142 EM–141 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 47. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration. : Seal Packing 3.0 mm or more (0.118 in.)
  • Page 143 (0.079 to 0.118 in.) (0.118 to 0.158 in.) Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Alternate long and short dashed line area...
  • Page 144 EM–143 2GR-FE ENGINE MECHANICAL – ENGINE UNIT NOTICE: • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  • Page 145 EM–144 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Bolt length Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTICE: Make sure that there is no oil on the bolt threads.
  • Page 146 EM–145 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Install the stud bolts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 9 mm (0.35 in.) 25 mm (0.98 in.) 9 mm (0.35 in.) A137975E01 (c) Install the water inlet with the 2 bolts and nut.
  • Page 147 EM–146 2GR-FE ENGINE MECHANICAL – ENGINE UNIT Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A129673 49. INSTALL FRONT ENGINE MOUNTING BRACKET NO. Stud Bolt 1 LH (a) Install the engine mounting bracket with the 6 bolts.
  • Page 148 EM–147 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 51. INSTALL OIL PAN SUB-ASSEMBLY (a) When replacing a stud bolt, install it by using an E8 "torx" socket wrench. Timing Chain Cover: Lower Cylinder Block: 16 mm (0.63 in.) 34 mm (1.34 in.) 12 mm (0.47 in.)
  • Page 149 EM–148 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Install the oil pan with the 16 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A A129682E01 52.
  • Page 150 EM–149 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Apply seal packing in a continuous line as shown in 3.0 to 4.0 mm the illustration. (0.118 to 0.156 in.) Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.)
  • Page 151 EM–150 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Install 3 new gaskets as shown in the illustration. (c) Install a new gasket to the head cover. A129699 (d) Install a head cover with the 12 bolts and a new washer.
  • Page 152 EM–151 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (d) Install the head cover with the 12 bolts and a new washer. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A HINT: Make sure the tightening torque of bolts 1 and 10.
  • Page 153 EM–152 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 59. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, the threads and Oil Filter O-ring groove. Element (b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
  • Page 154 EM–153 2GR-FE ENGINE MECHANICAL – ENGINE UNIT (b) Install the water drain cocks as shown in the RH Side: illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: 20° Do not rotate the drain cocks more than 1 12° revolution (360°) after tightening the drain cocks with the specified torque.
  • Page 155 EM–154 2GR-FE ENGINE MECHANICAL – ENGINE UNIT NOTICE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools. 63. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A129663 64.
  • Page 156 EM–155 2GR-FE ENGINE MECHANICAL – ENGINE UNIT 65. INSTALL CAMSHAFT POSITION SENSOR LH Bank: (a) Install the 4 sensors with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 66. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Apply adhesive around the ventilation valve.
  • Page 157 ES–1 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SFI SYSTEM PRECAUTION NOTICE: • Perform the RESET MEMORY (AT) initialization operation after replacing the automatic transmission assembly, engine assembly or ECM (See page AX-25). • Perform REGISTRATION (VIN registration) when replacing the ECM (See page ES-20).
  • Page 158 ES–2 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DEFINITION OF TERMS Terms Definition Monitor Description Description of what ECM monitors and how to detect malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by ECM based on the same malfunction detection logic.
  • Page 159 ES–3 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION MASS AIR FLOW METER ENGINE ROOM R/B - EFI RELAY - A/F RELAY - C/OPN RELAY - ST RELAY - ST CUT RELAY PURGE VSV - IG2 RELAY CANISTER FUEL PUMP...
  • Page 160 ES–4 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMBINATION METER DLC3 INSTRUMENT PANEL J/B - IGN FUSE - STOP FUSE ACCELERATOR PEDAL STOP LIGHT SWITCH A139510E01...
  • Page 161 ES–5 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VVT SENSOR (BANK 1 INTAKE SIDE) VVT SENSOR FOR INTAKE CAMSHAFT (BANK 2) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 1 INTAKE SIDE) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2 INTAKE SIDE)
  • Page 162 ES–6 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM THROTTLE BODY (THROTTLE POSITION SENSOR) ACIS ACTUATOR KNOCK SENSOR (BANK 1) (BANK 2) KNOCK SENSOR A114543E04...
  • Page 163 ES–7 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM Without Smart Key System: GAUGE No. 2 ST/AM2 IG SW IGSW PNP SW Combination Meter VVT OCV (Intake Side RH) OC1+ C/OPN OC1- VVT OCV (Intake Side LH) Fuel Pump...
  • Page 164 ES–8 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM APP Sensor EFI No. 3 VCP2 EFI No. 2 VPA2 EPA2 VCPA AICV VSV for ACIS Transmission CAN+ VSV for EVAP System Control ECU CAN- ACIS VSV for ACIS Transponder Key VSV for Active Control Mount System...
  • Page 165 ES–9 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pump Module KNK1 VPMP EKNK EPPM Knock Sensor (Bank 1) PPMP VCPP KNK2 MPMP EKN2 Knock Sensor (Bank 2) VVT Sensor VV1+ (Bank 1 Intake Side) VV1- No. 1 Fuel Injector...
  • Page 166 ES–10 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Crankshaft Position Sensor VTA1 VCTA Throttle Body Assembly VTA2 DLC3 GE01 Ignition Coil (No. 1) ECT Sensor IGT1 IGF1 ETHW Ignition Coil (No. 2) IGT2 A/F Sensor Ignition Coil (No. 3) HA1A...
  • Page 167 ES–11 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM To IG1 Relay GAUGE No. 1 Transmission Control SW To IG1 Relay ECU IG No. 2 Park / Neutral Position SW SFTD SFTU Spiral Cable Cruise Control SW Transmission Control A137634E02...
  • Page 168 ES–12 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM With Smart Key System: Main Body ECU GAUGE No. 2 To ECU-ACC Fuse STSW STSW ACCR ACCR Combinatiion Meter To IG2 Fuse IG2D ST CUT VVT OCV (Intake Side RH) STAR OC1+...
  • Page 169 ES–13 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM APP Sensor EFI No. 3 VCP2 EFI No. 2 VPA2 EPA2 VCPA AICV VSV for ACIS Transmission CAN+ VSV for EVAP System Control ECU CAN- ACIS VSV for ACIS Transponder Key VSV for Active Control Mount System...
  • Page 170 ES–14 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pump Module KNK1 VPMP EKNK EPPM Knock Sensor (Bank 1) PPMP VCPP KNK2 MPMP EKN2 Knock Sensor (Bank 2) VVT Sensor VV1+ (Bank 1 Intake Side) VV1- No. 1 Fuel Injector...
  • Page 171 ES–15 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Crankshaft Position Sensor VTA1 VCTA Throttle Body Assembly VTA2 DLC3 GE01 Ignition Coil (No. 1) ECT Sensor IGT1 IGF1 ETHW Ignition Coil (No. 2) IGT2 A/F Sensor Ignition Coil (No. 3) HA1A...
  • Page 172 ES–16 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM To IG1 Relay GAUGE No. 1 Transmission Control SW To IG1 Relay ECU IG No. 2 Park / Neutral Position SW SFTD SFTU Spiral Cable Cruise Control SW Transmission Control A137634E02...
  • Page 173 ES–17 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. VEHICLE BROUGHT TO WORKSHOP NEXT CUSTOMER PROBLEM ANALYSIS NEXT CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3.
  • Page 174 ES–18 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Result Proceed to Malfunction does not occur Malfunction occurs GO TO STEP 10 SIMULATE SYMPTOMS NEXT CHECK FOR DTCS* Result Result Proceed to Trouble code No code GO TO STEP 12...
  • Page 175 ES–19 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Proceed to Malfunctioning parts confirmed GO TO STEP 17 CHECK ECM POWER SOURCE CIRCUIT NEXT CONDUCT CIRCUIT INSPECTION Result Result Proceed to Malfunction not confirmed Malfunction confirmed GO TO STEP 18...
  • Page 176 ES–20 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONDUCT CONFIRMATION TEST NEXT...
  • Page 177 ES–21 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR INTERMITTENT PROBLEMS HINT: Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect with an intelligent tester when the ECM is in check mode. In check mode, the ECM uses 1 trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic.
  • Page 178 ES–22 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When the malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently.
  • Page 179 ES–23 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FUEL PRESSURE TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP CHECK FOR SPARKS TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP PROCEED TO PROBLEM SYMPTOMS TABLE...
  • Page 180 ES–24 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is in the form of a 17-digit alphanumeric vehicle identification number. An intelligent tester is required to register the VIN.
  • Page 181 ES–25 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN READ VIN Previously Stored VIN Not Stored DTC P0630 Set 17-digit VIN displayed [EXIT] [EXIT] [EXIT]...
  • Page 182 ES–26 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN WRITE VIN Previously Stored [NO] [YES] [YES] [YES] 17-digit VIN displayed To Menu [NO] Screen Continue to next illustration...
  • Page 183 ES–27 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM New Registration Input Instructions [ENTER] [ENTER] [ENTER] [ENTER] Input Error [EXIT] Continue to next illustration A103814E03...
  • Page 184 ES–28 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Writing Successful Writing Error Communication Error [ENTER] [EXIT] [EXIT] To Menu Screen To Menu Screen To Menu Screen A103815E03...
  • Page 185 Perform the following instructions to view the monitor status. Although the Toyota diagnostic tester is used in the following instructions, it can be checked using a generic OBD II scan tool. Refer to your scan tool operator's manual for specific procedures.
  • Page 186 ES–30 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ACCESS MONITOR RESULT (a) Select the following menus on the intelligent tester: DIAGNOSIS, ENHANCED OBDII, MONITOR INFO and MONITOR RESULT. The monitor status appears after the component name. • INCMP: The component has not been monitored yet.
  • Page 187 ES–31 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HO2S Bank 2 Sensor 2: Monitor ID Test ID Scaling Unit Description Multiply by 0.001 Minimum sensor voltage Multiply by 0.001 Maximum sensor voltage Multiply by 0.003 Maximum oxygen storage capacity Catalyst-Bank 1:...
  • Page 188 ES–32 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor ID Test ID Scaling Unit Description Misfire rate for cylinder 6: Misfire counts for last/current driving cycle- Multiply by 1 Time Total Rear Oxygen Sensor Heater: Monitor ID Test ID Scaling...
  • Page 189 ES–33 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READINESS MONITOR DRIVE PATTERN PURPOSE OF READINESS TESTS • The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emission- related components, and indicate any detected abnormalities with DTCs (Diagnostic Trouble Codes).
  • Page 190 ES–34 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CATALYST MONITOR (ACTIVE AIR-FUEL RATIO CONTROL TYPE) Vehicle Speed NOTICE: This test will not be completed if Between 40 mph and the vehicle is driven under absolute 70 mph (64 km/h and...
  • Page 191 ES–35 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Monitor Status (1) Connect an intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the tester or scan tool on. (4) Check the Readiness Monitor status displayed on the tester or scan tool.
  • Page 192 ES–36 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (9) Soon after performing procedure "A" above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control (Procedure "B"). (10)Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h) (Procedure "C").
  • Page 193 ES–37 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester or scan tool. If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and repeat the Drive Pattern.
  • Page 194 ES–38 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PROBLEM SYMPTOMS TABLE HINT: When a malfunction is not confirmed by a DTC (Diagnostic Trouble Code) check and the cause of problem cannot be identified through a basic inspection, troubleshoot according to the priority order indicated in the table below.
  • Page 195 ES–39 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symptom Suspected area See page 1. Electronic Throttle Control System (ETCS) ES-320 2. ECM power source circuit ES-432 3. A/C signal circuit (Compressor circuit) High engine idling speed (Poor idling) 4. Acoustic Control Induction System (ACIS) ES-462 5.
  • Page 196 ES–40 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TERMINALS OF ECM SFI SYSTEM A107881E29 HINT: The standard normal voltage between each pair of the ECM terminals is shown in the table below. The appropriate conditions for checking each pair of the terminals are also indicated.
  • Page 197 ES–41 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions Conditions STD Voltages Stop light switch signal Ignition switch on (IG), W-Brake ST1- (A55-35) - E1 (C55-81) GR - W-B 7.5 to 14 V (opposite to STP terminal)
  • Page 198 ES–42 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions Conditions STD Voltages #10 (C55-45) - E01 (C55-22) B - W-B #20 (C55-85) - E01 (C55-22) R - W-B #30 (C55-44) - E01 (C55-22) Y - W-B...
  • Page 199 ES–43 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions Conditions STD Voltages Camshaft timing Oil Control Valve (OCV) Pulse generation OE2+ (C55-14) - OE2- (C55-15) W-L - Y Ignition switch on (IG) operation signal (Exhaust...
  • Page 200 ES–44 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions Conditions STD Voltages Ignition coil with igniter IGF1 (C55-106) - E1 (C55-81) BR - W-B (ignition confirmation Ignition switch on (IG) 4.5 to 5.0 V...
  • Page 201 ES–45 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Colors Terminal Descriptions Conditions STD Voltages A1A- (B46-30) - E1 (C55-81) P - W-B A/F sensor Ignition switch on (IG) 3.0 V A2A- (C55-119) - E1 (C55-81) Y - W-B...
  • Page 202 ES–46 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) WAVEFORM 4 (1) Knock sensor signal 1 V/DIV ECM Terminal Names Between KNK1 and EKNK, or KNK2 and EKN2 Tester Ranges 0.01 to 10 V/DIV, 0.01 to 10 ms./DIV Engine speed is maintained at 4,000 rpm after engine...
  • Page 203 ES–47 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (h) WAVEFORM 8 (1) Vehicle speed signal 2 V/DIV ECM Terminal Names Between SPD and E1 Tester Ranges 2 V/DIV, 20 ms./DIV Conditions Driving at 12 mph (20 km/h) Ground HINT: • The wavelength becomes shorter as the vehicle speed increases.
  • Page 204 ES–48 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When troubleshooting OBD II (On-Board Diagnostics) vehicles, the intelligent tester (complying with SAE J1987) must be connected to the DLC3 (Data Link Connector 3) of the vehicle. Various data in the vehicle's ECM (Engine Control Module) can be then read.
  • Page 205 ES–49 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FREEZE FRAME DATA The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or...
  • Page 206 ES–50 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) The MIL should turn OFF when the engine is started. If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the engine switch is first...
  • Page 207 ES–51 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC CHECK / CLEAR NOTICE: When the diagnosis system is changed from the normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of DTCs and freeze frame data.
  • Page 208 ES–52 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FREEZE FRAME DATA DESCRIPTION The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or...
  • Page 209 ES–53 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL Measurement Item/Range Diagnostic Note (Intelligent Tester Display) KNOCK FB VAL Feedback value of knocking Absolute Accelerator Pedal Position (APP) ACCEL POS #1 No. 1 ACCEL POS #2 Absolute APP No. 2...
  • Page 210 ES–54 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL Measurement Item/Range Diagnostic Note (Intelligent Tester Display) AF FT B1 S1 Fuel trim at A/F sensor AF FT B2 S1 Fuel trim at A/F sensor CAT TEMP B1 S1 Catalyst temperature...
  • Page 211 ES–55 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL Measurement Item/Range Diagnostic Note (Intelligent Tester Display) IGNITION Ignition CYL ALL All cylinder misfire rate Displayed only during idling MISFIRE RPM Misfire RPM CYL ALL All cylinder misfire rate Displayed only during idling...
  • Page 212 ES–56 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK MODE PROCEDURE HINT: Intelligent tester only: Compared to the normal mode, check mode is more sensitive to malfunctions. Therefore, check mode can detect the malfunctions that cannot be detected in normal mode.
  • Page 213 ES–57 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE CHART If any of the following DTCs are set, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily. Fail-Safe Deactivation DTCs Components Fail-Safe Operations Conditions Air-Fuel Ratio (A/F) Sensor...
  • Page 214 ES–58 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DATA LIST / ACTIVE TEST DATA LIST HINT: By reading the DATA LIST displayed on an intelligent tester, you can check values, including those of the switches, sensors, and actuators, without removing any parts.
  • Page 215 ES–59 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) Ratio of evaporative purge flow to EVAP PURGE FLOW intake air volume: 0 to 8%: Idling Min.: 0%, Max.: 102.4% EVAP (PURGE) VSV control duty:...
  • Page 216 ES–60 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) Whether or not fail safe function FAIL #2 executed: ON: ETCS has failed ON or OFF Starter signal: ON: Cranking ON or OFF...
  • Page 217 ES–61 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) • When accelerator pedal is Throttle actuator opening duty depressed, duty ratio THROTL OPN DUTY ratio: 0 to 40%: Idling increaseds Min.: 0%, Max.: 100%...
  • Page 218 ES–62 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) Overall fuel compensation carried Long-term fuel trim of bank 2: out in long-term to compensate for LONG FT #2 -20 to 20% Min.: -100%, Max.: 99.2%...
  • Page 219 ES–63 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) Estimated catalyst temperature CAT TEMP B2S2 (bank 2 sensor 2): Min.: -40°C, Max.: 6,513.5°C Sub heated oxygen sensor S O2S B1S2 impedance (bank 1 sensor 2): Min.: 0 Ω, Max.: 21,247.68 Ω...
  • Page 220 ES–64 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) VSV for Acoustic Control ON: Open ACIS VSV Induction System Status: OFF: Closed ON or OFF Purge VSV status: EVAP (Purge) VSV...
  • Page 221 ES–65 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) VVT exhaust operation duty (bank Requested duty value for intrusive 2 Exhaust side): 0 to 100% VVT EX OCV D B2 operation Min.: 0%, Max.: 100%...
  • Page 222 ES–66 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) Running time from MIL ON: MIL ON RUN TIME Min.: 0 minutes, Running time after MIL ON Max.: 65,535 minutes Engine run time: ENG RUN TIME Min.: 0 seconds,...
  • Page 223 ES–67 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item: Range Intelligent Tester Display Diagnostic Note Normal Condition (Display) O2S (A/FS) heater monitor: HTR CMPL COMPL or INCMPL O2S (A/FS) monitor: O2S (A/FS) ENA UNABLE or ENABLE O2S (A/FS) monitor:...
  • Page 224 ES–68 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ACTIVE TEST HINT: Performing an ACTIVE TEST enables components including the relays, VSV (Vacuum Switching Valve) and actuators, to be operated without removing any parts. The ACTIVE TEST can be performed with an intelligent tester.
  • Page 225 ES–69 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Displays Test Details Control Ranges Diagnostic Note Test is possible when following conditions are met: COOLING FAN Control Electric Cooling Fan ON/OFF • Ignition switch is on (IG) • Ignition is stopped...
  • Page 226 ES–70 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM CHECK HINT: Performing a SYSTEM CHECK enables the system, which consists of multiple actuators, to be operated without removing any parts. In addition, it can show whether or not any DTCs are set, and can detect potential malfunctions in the system.
  • Page 227 ES–71 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: The parameters listed in the chart may not conform exactly to those read during the DTC check due to the type of instrument or other factors. If a trouble code is displayed during the DTC check in the check mode, check the circuit for the code listed in the table below.
  • Page 228 ES–72 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0020 Camshaft Position 1. Open or short in Comes on DTC stored ES-79 "A" Actuator Circuit Oil Control Valve (Bank 2) (OCV) for intake camshaft circuit 2.
  • Page 229 ES–73 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0051 Oxygen (A/F) Sensor 1. Open in A/F sensor Comes on DTC stored ES-107 Heater Control Circuit heater circuit Low (Bank 2 Sensor 2.
  • Page 230 ES–74 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0112 Intake Air 1. Short in IAT sensor Comes on DTC stored ES-136 Temperature Circuit circuit Low Input 2. IAT sensor (built into MAF meter) 3.
  • Page 231 ES–75 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0136 Oxygen Sensor 1. Open or short in Comes on DTC stored ES-171 Circuit Malfunction HO2 sensor (bank 1 (Bank 1 Sensor 2) sensor 2) circuit 2.
  • Page 232 ES–76 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0158 Oxygen Sensor 1. Short in HO2 Comes on DTC stored ES-171 Circuit High Voltage sensor (bank 2 (Bank 2 Sensor 2) sensor 2) circuit 2.
  • Page 233 ES–77 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0174 System Too Lean 1. Air induction Comes on DTC stored ES-191 (Bank 2) system 2. Injector blockage 3. MAF meter 4. ECT sensor 5.
  • Page 234 ES–78 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0300 Random / Multiple 1. Open or short in Comes on or flashes DTC stored ES-204 Cylinder Misfire engine wire harness Detected 2.
  • Page 235 ES–79 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0340 Camshaft Position 1. Open or short in Comes on DTC stored ES-228 Sensor Circuit VVT sensor for intake Malfunction camshaft circuit 2.
  • Page 236 ES–80 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0367 Camshaft Position 1. Open or short in Comes on DTC stored ES-243 Sensor "B" Circuit VVT sensor for Low Input (Bank 1)
  • Page 237 ES–81 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0430 Catalyst System 1. Gas leakage from Comes on DTC stored ES-249 Efficiency Below exhaust system Threshold (Bank 2) 2. A/F sensor (bank 2 sensor 1) 3.
  • Page 238 ES–82 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0455 Evaporative Emission 1. Fuel tank cap Comes on DTC stored ES-274 Control System Leak (loose) Detected (Gross 2. Leakage from Leak)
  • Page 239 ES–83 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P0607 Control Module Comes on (except DTC stored ES-302 Performance when there is a malfunction in the cruise control switch circuit) P0617 Starter Relay Circuit 1.
  • Page 240 ES–84 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P2122 Throttle / Pedal 1. Accelerator Pedal Comes on DTC stored ES-334 Position Sensor / Position (APP) Switch "D" Circuit sensor Low Input 2.
  • Page 241 ES–85 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P2197 Oxygen (A/F) Sensor 1. Open or short in A/ Comes on DTC stored ES-345 Signal Stuck Lean F sensor (bank 2...
  • Page 242 ES–86 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Suspected Trouble Memory See page Area P2256 Oxygen (A/F) Sensor Same as DTC P2241 Comes on DTC stored ES-364 Reference Ground Circuit High (Bank 2 Sensor 1) P2401 Evaporative Emission 1.
  • Page 243 ES–87 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Camshaft Position "A" Actuator Circuit (Bank P0010 Camshaft Position "A" Actuator Circuit (Bank P0020 DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, Oil Control Valve (OCV) and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller.
  • Page 244 ES–88 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION After the ECM sends the "target" duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an "actual" duty-cycle. The ECM detects a malfunction and sets a DTC when the actual duty- cycle ratio varies from the target duty-cycle ratio.
  • Page 245 ES–89 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM OCV for Intake Camshaft (Bank 1) OC1+ OC1- OCV for Intake Camshaft (Bank 2) OC2+ OC2- A133849E01 INSPECTION PROCEDURE HINT: • If DTC P0010 is displayed, check the intake camshaft circuit for the right bank VVT system.
  • Page 246 ES–90 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) CHECK FOR INTERMITTENT PROBLEMS (See page ES-33) INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the C43 or C47 OCV connector.
  • Page 247 ES–91 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ECM (See page ES-518)
  • Page 248 ES–92 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Camshaft Position "A" - Timing Over-Advanced P0011 or System Performance (Bank 1) Camshaft Position "A" - Timing Over-Retarded P0012 (Bank 1) Camshaft Position "A" - Timing Over-Advanced P0021 or System Performance (Bank 2) Camshaft Position "A"...
  • Page 249 ES–93 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake camshaft.
  • Page 250 ES–94 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Valve timing No change in retarded valve timing WIRING DIAGRAM Refer to DTC P0010 (See page ES-81). INSPECTION PROCEDURE HINT: Advanced timing over Retarded timing over Abnormal bank (Valve timing is out of specified range)
  • Page 251 ES–95 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON)
  • Page 252 ES–96 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TEETH ON TIMING CHAIN) (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0"...
  • Page 253 ES–97 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page 481) INSPECT OIL CONTROL VALVE FILTER AND PIPE (a) Remove the oil pipe No. 1 or No. 2. RH Bank: (b) Remove the oil control valve filter.
  • Page 254 ES–98 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: DTC P0011, P0012, P0021 or P0022 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay output even if the system returns to normal after a short time. These foreign objects are then captured by the oil filter, thus eliminating the source of the problem.
  • Page 255 ES–99 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Camshaft Position "B" Actuator Circuit / Open P0013 (Bank 1) Camshaft Position "B" Actuator Circuit / Open P0023 (Bank 2) DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, OCV and VVT controller. The ECM sends a target duty-cycle control signal to the OCV.
  • Page 256 ES–100 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT system to control the exhaust camshaft. The VVT system includes the ECM, the OCV and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV.
  • Page 257 ES–101 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM OCV for Exhaust Camshaft (Bank 1) OE1+ OE1- OCV for Exhaust Camshaft (Bank 2) OE2+ OE2- A133849E02 INSPECTION PROCEDURE HINT: • If DTC P0013 is displayed, check the exhaust camshaft circuit for the bank 1 VVT system.
  • Page 258 ES–102 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) Go to step 2 CHECK FOR INTERMITTENT PROBLEMS INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the C42 or C46 OCV connector.
  • Page 259 ES–103 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (OCV - ECM) (a) Disconnect the C42 or C46 OCV connector. Wire Harness Side Front View: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 260 ES–104 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Camshaft Position "B" - Timing Over-Advanced P0014 or System Performance (Bank 1) Camshaft Position "B" - Timing Over-Retarded P0015 (Bank 1) Camshaft Position "B" - Timing Over-Advanced P0024 or System Performance (Bank 2) Camshaft Position "B"...
  • Page 261 ES–105 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Crankshaft Position Sensor Duty Control Target Valve Timing MAF Meter Throttle Position Sensor Feedback Camshaft Timing ECT Sensor Oil Control Valve Correction (OCV) Vehicle Speed Signal Actual Valve Timing Camshaft Position Sensor A103843E02 DTC No.
  • Page 262 ES–106 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the exhaust camshaft.
  • Page 263 ES–107 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Retarded camshaft timing: Valve timing No change Valve timing Retard position WIRING DIAGRAM Refer to DTC P0013 (See page ES-93). INSPECTION PROCEDURE HINT: Advanced timing over Retarded timing over Abnormal bank (Valve timing is out of specified range)
  • Page 264 ES–108 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON)
  • Page 265 ES–109 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TEETH ON TIMING CHAIN) (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0"...
  • Page 266 ES–110 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page 481) INSPECT OIL CONTROL VALVE FILTER AND PIPE (a) Remove the oil pipe No. 1 or No. 2. RH Bank: (b) Remove the oil control valve filter.
  • Page 267 ES–111 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: DTC P0014, P0015, P0024 or P0025 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay output even if the system returns to normal after a short time. These foreign objects are then captured by the oil, thus eliminating the source of the problem.
  • Page 268 ES–112 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Crankshaft Position - Camshaft Position Corre- P0016 lation (Bank 1 Sensor A) Crankshaft Position - Camshaft Position Corre- P0017 lation (Bank 1 Sensor B) Crankshaft Position - Camshaft Position Corre- P0018 lation (Bank 2 Sensor A)
  • Page 269 ES–113 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components (Sub) Camshaft position sensor, Crankshaft position sensor Frequency of operation Once per drive cycle Duration Within 1 minute MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS...
  • Page 270 ES–114 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND A JUMPED TOOTH OF TIMING CHAIN) (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0"...
  • Page 271 ES–115 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Oxygen (A/F) Sensor Heater Control Circuit P0031 Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Heater Control Circuit P0032 High (Bank 1 Sensor 1) Oxygen (A/F) Sensor Heater Control Circuit P0051 Low (Bank 2 Sensor 1)
  • Page 272 ES–116 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Cover Platinum electrode Rich - Air Fuel Ratio - Lean Exhaust Gas A-A Section A107164E13 HINT: • When any of these DTCs are set, the ECM enters fail-safe mode. The ECM turns off the A/F sensor heater in fail-safe mode.
  • Page 273 ES–117 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area • Short in A/F sensor heater (bank 1, 2, sensor 1) circuit P0032 Air-Fuel Ratio (A/F) sensor heater (bank 1, 2, sensor 1) • A/F sensor heater (sensor 1)
  • Page 274 ES–118 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Time after engine start 10 seconds or more P0032 and P0052: Battery voltage Less than 20 V Engine Running Heater output duty More than 0 % TYPICAL MALFUNCTION THRESHOLDS P0031 and P0051: A/F sensor heater current Less than 0.8 A...
  • Page 275 ES–119 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. Component Side: (b) Measure the resistance according to the value(s) in the table below. Air Fuel Ratio Sensor...
  • Page 276 ES–120 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY, A/F RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the EFI relay. (1) Measure the EFI relay resistance.
  • Page 277 ES–121 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - A/F RELAY) (a) Disconnect the C15 or C35 A/F sensor connector. Wire Harness Side: (b) Remove the engine room junction block from the engine room R/B.
  • Page 278 ES–122 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Disconnect the C15 or C35 A/F sensor connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals. Standard resistance (Check for open)
  • Page 279 ES–123 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Oxygen Sensor Heater Control Circuit Low P0037 (Bank 1 Sensor 2) Oxygen Sensor Heater Control Circuit High P0038 (Bank 1 Sensor 2) Oxygen Sensor Heater Control Circuit Low P0057 (Bank 2 Sensor 2)
  • Page 280 ES–124 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Atmospheric Air Ideal Air-Fuel Mixture Housing Output Voltage Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Cover Richer - Air-Fuel Ratio - Leaner Coating (Ceramic) Exhaust Gas A088111E14 HINT: • Sensor 2 refers to the sensor mounted behind the Three-Way Catalytic Converter (TWC) and located far from the engine assembly.
  • Page 281 ES–125 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P0141 Cumulative heater resistance correction value exceeds • HO2 sensor heater P0161 the acceptable threshold. (2 trip detection logic) • HINT: • Bank 1 refers to the bank that includes cylinder No. 1.
  • Page 282 ES–126 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0037 and P0057: Battery voltage 10.5 to 20 V P0038 and P0058 (Case 1): Battery voltage 10.5 V or more Engine Running Starter P0038 and P0058 (Case 2): Battery voltage 10.5 to 20 V...
  • Page 283 ES–127 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the C52 heated oxygen sensor connector Component Side: (Bank 1 Sensor 2) or C51 heated oxygen sensor connector (Bank 2 Sensor 2). (b) Measure the resistance according to the value(s) in the table below.
  • Page 284 ES–128 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (EFI NO. 3) (a) Remove the EFI No. 3 fuse from the engine room R/B. (b) Measure the EFI No. 3 fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI No. 3 fuse.
  • Page 285 ES–129 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (EFI MAIN) (a) Remove the EFI MAIN fuse from the engine room R/B. (b) Measure the EFI MAIN fuse. EFI MAIN Standard resistance: Below 1 Ω (c) Reinstall the EFI MAIN fuse.
  • Page 286 ES–130 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HO2 SENSOR - EFI RELAY) (a) Disconnect the C52 or C51 HO2 sensor connector. Wire Harness Side: (b) Remove the engine room junction block from the engine room R/B.
  • Page 287 ES–131 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HO2 SENSOR - ECM) (a) Disconnect the C52 heated oxygen sensor connector Wire Harness Side: (Bank 1 Sensor 2) or C51 heated oxygen sensor connector (Bank 2 Sensor 2).
  • Page 288 ES–132 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read the DTCs. Result Display (DTC Output) Proceed to No output P0037, P0038, P0057 and/or P0058...
  • Page 289 ES–133 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0100 Mass or Volume Air Flow Circuit P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input DESCRIPTION The Mass Air Flow (MAF) meter is a sensor that measures the amount of air flowing through the valve.
  • Page 290 ES–134 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: When any of these DTCs are set, check the air-flow rate by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF.
  • Page 291 ES–135 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C2 MAF Meter EFI No. 3 EFI Relay MREL EFI MAIN FL MAIN Battery A117876E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored.
  • Page 292 ES–136 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Mass Air Flow Rate (gm/s) Proceed to 271.0 or more Between 1.0 and 270.0 (*1) *1: The value must be changed when the throttle valve is open or closed. Go to step 8...
  • Page 293 ES–137 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 294 ES–138 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ENGINE ROOM JUNCTION BLOCK) (a) Disconnect the C2 MAF meter connector. Wire Harness Side: (b) Remove the engine room junction block from the engine room R/B.
  • Page 295 ES–139 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the EFI relay. (1) Measure the EFI relay resistance. Engine Room Junction Block...
  • Page 296 ES–140 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 297 ES–141 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Mass Air Flow Circuit Range / Performance P0101 Problem DESCRIPTION The Mass Air Flow (MAF) meter is a sensor that measures the amount of air flowing through the valve. The ECM uses this information to determine the fuel injection time and to prove appropriate air-fuel ratio.
  • Page 298 ES–142 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio.
  • Page 299 ES–143 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data...
  • Page 300 ES–144 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0110 Intake Air Temperature Circuit Malfunction P0112 Intake Air Temperature Circuit Low Input P0113 Intake Air Temperature Circuit High Input DESCRIPTION Fig. 1 Resistance (kΩ) Acceptable (°C) Temperature (°F) A067628E20 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT.
  • Page 301 ES–145 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: When any of these DTCs are set, check the IAT by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR.
  • Page 302 ES–146 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM IAT Sensor (Built into MAF Meter) ETHA A110108E15 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data...
  • Page 303 ES–147 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (e) Read the value displayed on the tester. Standard: Same as actual Intake Air Temperature (IAT).
  • Page 304 ES–148 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the C2 MAF meter connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 305 ES–149 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER- ECM) (a) Disconnect the C2 MAF meter connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 306 ES–150 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Intake Air Temperature Sensor Gradient Too P0111 High DESCRIPTION Fig. 1 Resistance (kΩ) Acceptable (°C) Temperature (°F) A067628E20 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT.
  • Page 307 ES–151 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Main) Intake Air Temperature (IAT) sensor Required Sensors/Components (Sub) Frequency of Operation Once per driving cycle Duration 5 hours MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS...
  • Page 308 ES–152 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Read the DTCs. Result Display (DTC Output) Proceed to P0111 and other DTCs P0111 HINT: If any DTCs other than P0111 are output, troubleshoot those DTCs first. REPLACE MASS AIR FLOW METER (See...
  • Page 309 ES–153 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Coolant Temperature Circuit Malfunc- P0115 tion P0117 Engine Coolant Temperature Circuit Low Input P0118 Engine Coolant Temperature Circuit High Input DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor, of which the resistance value varies according to the ECT.
  • Page 310 ES–154 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY P0115: Engine coolant temperature sensor open/short (Fluctuating) P0117: Engine coolant temperature sensor short (Low electrical Related DTCs resistance) P0118: Engine coolant temperature sensor open (High electrical resistance) Required Sensors/Components (Main)
  • Page 311 ES–155 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data...
  • Page 312 ES–156 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR INTERMITTENT PROBLEMS CHECK ENGINE COOLANT TEMPERATURE SENSOR (CHECK FOR OPEN IN SENSOR) (a) Confirm good connection of the sensor. (b) Disconnect the C4 engine coolant temperature (ECT) sensor connector. (c) Connect terminals 1 and 2 of the ECT sensor connector ECT Sensor on the wire harness side.
  • Page 313 ES–157 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR - ECM) (a) Disconnect the C4 ECT sensor connector. Wire Harness Side Front View: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 314 ES–158 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR - ECM) (a) Disconnect the C4 ECT sensor connector. Wire Harness Side Front View: (b) Disconnect the C55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 315 ES–159 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Coolant Temperature Circuit Range / P0116 Performance Problem DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor, of which the resistance value varies according to the ECT. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor.
  • Page 316 ES–160 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECT sensor cold start monitor: Battery voltage 10.5 V or more Time after engine start 1 second or more ECT at engine start Less than 60°C (140°F) IAT sensor circuit Soak time...
  • Page 317 ES–161 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC output) Proceed to P0116 and other DTCs GO TO DTC CHART (See page ES-63) INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-13). (b) Check the valve opening temperature of the thermostat.
  • Page 318 ES–162 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle / Pedal Position Sensor / Switch "A" P0120 Circuit Malfunction Throttle / Pedal Position Sensor / Switch "A" P0122 Circuit Low Input Throttle / Pedal Position Sensor / Switch "A" P0123 Circuit High Input Throttle / Pedal Position Sensor / Switch "B"...
  • Page 319 ES–163 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail Safe Angle Sensor Output Voltage (V) VTA2 VTA1 2.55 Throttle Position 2.25 Sensor Magnet 0.93 0.69 6° IC No. 1 Usable Range 84° 0° Throttle Valve Opening Angle (degrees) VTA1 Note:...
  • Page 320 ES–164 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area • TP sensor (built into throttle body) Output voltage of VTA2 is 1.75 V or less for 2 seconds • Short in VTA2 circuit P0222 (1 trip detection logic) •...
  • Page 321 ES–165 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle position sensor 1 range check (Fluctuating): 2 seconds (Accelerator pedal ON) Throttle position sensor 1 range check (Low voltage): 2 seconds (Accelerator pedal ON) Throttle position sensor 1 range check (High voltage): 2 seconds...
  • Page 322 ES–166 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE VTA1 voltage 0.69 to 4.05 V VTA2 voltage 2.25 to 4.8 V FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode.
  • Page 323 ES–167 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS and THROTTLE POS #2. (d) Check the values displayed on the tester. Result TP#1 (VTA1)
  • Page 324 ES–168 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPAIR OR REPLACE HARNESS OR CONNECTOR INSPECT ECM (VC VOLTAGE) (a) Disconnect the C5 throttle body connector. Wire Harness Side Front View: (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the Throttle Body Connector table below.
  • Page 325 ES–169 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle / Pedal Position Sensor / Switch "A" P0121 Circuit Range / Performance Problem DESCRIPTION HINT: This ETC (Electrical Throttle Control System) does not use a throttle cable. The Throttle Position (TP) sensor is mounted on the throttle body, and detects the opening angle of the throttle valve.
  • Page 326 ES–170 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail Safe Angle Sensor Output Voltage (V) VTA2 VTA1 2.55 Throttle Position 2.25 Sensor Magnet 0.93 0.69 6° IC No. 1 Usable Range 84° 0° Throttle Valve Opening Angle (degrees) VTA1 Note:...
  • Page 327 ES–171 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM For each throttle opening angle, a specific voltage difference is expected between the outputs of VTA1 and VTA2. If the output voltage difference between the two signals deviates from the normal operating range, the ECM interprets this as a malfunction of the TP sensor.
  • Page 328 ES–172 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTC. Result Display (DTC output) Proceed to P0121 P0121 and other DTCs GO TO DTC CHART (See page ES-63)
  • Page 329 ES–173 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Insufficient Coolant Temperature for Closed P0125 Loop Fuel Control DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor, and its resistance value varies according to the ECT. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor.
  • Page 330 ES–174 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS 64 seconds or more: Engine coolant temperature at engine start is - 8.34°C (15°F) or more Time until actual engine coolant temperature reaches closed- 111.2 seconds or more: Engine coolant temperature at engine start is - 19.45 to loop fuel control enabling temperature 8.35°C (15 to 35°F)
  • Page 331 ES–175 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE THERMOSTAT (See page CO-13) CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as abnormal radiator fan operation or any modifications.
  • Page 332 ES–176 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Coolant Thermostat (Coolant Temperature P0128 Below Thermostat Regulating Temperature) DESCRIPTION This DTC is set when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time. DTC No.
  • Page 333 ES–177 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration 900 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS P0010, P0020 (VVT OCV Bank 1, 2) P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard)
  • Page 334 ES–178 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTC. Result Display (DTC Output) Proceed to P0128 P0128 and other DTCs HINT: If any DTC other than P0128 are output, troubleshoot those DTCs first.
  • Page 335 ES–179 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Oxygen Sensor Circuit Malfunction (Bank 1 P0136 Sensor 2) Oxygen Sensor Circuit Low Voltage (Bank 1 P0137 Sensor 2) Oxygen Sensor Circuit High Voltage (Bank 1 P0138 Sensor 2) Oxygen Sensor Circuit Malfunction (Bank 2...
  • Page 336 ES–180 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air Fuel Mixture Atmospheric Air Housing Output Voltage Platinum Electrode Solid Electrolyte (Zirconia Element) Heater Coating (Ceramic) Cover Richer - Air Fuel Ratio - Leaner Exhaust Gas A115539E08 DTC No. DTC Detection Condition Trouble Area •...
  • Page 337 ES–181 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION Active Air-Fuel Ratio Control The ECM usually performs air-fuel ratio feedback control so that the Air-Fuel Ratio (A/F) sensor output indicates a near stoichiometric air-fuel level. This vehicle includes active air-fuel ratio control in addition to regular air-fuel ratio control.
  • Page 338 ES–182 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM : The TWC has the capability to store oxygen. The OSC and the emission purification capacity of the TWC are mutually related. The ECM determines whether the catalyst has deteriorated, based on the calculated OSC value (See page ES-249).
  • Page 339 ES–183 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • DTCs P0136 and P0156 indicate the deterioration of the HO2 sensor. The ECM sets the DTCs by calculating the impedance of the sensor when the typical enabling conditions are satisfied (1 driving cycle).
  • Page 340 ES–184 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine rpm Less than 3,200 rpm A/F sensor status Activated Fuel system status Closed loop Fuel-cut Engine load 10 to 70% Shift position 4th or more HO2S low impedance (P0136, P0156): Battery voltage...
  • Page 341 ES–185 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HO2S high voltage (Extremely high) (P0138, P0158): Duration that following condition is met: 10 seconds or more Rear HO2S voltage 1.2 V or more COMPONENT OPERATING RANGE Duration that following condition is met:...
  • Page 342 ES–186 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Heated Oxygen Sensor (Bank 1 Sensor 2) HT1B HT1B OX1B C55 OX1B C55 EX1B Heated Oxygen Sensor (Bank 2 Sensor 2) HT2B HT2B OX2B C55 OX2B C55 EX2B EFI No. 3...
  • Page 343 ES–187 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN HINT: • This confirmation driving pattern is used in steps 5, 8 and 11 of the following diagnostic troubleshooting procedure when using an intelligent tester. • Performing this confirmation driving pattern will activate the Heated Oxygen (HO2) sensor monitor.
  • Page 344 ES–188 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning.
  • Page 345 ES–189 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) HO2 Sensor (Sensor 2) Main Suspected Case Output Voltage Output Voltage Trouble Area Injection Volume Injection Volume +25 % +25 % -12.5 % -12.5 % • HO2 sensor •...
  • Page 346 ES–190 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / O2S B1S2 or O2S B2S2. (d) Allow the engine to idle. (e) Read the Heated Oxygen (HO2) sensor output voltage while idling.
  • Page 347 ES–191 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) (a) Disconnect the C52 oxygen sensor connector (Bank 1 Component Side: Sensor 2) or C51 oxygen sensor connector (Bank 2 sensor 2). (b) Measure the resistance according to the value(s) in the table below.
  • Page 348 ES–192 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF OXYGEN SENSOR (OUTPUT VOLTAGE) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Start the engine. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2 or O2S B1S2.
  • Page 349 ES–193 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM CONFIRMATION DRIVING PATTERN NEXT CHECK WHETHER DTC OUTPUT RECURS (DTC P0136 or P0156) (a) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
  • Page 350 ES–194 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Injection Volume +12 % Malfunction -12 % A/F Sensor Output Normal 3.3 V HO2 Sensor Output Malfunction A087979E16 REPLACE AIR FUEL RATIO SENSOR (See page EC-19) CHECK AND REPAIR EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (INJECTOR, FUEL...
  • Page 351 ES–195 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the C52 oxygen sensor connector (Bank 1 Component Side: Sensor 2) or C51 oxygen sensor connector (Bank 2 sensor 2). (b) Measure the resistance according to the value(s) in the table below.
  • Page 352 ES–196 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI MAIN RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below.
  • Page 353 ES–197 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM) (a) Disconnect the C52 oxygen sensor connector (Bank 1 Wire Harness Side: Sensor 2) or C51 oxygen sensor connector (Bank 2 sensor 2).
  • Page 354 ES–198 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 2): HO2 Sensor EFI Relay Heater EFI MAIN EFI No. 3 HT1B HT1B From Battery Sensor OX1B OX1B Duty Control EX1B MREL Ground A103832E39 REPAIR OR REPLACE HARNESS OR...
  • Page 355 ES–199 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0171 System Too Lean (Bank 1) P0172 System Too Rich (Bank 1) P0174 System Too Lean (Bank 2) P0175 System Too Rich (Bank 2) DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim consists of both the short-term and long-term fuel trims.
  • Page 356 ES–200 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • When the total of the short-term and long-term fuel trim values is within the malfunction threshold (and the engine coolant temperature is more than 75°C [167°F]), the system is functioning normally.
  • Page 357 ES–201 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS Fuel-trim: P0010, P0020 (VVT VSV1, 2), P0011, P0012 (VVT System-Advance, Retard), P0021, P0022(VVT System2-Adavance, Retard), P0031, P0031, P0032, P0051, P0052 (A/F Sensor heater Sensor 1), P0100, P0101, P0102, P0103 (MAF Sensor),...
  • Page 358 ES–202 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display (Sensor) Injection Volumes Status Voltages O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds.
  • Page 359 ES–203 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0171, P0172, P0174 OR P0175) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on.
  • Page 360 ES–204 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by...
  • Page 361 ES–205 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP.
  • Page 362 ES–206 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR EXHAUST GAS LEAKS No gas leakage. REPAIR OR REPLACE EXHAUST SYSTEM CHECK FOR SPARKS AND IGNITION (a) Check for sparks and ignition (See page IG-3). HINT: If the spark plugs or ignition system malfunctions, engine misfire may occur.
  • Page 363 ES–207 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. A/F Sensor Bank 1...
  • Page 364 ES–208 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (A/F SENSOR HEATER RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Measure the A/F relay resistance. Standard resistance Engine Room Junction Block...
  • Page 365 ES–209 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 or C35 A/F sensor connector. Wire Harness Side: (b) Turn the ignition switch on (IG). (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground.
  • Page 366 ES–210 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Relay A/F Sensor Heater HA1A HA1A From Battery Sensor A1A- A1A+ A1A+ Duty Control From A1A- Relay A133850E04 REPAIR OR REPLACE HARNESS OR...
  • Page 367 ES–211 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Speed “F” Between 1,400 rpm Between 38 mph and and 3,200 rpm 75 mph (60 km/h and 120 km/h) “E” Idling 2 minutes 3 to 5 minutes Ignition Switch off Time “A”, “B”, “C”, “D”...
  • Page 368 ES–212 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0300 Random / Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected P0305 Cylinder 5 Misfire Detected...
  • Page 369 ES–213 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area • Open or short in engine wire harness • Connector connection • Vacuum hose connections • Ignition system • Injector for direct injector P0301 •...
  • Page 370 ES–214 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY P0300: Multiple cylinder misfire P0301: Cylinder 1 misfire P0302: Cylinder 2 misfire Related DTCs P0303: Cylinder 3 misfire P0304: Cylinder 4 misfire P0305: Cylinder 5 misfire P0306: Cylinder 6 misfire...
  • Page 371 ES–215 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). WIRING DIAGRAM No. 1 Fuel Injector Main Body ECU No. 2 Fuel Injector IG2D No. 3 Fuel Injector No. 4 Fuel Injector No.
  • Page 372 ES–216 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG). 3. Turn the tester on. 4. Record the DTC(s) and freeze frame data. 5. Using the tester, switch the ECM from normal mode to check mode (See page ES-49).
  • Page 373 ES–217 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d)Repair the cylinder(s) that has a high misfiring rate or is indicated by the DTC. (e)After finishing repairs, conduct the confirmation driving pattern again, in order to verify that DTC P0300 is not set.
  • Page 374 ES–218 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK MISFIRE COUNT (CYL #1, #2, #3, #4, #5 AND #6) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Clear DTCs.
  • Page 375 ES–219 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR SPARKS AND IGNITION (a) Disconnect the injector connectors, in order to prevent the engine from starting. (b) Install the spark plug to the ignition coil. (c) Attach the spark plug assembly to the cylinder head cover.
  • Page 376 ES–220 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE SPARK PLUG INSPECT ECM (#10, #20, #30, #40, #50 AND/OR #60 VOLTAGE)) (a) Disconnect the C55 ECM connector. Wire Harness Side Front View: (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals.
  • Page 377 ES–221 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FUEL INJECTOR ASSEMBLY (MISFIRING CYLINDER) (a) Check the injector injection (whether fuel volume high or low, and whether injection pattern is poor). REPLACE FUEL INJECTOR ASSEMBLY (See page FU-13) CHECK VALVE CLEARANCE (MISFIRING CYLINDER)
  • Page 378 ES–222 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (a) Remove the cylinder head covers. (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. (c) Check that the timing marks of the camshaft timing gears...
  • Page 379 ES–223 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the ignition switch on (IG). Turn the tester on. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the COOLANT TEMP twice, when the engine is both cold and warmed up.
  • Page 380 ES–224 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Knock Sensor 1 Circuit Low Input (Bank 1 or P0327 Single Sensor) Knock Sensor 1 Circuit High Input (Bank 1 or P0328 Single Sensor) P0332 Knock Sensor 2 Circuit Low Input (Bank 2)
  • Page 381 ES–225 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Item Content 0.01 to 10 V/DIV. Equipment Settings 0.01 to 10 ms./DIV. Keep engine speed at 4,000 rpm with Conditions warm engine MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knock. When spark knock occurs, the piezoelectric element of the sensor vibrates.
  • Page 382 ES–226 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Shielded Knock Sensor (Bank 1) KNK1 EKNK Knock Sensor (Bank 2) KNK2 EKN2 A133852E01 INSPECTION PROCEDURE HINT: • DTCs P0327 and P0328 are for the bank 1 knock sensor circuit.
  • Page 383 ES–227 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ OUTPUT DTC (CHECK KNOCK SENSOR CIRCUIT) (a) Disconnect the CV1 connector. (b) Using lead wires, connect the connectors as follows: Knock Sensor Male Connector - Female Connector Terminal 2 - Terminal 4...
  • Page 384 ES–228 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK WIRE HARNESS AND CONNECTOR (CONNECTOR - ECM) (a) Disconnect the CV1 connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below.
  • Page 385 ES–229 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT KNOCK SENSOR (a) Disconnect the CV1 connector. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition CV1 male connector 1 - 2 120 to 280 kΩ...
  • Page 386 ES–230 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0335 Crankshaft Position Sensor "A" Circuit Crankshaft Position Sensor "A" Circuit Inter- P0339 mittent DESCRIPTION The crankshaft position (CKP) sensor system consists of a crankshaft position sensor plate and a magnetic coil.
  • Page 387 ES–231 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION If there is no signal from the crankshaft position sensor despite the engine revolving, the ECM interprets this as a malfunction of the sensor. If the malfunction is not repaired successfully, these DTCs are set 10 seconds after the engine is next started.
  • Page 388 ES–232 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM VCV1 C41 VVT Sensor (for Intake Camshaft (bank 1)) VV1+ VVR+ VVR- VV1- VCE1 C40 VVT Sensor (for Exhaust Camshaft (bank 1)) EV1+ EV1- Crankshaft Position Sensor VCE2 C44 VVT Sensor (for Exhaust Camshaft (bank 2))
  • Page 389 ES–233 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: • If no problem is found by this diagnostic troubleshooting procedure, troubleshoot the engine mechanical system. • Check the engine speed. The engine speed can be checked by using the intelligent tester. To check, follow the procedure below: (a)Connect the intelligent tester to the DLC3.
  • Page 390 ES–234 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) (a) Disconnect the C50 CKP sensor connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the Crankshaft Position Sensor table below.
  • Page 391 ES–235 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sensor plate does not have any cracks or deformation. REPLACE CRANKSHAFT POSITION SENSOR PLATE REPLACE ECM (See page ES-518)
  • Page 392 ES–236 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0340 Camshaft Position Sensor Circuit Malfunction Camshaft Position Sensor "A" Circuit Low P0342 Input (Bank 1 or Single Sensor) Camshaft Position Sensor "A" Circuit High P0343 Input (Bank 1 or Single Sensor) P0345 Camshaft Position Sensor "A"...
  • Page 393 ES–237 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference: Inspection using an oscilloscope VV1, VV2 and NE Signal Waveforms 5 V/DIV. 20 ms./DIV. A107148E09 HINT: • The correct waveform is as shown. • VV1+ and VV2+ stand for the VVT sensor signal, and NE+ stands for the CKP sensor signal.
  • Page 394 ES–238 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0340 (Engine running): Engine speed 600 rpm or more Starter P0345 (Engine running): Engine speed 600 rpm or more Battery voltage 8 V or more Starter Engine switch P0340 (Cranking): Starter Minimum battery voltage...
  • Page 395 ES–239 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0348 (High voltage): VVT sensor voltage More than 4.7 V COMPONENT OPERATING RANGE VVT sensor voltage 0.3 to 4.7 V WIRING DIAGRAM Refer to DTC P0335 (See page ES-224). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester.
  • Page 396 ES–240 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VVT SENSOR FOR INTAKE CAMSHAFT - ECM) (a) Disconnect the C41 or C45 VVT sensor connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the VVT Sensor table below.
  • Page 397 ES–241 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sensor plate teeth do not have any cracks or deformation. REPLACE CAMSHAFT TIMING GEAR ASSEMBLY REPLACE VVT SENSOR NEXT CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3.
  • Page 398 ES–242 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0351 Ignition Coil "A" Primary / Secondary Circuit P0352 Ignition Coil "B" Primary / Secondary Circuit P0353 Ignition Coil "C" Primary / Secondary Circuit P0354 Ignition Coil "D" Primary / Secondary Circuit P0355 Ignition Coil "E"...
  • Page 399 ES–243 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM From Battery Igniter No. 1 Ignition Coil IGT1 No. 1 Cylinder Crankshaft Position Sensor Spark Plug Ignition Coil No. 2 Ignition Coil IGT2 No. 2 Cylinder No. 3 Ignition Coil IGT3 Camshaft Position Sensor No.
  • Page 400 ES–244 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P0351 • Ignition system P0352 • Open or short in IGF1 or IGT circuit (1 to 6) P0353 No IGF signal to ECM while engine is running...
  • Page 401 ES–245 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION Ignition Coil Ignition Coil Igniter Ignition Signal (IGT) Normal Ignition Confirmation Malfunction Signal (IGF) Circuit Open Time A082388E07 If the ECM does not receive any IGF signals despite transmitting the IGT signal, it interprets this as a fault in the igniter and sets a DTC.
  • Page 402 ES–246 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C. Both of the following conditions are met: (a) Engine speed 500 rpm or less (b) Battery voltage 6 V or more D. All of the following conditions are met: (a) Engine speed...
  • Page 403 ES–247 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM IGT1 IGT1 C11 No. 1 Ignition Coil IGT3 IGT3 C12 No. 3 Ignition Coil IGT5 IGT5 C38 No. 5 Ignition Coil IGT2 IGT2 IGF1 C13 No. 2 Ignition Coil IGT4 IGT4 C14 No.
  • Page 404 ES–248 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IG2 Relay Ignition SW FL MAIN ST/AM2 *1: with Smart Key System Battery *2: without Smart Key System IG2D Main Body ECU A133855E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored.
  • Page 405 ES–249 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition Below 1 Ω C12-4 - Body ground Below 1 Ω C14-4 - Body ground Below 1 Ω C38-4 - Body ground Below 1 Ω C39-4 - Body ground...
  • Page 406 ES–250 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition IGF (C38-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher IGF (C39-2) or IGF1 (C55-106) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR...
  • Page 407 ES–251 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0365 Camshaft Position Sensor "B" Circuit (Bank 1) Camshaft Position Sensor "B" Circuit Low P0367 Input (Bank 1) Camshaft Position Sensor "B" Circuit High P0368 Input (Bank 1) P0390 Camshaft Position Sensor "B" Circuit (Bank 2) Camshaft Position Sensor "B"...
  • Page 408 ES–252 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference: Inspection using an oscilloscope EV1, EV2 and NE Signal Waveform 5 V/DIV. 20 ms./DIV. A140642E02 HINT: • The correct waveform is as shown. • EV1+ and EV2+ stand for the VVT sensor signal, and NE+ stands for the CKP sensor signal.
  • Page 409 ES–253 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Chattering, Low voltage, High voltage: Starter Engine switch Time after engine switch off to on 2 seconds or more Battery voltage 8 V or more P0365, P0390 (Engine running): Engine speed 600 rpm or more...
  • Page 410 ES–254 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (SENSOR POWER SOURCE) (a) Disconnect the C40 or C44 VVT sensor connector. Wire Harness Side: (b) Measure the voltage according to the value(s) in the table below. Standard voltage...
  • Page 411 ES–255 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VVT SENSOR FOR EXHAUST CAMSHAFT (SENSOR INSTALLATION) (a) Check the VVT sensor installation condition. Sensor is installed correctly. REPAIR OR REPLACE VVT SENSOR Clearance Normal Abnormal BR03795E18 CHECK EXHAUST CAMSHAFT (a) Check the teeth of the camshaft.
  • Page 412 ES–256 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM...
  • Page 413 ES–257 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Catalyst System Efficiency Below Threshold P0420 (Bank 1) Catalyst System Efficiency Below Threshold P0430 (Bank 2) MONITOR DESCRIPTION The ECM uses the sensors mounted in front of and behind the Three-Way Catalytic Converter (TWC) to monitor its efficiency.
  • Page 414 ES–258 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS P0011, 14 (VVT System 1 - Advance) P0012, 15 (VVT System 1 - Retard) P0031, 32, 51, 52 (A/F Sensor heater - Sensor 1) P0037, 38, 58, 59 (O2 Sensor heater - Sensor 2)
  • Page 415 ES–259 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Speed 3,000 rpm 2,000 rpm Idling Time Engine Switch Off Check Warming up At least 3 minutes 2 seconds A093766E21 1. Connect the intelligent tester to the DLC3 (Procedure "A"). 2. Start the engine and warm it up with all the accessories switched OFF, until the engine coolant temperature stabilizes (Procedure "B").
  • Page 416 ES–260 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Following the A/F CONTROL procedure enables technicians to check and graph the output voltages of both the A/F and HO2 sensors. • To display the graph, enter the following menus on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1 S1 and O2S B1 S2 or AFS B2 S1 and O2S B2 S2, and press the YES button and then the ENTER button followed by the F4 button.
  • Page 417 ES–261 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Tester Display Injection Volume Status Voltage (Sensor) AFS B1 S1 or AFS B2 S1 +25 % Rich Less than 3.0 V...
  • Page 418 ES–262 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AND REPLACE HEATED OXYGEN SENSOR, AND CHECK AND REPAIR EXHAUST GAS LEAKAGE CHECK FOR EXHAUST GAS LEAKAGE No gas leakage. REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT REPLACE THREE-WAY CATALYTIC CONVERTER...
  • Page 419 ES–263 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Evaporative Emission System Reference Ori- P043E fice Clog Up Evaporative Emission System Reference Ori- P043F fice High Flow Evaporative Emission System Leak Detection P2401 Pump Control Circuit Low Evaporative Emission System Leak Detection...
  • Page 420 ES–264 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence Operations Descriptions Duration Vent valve turned OFF (vent) and EVAP system pressure measured Atmospheric pressure by ECM in order to register atmospheric pressure. 10 seconds measurement If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor.
  • Page 421 ES–265 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure during EVAP key-off monitor ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve ON: Vent Pump EVAP Pressure (mmHg) Malfunction Sequence 10 seconds Within 15 minutes Time seconds seconds...
  • Page 422 ES–266 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are met before Conditions 1 and 2 key-off 1.
  • Page 423 ES–267 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure just after reference pressure More than -1 kPa (-7.5 mmHg) measurement start Reference pressure Less than -4.85 kPa (-36.384 mmHg) Reference pressure -1.057 kPa (-7.929 mmHg) or more Reference pressure...
  • Page 424 ES–268 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Evaporative Emission Control System Incorrect P0441 Purge Flow DTC SUMMARY Detection DTC No. Monitoring Item DTC Detection Condition Trouble Area Detection Timing Logic Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system •...
  • Page 425 ES–269 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM KEY-OFF MONITOR 5 hours* after the engine switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure.
  • Page 426 ES–270 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement VSV (for EVAP): OFF Canister Fuel tank OFF (vent) Vent Valve: OFF (vent) 0.02 Inch Pump Module Orifice Air Filter...
  • Page 427 ES–271 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) EVAP VSV stuck open In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The EVAP system pressure is then measured by the ECM using the pressure sensor.
  • Page 428 ES–272 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) EVAP VSV stuck closed In operation D, the pressure sensor measures the EVAP (Evaporative Emission) system pressure. The pressure measurement for EVAP VSV monitor is begun when the EVAP VSV is turned ON (open) after the EVAP leak check.
  • Page 429 ES–273 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM In order to ensure reliable malfunction detection, the variation between the atmospheric pressure, before and after conduction of the purge flow monitor, is measured by the ECM. OBD II MONITOR SPECIFICATIONS Key-off Monitor...
  • Page 430 ES–274 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP pressure change after purge VSV ON 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if all of following conditions are met: Conditions 1, 2, 3 and 4 1.
  • Page 431 ES–275 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Evaporative Emission Control System Pressure P0450 Sensor / Switch Evaporative Emission Control System Pressure P0451 Sensor Range / Performance Evaporative Emission Control System Pressure P0452 Sensor / Switch Low Input Evaporative Emission Control System Pressure...
  • Page 432 ES–276 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION 1. DTC P0450: Pressure sensor voltage abnormal fluctuation If the pressure sensor output voltage rapidly fluctuates between less than 0.45 V and more than 4.9 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP (Evaporative Emission) system monitor.
  • Page 433 ES–277 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Immediate: P0450, P0452, P0453 MIL Operation 2 driving cycles: P0451 Sequence of Operation None TYPICAL ENABLING CONDITIONS P0450, P0452 and P0453 (Pressure sensor chattering, low voltage, high voltage): Monitor runs whenever following DTCs are not present:...
  • Page 434 ES–278 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C6 VSV (Purge) N17 Pump Module VPMP Canister Closed Valve MPMP Vacuum Pump Canister VCPP Pressure Sensor PPMP EPPM EFI No. 3 EFI No. 2 EFI Relay EFI MAIN MREL...
  • Page 435 ES–279 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into a workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel tank cap.
  • Page 436 ES–280 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Air Inlet Port Fuel Tank Vent Hose Inspection Area* Vent Hose Vent Hose *: Check for disconnection and/or crack A132283E04 NEXT Go to step 5 CHECK HARNESS AND CONNECTOR (a) Disconnect the N17 canister pump module connector.
  • Page 437 ES–281 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ECM (a) Replace the ECM (See page ES-518). NEXT CHECK WHETHER DTC OUTPUT RECURS (AFTER REPAIR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) (do not start the engine).
  • Page 438 ES–282 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Evaporative Emission Control System Leak P0455 Detected (Gross Leak) Evaporative Emission Control System Leak P0456 Detected (Very Small Leak) DTC SUMMARY Malfunction Detection Detection DTC No. Monitoring Item Trouble Area Detection Timing...
  • Page 439 ES–283 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence Operation Description Duration In order to determine 0.02 inch leak pressure standard, First 0.02 inch leak pressure vacuum pump creates negative pressure (vacuum) 60 seconds measurement through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally.
  • Page 440 ES–284 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P0456: EVAP very small leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than the second 0.02 inch leak pressure standard, the ECM determines that the EVAP system has a small leak, illuminates the MIL and sets the DTC (2 trip detection logic).
  • Page 441 ES–285 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Time after key off 5, 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0451, P0452 and Not detected P0453) EVAP VSV Not operated by scan tool Vent valve Not operated by scan tool...
  • Page 442 ES–286 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0456: EVAP small leak EVAP pressure when vacuum introduction is complete Between reference pressure and reference pressure x 0.2 MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25).
  • Page 443 ES–287 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0500 Vehicle Speed Sensor "A" DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the ECM via the combination meter.
  • Page 444 ES–288 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine speed 2,000 to 5,000 rpm Engine load 30.37 % or more Fuel cut high engine speed Not executing Battery voltage 8 V or more Engine switch ETC sensor circuit fail Not detected...
  • Page 445 ES–289 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If the speedometer does not operate, check it by following the procedure described in speedometer malfunction. GO TO SPEEDOMETER CIRCUIT READ VALUE OF INTELLIGENT TESTER (VEHICLE SPEED) (a) Connect the intelligent tester to the DLC3.
  • Page 446 ES–290 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK COMBINATION METER ASSEMBLY (SPD SIGNAL WAVEFORM) (a) Shift the transmission gear selector lever to the neutral Wire Harness Side: position. (b) Jack up the vehicle. Combination Meter Connector (c) Turn the ignition switch on (IG).
  • Page 447 ES–291 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ECM (See page ES-518)
  • Page 448 ES–292 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0504 Brake Switch "A" / "B" Correlation P0724 Brake Switch "B" Circuit High DESCRIPTION The stop light switch is a duplex system that transmits two signals: STP and ST1-. These two signals are used by the ECM to monitor whether or not the brake system is working properly.
  • Page 449 ES–293 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM Main Body ECU IG2D A19 Stop Light SW IG2 Relay ST1- STOP Ignition SW ST/AM2 5 AM2...
  • Page 450 ES–294 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK STOP LIGHT (OPERATION OF STOP LIGHT) (a) Check whether the stop lights turn on and off normally when the brake pedal is depressed and released. Stop lights turn ON when brake pedal is depressed.
  • Page 451 ES–295 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE STOP LIGHT SWITCH ASSEMBLY (See page LI-125) CHECK ECM (STP, ST1 - VOLTAGE) (a) Disconnect the A55 ECM connector. Brake Pedal Brake Pedal (b) Measure the voltage according to the value(s) in the...
  • Page 452 ES–296 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0505 Idle Control System Malfunction DESCRIPTION The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is comprised of: 1) one valve type throttle body; 2) the throttle actuator, which operates the throttle valve; 3) the throttle position sensor, which detects the opening angle of the throttle valve;...
  • Page 453 ES–297 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P0505: ISC function Required Sensors/Components (Main) ETCS Crankshaft position sensor, Engine coolant temperature sensor, and Required Sensors/Components (Sub) Vehicle speed sensor Frequency of Operation Continuous Duration 10 minutes...
  • Page 454 ES–298 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC output) Proceed to P0505 and other DTCs HINT: If any DTCs other than P0505 are output, troubleshoot those DTCs first. GO TO DTC CHART (See page ES-63) CHECK PCV HOSE (HOSE CONNECTIONS) PCV hose is connected correctly and is not damaged.
  • Page 455 ES–299 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P050A Cold Start Idle Air Control System Performance P050B Cold Start Ignition Timing Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed.
  • Page 456 ES–300 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM The ECM monitors the intake air amount during idling and the ignition timing. When the Engine Coolant Temperature (ECT) is between -10°C and 50°C (14°F and 122°F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts.
  • Page 457 ES–301 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P050A: Accumulated mass air flow Varies with ECT (Example: Less than 42.5 g) P050B: Accumulated time when ignition timing retard is cut off 5 seconds or more INSPECTION PROCEDURE HINT: Read freeze frame data using an intelligent tester.
  • Page 458 ES–302 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Total of SHORT FT #1 and LONG FT #1 values is between -20 % and 20 %. Go to step 12 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE OCV) (a) Connect the intelligent tester to the DLC3.
  • Page 459 ES–303 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Go to step 11 REPLACE MASS AIR FLOW METER NEXT Go to step 15 CHECK AND REPAIR VVT SYSTEM NEXT Go to step 15 REPAIR OR REPLACE PCV HOSE NEXT Go to step 15...
  • Page 460 ES–304 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK WHETHER DTC OUTPUT RECURS (DTC P050A AND/OR P050B) NOTICE: In this operation, the engine must be cold (the same level as the engine coolant temperature recorded in the freeze frame data).
  • Page 461 ES–305 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0560 System Voltage DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is off. This power allows the ECM to store data such as DTC history, freeze frame data and fuel trim values. If the battery voltage falls below a minimum level, these memories are cleared and the ECM determines that there is a malfunction in the power supply circuit.
  • Page 462 ES–306 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM EFI No. 1 BATT FL MAIN Battery A122745E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data...
  • Page 463 ES–307 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (EFI NO. 1) (a) Remove the EFI No. 1 fuse from the engine room R/B. (b) Measure the EFI No. 1 fuse resistance. Engine Room Standard resistance: Relay Block Below 1 Ω...
  • Page 464 ES–308 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Check the harness and connector between the EFI No. 1 fuse and ECM. (1) Remove the EFI No. 1 fuse from the engine room R/ (2) Disconnect the A55 ECM connector.
  • Page 465 ES–309 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. Battery terminals are not loose or corroded. REPAIR OR REPLACE BATTERY TERMINAL CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3.
  • Page 466 ES–310 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Internal Control Module Random Access Mem- P0604 ory (RAM) Error P0606 ECM / PCM Processor P0607 Control Module Performance P0657 Actuator Supply Voltage Circuit / Open DESCRIPTION The ECM continuously monitors its internal memory status, internal circuits, and output signals sent to the throttle actuator.
  • Page 467 ES–311 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM CPU malfunction (P0607): Either A or B is met A. Following conditions are met: CPU reset 1 time or more Learned TP - learned APP 0.4 V or more Throttle actuator B.
  • Page 468 ES–312 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0617 Starter Relay Circuit High DESCRIPTION While the engine is being cranked, the positive battery voltage is applied to terminal STA of the ECM. If the ECM detects the Starter Control (STA) signal while the vehicle is being driven, it determines that there is a malfunction in the STA circuit.
  • Page 469 ES–313 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM With Smart Key System: Main Body ECU STSW A55 STSW ACCR A55 ACCR STR2 ST CUT C55 STAR IG2D C55 NSW Park / Neutral Position SW ST/AM2 Starter FL MAIN...
  • Page 470 ES–314 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Without Smart Key System: Ignition Switch C55 NSW ST/AM2 Park / Neutral Position SW Starter FL MAIN Battery A133859E02 INSPECTION PROCEDURE HINT: • The following troubleshooting flowchart is based on the premise that the engine is cranked normally. If the engine does not crank, proceed to the problem symptoms table (See page ES-33).
  • Page 471 ES–315 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (d) Check the value displayed on the tester when the ignition switch is turned on (IG) and the engine is started.
  • Page 472 ES–316 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT IGNITION SWITCH ASSEMBLY (a) Disconnect the E23 ignition switch connector. (b) Measure the resistance according to the value(s) in the Component Side: table below. Standard resistance Switch Condition Tester Connection Specified Condition...
  • Page 473 ES–317 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0630 VIN not Programmed or Mismatch - ECM / PCM DESCRIPTION DTC P0630 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control Module (ECM) or the input VIN is not accurate. Input the VIN with the intelligent tester.
  • Page 474 ES–318 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: If P0630 is set, the VIN must be input to the ECM using the intelligent tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630 are set, check them first.
  • Page 475 ES–319 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Transmission Range Sensor Circuit Malfunc- P0705 tion (PRNDL Input) DESCRIPTION The park / neutral position switch detects the shift lever position and sends signals to the ECM. DTC No. DTC Detection Condition...
  • Page 476 ES–320 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Neutral position switch (d) R range position switch TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition (A), (B) and (C) Condition (A): Number of the following signal input at the same time...
  • Page 477 ES–321 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Park/Neutral Position Switch To GAUGE No. 1 Fuse To ST Relay Transmission Control Switch To ECU IG No. 2 Fuse A140667E01 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal.
  • Page 478 ES–322 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM According to the display on the tester, read the "DATA LIST". Measurement Item / Range Item Normal Condition Diagnostic Note (Display) When the shift lever position Shift lever position is; displayed on the intelligent tester...
  • Page 479 ES–323 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - BODY GROUND) (a) Disconnect the C1 park/neutral position switch Wire Harness Side: connector. (b) Measure the resistance between the terminals. Standard resistance Park / Neutral Position SW...
  • Page 480 ES–324 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Connect the park / neutral position switch connector. Wire Harness Side: (b) Disconnect the ECM connectors. (c) Turn the ignition switch on (IG), and measure the voltage...
  • Page 481 ES–325 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Disconnect the transmission control switch connector of the shift lock control unit assembly. Wire Harness Side: (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals.
  • Page 482 ES–326 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Connect the transmission control switch connector of the Wire Harness Side: shift lock control unit assembly. (b) Turn the ignition switch on (IG), and measure the voltage...
  • Page 483 ES–327 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PARK / NEUTRAL POSITION SWITCH - ECM) (a) Disconnect the ECM connectors. Wire Harness Side: (b) Turn the ignition switch off. (c) Measure the resistance according to the value(s) in the table below.
  • Page 484 ES–328 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2102 Throttle Actuator Control Motor Circuit Low P2103 Throttle Actuator Control Motor Circuit High SYSTEM DESCRIPTION The throttle actuator is operated by the ECM and opens and closes the throttle valve using the gears.
  • Page 485 ES–329 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2102: Throttle motor Duty-cycle ratio to open throttle actuator 80 % or more Throttle actuator power supply 8 V or more Current motor current - Motor current at 0.016 sec. before Less than 0.2 A...
  • Page 486 ES–330 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Shielded Throttle Actuator Throttle Actuator Control Circuit C55 GE01 A133860E01 INSPECTION PROCEDURE HINT: • Read freeze frame data using an intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame...
  • Page 487 ES–331 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (THROTTLE CONTROL MOTOR - ECM) (a) Disconnect the C5 throttle body connector. Wire Harness Side Front View: (b) Disconnect the C55 ECM connector. (c) Measure the resistance according to the value(s) in the table below.
  • Page 488 ES–332 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2111 Throttle Actuator Control System - Stuck Open Throttle Actuator Control System - Stuck P2112 Closed SYSTEM DESCRIPTION The throttle actuator is operated by the ECM, and opens and closes the throttle valve using the gears.
  • Page 489 ES–333 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM *System guard set when following conditions are met: Throttle actuator Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more...
  • Page 490 ES–334 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM GO TO DTC CHART (See page ES-63) INSPECT THROTTLE BODY (VISUALLY CHECK THROTTLE VALVE) (a) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly.
  • Page 491 ES–335 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle Actuator Control Motor Current Range P2118 / Performance DESCRIPTION The ETCS (Electronic Throttle Control System) has a dedicated power supply circuit. When the monitored voltage (+BM) is low (less than 4 V), the ECM determines that there is a malfunction in the ETCS and cuts off the current to the throttle actuator.
  • Page 492 ES–336 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None Battery voltage 8 V or more Throttle actuator power TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage (+BM)
  • Page 493 ES–337 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data...
  • Page 494 ES–338 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - ETCS FUSE, ETCS FUSE - BATTERY) (a) Check the harness and connector between the ETCS fuse and ECM. Engine Room Junction Block (1) Remove the ETCS fuse from the engine room R/B.
  • Page 495 ES–339 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle Actuator Control Throttle Body Range / P2119 Performance SYSTEM DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of the throttle actuator, Throttle Position (TP) sensor, Accelerator Pedal Position (APP) sensor, and ECM. The ECM operates the throttle actuator to regulate the throttle valve in response to driver inputs.
  • Page 496 ES–340 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE When this DTC, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6°...
  • Page 497 ES–341 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Securely apply the parking brake and move the gear selector lever to the D position (Procedure "A"). (g) While depressing the brake pedal securely, fully depress the accelerator pedal for 5 seconds (Procedure "B").
  • Page 498 ES–342 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle / Pedal Position Sensor / Switch "D" P2120 Circuit Throttle / Pedal Position Sensor / Switch "D" P2122 Circuit Low Input Throttle / Pedal Position Sensor / Switch "D" P2123 Circuit High Input Throttle / Pedal Position Sensor / Switch "E"...
  • Page 499 ES–343 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Accelerator Pedal Position Sensor Output Voltage (V) Accelerator Pedal Position Sensor Magnet 3.4 to 5.0 2.6 to 4.5 IC No. 1 VCPA VPA2 EPA2 Usable Range VCP2 IC No. 2 Accelerator Pedal Turning Angle (deg)
  • Page 500 ES–344 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area Condition (a) or (b) continues for 2.0 seconds or more • Short between VPA and VPA2 circuits (1 trip detection logic): P2138 • APP sensor (a) Difference between VPA and VPA2 is 0.02 V or less...
  • Page 501 ES–345 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P2120: One of the following conditions is met: VPA voltage when VPA2 is 0.04 V or more 0.4 V or less...
  • Page 502 ES–346 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Accelerator Pedal Position Sensor VCPA VCPA VPA2 VPA2 EPA2 EPA2 VCP2 VCP2 A105237E15 INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored.
  • Page 503 ES–347 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) Disconnect the A17 Accelerator Pedal Position (APP) Wire Harness Side Front View: sensor connector. (b) Disconnect the A55 ECM connector. APP Sensor Connector (c) Measure the resistance according to the value(s) in the table below.
  • Page 504 ES–348 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ACCELERATOR PEDAL ROD ASSEMBLY NEXT CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on.
  • Page 505 ES–349 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle / Pedal Position Sensor / Switch "D" P2121 Circuit Range / Performance DESCRIPTION This ETCS (Electronic Throttle Control System) does not use a throttle cable. The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal bracket and has 2 sensor circuits: VPA (main) and VPA2 (sub).
  • Page 506 ES–350 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal position sensor has 2 sensor elements and 2 signal outputs: VPA and VPA2. VPA is used to detect the actual accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA.
  • Page 507 ES–351 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on.
  • Page 508 ES–352 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ACCELERATOR PEDAL ROD ASSEMBLY NEXT CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on.
  • Page 509 ES–353 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 P2195 Sensor 1) Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 P2196 Sensor 1) Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 P2197 Sensor 1)
  • Page 510 ES–354 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Cover Platinum electrode Rich - Air Fuel Ratio - Lean Exhaust Gas A-A Section A107164E14 DTC No. DTC Detection Condition Trouble Area •...
  • Page 511 ES–355 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If a A/F sensor malfunction is detected, the ECM sets a DTC. MONITOR DESCRIPTION Sensor voltage detection monitor Under the air-fuel ratio feedback control, if the A/F sensor output voltage indicates rich or lean for a certain period of time, the ECM determines that there is a malfunction in the A/F sensor.
  • Page 512 ES–356 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) HO2 sensor Frequency of Operation Continuous Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Sensor voltage detection monitor (Lean side malfunction P2195, P2197):...
  • Page 513 ES–357 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sensor current detection monitor (High and low side malfunction P2195, P2196, P2197 and P2198): P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (HO2 sensor heater - Sensor 2)
  • Page 514 ES–358 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C15 Air Fuel Ratio Sensor HA1A HA1A A1A- A1A+ A1A+ A1A- C35 Air Fuel Ratio Sensor HA2A HA2A A2A- A2A+ A2A+ A2A- EFI MAIN MREL FL MAIN *: Shielded Battery...
  • Page 515 ES–359 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor Driving Pattern ECT: 75°C (167°F) or more Accelerator Pedal Accelerator Pedal Between 38 and 75 mph At least 3 times Depressed Released (Fuel-cut) Vehicle Speed (60 and 120 km/h) 40 mph (64 km/h)
  • Page 516 ES–360 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9. Drive the vehicle at a proper vehicle speed to perform fuel-cut operation (refer to the following HINT ) (Procedure "D"). HINT: Fuel-cut is performed when the following conditions are met: • Accelerator pedal is fully released.
  • Page 517 ES–361 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) HO2 Sensor (Sensor 2) Main Suspected Case Output Voltage Output Voltage Trouble Areas Injection Volume Injection Volume +25 % +25 % -12.5 % -12.5 % Output Voltage Output Voltage More than 3.35 V...
  • Page 518 ES–362 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2195, P2196, P2197, or P2198 P2195, P2196, P2197, or P2198 and other DTCs HINT: If any DTCs other than P2195, P2196, P2197 or P2198 are output, troubleshoot those DTCs first.
  • Page 519 ES–363 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Warm up the Air-Fuel Ratio (A/F) sensor at an engine speed of 2,500 rpm for 90 seconds. (e) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA / AFS B1 S1 or AFS B2 S1 and ENGINE SPD.
  • Page 520 ES–364 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • The ECM stops fuel injection (fuel cut) during engine deceleration. This causes a lean condition and results in a momentary increase in the A/F sensor output voltage. • The ECM must establish a closed throttle valve position learning value to perform fuel cut.
  • Page 521 ES–365 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM CONFIRMATION DRIVING PATTERN NEXT CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
  • Page 522 ES–366 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. Component Side: (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 1)
  • Page 523 ES–367 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (A/F RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the A/F relay. (1) Measure the A/F relay resistance. Engine Room Junction Block...
  • Page 524 ES–368 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 and C35 A/F sensor connectors. Wire Harness Side: (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below.
  • Page 525 ES–369 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Relay A/F Sensor Heater HA1A HA1A From Battery Sensor A1A- A1A+ A1A+ Duty Control From A1A- Relay A133850E06 REPAIR OR REPLACE HARNESS OR...
  • Page 526 ES–370 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM CONFIRMATION DRIVING PATTERN NEXT CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read the DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
  • Page 527 ES–371 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to No output P2195, P2196, P2197 or P2198 (A/F sensor pending DTCs) REPLACE ECM (See page ES-518)
  • Page 528 ES–372 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Oxygen (A/F) Sensor Pumping Current Circuit P2238 Low (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit P2239 High (Bank 1 Sensor 1) Oxygen (A/F) Sensor Pumping Current Circuit P2241 Low (Bank 2 Sensor 1)
  • Page 529 ES–373 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Cover Platinum electrode Rich - Air Fuel Ratio - Lean Exhaust Gas A-A Section A107164E14 DTC No. DTC Detection Condition Trouble Area •...
  • Page 530 ES–374 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The Air-Fuel Ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. If the A/F sensor impedance (alternating current resistance) or output voltage deviates greatly from the standard range, the ECM determines that there is an open or short malfunction in the A/F sensor circuit.
  • Page 531 ES–375 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P2238 and P2241 (Open circuit between AF+ and AF-): A/F sensor admittance Below 0.022 1/Ω P2238 and P2241 (Short circuit between AF+ and GND): AF+ terminal voltage 0.5 V or less...
  • Page 532 ES–376 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. A/F Sensor (Sensor 1)
  • Page 533 ES–377 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector. Component Side: (b) Measure the resistance according to the value(s) in the table below. Standard resistance (Bank 1 sensor 1)
  • Page 534 ES–378 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (A/F RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Inspect the A/F relay. (1) Measure the A/F relay resistance. Engine Room Junction Block...
  • Page 535 ES–379 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 and C35 A/F sensor connectors. Wire Harness Side: (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below.
  • Page 536 ES–380 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Relay A/F Sensor Heater HA1A HA1A From Battery Sensor A1A- A1A+ A1A+ Duty Control From A1A- Relay A133850E02 REPAIR OR REPLACE HARNESS OR...
  • Page 537 ES–381 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Evaporative Emission System Switching Valve P2420 Control Circuit High DTC SUMMARY Detection DTC No. Monitoring Item DTC Detection Condition Trouble Area Detection Timing Logic • Pump module (0.02 inch The following condition is met...
  • Page 538 ES–382 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: Vent Valve: OFF (vent) (vent) 0.02 Inch Orifice Pressure Sensor Air Filter Vacuum Pump: OFF...
  • Page 539 ES–383 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTC P2420: Vent valve stuck open (vent) Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes MIL Operation 2 driving cycles...
  • Page 540 ES–384 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6. Second reference pressure measurement Next sequence is run if the following conditions are met Conditions 1, 2, 3 and 4 1. EVAP pressure just after reference pressure -1 kPa (-7.5 mmHg) or less 2.
  • Page 541 ES–385 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM / PCM Internal Engine Off Timer Perfor- P2610 mance DTC SUMMARY Detection DTC No. Monitoring Item DTC Detection Condition Trouble Area Detection Timing Logic Soak timer (built P2610 ECM internal malfunction...
  • Page 542 ES–386 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Case 1: Engine switch Engine Running Battery voltage 8 V or more Starter Case 2: Internal engine OFF timer (elapsed time from engine stop)
  • Page 543 ES–387 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on. (c) Clear the DTCs (See page ES-45). (d) Start the engine and wait for 10 minutes or more.
  • Page 544 ES–388 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor Circuit Slow Response (Bank 1 P2A00 Sensor 1) A/F Sensor Circuit Slow Response (Bank 2 P2A03 Sensor 1) DESCRIPTION HINT: • DTC P2A00 indicates malfunctions related to the bank 1 A/F sensor.
  • Page 545 ES–389 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air-Fuel Mixture Output Voltage Heater Solid electrolyte (Zirconia Element) Element Cover Platinum electrode Rich - Air Fuel Ratio - Lean Exhaust Gas A-A Section A107164E13 DTC No. DTC Detection Conditions Trouble Area •...
  • Page 546 ES–390 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Air-fuel Ratio Sensor Output: Approximately 10 seconds Active A/F Ratio Control Normal Malfunction A/F Sensor Output Increase Fuel Injection Volume Decrease G034991E09 CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the A/F sensor response monitor.
  • Page 547 ES–391 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. Turn the ignition switch on (IG). 3. Turn the tester on. 4. Clear the DTCs (where set). 5. Select the following menu items: DIAGNOSIS /ENHANCED OBD II / MONITOR INFO / MONITOR RESULT.
  • Page 548 ES–392 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level Less than 0.18 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-25). WIRING DIAGRAM Refer to DTC P2195 (See page ES-350). INSPECTION PROCEDURE...
  • Page 549 ES–393 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) HO2 Sensor (Sensor 2) Main Suspected Case Output Voltage Output Voltage Trouble Area Injection Volume Injection Volume +25 % +25 % -12.5 % -12.5 % • A/F sensor •...
  • Page 550 ES–394 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If any DTCs other than P2A00 or P2A03 are output, troubleshoot those DTCs first. GO TO DTC CHART (See page ES-63) INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the C15 or C35 A/F sensor connector.
  • Page 551 ES–395 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the C15 and C35 A/F sensor connectors. Wire Harness Side: (b) Turn the ignition switch on (IG). (c) Measure the voltage according to the value(s) in the table below.
  • Page 552 ES–396 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2A00 and/or P2A03 No output REPLACE ECM (See page ES-518) REPLACE AIR FUEL RATIO SENSOR (a) Replace the air fuel ratio sensor (See page EC-19). NEXT...
  • Page 553 ES–397 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM U0101 Lost Communication with TCM DESCRIPTION The Transmission Control Module (TCM) and ECM perform 2-way communications with each other via the Controller Area Network (CAN). The TCM sends signals to the ECM concerning required engine rpm, required engine torques, warning indicators in the combination meter, DTCs and other data.
  • Page 554 ES–398 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC U0101) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG). (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
  • Page 555 ES–399 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Disconnect the C56 TCM connector. Wire Harness Side: (b) Disconnect the C55 ECM connector. (c) Measure the resistance of the wire harness side ECM Connector (Front View) connectors.
  • Page 556 ES–400 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE TCM...
  • Page 557 ES–401 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Active Control Engine Mount System DESCRIPTION LOCATION Hose B Hose A Vacuum Switching Valve Engine Mounting Insulator Engine Room R/B: EFI No. 3 Fuse A136282E01 The Active Control Engine Mount (ACM) system decreases engine vibration at a low engine speed using the ACM VSV.
  • Page 558 ES–402 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM EFI No. 3 ACM VSV EFI MAIN MREL FL MAIN Battery A137040E01 INSPECTION PROCEDURE CHECK VACUUM HOSES (a) If the hose is damaged, replace the vacuum hose Intake Air Control assembly.
  • Page 559 ES–403 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VACUUM (a) Start the engine. (b) Disconnect the vacuum hose from the air cleaner cap. (c) Check that the disconnected port located on the vacuum tank applies suction to your finger.
  • Page 560 ES–404 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE MOUNTING INSULATOR ASSEMBLY FRONT (a) Disconnect the vacuum hose from the front engine mount insulator. (b) Using a vacuum pump, apply vacuum of 80 kPa (600 mmHg, 25 in.Hg) and wait for 1 minute.
  • Page 561 ES–405 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT DUTY VACUUM SWITCHING VALVE (VOLTAGE) (a) Disconnect the C34 VSV connector. Wire Harness Side: (b) Turn the ignition switch on (IG). (c) Measure the voltage between the terminals. Standard voltage Tester Connection...
  • Page 562 ES–406 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VSV FOR ACM - ENGINE JUNCTION BLOCK (EFI RELAY)) (a) Check the wire harness between the VSV for ACM and the EFI relay. Wire Harness Side: (1) Disconnect the C34 VSV connector.
  • Page 563 ES–407 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY) (a) Remove the engine room junction block. (b) Measure the EFI relay resistance. Standard resistance Engine Room Junction Block Tester Connection Specified Condition 1E-12 - 1E-6 10 kΩ...
  • Page 564 ES–408 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP System RELATED DTCS DTCs Monitoring Items See page P043E Reference orifice clogged (built into canister pump module) ES-255 P043F Reference orifice high-flow (built into canister pump module) • Purge VSV (Vacuum Switching Valve) stuck closed P0441 •...
  • Page 565 ES–409 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs P043E P2401 P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2419 P2420 Malfunctioning Areas P043F P2402 Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed Canister pressure sensor fixed...
  • Page 566 ES–410 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION Location of EVAP (Evaporative Emission) System: Purge VSV (Vacuum EVAP Hose (To Switching Valve) Throttle Body) Fuel Tank Air Inlet Refueling Valve Port Canister To Purge VSV EVAP Pump Module Hose (From Canister)
  • Page 567 ES–411 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM The following two monitors run to confirm the appropriate EVAP system operation. Key-off monitor This monitor checks for EVAP (Evaporative Emission) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned off. At least 5 hours are required for the fuel to cool down to stabilize the EVAP pressure, thus making the EVAP system monitor more accurate.
  • Page 568 ES–412 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Components Operations Canister Contains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100 % full. Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order Purge VSV (Vacuum to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV.
  • Page 569 ES–413 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification (fig. 2): Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V Pressure kPa-a (450) (825) (mmHg-a) HINT: Standard atmospheric pressure is 101.3 kPa-a (760 mmHg-a) A115543E06 Soak Timer Circuit (fig.
  • Page 570 ES–414 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Pump Module Leak Detection Pump MGND MTRB A55 MPMP VCPP Canister Pressure Sensor VOUT PPNP EPPM SGND Vent Valve VLVB VGND VPMP Purge VSV EFI No. 2 EFI No. 3...
  • Page 571 ES–415 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See page ES-45).
  • Page 572 ES–416 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs P043E P2401 P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2419 P2420 Malfunctioning Areas P043F P2402 Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed Canister pressure sensor fixed...
  • Page 573 ES–417 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the EVAP SYSTEM CHECK is completed, check...
  • Page 574 ES–418 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
  • Page 575 ES–419 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Leak Detection Pump EVAP Pressure Positive Negative Leak Detection Pump Stuck ON...
  • Page 576 ES–420 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 2/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Leak Detection Pump Leak Detection Pump Stuck OFF EVAP Pressure Reference Orifice High-flow 4 seconds...
  • Page 577 ES–421 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Go to step 11 Go to step 29 Go to step 20 PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent...
  • Page 578 ES–422 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Go to step 29 PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Leak Detection Pump EVAP Pressure Positive Negative First Reference Pressure...
  • Page 579 ES–423 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 4/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Leak Detection Pump EVAP Pressure Positive Negative Purge VSV Stuck Closed First Reference Pressure...
  • Page 580 ES–424 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 5/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Leak Detection Pump EVAP Pressure Gross Leak Positive Negative Small Leak [Second Reference Pressure] x 0.2...
  • Page 581 ES–425 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON: Open Purge VSV OFF: Closed ON: Closed Vent Valve OFF: Vent Leak Detection Pump Leak Detection Pump EVAP Pressure Stuck OFF Positive Negative Reference Orifice...
  • Page 582 ES–426 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM ACTIVE TEST USING INTELLIGENT TESTER (PURGE VSV) (a) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV (ALONE). (b) Disconnect the hose (connected to the canister) from the purge VSV.
  • Page 583 ES–427 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test Results Suspected Trouble Areas Proceed to • Fuel cap improperly installed Fuel cap loose • Defective fuel cap • Fuel cap does not meet OEM specifications Defective fuel cap No fuel cap (c) Reinstall the fuel cap.
  • Page 584 ES–428 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas Proceed to EVAP hose between purge VSV and intake manifold Suction applied normal • Intake manifold port No suction • EVAP hose between purge VSV and intake manifold (d) Reconnect the hose.
  • Page 585 ES–429 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Reconnect the purge VSV connector. Go to step 31 CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the C55 ECM connector and the C6 purge Wire Harness Side: VSV connector.
  • Page 586 ES–430 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE) (a) Turn the ignition switch off. (b) Disconnect the N17 canister pump module connector. (c) Turn the ignition switch on (IG). (d) Measure the voltage between the VLVB terminal of the canister pump module connector and body ground.
  • Page 587 ES–431 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) (a) Turn the ignition switch off. Charcoal Canister Assembly: (b) Disconnect the N17 canister pump module connector. (c) Apply battery voltage to the VLVB and VGND terminals VGND (-) of the canister pump module.
  • Page 588 ES–432 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Reconnect the ECM connector. (e) Reconnect the canister pump module connector. Go to step 34 Go to step 31 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (VACUUM PUMP (ALONE)) (a) Turn the ignition switch off.
  • Page 589 ES–433 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND) (a) Turn the ignition switch off. (b) Disconnect the N17 canister pump module connector. (c) Measure the resistance between the MGND terminal of the canister pump module connector and body ground.
  • Page 590 ES–434 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) (a) Turn the ignition switch off. Wire Harness Side: (b) Disconnect the N17 canister pump module connector. (c) Disconnect the C55 ECM connector.
  • Page 591 ES–435 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CORRECTLY REINSTALL OR REPLACE FUEL CAP HINT: • When reinstalling the fuel cap, tighten it until a few click sounds are heard. • When replacing the fuel cap, use a fuel cap that meets OEM specifications, and install it until a few click sounds are heard.
  • Page 592 ES–436 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg). (d) Apply soapy water to the piping and connecting parts of the EVAP system. (e) Look for areas where bubbles appear. This indicates the leak point.
  • Page 593 ES–437 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NEXT Go to step 36 REPLACE DUTY VACUUM SWITCHING VALVE (PURGE VSV) (a) Disconnect the connector and the hoses from the purge VSV. (b) Remove the purge VSV (See page EC-13). (c) Install a new purge VSV (See page EC-14).
  • Page 594 ES–438 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of 5 steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes.
  • Page 595 ES–439 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Monitor Status 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the tester on. 3. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS.
  • Page 596 ES–440 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Power Source Circuit DESCRIPTION When the ignition switch is turned on (IG), the battery voltage is applied to terminal IGSW of the ECM. The ECM MREL output signal causes a current to flow to the coil, closing the contacts of the EFI MAIN relay and supplying power to terminal +B of the ECM.
  • Page 597 ES–441 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Main Body ECU MREL IG2D EFI No. 3 EFI MAIN IGSW E23 Ignition SW ST/AM2 MAIN Battery A134882E01...
  • Page 598 ES–442 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the C55 ECM connector. Wire Harness Side: (b) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition Below 1 Ω...
  • Page 599 ES–443 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT EFI MAIN FUSE (a) Remove the EFI MAIN fuse from the engine room R/B. (b) Measure the EFI MAIN fuse resistance. Engine Room Standard resistance: Relay Block Below 1 Ω (c) Reinstall the EFI MAIN fuse.
  • Page 600 ES–444 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM JUNCTION BLOCK (EFI RELAY) (a) Remove the engine room junction block from the engine room R/B. (b) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 1E-6 - 1E-12 10 kΩ...
  • Page 601 ES–445 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT EFI NO. 2 FUSE (a) Remove the EFI No. 2 fuse from the engine room R/B. (b) Measure the EFI No. 2 fuse resistance. Engine Room Standard resistance: R/B: Below 1 Ω...
  • Page 602 ES–446 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - ENGINE ROOM JUNCTION BLOCK) (a) Disconnect the A55 ECM connector. Wire Harness Side: (b) Remove the engine room junction block from the engine room R/B. (c) Measure the resistance between the terminals.
  • Page 603 ES–447 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the A55 ECM connector. Wire Harness Side: (b) Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition A55 ECM Connector IGSW (A55-28) - Body ground 9 to 14 V (c) Reconnect the ECM connector.
  • Page 604 ES–448 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (IG2 RELAY - BODY GROUND) (a) Remove the IG2 relay from the engine room R/B. Wire Harness Side: (b) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition Below 1 Ω...
  • Page 605 ES–449 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the A55 ECM connector. (b) Measure the resistance between the terminals. Wire Harness Side: Standard resistance Tester Connection Specified Condition ECM Connector Below 1 Ω...
  • Page 606 ES–450 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VC Output Circuit DESCRIPTION The ECM constantly uses 5 V from the battery voltages supplied to the +B (BATT) terminal to operate the microprocessor. The ECM also provides this power to the sensors through the VC output circuit.
  • Page 607 ES–451 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM VCTA Throttle Position Sensor VTA1 VTA2 VTA2 VCPA Accelerator Pedal VCPA Position Sensor VCP2 VCP2 VPA2 VPA2 EPA2 EPA2 VCPP Canister Pressure Sensor (bulit into Canister VOUT PPMP Pump Module)
  • Page 608 ES–452 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VCV1 C41 VVT Sensor (for Intake Camshaft (bank 1)) VV1+ VVR+ VVR- VV1- VCE1 C40 VVT Sensor (for Exhaust Camshaft (bank 1)) EV1+ EV1- VCE2 C44 VVT Sensor (for Exhaust Camshaft (bank 2))
  • Page 609 ES–453 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM GO TO MIL CIRCUIT (See page ES-471) CHECK CONNECTION BETWEEN INTELLIGENT TESTER AND ECM (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and tester on.
  • Page 610 ES–454 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VVT SENSOR FOR INTAKE CAMSHAFT BANK 1 (CHECK MIL ILLUMINATED) (a) Disconnect the VVT sensor for intake camshaft bank 1 connector. (b) Turn the ignition switch on (IG). (c) Check the MIL.
  • Page 611 ES–455 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE VVT SENSOR FOR INTAKE CAMSHAFT BANK 2 (See page ES-489) CHECK VVT SENSOR FOR EXHAUST CAMSHAFT BANK 2 (CHECK MIL ILLUMINATED) (a) Disconnect the VVT sensor for exhaust camshaft bank 2 connector.
  • Page 612 ES–456 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (a) Disconnect the throttle body connector. Wire Harness Side: (b) Disconnect the accelerator pedal position sensor connector. (c) Disconnect the VVT sensor for intake camshaft bank 1 ECM Connector connector.
  • Page 613 ES–457 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fuel Pump Control Circuit DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST1 (STR) of the ignition switch (power source control ECU) to the starter relay (Marking: ST) coil and also current flows to terminal STA of ECM (STA signal).
  • Page 614 ES–458 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C/OPN Fuel Pump EFI MAIN MREL Main Body ECU Ignition Switch IG2D ST/AM2 Park / Neutral position Switch FL MAIN To Starter NE Signal *1: with Smart Key System Battery *2: without Smart Key System...
  • Page 615 ES–459 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Main Body ECU MREL C/OPN IG2D EFI MAIN E23 Ignition SW ST/AM2 IG2 6 FL MAIN N10 Fuel Pump Battery *1: with Smart Key System *2: without Smart Key System...
  • Page 616 ES–460 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (d) Check whether the fuel pump operation sound occurs when performing the Active Test on the tester.
  • Page 617 ES–461 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (FC VOLTAGE) (a) Disconnect the A55 and C55 ECM connectors. Wire Harness Side: (b) Measure the voltage between the terminals of the A24 and C24 ECM connectors. Standard voltage Tester Connection...
  • Page 618 ES–462 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (C/OPN RELAY - FUEL PUMP - BODY GROUND) (a) Check the harness and the connectors between the engine room relay block and the fuel pump. Wire Harness Side: (1) Disconnect the integration relay connector.
  • Page 619 ES–463 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Cranking Holding Function Circuit DESCRIPTION The cranking holding control system provides current to the starter when the ECM detects the engine switch's start signal (STSW). When the ECM performs a firing judgment, the system cuts current to the starter.
  • Page 620 ES–464 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE CHECK CRANKING (a) When starting the engine, check whether the starter motor starts. CHECK FOR INTERMITTENT PROBLEMS READ VALUE OF INTELLIGENT TESTER (STA SIGNAL) (a) Connect the intelligent tester to the DLC3.
  • Page 621 ES–465 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (STAR VOLTAGE) (a) Remove the ST CUT relay from the engine room R/B. Wire Harness Side: (b) Measure the voltage between the terminals of the engine room R/B and body ground while cranking the engine.
  • Page 622 ES–466 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT PARK/NEUTRAL SWITCH ASSEMBLY (a) Inspect the Park / Neutral Position (PNP) switch. Component Side: (1) Disconnect the C1 switch connector. (2) Measure the resistance according to the value(s) in the table below.
  • Page 623 ES–467 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PARK / NEUTRAL POSITION SWITCH - STARTER RELAY) (a) Disconnect the C1 park/neutral position switch connector. Wire Harness Side: (b) Remove the ST relay from the engine room R/B.
  • Page 624 ES–468 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE ROOM RELAY BLOCK (STARTER RELAY VOLTAGE) (a) Remove the ST relay from the engine room R/B. Wire Harness Side: (b) Measure the voltage between the terminals of the engine room R/B and body ground.
  • Page 625 ES–469 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - ECM) (a) Disconnect the E6 main body ECU connector. Wire Harness Side: (b) Disconnect the A55 ECM connector. (c) Measure the resistance between the terminals.
  • Page 626 ES–470 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ACIS Control Circuit DESCRIPTION This circuit opens and closes the Intake Air Control Valve (IACV) in response to changes in the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System).
  • Page 627 ES–471 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM VSV (ACIS) EFI No. 3 ACIS EFI MAIN MREL FL MAIN Battery A137320E01 INSPECTION PROCEDURE PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE VSV FOR ACIS) (a) Connect the intelligent tester to the DLC3.
  • Page 628 ES–472 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK INTAKE AIR CONTROL VALVE (OPERATION) (a) Disconnect the C48 air intake valve connector. Component Side: (b) Apply battery voltage between the terminals of the air intake valve connector. (c) Check the air intake valve operation.
  • Page 629 ES–473 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VSV FOR ACIS - ECM, VSV FOR ACIS - EFI RELAY) (a) Check the wire harness and connectors between the VSV for ACIS and ECM. Wire Harness Side: (1) Disconnect the C48 VSV for ACIS connector.
  • Page 630 ES–474 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ECM (See page ES-518)
  • Page 631 ES–475 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Air Intake Control Circuit DESCRIPTION The air cleaner is equipped with two inlets, one of which is opened or closed by the Air Intake Control Valve (AICV). This system reduces intake noise and increases engine power at low-to-high engine speeds range.
  • Page 632 ES–476 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE PERFORM ACTIVE TEST BY INTELLIGENT TESTER (VSV FOR AICV) (a) Turn the ignition switch on (IG) and turn the intelligent VSV is ON VSV is OFF tester ON. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1 and operate the VSV for AICV.
  • Page 633 ES–477 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VSV FOR AICV - ECM, VSV FOR AICV - EFI RELAY) (a) Check the wire harness between the VSV for AICV Wire Harness Side: connector and the ECM connector.
  • Page 634 ES–478 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT VACUUM TANK (a) Inspect the vacuum tank (See page IT-3). REPAIR OR REPLACE AIR CLEANER CAP REPLACE ECM (See page ES-518)
  • Page 635 ES–479 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Circuit DESCRIPTION The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunctions detected by the ECM. When the ignition switch is turned on (IG), power is supplied to the MIL circuit, and the ECM provides the circuit ground which illuminates the MIL.
  • Page 636 ES–480 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK WHETHER MIL TURNS OFF (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
  • Page 637 ES–481 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the A55 ECM connector. Wire Harness Side: (b) Disconnect the F2 combination meter connector. (c) Measure the resistance. Standard resistance (Check for short)
  • Page 638 ES–482 2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: *: The intelligent tester cannot communicate with the ECM. GO TO VC OUTPUT CIRCUIT (See page 442) INSPECT COMBINATION METER ASSEMBLY (MIL CIRCUIT) (a) Check the MIL circuit (See page ME-19).
  • Page 639 ES–475 2GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER MASS AIR FLOW METER ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS MASS AIR FLOW METER CONNECTOR MASS AIR FLOW METER A135627E01...
  • Page 640 ES–476 2GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ON-VEHICLE INSPECTION CHECK MASS AIR FLOW METER NOTICE: • Perform the MAF meter inspection by following the procedures below. • Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range.
  • Page 641 ES–477 2GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER (2) Read the values displayed on the tester. Standard value: Within -15 to +15 % If the result is not within the specified range, perform the inspection below. (c) Read values using the intelligent tester (MAF).
  • Page 642 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–478 ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf)
  • Page 643 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–479 ASSEMBLY 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD 7.5 (77, 66 in.*lbf)
  • Page 644 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–480 ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 10 (102, 7) 10 (102, 7) 10 (102, 7) O-RING 10 (102, 7) O-RING O-RING O-RING...
  • Page 645 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–481 ASSEMBLY ON-VEHICLE INSPECTION Intelligent Tester INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch on (IG).
  • Page 646 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–482 ASSEMBLY REMOVAL REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT (See page CO-5) REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9)
  • Page 647 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–483 ASSEMBLY 19. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 1 Intake Side) (a) Disconnect the camshaft timing oil control valve connector. (b) Remove the bolt and camshaft timing oil control valve.
  • Page 648 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–484 ASSEMBLY INSPECTION INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) If necessary, replace the camshaft timing oil control valve assembly.
  • Page 649 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–485 ASSEMBLY INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (for Bank 2 Exhaust Side) New O-Ring (a) Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve.
  • Page 650 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–486 ASSEMBLY (b) Install the camshaft timing oil control valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTICE: Make sure that the O-ring is not cracked or jammed when installing the oil control valve.
  • Page 651 2GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ES–487 ASSEMBLY 22. INSTALL ENGINE UNDER COVER LH...
  • Page 652 ES–487 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR VVT SENSOR ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf)
  • Page 653 ES–488 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD 7.5 (77, 66 in.*lbf) WIPER ARM...
  • Page 654 ES–489 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR VVT SENSOR VVT SENSOR 10 (102, 7) 10 (102, 7) VVT SENSOR VVT SENSOR 10 (102, 7) 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque A132949E01...
  • Page 655 ES–490 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR REMOVAL REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT (See page CO-5) REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) REMOVE WINDSHIELD WIPER ARM AND BLADE...
  • Page 656 ES–491 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR 19. REMOVE VVT SENSOR (for Bank 1 Exhaust Side) (a) Disconnect the VVT sensor connector. (b) Remove the bolt and VVT sensor. A135702 20. REMOVE VVT SENSOR (for Bank 2 Intake Side) (a) Disconnect the VVT sensor connector.
  • Page 657 ES–492 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR INSTALL VVT SENSOR (for Bank 1 Exhaust Side) (a) Install the VVT sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Connect the VVT sensor connector. A135702 INSTALL VVT SENSOR (for Bank 1 Intake Side) (a) Install the VVT sensor with the bolt.
  • Page 658 ES–493 2GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR 22. INSTALL ENGINE UNDER COVER LH...
  • Page 659 ES–493 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET...
  • Page 660 ES–494 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR 7.0 (71, 62 in.*lbf) RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY 7.5 (77, 66 in.*lbf) HORN CONNECTOR 7.0 (71, 62 in.*lbf) RADIATOR GRILLE 7.5 (77, 66 in.*lbf) PROTECTOR FRONT BUMPER ENERGY ABSORBER...
  • Page 661 ES–495 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR V-RIBBED BELT FRONT FENDER APRON SEAL RH 9.8 (100, 87 in.*lbf) WIRE HARNESS 8.4 (86, 74 in.*lbf) CLAMP STAY 43 (438, 32) RADIATOR INLET HOSE RADIATOR OUTLET HOSE 20 (204, 15)
  • Page 662 ES–496 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 9.8 (100, 87 in.*lbf) O-RING COMPRESSOR AND MAGNETIC CLUTCH O-RING 9.8 (100, 87 in.*lbf) 25 (255, 18) NO. 1 COOLER REFRIGERANT SUCTION HOSE 10 (102, 7)
  • Page 663 ES–497 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR REMOVAL REMOVE GENERATOR ASSEMBLY HINT: (See page CH-13) DISCONNECT COOLER COMPRESSOR ASSEMBLY HINT: (See page AC-219) REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt and crankshaft position sensor.
  • Page 664 ES–498 2GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR INSTALLATION INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring of the crankshaft position sensor. (b) Install the crankshaft position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (c) Connect the crankshaft position sensor connector.
  • Page 665: Engine Coolant Temperature Sensor

    ES–498 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf)
  • Page 666 ES–499 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR 20 (204, 15) ENGINE COOLANT TEMPERATURE SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque A135635E01...
  • Page 667 ES–500 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR REMOVAL REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT (See page CO-5) REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE AIR CLEANER INLET ASSEMBLY (See...
  • Page 668 ES–501 2GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the engine coolant temperature sensor. (b) Install the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (c) Connect the engine coolant temperature sensor connector.
  • Page 669: Throttle Body

    ES–502 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY THROTTLE BODY ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY COOL AIR INTAKE DUCT SEAL V-BANK COVER SUB-ASSEMBLY AIR CLEANER SUB-ASSEMBLY AIR CLEANER INLET ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) GASKET 5.0 (51, 44 in.*lbf)
  • Page 670 ES–503 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ON-VEHICLE INSPECTION INSPECTION THROTTLE BODY (a) Inspect the throttle control motor for operating sounds. (1) Turn the ignition switch on (IG). (2) When turning the accelerator pedal position sensor lever, check for running sounds of the motor.
  • Page 671 ES–504 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY REMOVAL REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT (See page CO-5) REMOVE COOL AIR INTAKE DUCT SEAL (See page EM-23) REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23)
  • Page 672 ES–505 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY 10. REMOVE THROTTLE BODY (a) Disconnect the throttle body connector and clamp. A135707 (b) Disconnect the 2 water by-pass hoses from the throttle body. A135708 (c) Remove the 4 bolts and throttle body.
  • Page 673 ES–506 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY (b) Install the throttle body with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) A135709 (c) Connect the 2 water by-pass hoses. A135708 (d) Connect the throttle body connector and clamp.
  • Page 674 ES–507 2GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY (e) Connect the 3 vacuum hoses. INSTALL AIR CLEANER INLET ASSEMBLY (See page EM-50) INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) ADD ENGINE COOLANT (See page CO-6) CHECK FOR ENGINE COOLANT LEAKS (See page...
  • Page 675: Knock Sensor

    ES–507 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR KNOCK SENSOR ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf)
  • Page 676 ES–508 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY WINDSHIELD 7.5 (77, 66 in.*lbf) WIPER ARM...
  • Page 677 ES–509 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR VACUUM HOSE CLAMP UNION TO CHECK VALVE HOSE THROTTLE BODY BRACKET 21 (214, 15) SURGE TANK STAY NO. 1 VENTILATION HOSE NO. 2 16 (163, 12) 5.4 (55, 48 in.*lbf) INTAKE AIR SURGE TANK...
  • Page 678 ES–510 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR REMOVAL DISCHARGE FUEL SYSTEM PRESSURE (See page FU-13) REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT (See page CO-5) REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9)
  • Page 679 ES–511 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 21. REMOVE KNOCK CONTROL SENSOR (a) Disconnect the 2 knock control sensor connectors. (b) Remove the 2 bolts and 2 knock control sensors. A129615 INSPECTION INSPECT KNOCK CONTROL SENSOR (a) Using an ohmmeter, measure the resistance between the terminals.
  • Page 680 ES–512 2GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 13. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (See page WW-15) 14. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 15. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 16.
  • Page 681 ES–513 2GR-FE ENGINE CONTROL SYSTEM – IG2 RELAY IG2 RELAY INSPECTION INSPECT IG2 RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition B016200 3 - 5 10 kΩ or higher Below 1 Ω...
  • Page 682 ES–514 2GR-FE ENGINE CONTROL SYSTEM – EFI RELAY EFI RELAY Engine Room R/B Unit D: INSPECTION INSPECT EFI RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified Condition Below 1 Ω...
  • Page 683 ES–515 2GR-FE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY Engine Room R/B Unit D: INSPECTION INSPECT CIRCUIT OPENING RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified Condition Below 1 Ω...
  • Page 684 ES–516 2GR-FE ENGINE CONTROL SYSTEM – AIR FUEL RATIO SENSOR RELAY AIR FUEL RATIO SENSOR RELAY Engine Room R/B Unit D: INSPECTION INSPECT AIR FUEL RATIO SENSOR RELAY (a) Using an ohmmeter, measure the resistance according to the value(s) in the table below.
  • Page 685 ES–517 2GR-FE ENGINE CONTROL SYSTEM – ECM ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH FRONT FENDER TO COWL SIDE SEAL LH...
  • Page 686 ES–518 2GR-FE ENGINE CONTROL SYSTEM – ECM REMOVAL REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9) REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9)
  • Page 687 ES–519 2GR-FE ENGINE CONTROL SYSTEM – ECM (c) Remove the 4 screws and 2 ECM brackets. A135713 INSTALLATION INSTALL ECM (a) Install the ECM bracket with the 4 screws. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) (b) Connect the 2 ECM connectors.
  • Page 688 ES–520 2GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ACCELERATOR PEDAL ENGINE 2GR-FE ENGINE CONTROL SYSTEM COMPONENTS 5.4 (55, 48 in.*lbf) ACCELERATOR PEDAL ROD N*m (kgf*cm, ft.*lbf) : Specified torque A135645E01...
  • Page 689 ES–521 2GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ON-VEHICLE INSPECTION Intelligent Tester CHECK ACCELERATOR PEDAL ROD (a) Measure the voltage. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the intelligent tester ON.
  • Page 690 ES–522 2GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL INSTALLATION INSTALL ACCELERATOR PEDAL NOTICE: • Avoid physical shock to the accelerator pedal assembly. • Do not disassemble the accelerator pedal assembly. (a) Install the accelerator pedal assembly with the 2 bolts.
  • Page 691 EC–1 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM ENGINE 2GR-FE EMISSION CONTROL PARTS LOCATION FUEL TANK CAP CANISTER HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1)
  • Page 692 EC–2 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM SYSTEM DIAGRAM VSV for EVAP to Charcoal Canister Air Fuel Ratio Sensor Air Fuel Ratio Sensor Engine Coolant (Bank 2) (Bank 1) Temperature Sensor Heated Oxygen Sensor (Bank 2) Heated Oxygen Sensor...
  • Page 693 EC–3 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EVAP System Circuit : Air Cleaner Intake Manifold Soak Timer Air Filter Canister EVAP VSV Service Port Fuel Cap Pump Module Roll-over Valve Cut-off Valve Fuel Tank A128936E03...
  • Page 694 EC–4 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM Air Fuel Ratio Sensor (Bank 1 Sensor 1) C55 HA1A HA1A (*1) C55 A1A+ A1A- A1A+ C55 A1A- Air Fuel Ratio Sensor (Bank 2 Sensor 1) C55 HA2A HA2A (*1) C55 A2A+...
  • Page 695 EC–5 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM VSV (Purge) C55 PRG Canister Pump Module Vent Valve VGND VLVB A55 MPMP C55 VCPP Canister Pressure Sensor VOUT C55 PPMP SGND C55 EPPM MGND MTRB A55 VPMP Leak Detection Pump EFI MAIN EFI No.
  • Page 696 EC–6 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM ON-VEHICLE INSPECTION INSPECT FUEL CUT-OFF RPM (a) Increase the engine speed to at least 3,500 rpm. (b) Use a sound scope to check for injector operating sounds. (c) Check that when the throttle lever is released, injector operating sounds stop momentarily (at 2,500 rpm) and then resume (at 1,400 rpm).
  • Page 697 EC–7 2GR-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM CHECK AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal Air Inlet Hose canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it.
  • Page 698 EC–8 2GR-FE EMISSION CONTROL – CANISTER CANISTER ENGINE 2GR-FE EMISSION CONTROL COMPONENTS CHARCOAL CANISTER ASSEMBLY 39 (398, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A135648E04...
  • Page 699 EC–9 2GR-FE EMISSION CONTROL – CANISTER REMOVAL REMOVE FUEL TANK ASSEMBLY HINT: (See page FU-36) REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the fuel tank vent hose from the charcoal canister. Pinch A (1) Push the connector deep inside. (2) Pinch portion A.
  • Page 700 EC–10 2GR-FE EMISSION CONTROL – CANISTER (b) Check charcoal canister operation. Purge Port (1) With the purge port closed, blow 1.67 kPa (17.0 gf/cm , 0.24 psi) of air into the vent port, and check that air flows from the air inlet port.
  • Page 701 EC–11 2GR-FE EMISSION CONTROL – CANISTER (3) Connect the positive (+) lead to terminal 7 and Closed the negative (-) lead to terminal 6. Valve (4) Check that the valve is closed. If the result is not as specified, replace the charcoal canister assembly.
  • Page 702 EC–12 2GR-FE EMISSION CONTROL – VACUUM SWITCHING VALVE (for EVAP) VACUUM SWITCHING VALVE (for EVAP) ENGINE 2GR-FE EMISSION CONTROL COMPONENTS V-BANK COVER SUB-ASSEMBLY VACUUM HOSE 5.0 (51, 44 in.*lbf) VACUUM HOSE NO. 1 VACUUM SWITCHING VALVE N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 703 EC–13 2GR-FE EMISSION CONTROL – VACUUM SWITCHING VALVE (for EVAP) REMOVAL REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE NO. 1 VACUUM SWITCHING VALVE (a) Disconnect the 2 vacuum hoses and No. 1 vacuum switching valve connector. A132952E01 (b) Remove the bolt and No. 1 vacuum switching valve.
  • Page 704 EC–14 2GR-FE EMISSION CONTROL – VACUUM SWITCHING VALVE (for EVAP) (b) Check VSV operation. (1) Check that air does not flow from the port as shown in the illustration. A128937E01 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from the ports.
  • Page 705 EC–15 2GR-FE EMISSION CONTROL – VENTILATION VALVE VENTILATION VALVE ENGINE 2GR-FE EMISSION CONTROL COMPONENTS V-BANK COVER SUB-ASSEMBLY 27(275, 20) VENTILATION HOSE VENTILATION VALVE N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part A135651E03...
  • Page 706 EC–16 2GR-FE EMISSION CONTROL – VENTILATION VALVE REMOVAL REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) DISCONNECT VENTILATION HOSE (a) Disconnect the ventilation hose from the ventilation valve. A135715E01 REMOVE VENTILATION VALVE (a) Remove the ventilation valve. A138519E01 INSPECTION INSPECT VENTILATION VALVE (a) Install a clean hose to the ventilation valve.
  • Page 707 EC–17 2GR-FE EMISSION CONTROL – VENTILATION VALVE INSTALLATION Adhesive INSTALL VENTILATION VALVE (a) Install the ventilation valve. (1) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. A105280E01 (2) Install the ventilation valve.
  • Page 708 EC–18 2GR-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR AIR FUEL RATIO SENSOR ENGINE 2GR-FE EMISSION CONTROL COMPONENTS AIR FUEL RATIO SENSOR 44 (449, 33) 44 (449, 33) AIR FUEL RATIO SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque A135655E03...
  • Page 709 EC–19 2GR-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR REMOVAL Bank 1: REMOVE AIR FUEL RATIO SENSOR (a) Disconnect the 2 air fuel ratio sensor connectors. (b) Using SST, remove the 2 air fuel ratio sensors from the front pipe assembly.
  • Page 710 EC–20 2GR-FE EMISSION CONTROL – HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR ENGINE 2GR-FE EMISSION CONTROL COMPONENTS FRONT EXHAUST PIPE ASSEMBLY GASKET 56 (571, 41) HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) GASKET 56 (571, 41) 62 (632, 46) GASKET 62 (632, 46)
  • Page 711 EC–21 2GR-FE EMISSION CONTROL – HEATED OXYGEN SENSOR REMOVAL REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) REMOVE HEATED OXYGEN SENSOR (for Bank 1) (a) Using SST, remove the oxygen sensor.
  • Page 712 EC–22 2GR-FE EMISSION CONTROL – HEATED OXYGEN SENSOR INSTALL HEATED OXYGEN SENSOR (for Bank 1) (a) Using SST, install the heated oxygen sensor. 09224-00010 INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-4) INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH...
  • Page 713: Fuel Tank Cap

    EC–23 2GR-FE EMISSION CONTROL – FUEL TANK CAP FUEL TANK CAP INSPECTION REMOVE FUEL TANK CAP ASSEMBLY (a) Visually check if the cap and gasket are deformed or damaged. If necessary, replace the cap. A126203...
  • Page 714: Fuel System

    FU–1 2GR-FE FUEL – FUEL SYSTEM FUEL SYSTEM PRECAUTION EXPRESSIONS OF IGNITION SWITCH (a) The type of the ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section.
  • Page 715 FU–2 2GR-FE FUEL – FUEL SYSTEM FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (1) Discharge the fuel system pressure. (step 3) (2) Disconnect the fuel pump tube (See page 27).
  • Page 716 FU–3 2GR-FE FUEL – FUEL SYSTEM (d) Observe the following precautions when disconnecting the fuel tube connectors (Quick type (1) Remove the No. 1 fuel pipe clamp. (2) Check that there is no dirt or other foreign No. 1 Fuel...
  • Page 717 FU–4 2GR-FE FUEL – FUEL SYSTEM Observe the following precautions when Quick Type B disconnecting the fuel tube connector (Quick type (1) Before disconnecting the connector, clean off any dirt that may be present. (2) Pinch the tabs of the fuel tube retainer to disengage the 2 claws.
  • Page 718 FU–5 2GR-FE FUEL – FUEL SYSTEM • Do not remove the EPDM protector on the outside of the nylon tube. • Do not close the piping by bending the nylon tube. CHECK FOR FUEL LEAKS (a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (See page FU-8).
  • Page 719 FU–6 2GR-FE FUEL – FUEL SYSTEM PARTS LOCATION FUEL PUMP ENGINE ROOM RELAY BLOCK FUEL INJECTOR A136014E01...
  • Page 720 FU–7 2GR-FE FUEL – FUEL SYSTEM SYSTEM DIAGRAM C7 Fuel Injector (No. 1) From Battery C9 Fuel Injector (No. 2) C8 Fuel Injector (No. 3) E23 Ignition Switch C10 Fuel Injector (No. 4) ST/AM2 From Battery C36 Fuel Injector (No. 5) E6 Main Body ECU C37 Fuel Injector (No.
  • Page 721 FU–8 2GR-FE FUEL – FUEL SYSTEM ON-VEHICLE INSPECTION CHECK FOR FUEL PUMP OPERATION AND FUEL LEAKS (a) Check fuel pump operation. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG) and push the intelligent tester main switch on.
  • Page 722 FU–9 2GR-FE FUEL – FUEL SYSTEM (e) Install SST (pressure gauge) using SST and a fuel tube connector as shown in the illustration. 09268-31011 (09268-41500, 90467-13001, SST (Clip) SST (T-joint) 95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) Wipe up any gasoline. SST (Clip) (g) Connect the negative (-) battery terminal.
  • Page 723: Fuel Injector

    FU–10 2GR-FE FUEL – FUEL INJECTOR FUEL INJECTOR ENGINE 2GR-FE FUEL COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR...
  • Page 724 FU–11 2GR-FE FUEL – FUEL INJECTOR UNION TO CHECK VALVE HOSE INTAKE AIR SURGE TANK ASSEMBLY CONNECTOR 21 (214, 15) 5.4 (55, 48 in.*lbf) NO. 1 VENTILATION HOSE 16 (163, 12) HOSE CLAMP 21 (214, 15) 18 (184, 13) VACUUM HOSE...
  • Page 725 FU–12 2GR-FE FUEL – FUEL INJECTOR WIRE HARNESS 21 (214, 15) 21 (214, 15) FUEL TUBE SUB-ASSEMBLY 21 (214, 15) 21 (214, 15) NO. 2 FUEL PIPE CLAMP O-RING WIRE HARNESS FUEL DELIVERY PIPE FUEL INJECTOR ASSEMBLY SUB-ASSEMBLY INJECTOR VIBRATION INSULATOR N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 726 FU–13 2GR-FE FUEL – FUEL INJECTOR REMOVAL DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL DRAIN ENGINE COOLANT (See page CO-5) REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9) REMOVE FRONT WIPER ARM AND BLADE...
  • Page 727 FU–14 2GR-FE FUEL – FUEL INJECTOR Remove the bolt and vacuum hose clamp. A129466 (g) Disconnect the connector. A129467 (h) Using a 5 mm socket hexagon wrench, remove the 4 bolts. Remove the 2 nuts, 2 bolts and intake air surge tank.
  • Page 728 FU–15 2GR-FE FUEL – FUEL INJECTOR 15. REMOVE FUEL INJECTOR ASSEMBLY (a) Disconnect the 6 fuel injector connectors. A137341 (b) Remove the 5 bolts and fuel delivery pipe together with the 6 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
  • Page 729 FU–16 2GR-FE FUEL – FUEL INJECTOR INSPECTION INSPECT FUEL INJECTOR ASSEMBLY (a) Inspect injector resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 11.6 to 12.4 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector.
  • Page 730 FU–17 2GR-FE FUEL – FUEL INJECTOR (c) Check for leakage. (1) In the condition above, disconnect the tester probes of SST (wire) from the battery and check for fuel leakage from the injector. Fuel drop: 1 drop or less in 16 minutes...
  • Page 731 FU–18 2GR-FE FUEL – FUEL INJECTOR (h) Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Connect the 6 fuel injector connectors. A137341 CONNECT FUEL TUBE SUB-ASSEMBLY (a) Push in the tube connector to the pipe until the tube connector makes a "click"...
  • Page 732 FU–19 2GR-FE FUEL – FUEL INJECTOR (d) Connect the connector. A129467 (e) Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A129466 Connect the union to check valve hose. (g) Connect the No. 1 ventilation hose.
  • Page 733 FU–20 2GR-FE FUEL – FUEL INJECTOR 11. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (See page WW-15) 12. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-15) 13. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-15) 14.
  • Page 734 FU–21 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER FUEL PRESSURE PULSATION DAMPER ENGINE 2GR-FE FUEL COMPONENTS FRONT WIPER ARM AND BLADE ASSEMBLY LH 20 (204, 15) FRONT WIPER ARM AND BLADE ASSEMBLY RH 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH...
  • Page 735 FU–22 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER UNION TO CHECK VALVE HOSE INTAKE AIR SURGE TANK ASSEMBLY CONNECTOR 21 (214, 15) 5.4 (55, 48 in.*lbf) NO. 1 VENTILATION HOSE 16 (163, 12) HOSE CLAMP 21 (214, 15) 18 (184, 13)
  • Page 736 FU–23 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER REMOVAL DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL DRAIN ENGINE COOLANT (See page CO-5) REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9)
  • Page 737 FU–24 2GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See page FU-18) INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) ADD ENGINE COOLANT (See page CO-6) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CHECK FOR ENGINE COOLANT LEAKS (See page...
  • Page 738: Fuel Pump

    FU–25 2GR-FE FUEL – FUEL PUMP FUEL PUMP ENGINE 2GR-FE FUEL COMPONENTS REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY TUBE JOINT CLIP 5.9 (60, 52 in.*lbf) FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY...
  • Page 739 FU–26 2GR-FE FUEL – FUEL PUMP FUEL SUCTION PLATE SUB-ASSEMBLY FUEL PUMP HARNESS FUEL FILTER FUEL SENDER GAUGE ASSEMBLY FUEL PUMP O-RING FUEL PRESSURE REGULATOR ASSEMBLY FUEL PUMP CUSHION RUBBER NO. 2 FUEL SUCTION SUPPORT Non-reusable part A136243E01...
  • Page 740 FU–27 2GR-FE FUEL – FUEL PUMP REMOVAL DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47)
  • Page 741 FU–28 2GR-FE FUEL – FUEL PUMP REMOVE FUEL TANK VENT TUBE SET PLATE (a) Remove the 8 bolts and set plate. A129480 REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Pull out the fuel suction tube from the fuel tank.
  • Page 742 FU–29 2GR-FE FUEL – FUEL PUMP REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY Tape (a) Disconnect the fuel pump connector ( (b) Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and pull out the fuel suction plate.
  • Page 743 FU–30 2GR-FE FUEL – FUEL PUMP INSPECTION Component Side: Fuel Pump INSPECT FUEL PUMP (a) Inspect fuel pump resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.2 to 3.0 Ω at 20°C (68°F) If the result is not as specified, replace the fuel pump assembly.
  • Page 744 FU–31 2GR-FE FUEL – FUEL PUMP INSTALL FUEL PUMP (a) Apply a light coat of gasoline or grease to the O-ring of the fuel pump. (b) Push in the fuel pump to the fuel filter. A079496E01 INSTALL FUEL PUMP HARNESS...
  • Page 745 FU–32 2GR-FE FUEL – FUEL PUMP INSTALL NO. 2 FUEL SUCTION SUPPORT (a) Install the No. 2 fuel suction support. A129487 INSTALLATION INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Install a new gasket to the fuel suction tube.
  • Page 746 FU–33 2GR-FE FUEL – FUEL PUMP CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (a) Install the fuel pump tube with the tube joint clip. Tube Joint Clip NOTICE: • Check that there are no scratches or foreign objects on the connecting part.
  • Page 747: Fuel Tank

    FU–34 2GR-FE FUEL – FUEL TANK FUEL TANK ENGINE 2GR-FE FUEL COMPONENTS REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL PUMP TUBE SUB-ASSEMBLY TUBE JOINT CLIP 5.9 (60, 52 in.*lbf) FUEL TANK VENT TUBE SET PLATE FUEL SUCTION TUBE ASSEMBLY...
  • Page 748 FU–35 2GR-FE FUEL – FUEL TANK NO. 1 FUEL TUBE FUEL TANK ASSEMBLY HOSE CLAMP FUEL TANK TO FILLER PIPE HOSE For SE Grade: FUEL TANK PROTECTOR LOWER CENTER FUEL TANK PROTECTOR LOWER CENTER 5.4 (55, 48 in.*lbf) FUEL TANK BAND...
  • Page 749 FU–36 2GR-FE FUEL – FUEL TANK FUEL PUMP TUBE SUB-ASSEMBLY FUEL TANK ASSEMBLY NO. 2 FUEL TANK CUSHION FUEL TANK VENT HOSE CLIP NUT 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque FUEL MAIN TUBE SUPPORT Non-reusable part...
  • Page 750 FU–37 2GR-FE FUEL – FUEL TANK REMOVAL DISCHARGE FUEL SYSTEM PRESSURE HINT: See page FU-1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) (See page SE-77) REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) (See page SE-47)
  • Page 751 FU–38 2GR-FE FUEL – FUEL TANK 14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET (a) Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets. A136008E01 15. REMOVE FUEL TANK PROTECTOR LOWER CENTER (a) Remove the 4 bolts and fuel tank protector (Except SE Grade).
  • Page 752 FU–39 2GR-FE FUEL – FUEL TANK • If the pipe and connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully. (b) Disconnect the No. 1 fuel tube.
  • Page 753 FU–40 2GR-FE FUEL – FUEL TANK (d) Remove the 2 set bolts of the fuel tank bands. ( (e) Remove the hose clamp and disconnect the fuel tank to filter pipe hose. ( Slightly lower the transmission jack. (g) Disconnect the fuel tank vent hose from the charcoal canister.
  • Page 754 FU–41 2GR-FE FUEL – FUEL TANK 17. REMOVE FUEL TANK VENT HOSE (a) Push the connector deep into the charcoal canister to release the locking pin. (b) Pinch portion A. Push (c) Pull out the connector. Pinch Pinch A079479E03 18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY (a) Remove the fuel pump tube from the fuel main tube support.
  • Page 755 FU–42 2GR-FE FUEL – FUEL TANK INSTALL FUEL MAIN TUBE SUPPORT (a) Install the fuel main tube support with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A079481 INSTALL FUEL PUMP TUBE SUB-ASSEMBLY (a) Install the fuel pump tube to the fuel main tube support.
  • Page 756 FU–43 2GR-FE FUEL – FUEL TANK (c) Install the 2 fuel tank bands with the 2 pins. (d) Set the fuel tank assembly onto the transmission jack. A129491 (e) Raise the transmission jack so that the fuel tank vent hose can be connected. (*1)
  • Page 757 FU–44 2GR-FE FUEL – FUEL TANK • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. INSTALL FUEL TANK PROTECTOR LOWER CENTER (a) Install the 4 bolts and fuel tank protector (Except SE Grade).
  • Page 758 FU–45 2GR-FE FUEL – FUEL TANK INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Install the No. 2 parking brake cable assembly with the bolt and nut. Torque: Bolt 6.0 N*m (61 kgf*cm, 53 in.*lbf) 8.5 N*m (87 kgf*cm, 75 in.*lbf) 10.
  • Page 759 IT–1 2GR-FE INTAKE – INTAKE AIR CONTROL SYSTEM INTAKE AIR CONTROL SYSTEM ENGINE 2GR-FE INTAKE PARTS LOCATION INTAKE AIR CONTROL VALVE AIR CLEANER CASE SUB-ASSEMBLY VACUUM SWITCHING VALVE A135658E03...
  • Page 760 IT–2 2GR-FE INTAKE – INTAKE AIR CONTROL SYSTEM SYSTEM DIAGRAM VTA1 VTA2 VC VTA2 Throttle Body M+ 2 Assembly GE01 (*1) Mass Air Flow Meter VSV (ACIS) ACIS A13 VSV (AICV) AICV Engine Room R/B & J/B EFI No. 2 EFI Relay EFI No.
  • Page 761 IT–3 2GR-FE INTAKE – INTAKE AIR CONTROL SYSTEM ON-VEHICLE INSPECTION INSPECT INTAKE AIR CONTROL VALVE ASSEMBLY (a) Inspection procedure when using the intelligent tester: (1) Warm up the engine. (2) Stop the engine. (3) Connect the intelligent tester to the DLC3.
  • Page 762 IT–4 2GR-FE INTAKE – VACUUM SWITCHING VALVE VACUUM SWITCHING VALVE ENGINE 2GR-FE INTAKE COMPONENTS VACUUM SWITCHING VALVE VACUUM HOSE VACUUM SWITCHING VALVE CONNECTOR VACUUM HOSE A135659E02...
  • Page 763 IT–5 2GR-FE INTAKE – VACUUM SWITCHING VALVE REMOVAL REMOVE VACUUM SWITCHING VALVE (a) Remove the 2 vacuum hoses and vacuum switching valve connector. (b) Remove the screw and vacuum switching valve. A133294E01 INSPECTION Ohmmeter 37 to 44 Ω INSPECT VACUUM SWITCHING VALVE (a) Measure the VSV resistance.
  • Page 764 IT–6 2GR-FE INTAKE – VACUUM SWITCHING VALVE (b) Check VSV operation. (1) When vacuum is applied to the E port, check that air is sucked into the filter. If the result is not as specified, replace the VSV. Filter A128950E01 (2) Apply battery voltage across the terminals.
  • Page 765: Cooling System

    LOW and FULL lines when the engine is cold. If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non- amine, non-nitrite and non-borate coolant with long- life hybrid organic acid technology to the FULL line.
  • Page 766 CO–2 2GR-FE COOLING – COOLING FAN SYSTEM COOLING FAN SYSTEM ENGINE 2GR-FE COOLING PARTS LOCATION INSTRUMENT PANEL JUNCTION BLOCK -ECU IG NO. 1 COOLING FAN ASSEMBLY ENGINE ROOM RELAY BLOCK -MAIN FAN MOTOR -FAN MAIN FUSE -SUB FAN MOTOR -COOLING FAN RELAY...
  • Page 767 CO–3 2GR-FE COOLING – COOLING FAN SYSTEM SYSTEM DIAGRAM Cooling Fan ECU Main Fan Motor M+ (M) FAN MAIN M- (M) FAN MAIN Sub Fan Motor From Battery M+ (S) From Battery ECU IG No. 1 M- (S) A136998...
  • Page 768 CO–4 2GR-FE COOLING – COOLING FAN SYSTEM ON-VEHICLE INSPECTION INSPECT COOLING FAN SYSTEM (a) Put the vehicle in the following conditions: (1) The ignition switch is off. (2) The coolant temperature is less than 95°C (203°F). (3) The battery voltage is between 9 and 14 V.
  • Page 769 CO–5 2GR-FE COOLING – COOLING FAN SYSTEM (g) After the engine is warmed up, check that the fan operates as shown in the illustration on the left. Operating Diagram HINT: • The coolant temperature at which the fan starts A/C OFF operating is approximately 95°C (203°F).
  • Page 770 CO–5 2GR-FE COOLING – COOLANT COOLANT ON-VEHICLE INSPECTION REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE COOL AIR INTAKE DUCT SEAL (See page...
  • Page 771 (a) Close the radiator drain cock plug and 2 cylinder block drain cock plugs. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for cylinder block drain cock plug (b) Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC). Specified capacity: 9.0 liters (9.5 US qts, 7.9 lmp. qts) HINT: •...
  • Page 772: Water Pump

    CO–7 2GR-FE COOLING – WATER PUMP WATER PUMP ENGINE 2GR-FE COOLING COMPONENTS WATER PUMP ASSEMBLY GASKET 9.1 (93, 81 in.*lbf) ×5 9.1 (93, 81 in.*lbf) 21 (214, 15) ×9 21 (214, 15) 43 (438, 32) 43 (438, 32) NO. 2 IDLER PULLEY...
  • Page 773 CO–8 2GR-FE COOLING – WATER PUMP REMOVAL REMOVE ENGINE ASSEMBLY AND TRANSAXLE HINT: See page EM-23 SECURE ENGINE STAND HINT: See page EM-30 REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (See page EM-35) REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY...
  • Page 774 CO–9 2GR-FE COOLING – WATER PUMP REMOVE WATER INLET HOUSING (a) Disconnect the water hose. (b) Remove the 2 bolts, nut and water inlet housing. Water Hose Water Inlet Housing A133375E01 (c) Remove the water inlet housing gasket and water outlet pipe O-ring.
  • Page 775 CO–10 2GR-FE COOLING – WATER PUMP • Be sure to replace 2 bolts C with new ones or reuse them after applying adhesive 1344. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent INSTALL WATER INLET HOUSING (a) Install a new water inlet housing No. 1 gasket and water outlet pipe O-ring.
  • Page 776 CO–11 2GR-FE COOLING – WATER PUMP INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY FR Side: (a) Install the 2 idler pulley cover plates and idler pulley sub-assemblies with the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) INSTALL NO. 1 ENGINE MOUNTING BRACKET...
  • Page 777 CO–12 2GR-FE COOLING – THERMOSTAT THERMOSTAT ENGINE 2GR-FE COOLING COMPONENTS V-BANK COVER SUB-ASSEMBLY 38 (388, 28) V-RIBBED BELT 38 (388, 28) ENGINE MOVING CONTROL FRONT FENDER APRON SEAL RH ROD SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH 43 (438, 32) THERMOSTAT NO.
  • Page 778 CO–13 2GR-FE COOLING – THERMOSTAT REMOVAL DRAIN ENGINE COOLANT REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE FRONT FENDER APRON SEAL RH REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-25) REMOVE ENGINE MOVING CONTROL ROD SUB- ASSEMBLY (See page EM-25) REMOVE V-RIBBED BELT (See page EM-6) REMOVE NO.
  • Page 779 CO–14 2GR-FE COOLING – THERMOSTAT (d) Check the valve lift. Valve lift: 7.7 mm (0.3031 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (e) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C...
  • Page 780 CO–15 2GR-FE COOLING – COOLING FAN MOTOR COOLING FAN MOTOR ON-VEHICLE INSPECTION COOLING FAN MOTOR (a) Check that the motor turns smoothly when the battery is connected to the fan motor connector. (b) Measure the current while the motor is turning.
  • Page 781 CO–16 2GR-FE COOLING – COOLING FAN ECU COOLING FAN ECU ON-VEHICLE INSPECTION INSPECT COOLING FAN ECU (a) Inspect the input voltage. (1) Disconnect the cooling fan ECU connector. (2) Turn the ignition switch on (IG). Check the voltage of the +B terminal of the disconnected wire harness side connector.
  • Page 782 CO–17 2GR-FE COOLING – COOLING FAN ECU (e) Inspect the input signal and output current. NOTICE: Be sure to perform the inspection with the Waveform 1 radiator coolant temperature less than 95°C (203 °F). 1 V/DIV (1) Connect the 400 A probe of the ammeter to 20 ms/DIV terminal M+ of the cooling fan motor.
  • Page 783 CO–18 2GR-FE COOLING – COOLING FAN RELAY COOLING FAN RELAY ON-VEHICLE INSPECTION COOLING FAN RELAY (a) Remove the relay from engine room relay block No. (b) Measure the resistance of the relay. Standard resistance A035654 Tester Connection Specified Condition 3 - 5 10 kΩ...
  • Page 784 CO–19 2GR-FE COOLING – RADIATOR RADIATOR ENGINE 2GR-FE COOLING COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER INLET SUB-ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 785 CO–20 2GR-FE COOLING – RADIATOR 7.0 (71, 62 in.*lbf) RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY 7.5 (77, 66 in.*lbf) HORN CONNECTOR 7.0 (71, 62 in.*lbf) RADIATOR GRILLE 7.5 (77, 66 in.*lbf) PROTECTOR FRONT BUMPER ENERGY ABSORBER ENGINE UNDER COVER LH...
  • Page 786 CO–21 2GR-FE COOLING – RADIATOR RADIATOR HOSE INLET RADIATOR HOSE OUTLET RADIATOR SUPPORT CUSHION RADIATOR SUPPORT CUSHION FAN MOTOR CONNECTOR RADIATOR ASSEMBLY FAN SHROUD RADIATOR SUPPORT RADIATOR SUPPORT LOWER LOWER 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 787 CO–22 2GR-FE COOLING – RADIATOR RADIATOR CAP SUB-ASSEMBLY RADIATOR TANK UPPER O-RING FAN SHROUD OIL COOLER PIPE CORE SUB-ASSEMBLY 15 (150, 11) 15 (150, 11) With Hose O-RING O-RING 15 (150, 11) 8.3 (85, 73 in.*lbf) O-RING OIL COOLER ASSEMBLY...
  • Page 788 CO–23 2GR-FE COOLING – RADIATOR (6) Pump the cap tester several times, and check the maximum pressure Radiator Cap Tester Pumping speed: 1 pumps every second *1: Even if the cap cannot maintain the maximum pressure, it is not a defect.
  • Page 789 CO–24 2GR-FE COOLING – RADIATOR REMOVAL REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE COOLANT (See page CO-5) REMOVE V-BANK COVER SUB-ASSEMBLY (See...
  • Page 790 CO–25 2GR-FE COOLING – RADIATOR 16. DISCONNECT RADIATOR HOSE OUTLET (a) Separate the radiator outlet hose from the radiator assembly. A133364 17. DISCONNECT NO. 1 OIL COOLER INLET HOSE (a) Separate the No. 1 oil cooler inlet hose from the radiator assembly.
  • Page 791 CO–26 2GR-FE COOLING – RADIATOR (d) Remove the 5 bolts and radiator support upper. A133369 20. REMOVE FAN SHROUD (a) Remove the 3 clamps and connector. A139341E01 (b) Release the 3 snap fits and lift the fan assembly with motor from the radiator.
  • Page 792 CO–27 2GR-FE COOLING – RADIATOR 22. REMOVE RADIATOR SUPPORT CUSHION (a) Remove the 2 radiator support cushions from the radiator assembly. Radiator Support Cushion A133371E02 23. REMOVE RADIATOR SUPPORT LOWER (a) Remove the 2 radiator support lowers from the radiator assembly.
  • Page 793 CO–28 2GR-FE COOLING – RADIATOR DISASSEMBLY REMOVE DRAIN PLUG (a) Remove the drain plug. (b) Remove the O-ring. REMOVE RADIATOR TANK UPPER (a) Install the claw to the overhaul handle, inserting it in Stopper Bolt the hole in part A as shown in the illustration.
  • Page 794 CO–29 2GR-FE COOLING – RADIATOR REMOVE RADIATOR TANK LOWER (a) With hose: (1) Remove the 2 clips and hose from the radiator assembly. (b) Removal procedure of the radiator tank lower is the same as that of the radiator tank upper.
  • Page 795 CO–30 2GR-FE COOLING – RADIATOR INSTALL RADIATOR TANK UPPER (a) Install the punch assembly to the overhaul handle, Stopper Bolt inserting it in the hole in part A as shown in the illustration. Part A 09230-01010, 09231-14010 Dimension B Punch Assembly...
  • Page 796 CO–31 2GR-FE COOLING – RADIATOR (d) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
  • Page 797 CO–32 2GR-FE COOLING – RADIATOR INSPECT FOR WATER LEAKS (a) Plug the inlet and outlet pipes of the radiator with SST. 09230-01010 (b) Using the radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm , 26 psi) (c) Submerge the radiator in water.
  • Page 798 CO–33 2GR-FE COOLING – RADIATOR (b) Install the condenser assembly with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A133370 INSTALL FAN SHROUD (a) Install the fan assembly with motor to the radiator with the 2 guides at the bottom and 3 snap fits on the top.
  • Page 799 CO–34 2GR-FE COOLING – RADIATOR (c) Install the hood lock control cable assembly to the radiator support upper with the clamp. (d) Connect the 2 horn connectors. A133368 CONNECT NO. 1 OIL COOLER OUTLET TUBE (a) Connect the No. 1 oil cooler outlet tube to the radiator assembly.
  • Page 800 CO–35 2GR-FE COOLING – RADIATOR 10. CONNECT RADIATOR RESERVOIR TANK HOSE (a) Connect the radiator reservoir tank hose to the radiator assembly. 11. INSTALL FRONT BUMPER ENERGY ABSORBER (See page ET-10) 12. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light) (See page ET-14) 13.
  • Page 801 EX–1 2GR-FE EXHAUST – EXHAUST PIPE EXHAUST PIPE ENGINE 2GR-FE EXHAUST COMPONENTS EXHAUST PIPE SUPPORT NO. 4 EXHAUST FRONT PIPE ASSEMBLY 56 (571, 41) HEATED OXYGEN SENSOR GASKET (BANK 1 SENSOR 2) GASKET 56 (571, 41) 62 (632, 46) EXHAUST TAIL...
  • Page 802 EX–2 2GR-FE EXHAUST – EXHAUST PIPE REMOVAL REMOVE EXHAUST TAIL PIPE ASSEMBLY (a) Remove the 4 nuts and 2 exhaust tail pipes. A135718 (b) Remove the 2 gaskets from the exhaust center pipe assembly. REMOVE EXHAUST CENTER PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and exhaust center pipe assembly.
  • Page 803 EX–3 2GR-FE EXHAUST – EXHAUST PIPE (b) Remove the gasket from the exhaust pipe assembly. REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Remove the 2 nuts and front support brackets. REMOVE EXHAUST FRONT PIPE ASSEMBLY (a) Disconnect the 2 heated oxygen sensor (bank 1, 2 sensor 2) connectors.
  • Page 804 EX–4 2GR-FE EXHAUST – EXHAUST PIPE INSTALLATION INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET (a) Install the rear support bracket with the 2 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) NOTICE: Be sure to install the bracket in the correct direction.
  • Page 805 EX–5 2GR-FE EXHAUST – EXHAUST PIPE (b) Install the exhaust center pipe to the exhaust front pipe with the 2 nuts and 2 bolts. A135719 Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) INSTALL EXHAUST TAIL PIPE ASSEMBLY (a) Install 2 new gaskets to the exhaust tail pipes.
  • Page 806: Ignition System

    IG–1 2GR-FE IGNITION – IGNITION SYSTEM IGNITION SYSTEM ENGINE 2GR-FE IGNITION PARTS LOCATION ENGINE ROOM R/B - IG2 FUSE - ST/AM FUSE IGNITION COIL NOISE FILTER NOISE FILTER A137458E01...
  • Page 807 IG–2 2GR-FE IGNITION – IGNITION SYSTEM SYSTEM DIAGRAM Ignition Coil (No. 1) From Battery IGT1 C55 IGT1 Ignition Coil (No. 2) E23 Ignition Switch IGT2 C55 IGT2 Ignition Coil (No. 3) ST/AM2 From Battery IGT3 C55 IGT3 E6 Main Body ECU Ignition Coil (No.
  • Page 808 IG–3 2GR-FE IGNITION – IGNITION SYSTEM ON-VEHICLE INSPECTION NOTICE: In this section, the terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately - 10°C (14°F) to 50°C (122°F). "HOT" means approximately 50°C (122°F) to 100°C (212°F).
  • Page 809 IG–4 2GR-FE IGNITION – IGNITION SYSTEM (7) Ground the spark plugs. (8) Check if a spark occurs at each spark plug while the engine is being cranked. NOTICE: • Be sure to ground the spark plugs when checking. • Replace the ignition coil if it receives an impact.
  • Page 810 IG–5 2GR-FE IGNITION – IGNITION SYSTEM Result Result Proceed to Replace crankshaft position sensor Go to next step (6) Check the IGT signal from the ECM. Result Result Proceed to Check ECM (See page ES-234) Repair wiring between ignition coil and ECM (d) Using a 16 mm (0.63 in.) plug wrench, install the...
  • Page 811 IG–6 2GR-FE IGNITION – IGNITION SYSTEM NOTICE: Use only the listed spark plug or equivalent to ensure engine performance and smooth driveability. (d) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.4 mm (0.055 in.) If the gap is greater than the maximum, replace the spark plug.
  • Page 812: Ignition Coil

    IG–7 2GR-FE IGNITION – IGNITION COIL IGNITION COIL ENGINE 2GR-FE IGNITION COMPONENTS FRONT WIPER ARM AND 20 (204, 15) BLADE ASSEMBLY RH FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND COWL TOP VENTILATOR BLADE ASSEMBLY LH LOUVER SUB-ASSEMBLY 85 (867, 63) 7.5 (77, 66 in.*lbf)
  • Page 813 IG–8 2GR-FE IGNITION – IGNITION COIL UNION TO CHECK VALVE HOSE 21 (214, 15) 5.4 (55, 48 in.*lbf) VACUUM HOSE CLAMP THROTTLE BODY BRACKET VENTILATION HOSE 21 (214, 15) NO. 1 SURGE TANK STAY 16 (163, 12) NO. 3 WATER BY-PASS HOSE NO.
  • Page 814 IG–9 2GR-FE IGNITION – IGNITION COIL V-BANK COVER SUB-ASSEMBLY 10 (102, 10) IGNITION COIL ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY IGNITION COIL CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque A134977E01...
  • Page 815 IG–10 2GR-FE IGNITION – IGNITION COIL REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL DRAIN ENGINE COOLANT (See page CO-5) REMOVE WINDSHIELD WIPER LINK ASSEMBLY (See page WW-9) REMOVE COWL TOP PANEL OUTER SUB- ASSEMBLY (See page ES-424) REMOVE V-BANK COVER SUB-ASSEMBLY (See...
  • Page 816 IG–11 2GR-FE IGNITION – IGNITION COIL REMOVE IGNITION COIL ASSEMBLY LH Bank: (a) Disconnect the 6 ignition coil connectors. (b) Remove the 6 bolts and 6 ignition coils. RH Bank: A134966E01 INSTALLATION LH Bank: INSTALL IGNITION COIL ASSEMBLY (a) Install the 6 ignition coils with the 6 bolts.
  • Page 817 IG–12 2GR-FE IGNITION – IGNITION COIL (b) Install the bolt and clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See page EM-42) INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-506) CONNECT CABLE TO NEGATIVE BATTERY...
  • Page 818: Lubrication System

    LU–1 2GR-FE LUBRICATION – LUBRICATION SYSTEM LUBRICATION SYSTEM ON-VEHICLE INSPECTION CHECK ENGINE OIL LEVEL (a) Warm up the engine, stop it and wait 5 minutes. The oil level should be between the dipstick's low level mark and full level mark.
  • Page 819 LU–2 2GR-FE LUBRICATION – LUBRICATION SYSTEM (h) Remove the oil pressure gauge. Adhesive Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent A050082E14 Using a 24 mm deep socket wrench, install the oil pressure switch.
  • Page 820: Oil Filter

    LU–3 2GR-FE LUBRICATION – OIL FILTER OIL FILTER ENGINE 2GR-FE LUBRICATION COMPONENTS OIL FILTER ELEMENT 25 (255, 18) O-RING OIL FILTER CAP ASSEMBLY 13 (127, 10) OIL FILTER DRAIN PLUG Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque A133361E01...
  • Page 821 LU–4 2GR-FE LUBRICATION – OIL FILTER REPLACEMENT CAUTION: • Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
  • Page 822 LU–5 2GR-FE LUBRICATION – OIL FILTER (c) Insert the pipe with the hose into the oil filter cap. NOTICE: Be sure to insert the pipe with the O-ring installed on the oil filter cap side. HINT: Place the hose end into a container before draining the oil from the hose.
  • Page 823 LU–6 2GR-FE LUBRICATION – OIL FILTER (d) Remove all dirt and foreign matter from the installation surface and the inside of the cap on the engine side. (e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
  • Page 824: Oil Pump

    LU–7 2GR-FE LUBRICATION – OIL PUMP OIL PUMP ENGINE 2GR-FE LUBRICATION COMPONENTS OIL LEVEL GAUGE OIL STRAINER SUB-ASSEMBLY NO. 2 OIL LEVEL GASKET GAUGE GUIDE 21 (214, 15) 10 (102, 7) 10 (102, 7) 21 (214, 15) GASKET 21 (214, 15) O-RING NO.
  • Page 825 LU–8 2GR-FE LUBRICATION – OIL PUMP SEAL WASHER 10 (102, 7) CYLINDER HEAD CYLINDER HEAD COVER SUB-ASSEMBLY 21 (214, 15) COVER SUB-ASSEMBLY (for Bank 1) (for Bank 2) 10 (102, 7) 10 (102, 7) 10 (102, 7) SEAL WASHER OIL CONTROL...
  • Page 826 LU–9 2GR-FE LUBRICATION – OIL PUMP OIL PUMP GASKET TIMING CHAIN COVER SUB-ASSEMBLY 43 (438, 32) TIMING CHAIN CASE OIL SEAL 21 (214, 15) CRANKSHAFT PULLEY 250 (2,550, 184) 21 (214, 15) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part...
  • Page 827 LU–10 2GR-FE LUBRICATION – OIL PUMP TIMING CHAIN COVER SUB-ASSEMBLY OIL PUMP ROTOR SET DRIVEN ROTOR DRIVE ROTOR OIL PUMP COVER OIL PUMP RELIEF VALVE RELIEF VALVE SPRING 9.1 (93, 81 in.*lbf) 49 (500, 37) PLUG N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 828 LU–11 2GR-FE LUBRICATION – OIL PUMP REMOVAL REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page EM-29) SECURE ENGINE (See page EM-30) REMOVE INTAKE AIR SURGE TANK ASSEMBLY (See page FU-13) REMOVE IGNITION COIL ASSEMBLY (See page REMOVE NO. 2 ENGINE MOUNTING STAY RH (See...
  • Page 829 LU–12 2GR-FE LUBRICATION – OIL PUMP 25. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See page EM-70) 26. REMOVE OIL STRAINER SUB-ASSEMBLY (See page EM-70) 27. REMOVE OIL PAN SUB-ASSEMBLY (See page 28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove the 23 bolts and 2 nuts as shown in the illustration.
  • Page 830 LU–13 2GR-FE LUBRICATION – OIL PUMP 29. REMOVE TIMING CHAIN CASE OIL SEAL Protective Tape (a) Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. Wooden Block A128007E01 DISASSEMBLY REMOVE OIL PUMP RELIEF VALVE (a) Using a 27 mm socket wrench, remove the relief valve plug.
  • Page 831 LU–14 2GR-FE LUBRICATION – OIL PUMP (b) Check the tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotors, as shown in the illustration. Tip clearance Standard Maximum 0.060 to 0.160 mm (0.0024 to 0.0063 in.) 0.16 mm (0.0063 in.)
  • Page 832 LU–15 2GR-FE LUBRICATION – OIL PUMP INSTALL OIL PUMP RELIEF VALVE (a) Coat the oil pump relief valve with engine oil. (b) Insert the relief valve and relief valve spring into the oil pump cover hole. (c) Using a 27 mm socket wrench, install the plug.
  • Page 833 LU–16 2GR-FE LUBRICATION – OIL PUMP Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 mm (0.118 in.) NOTICE: • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
  • Page 834 (0.079 to 0.118 in.) (0.118 to 0.158 in.) Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent) Alternate long and short dashed line area...
  • Page 835 LU–18 2GR-FE LUBRICATION – OIL PUMP NOTICE: • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing. • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  • Page 836 LU–19 2GR-FE LUBRICATION – OIL PUMP Bolt length Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTICE: Make sure that there is no oil on the bolt threads.
  • Page 837 LU–20 2GR-FE LUBRICATION – OIL PUMP 17. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See page EM-39) 18. INSTALL NO. 2 TIMING GEAR COVER (See page 19. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-39) 20. INSTALL ENGINE MOUNTING BRACKET RH (See page EM-40) 21.
  • Page 838: Charging System

    CH–1 2GR-FE CHARGING – CHARGING SYSTEM CHARGING SYSTEM PRECAUTION Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester.
  • Page 839 CH–2 2GR-FE CHARGING – CHARGING SYSTEM PARTS LOCATION COMBINATION METER -CHARGE WARNING LIGHT GENERATOR INSTRUMENT PANEL J/B -GAUGE NO. 1 FUSE -GAUGE NO. 2 FUSE ENGINE ROOM R/B -ALT-S FUSE -ALT FUSE A135521E01...
  • Page 840 CH–3 2GR-FE CHARGING – CHARGING SYSTEM SYSTEM DIAGRAM ALT-S From Battery GAUGE No. 1 From IG1 Relay Combination Meter GAUGE No. 2 CHG- From IG2 Relay Charge Generator Regulator FL MAIN Battery A138773E01...
  • Page 841 CH–4 2GR-FE CHARGING – CHARGING SYSTEM PROBLEM SYMPTOMS TABLE Result Symptom Suspected area See page 1. Clutch pulley Charge Warning Light Comes ON while Driving CH-7 2. Generator assembly 1. V-ribbed belt Noise Occurs from Generator while Engine is Running 2.
  • Page 842 CH–5 2GR-FE CHARGING – CHARGING SYSTEM ON-VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte level. (1) If the electrolyte level is low, replace the battery (or add distilled water) and check the charging system. CHECK BATTERY SPECIFIC GRAVITY (a) Check the color of the indicator.
  • Page 843 CH–6 2GR-FE CHARGING – CHARGING SYSTEM (b) Check that the belt fits properly in the ribbed grooves. CORRECT INCORRECT HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
  • Page 844 CH–7 2GR-FE CHARGING – CHARGING SYSTEM 11. CHECK CHARGING CIRCUIT WITH LOAD (a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights, and turn the heater blower switch to the "HI" position. (b) Check the reading on the ammeter.
  • Page 845 CH–8 2GR-FE CHARGING – CHARGING SYSTEM Charge Warning Light Comes ON while Driving INSPECTION PROCEDURE CHECK LOCK FUNCTION OF CLUTCH PULLEY (a) Check the lock function with the pulley installed in the vehicle. (1) Visually check that the rotor in the generator operates with the engine started.
  • Page 846 CH–9 2GR-FE CHARGING – CHARGING SYSTEM Noise Occurs from Generator while Engine is Running INSPECTION PROCEDURE CHECK LOOSENESS OF V-RIBBED BELT (a) Check the tension of the belt by pushing it down with a finger. The tension of the belt is enough.
  • Page 847 CH–9 2GR-FE CHARGING – GENERATOR GENERATOR ENGINE 2GR-FE CHARGING COMPONENTS V-BANK COVER SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 1 AIR CLEANER INLET AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 848 CH–10 2GR-FE CHARGING – GENERATOR 7.0 (71, 62 in.*lbf) RADIATOR SUPPORT UPPER HOOD LOCK ASSEMBLY 7.5 (77, 66 in.*lbf) HORN CONNECTOR 7.0 (71, 62 in.*lbf) RADIATOR GRILLE 7.5 (77, 66 in.*lbf) PROTECTOR FRONT BUMPER ENERGY ABSORBER ENGINE UNDER COVER LH...
  • Page 849 CH–11 2GR-FE CHARGING – GENERATOR V-RIBBED BELT FRONT FENDER APRON SEAL RH 9.8 (100, 87 in.*lbf) WIRE HARNESS 8.4 (86, 74 in.*lbf) CLAMP STAY 43 (438, 32) RADIATOR INLET HOSE RADIATOR OUTLET HOSE 20 (204, 15) 43 (438, 32) 20 (204, 15)
  • Page 850 CH–12 2GR-FE CHARGING – GENERATOR GENERATOR DRIVE END FRAME BEARING RETAINER GENERATOR PULLEY CAP GENERATOR WASHER 2.3 (23, 20 in.*lbf) GENERATOR ROTOR ASSEMBLY GENERATOR DRIVE END FRAME BEARING 111 (1,125, 81) GENERATOR CLUTCH PULLEY GENERATOR REAR END COVER GENERATOR TERMINAL INSULATOR 4.6 (47, 41 in.*lbf)
  • Page 851 CH–13 2GR-FE CHARGING – GENERATOR REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH...
  • Page 852 CH–14 2GR-FE CHARGING – GENERATOR 26. REMOVE GENERATOR ASSEMBLY (a) Remove the terminal cap. (b) Remove the nut and disconnect the wire harness from terminal B. (c) Disconnect the generator connector from the generator assembly. (d) Disconnect the connector from the compressor and magnetic clutch.
  • Page 853 CH–15 2GR-FE CHARGING – GENERATOR DISASSEMBLY REMOVE GENERATOR CLUTCH PULLEY (a) Using a screwdriver, remove the generator pulley cap. A128068E01 (b) Set SST (A) and (B). 09820-63020 (c) Clamp SST (A) in a vise. SST (A) SST (B) A128069E01 (d) Place the rotor shaft end into SST (A).
  • Page 854 CH–16 2GR-FE CHARGING – GENERATOR REMOVE GENERATOR REAR END COVER (a) Place the generator assembly on the clutch pulley. A135197 (b) Remove the 3 nuts and generator rear end cover. A128071 REMOVE GENERATOR TERMINAL INSULATOR (a) Remove the terminal insulator from the generator coil.
  • Page 855 CH–17 2GR-FE CHARGING – GENERATOR (b) Using SST, remove the generator coil assembly. Turn 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) Hold A118275E01 REMOVE GENERATOR ROTOR ASSEMBLY (a) Remove the generator washer. A118365E01 (b) Remove the generator rotor assembly.
  • Page 856 CH–18 2GR-FE CHARGING – GENERATOR INSPECTION INSPECT GENERATOR CLUTCH PULLEY (a) Hold the center of the pulley, and confirm that the Free Lock outer ring turns counterclockwise and does not turn clockwise. If the result is not as specified, replace the clutch pulley.
  • Page 857 CH–19 2GR-FE CHARGING – GENERATOR (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: Diameter 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than the minimum, replace the generator rotor assembly.
  • Page 858 CH–20 2GR-FE CHARGING – GENERATOR (c) Place a new generator washer on the generator rotor. A118365E01 INSTALL GENERATOR COIL ASSEMBLY Deep socket (a) Using a deep socket wrench (21 mm) and a press, wrench (21 mm) slowly press in the generator coil assembly.
  • Page 859 CH–21 2GR-FE CHARGING – GENERATOR INSTALL GENERATOR TERMINAL INSULATOR (a) Install the terminal insulator to the generator coil. NOTICE: Pay attention to installation direction of the terminal insulator. A128083E01 INSTALL GENERATOR REAR END COVER (a) Install the generator rear end cover to the generator coil with the 3 nuts.
  • Page 860 CH–22 2GR-FE CHARGING – GENERATOR Tighten the pulley by turning SST (B) in the direction shown in the illustration. Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf) NOTICE: The torque shown above should be used for tightening without using the SST. When the SST...
  • Page 861 CH–23 2GR-FE CHARGING – GENERATOR (e) Install the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) A133866 Connect the generator connector to the generator assembly. (g) Install the generator wire with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (h) Install the terminal cap.
  • Page 862 CH–24 2GR-FE CHARGING – GENERATOR 17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-51) 18. ADD ENGINE COOLANT (See page CO-6) 19. CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) 20. INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) 21. INSTALL COOL AIR INTAKE DUCT SEAL (See page EM-52) 22.
  • Page 863: Starting System

    ST–1 2GR-FE STARTING – STARTING SYSTEM STARTING SYSTEM ENGINE 2GR-FE STARTING PARTS LOCATION STARTER TRANSMISSION ENGINE ROOM R/B CONTROL ECU -STARTER RELAY -IGNITION RELAY PARK/NEUTRAL POSITION SWITCH -STARTER CUT RELAY -IG2 FUSE -AM2 FUSE -ST/AM2 FUSE -ALT FUSE MAIN BODY ECU...
  • Page 864 ST–2 2GR-FE STARTING – STARTING SYSTEM SYSTEM DIAGRAM without Smart Key System: Transmission Control ECU NSW C56 Park/Neutral Position Switch STA C56 E23 Ignition Switch ST/AM2 Starter FL MAIN Battery A135061E01...
  • Page 865 ST–3 2GR-FE STARTING – STARTING SYSTEM with Smart Key System: Main Body ECU From Battery STR2 ST CUT STAR From Battery IG2D ST/AM2 From Battery Park/Neutral Position Switch A135062E01...
  • Page 866 ST–4 2GR-FE STARTING – STARTING SYSTEM SSW1 SSW2 Engine Switch Free Full Traveling GND 5 Starter Battery A135063E01...
  • Page 867 ST–5 2GR-FE STARTING – SMART KEY SYSTEM SMART KEY SYSTEM PRECAUTION EMERGENCY ENGINE START CONTROL (a) If there is a malfunction in the stop light switch or STOP fuse, their signals may not be correctly transmitted to the main body ECU. This may result...
  • Page 868 ST–6 2GR-FE STARTING – SMART KEY SYSTEM PARTS LOCATION PARK / NEUTRAL POSITION SWITCH ECM (2GR-FE) ENGINE ROOM J/B AND R/B - AM2 FUSE - ST / AM2 FUSE WIRELESS BUZZER - IG2 FUSE - ECU-B NO. 1 FUSE - IG2 RELAY...
  • Page 869 ST–7 2GR-FE STARTING – SMART KEY SYSTEM CERTIFICATION ID CODE BOX COMBINATION METER TURN SIGNAL FLASHER ASSEMBLY STOP LIGHT SWITCH DLC3 MAIN BODY ECU SHIFT LOCK CONTROL ECU (INSTRUMENT PANEL J/B) ENGINE SWITCH - IG1 RELAY - ACC RELAY STEERING LOCK ECU - ECU-ACC FUSE - ECU IG NO.
  • Page 870 ST–8 2GR-FE STARTING – SMART KEY SYSTEM SYSTEM DIAGRAM Engine Switch MAIN BODY ECU From Battery SSW1 SSW2 CAN Line Stop Light Switch Shift Lock Control ECU Combination Meter Steering Lock ECU LIN1 IG1D ID Code Box IG2D Certification ECU...
  • Page 871 ST–9 2GR-FE STARTING – SMART KEY SYSTEM STSW Park / Neutral Position Switch TACH GND1 GND2 ACCR Transmission Control ECU MAIN BODY ECU STAR ACCR TACH STSW Starter Crankshaft Position Sensor Battery B137970E01 Communication table: Transmitting ECU Receiving ECU Signal...
  • Page 872 ST–10 2GR-FE STARTING – SMART KEY SYSTEM Transmitting ECU Receiving ECU Signal Communication method (Transmitter) (Receiver) Starter signal Main body ECU Shift position signal Engine revolution speed signal Engine switch position signal Courtesy light switch signal Main body ECU Certification ECU...
  • Page 873 ST–11 2GR-FE STARTING – SMART KEY SYSTEM SYSTEM DESCRIPTION PUSH-BUTTON START FUNCTION DESCRIPTION (a) The push-button start function uses a push-type engine switch, which the driver can operate by merely carrying the electrical key. This system consists primarily of the main body ECU, engine...
  • Page 874 ST–12 2GR-FE STARTING – SMART KEY SYSTEM CONSTRUCTION AND OPERATION Indicator Light (a) Engine Switch The engine switch consists of a momentary type switch, 3 color (amber, green, greenish white) LEDs, and a transponder key amplifier. START • The greenish white LED is for illumination.
  • Page 875 ST–13 2GR-FE STARTING – SMART KEY SYSTEM Brake Pedal Shift Lever Power Source Mode Pattern When the engine switch is pushed with power P position source mode on (IG) (engine running). on (IG) → off • When the engine switch is pushed with power Except P position source mode on (IG) (engine running).
  • Page 876 ST–14 2GR-FE STARTING – SMART KEY SYSTEM • The illustration below shows the transition of power source modes. Transition of power source mode: Shift Position Except P and N Engine Switch Position Engine Engine Engine Engine Engine Engine switch switch...
  • Page 877 ST–15 2GR-FE STARTING – SMART KEY SYSTEM HINT: While the vehicle is being driven normally, operation of the engine switch is disabled. However, if the engine must be stopped in an emergency while the vehicle is being driven, pressing the engine switch for 3 seconds or more stops the engine.
  • Page 878 ST–16 2GR-FE STARTING – SMART KEY SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the push- button start function. • The intelligent tester should be used in steps 4, 5 and 8. VEHICLE BROUGHT TO WORKSHOP...
  • Page 879 ST–17 2GR-FE STARTING – SMART KEY SYSTEM Result Result Proceed to CAN DTC is not output CAN DTC is output GO TO CAN COMMUNICATION SYSTEM CHECK FOR DTC (a) Check for DTCs and note any codes that are output (See page ST-26).
  • Page 880 ST–18 2GR-FE STARTING – SMART KEY SYSTEM Go to step 9 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page ST-19) (b) DATA LIST/ACTIVE TEST (See page ST-26) NEXT REPAIR OR REPLACE NEXT CONFIRMATION TEST NEXT...
  • Page 881 ST–19 2GR-FE STARTING – SMART KEY SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area"...
  • Page 882 ST–20 2GR-FE STARTING – SMART KEY SYSTEM TERMINALS OF ECU CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B) Front Side: Back Side: B112605E03 (a) Disconnect the IR, IA, IK, ID, IF, IM E6, E7 and E8 ECU connectors.
  • Page 883 ST–21 2GR-FE STARTING – SMART KEY SYSTEM (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AM1 (E7-6) - Body ground L - Body ground +B power supply...
  • Page 884 ST–22 2GR-FE STARTING – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Output voltage at terminal P (E9-2) - GND3 (E8-1) G - W-B Shift lock signal Shift lever P position AM1 or AM2 is -2 V or more.
  • Page 885 ST–23 2GR-FE STARTING – SMART KEY SYSTEM (2) Waveform 2 Waveform 2 (Reference): Terminal No. E8-8 (TACH) - Body ground Tool Setting 5 V/DIV., 10 ms./DIV. Vehicle Condition Engine idling HINT: As the engine revolution speed increases, the wavelength shortens.
  • Page 886 ST–24 2GR-FE STARTING – SMART KEY SYSTEM CHECK ECM A107881E32 (a) Disconnect the C55 and A55 ECM connectors. (b) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition...
  • Page 887 ST–25 2GR-FE STARTING – SMART KEY SYSTEM If the result is not as specified, the ECM may have a malfunction. (e) Using an oscilloscope, check the signal waveform of the ECM. Waveform 1 (Reference): Terminal No. A55-15 (TACH) - C55-81 (E1) Tool Setting 5 V/DIV., 10 ms./DIV.
  • Page 888 ST–26 2GR-FE STARTING – SMART KEY SYSTEM DIAGNOSIS SYSTEM DESCRIPTION (a) Push-button start function data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the function seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs.
  • Page 889 ST–27 2GR-FE STARTING – SMART KEY SYSTEM HINT: Connect the cable of the intelligent tester to the DLC3, turn the engine switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester.
  • Page 890 ST–28 2GR-FE STARTING – SMART KEY SYSTEM DATA LIST / ACTIVE TEST READ DATA LIST HINT: Using the intelligent tester to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This...
  • Page 891 ST–29 2GR-FE STARTING – SMART KEY SYSTEM Measurement Item / Display Item Normal Condition Diagnostic Note (Range) Starter request signal monitor / ON: ST relay is ON Engine switch pressed and held ST REQUEST SIG ON or OFF OFF: ST relay is OFF...
  • Page 892 ST–30 2GR-FE STARTING – SMART KEY SYSTEM DIAGNOSTIC TROUBLE CODE CHART PUSH-BUTTON START FUNCTION: DTC No. Detection Item Trouble Area See page B2271 Ignition Hold Monitor Malfunction 1. AM2 fuse ST-31 2. Main body ECU (Instrument panel J/B) 3. Wire harness or connector...
  • Page 893 ST–31 2GR-FE STARTING – SMART KEY SYSTEM DTC No. Detection Item Trouble Area See page B2287 LIN Communication Master 1. Main body ECU (Instrument ST-85 Malfunction panel J/B) 2. Certification ECU 3. Wire harness or connector B2288 Steering Lock Signal Circuit 1.
  • Page 894 ST–32 2GR-FE STARTING – SMART KEY SYSTEM ON-VEHICLE INSPECTION CHECK POWER SOURCE MODE CHANGE FUNCTION (a) Check the function of the engine switch. (1) Check that power source mode changes in accordance with the conditions of the shift position and brake pedal.
  • Page 895 ST–33 2GR-FE STARTING – SMART KEY SYSTEM B2271 Ignition Hold Monitor Malfunction DESCRIPTION This DTC is output when a problem such as an open in the AM2 fuse, an open or short in the wire harness between the fuse and main body ECU, a short in the IG output circuit inside the main body ECU, a short between the main body ECU and relay, and a short in the relay is detected.
  • Page 896 ST–34 2GR-FE STARTING – SMART KEY SYSTEM No DTC is output. Go to step 2 CHECK INTERMITTENT PROBLEMS INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω...
  • Page 897 ST–35 2GR-FE STARTING – SMART KEY SYSTEM REPLACE MAIN BODY ECU...
  • Page 898 ST–36 2GR-FE STARTING – SMART KEY SYSTEM B2272 Ignition 1 Monitor Malfunction DESCRIPTION This DTC is output when there is a problem in the IG1D output circuit, which is from the inside of the main body ECU to the IG1 relay.
  • Page 899 ST–37 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Select the item below in the Data List, and read the display on the tester. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until...
  • Page 900 ST–38 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (IG1 RELAY) (a) Remove the IG1 relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3 - 5 10 kΩ...
  • Page 901 ST–39 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below.
  • Page 902 ST–40 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified value Below 1 Ω IF-10 - IG1 relay terminal-1 Always Below 1 Ω Il-9 - IG1 relay terminal-2 Always IF-10 - Body ground Always 10 kΩ or higher...
  • Page 903 ST–41 2GR-FE STARTING – SMART KEY SYSTEM B2273 Ignition 2 Monitor Malfunction DESCRIPTION This DTC is output when there is a problem in the IG2D output circuit, which is from the inside of the main body ECU to the IG2 relay.
  • Page 904 ST–42 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Read the Data List according to the displays on the tester. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until...
  • Page 905 ST–43 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (IG2 RELAY) (a) Remove the IG2 relay from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3 - 5 10 kΩ...
  • Page 906 ST–44 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Specified Terminal No. (Symbol) Condition Condition Engine Room R/B IG2 relay terminal 1 - Below 1 Ω Always E6-11 (IG2D) Engine Room R/B IG2 relay terminal 2 - Below 1 Ω...
  • Page 907 ST–45 2GR-FE STARTING – SMART KEY SYSTEM B2274 ACC Monitor Malfunction DESCRIPTION This DTC is output when there is a problem in the ACCD output circuit, which is from the inside of the main body ECU to the ACC relay.
  • Page 908 ST–46 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG) and turn the intelligent tester main switch on. (c) Read the Data List according to the displays on the tester. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until...
  • Page 909 ST–47 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (ACC RELAY) (a) Remove the ACC relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3 - 5 10 kΩ...
  • Page 910 ST–48 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below.
  • Page 911 ST–49 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified Condition ACC relay terminal 1 - Below 1 Ω Always IF-10 ACC relay terminal 2 - II- Below 1 Ω Always IF-10 - Body ground Always 10 kΩ or higher...
  • Page 912 ST–50 2GR-FE STARTING – SMART KEY SYSTEM B2275 STSW Monitor Malfunction DESCRIPTION This DTC is output when there is an open, short, or any other problem in the engine start request output circuit inside the main body ECU or in the external circuit.
  • Page 913 ST–51 2GR-FE STARTING – SMART KEY SYSTEM CHECK INTERMITTENT PROBLEMS CHECK WIRE HARNESS (MAIN BODY ECU - ECM) (a) Disconnect the E9 ECU connector. Wire Harness Side: Main Body ECU STSW STSW B137996E02 (b) Disconnect the A55 ECM connector. (c) Measure the resistance according to the value(s) in the table below.
  • Page 914 ST–52 2GR-FE STARTING – SMART KEY SYSTEM INSPECT MAIN BODY ECU (a) Reconnect the connectors. (b) Measure the voltage according to the value(s) in the table below. Main Body ECU Standard voltage Terminal No. (Symbol) Condition Specified Condition Brake pedal depressed,...
  • Page 915 ST–53 2GR-FE STARTING – SMART KEY SYSTEM B2276 ACCR Signal Circuit Malfunction DESCRIPTION This DTC is output when the ACCR output circuit inside the main body ECU is open or shorted. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode.
  • Page 916 ST–54 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - ECM) (a) Disconnect the E6 ECU connector. Wire Harness Side: Main Body ECU ACCR ACCR B138005E01 (b) Disconnect the A55 ECM connector. (c) Measure the resistance according to the value(s) in the table below.
  • Page 917 ST–55 2GR-FE STARTING – SMART KEY SYSTEM INSPECT MAIN BODY ECU (a) Reconnect the connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Terminal No. (Symbol) Condition Specified Condition Main Body ECU Brake pedal depressed, 0.1 to 0.8 V →...
  • Page 918 ST–56 2GR-FE STARTING – SMART KEY SYSTEM B2277 Detecting Vehicle Submersion DESCRIPTION This DTC is output when the submersion circuit monitor inside the main body ECU detects that the vehicle is submerged in water. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode.
  • Page 919 ST–57 2GR-FE STARTING – SMART KEY SYSTEM B2278 Engine Switch Circuit Malfunction DESCRIPTION This DTC is output when 1) a malfunction is detected between the main body ECU and the engine switch; or 2) either of the switches inside the engine switch is malfunctioning.
  • Page 920 ST–58 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Switch SSW1 SSW2 SS1 GND Free Full Travelling B112447E03 INSPECTION PROCEDURE READ VALUE OF INTELLIGENT TESTER (START SWITCH) (a) Connect the intelligent tester to the DLC3. (b) Check the DATA LIST for proper functioning of the start switch.
  • Page 921 ST–59 2GR-FE STARTING – SMART KEY SYSTEM MAIN BODY: Measurement Item/Display Item Normal Condition Diagnostic Note (Range) ON: Engine switch on (IG) STSW1 Start Switch 1/ON or OFF OFF: Engine switch off ON: Engine switch on (IG) START SW2 Start Switch 2/ON or OFF...
  • Page 922 ST–60 2GR-FE STARTING – SMART KEY SYSTEM (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Condition Specified Condition (Symbols) Below 1 Ω 7 (SS1) - 5 (GND) Pushed Below 1 Ω...
  • Page 923 ST–61 2GR-FE STARTING – SMART KEY SYSTEM REPLACE MAIN BODY ECU...
  • Page 924 ST–62 2GR-FE STARTING – SMART KEY SYSTEM B2281 "P" Signal Malfunction DESCRIPTION The main body ECU and the shift lock control ECU are connected by a cable and the CAN. If the cable information and CAN information are inconsistent, this DTC will be output.
  • Page 925 ST–63 2GR-FE STARTING – SMART KEY SYSTEM "ON" (P signal is ON) and "OFF" (P signal is OFF) appear on the screen. Go to step 2 GO TO SHIFT CONTROL SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - SHIFT LOCK CONTROL ECU) (a) Disconnect the E9 and E57 ECU connectors.
  • Page 926 ST–64 2GR-FE STARTING – SMART KEY SYSTEM Engine can start normally. GO TO SHIFT CONTROL SYSTEM END (MAIN BODY ECU DEFECTIVE)
  • Page 927 ST–65 2GR-FE STARTING – SMART KEY SYSTEM B2282 Vehicle Speed Signal Malfunction DESCRIPTION The main body ECU and the combination meter are connected by a cable and the CAN. DTC B2282 is output when: 1) the cable information and CAN information are inconsistent; and 2) a malfunction is detected between the vehicle speed sensor and combination meter.
  • Page 928 ST–66 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Combination Meter Main Body ECU Stereo Component Amplifier Radio Receiver Radio and Display Tire Pressure Warning ECU Transmission Control ECU A55 ECM SPD1 B137981E01 HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter.
  • Page 929 ST–67 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer in the combination meter is normal. Actual vehicle speed and the speed indicated on the speedometer are the same.
  • Page 930 ST–68 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Combination Meter Main Body ECU B137982E01 (b) Disconnect the F2 meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition...
  • Page 931 ST–69 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) Measure the resistance according to the value(s) in the Wire Harness Side: table below. Standard resistance E8 Main Body ECU Tester Connection Condition Specified Condition...
  • Page 932 ST–70 2GR-FE STARTING – SMART KEY SYSTEM INSPECT MAIN BODY ECU (SPEED SIGNAL) (a) Check the input signal waveform. (1) Reconnect the connectors. (2) Remove the combination meter assembly with the connector(s) still connected. Main Body ECU (3) Connect an oscilloscope to terminal E8-9 (SPD) and body ground.
  • Page 933 ST–71 2GR-FE STARTING – SMART KEY SYSTEM B2283 Vehicle Speed Sensor Malfunction DESCRIPTION The skid control ECU converts these signals into 4-pulse signals and sends them to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the main body ECU.
  • Page 934 ST–72 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE CHECK DTC OUTPUT (SMART KEY SYSTEM) (a) Delete the DTCs (See page ST-26). (b) After all DTCs are cleared, check if the trouble occurs again 320 seconds after the engine switch is turned on (IG).
  • Page 935 ST–73 2GR-FE STARTING – SMART KEY SYSTEM REPLACE MAIN BODY ECU...
  • Page 936 ST–74 2GR-FE STARTING – SMART KEY SYSTEM B2284 Brake Signal Malfunction DESCRIPTION This DTC is output when: 1) the brake signal circuit between the main body ECU and the stop light switch is malfunctioning; and 2) the CAN information is inconsistent.
  • Page 937 ST–75 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Instrument Panel J/B Stop Light Switch To ECM From Battery Instrument Panel J/B STOP SW From Battery CAN Line B137985E01 INSPECTION PROCEDURE EMERGENCY ENGINE START CONTROL (a) If there is a malfunction in the stop light switch or STOP fuse, their signals may not be correctly transmitted to the main body ECU.
  • Page 938 ST–76 2GR-FE STARTING – SMART KEY SYSTEM HINT: Before performing the inspection, depress the brake pedal and check that the stop lights come on. If the stop lights do not come on when the brake pedal is depressed, refer to the page shown in the brackets (See page LI-12).
  • Page 939 ST–77 2GR-FE STARTING – SMART KEY SYSTEM INSPECT FUSE (STOP SW) (a) Remove the STOP SW fuse from the instrument panel J/ (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω REPLACE FUSE CHECK WIRE HARNESS (BATTERY - MAIN BODY ECU) (a) Disconnect the IL ECU connector.
  • Page 940 ST–78 2GR-FE STARTING – SMART KEY SYSTEM REPLACE MAIN BODY ECU...
  • Page 941 ST–79 2GR-FE STARTING – SMART KEY SYSTEM Steering Lock Position Signal Circuit Malfunc- B2285 tion DESCRIPTION This DTC is output when serial communication signals and LIN communication signals in the circuit between the main body ECU and steering lock actuator (steering lock ECU) are inconsistent.
  • Page 942 ST–80 2GR-FE STARTING – SMART KEY SYSTEM (b) Check the DATA LIST for proper functioning of the steering lock function. HINT: When using the intelligent tester with the engine switch off, turn on and off any of the door courtesy light switches repeatedly at 1.5 second intervals or less until...
  • Page 943 ST–81 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Main Body ECU Main Body ECU LIN1 Steering Lock ECU SLP1 B137995E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition...
  • Page 944 ST–82 2GR-FE STARTING – SMART KEY SYSTEM CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the engine starts (See page ST-30). Engine can start normally. REPLACE STEERING LOCK ECU...
  • Page 945 ST–83 2GR-FE STARTING – SMART KEY SYSTEM B2286 Runnable Signal Malfunction DESCRIPTION This DTC is output when serial communication signals and CAN communication signals in the circuit between the main body ECU and ECM are inconsistent. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode.
  • Page 946 ST–84 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU DLC3 TACH TACH B137988E01 INSPECTION PROCEDURE CHECK OPERATION OF TACHOMETER (a) Run the engine and check if the function of the tachometer in the combination meter is normal.
  • Page 947 ST–85 2GR-FE STARTING – SMART KEY SYSTEM CHECK DTC OUTPUT (CAN COMMUNICATION SYSTEM) (a) Delete the DTCs (See page ST-26). (b) Check for CAN communication system DTC U0146. HINT: If the DTCs for the CAN communication system malfunction are output, inspect those DTCs first (See page CA-31).
  • Page 948 ST–86 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Tester Connection Condition Specified Condition (Symbols) E8-8 (TACH) - A55-15 Below 1 Ω Always (TACH) E8-8 (TACH) or A55-15 Always 10 kΩ or higher (TACH) - Body ground REPAIR OR REPLACE HARNESS OR...
  • Page 949 ST–87 2GR-FE STARTING – SMART KEY SYSTEM B2287 LIN Communication Master Malfunction DESCRIPTION This DTC is output when there is a LIN communication problem between the main body ECU and certification ECU. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode.
  • Page 950 ST–88 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Certification ECU Instrument Panel J/B LIN1 B137989E01 INSPECTION PROCEDURE CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). (b) Check for DTC B2287 and B2785. Result Display (DTC output) Proceed to "DTC B2287"...
  • Page 951 ST–89 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Certification ECU Main Body ECU LIN1 B137998E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (Symbols) IR-9 (LIN1) - E58-10 Below 1 Ω...
  • Page 952 ST–90 2GR-FE STARTING – SMART KEY SYSTEM B2288 Steering Lock Signal Circuit Malfunction DESCRIPTION This DTC is output when the main body ECU cannot detect the unlock condition of the steering lock within a specified time. HINT: When the main body ECU is replaced with a new one and the negative (-) battery terminal is connected, the power source mode becomes the IG-ON mode.
  • Page 953 ST–91 2GR-FE STARTING – SMART KEY SYSTEM DTC B2785, DTC B2287 and DTC B2781 are not output. HINT: • If DTC B2785 is output (See page EI-29). • If DTC B2287 is output (See page ST-85). • If DTC B2271 is output (See page ST-31).
  • Page 954 ST–92 2GR-FE STARTING – SMART KEY SYSTEM CHECK MAIN BODY ECU OPERATION (a) After replacing the main body ECU with a normally functioning ECU, check that the steering lock/unlock function operates normally. Steering lock/unlock function operates normally. HINT: If steering lock/unlock function does not operate, refer to...
  • Page 955 ST–93 2GR-FE STARTING – SMART KEY SYSTEM B2289 Key Collation Waiting Time Over DESCRIPTION This DTC is output when there is a LIN communication problem between the main body ECU and certification ECU or when there is a problem in the engine immobiliser system.
  • Page 956 ST–94 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Certification ECU Instrument Panel J/B LIN1 B137989E02 INSPECTION PROCEDURE CHECK FOR DTCS (a) Delete the DTCs (See page ST-26). (b) Check for DTC B2289 and B2785. Result Display (DTC output) Proceed to "DTC B2289"...
  • Page 957 ST–95 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Certification ECU Main Body ECU LIN1 B137998E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (Symbols) IR-9 (LIN1) - E58-10 Below 1 Ω...
  • Page 958 ST–96 2GR-FE STARTING – SMART KEY SYSTEM END (MAIN BODY ECU DEFECTIVE)
  • Page 959 ST–97 2GR-FE STARTING – SMART KEY SYSTEM Engine does not Start DESCRIPTION ENGINE START SYSTEM FUNCTION (a) If the engine switch is pressed with the shift lever in the P or N position and the brake pedal depressed, the main body ECU determines that it is an engine start request.
  • Page 960 ST–98 2GR-FE STARTING – SMART KEY SYSTEM MAIN BODY ECU Engine Switch From Battery SSW1 SSW2 CAN Line Stop Light Switch Shift Lock Control ECU Combination Meter Steering Lock ECU LIN1 IG1D ID Code Box IG2D Certification ECU ACCD ST CUT...
  • Page 961 ST–99 2GR-FE STARTING – SMART KEY SYSTEM STSW Park / Neutral Position Switch TACH GND1 GND2 ACCR Transmission Control ECU MAIN BODY ECU STAR ACCR TACH STSW Starter Crankshaft Position Sensor Battery B137970E02 WIRING DIAGRAM See CRANKING HOLDING FUNCTION CIRCUIT (See page ES-455).
  • Page 962 ST–100 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE EMERGENCY ENGINE START CONTROL (a) If there is a malfunction in the stop light switch or STOP fuse, their signals may not be correctly transmitted to the main body ECU. This may result in the engine not starting even if the engine switch is pressed while the brake pedal is depressed and the shift lever is in the P position.
  • Page 963 ST–101 2GR-FE STARTING – SMART KEY SYSTEM HINT: • If smart key system (start) DTCs are output (See page ST-28). • If smart key system (entry) DTCs are output (See page DL-159). • If electrical steering lock DTCs are output (See page EI-25).
  • Page 964 ST–102 2GR-FE STARTING – SMART KEY SYSTEM (b) Turn the engine switch on (IG). (c) Read the DATA LIST according to the displays on the tester screen. MAIN BODY: Measurement Item/Range Item Normal Condition Diagnostic Note (Display) ON: Shift position is P...
  • Page 965 ST–103 2GR-FE STARTING – SMART KEY SYSTEM HINT: If the result is not as specified, perform troubleshooting for DTCs B2285 and B2288 first (See page ST-28). GO TO DTC B2285 CHECK STEERING LOCK (a) Check if the steering lock is released when turning the engine switch on (ACC).
  • Page 966 ST–104 2GR-FE STARTING – SMART KEY SYSTEM INSPECT ECM (ACCR VOLTAGE) (a) Reconnect the connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Main Body ECU Condition Specified Condition (Symbols) Brake pedal depressed, →...
  • Page 967 ST–105 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Main Body ECU Engine Room R/B STR2 ST CUT Relay Terminal STAR B138009E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition...
  • Page 968 ST–106 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (ST CUT) (a) Measure the resistance of the ST CUT relay. Standard resistance Tester Connection Specified Condition 3 - 5 10 kΩ or higher Below 1 Ω 3 - 5 (when battery voltage is applied to terminals 1 and 2)
  • Page 969 ST–107 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: PNP Switch B138010E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (Symbols) Below 1 Ω C55-62 (NSW) - C1-4...
  • Page 970 ST–108 2GR-FE STARTING – SMART KEY SYSTEM CHECK HARNESS AND CONNECTOR (ECM AND STARTER - ST RELAY) (a) Disconnect the A55 ECM connector. Engine Room R/B Starter ST Relay Terminal B138011E01 (b) Disconnect the C3 starter connector. (c) Measure the resistance according the the value(s) in the table below.
  • Page 971 ST–109 2GR-FE STARTING – SMART KEY SYSTEM INSPECT ENGINE ROOM RELAY BLOCK (ST RELAY VOLTAGE) (a) Measure the voltage according to the value(s) in the table below. Engine Room R/B Standard voltage Tester Connection Condition Specified Condition ST relay terminal - 5 -...
  • Page 972 ST–110 2GR-FE STARTING – SMART KEY SYSTEM (c) Turn the engine switch on (IG). SMART ACCESS (Certification ECU): Measurement Item/Display Item Normal Condition Diagnostic Note (Range) OK: Normal L CODE CHK L code check / ON or NG Electrical key in the cabin NG: Malfunction OK is displayed on the screen.
  • Page 973 ST–111 2GR-FE STARTING – SMART KEY SYSTEM OK is displayed on the screen. HINT: If the result is not as specified, there may be a malfunction with the certification ECU or the ID code box. GO TO ENGINE IMMOBILISER SYSTEM INSPECT ID CODE BOX (a) Check the input signal waveform.
  • Page 974 ST–112 2GR-FE STARTING – SMART KEY SYSTEM Engine Switch Indicator Circuit DESCRIPTION Engine start conditions or system malfunctions can be checked by the status of the engine switch indicator light. Engine switch indicator light condition: Indicator Light Condition Power Source Mode/Condition...
  • Page 975 ST–113 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Switch INDS INDS Indicator Light INDW INDW Indicator Light SWIL SWIL Illumination B112453E04 INSPECTION PROCEDURE INSPECT ENGINE SWITCH (a) Remove the engine switch.
  • Page 976 ST–114 2GR-FE STARTING – SMART KEY SYSTEM Indicator Light INDS START STOP Illumination INDW SWIL A109252E10 (b) Apply battery voltage between the terminals of the switch, and check the illumination condition of the switch. NOTICE: • If the positive (+) lead and the negative (-) lead are incorrectly connected, the engine switch indicator will not illuminate.
  • Page 977 ST–115 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Tester Connection Condition Specified Condition E52-11 (SWIL) - E7-25 Below 1 Ω Always (SWIL) E52-12 (INDS) - E7-15 Below 1 Ω Always (INDS) E52-13 (INDW) - E7-14 Below 1 Ω Always...
  • Page 978 ST–116 2GR-FE STARTING – SMART KEY SYSTEM Power Source Mode does not Change to ON (IG and ACC) DESCRIPTION When the engine switch is pushed with the electrical key in the cabin, the main body ECU receives signals to switch the power source mode.
  • Page 979 ST–117 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Engine Room J/B Main Body ECU From Battery From IG2 Fuse Engine Room R/B To Each System IG2D Engine Switch SSW1 SSW2 Instrument Panel J/B ID Code Box LIN1 LIN1 GND1...
  • Page 980 ST–118 2GR-FE STARTING – SMART KEY SYSTEM To Each Fuse From ALT Fuse To Each Fuse Instrument Panel J/B ACCD IG1D B137992E01 INSPECTION PROCEDURE CHECK ENTRY FUNCTION DETECTION AREA (a) Inspect entry detection area. Inspection (1) When the electrical key is in either of the 2...
  • Page 981 ST–119 2GR-FE STARTING – SMART KEY SYSTEM INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω REPLACE FUSE CHECK CONNECTORS (a) Check that the connectors are securely connected and the terminals are not deformed or loose.
  • Page 982 ST–120 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. Wire Harness Side: (b) Measure the voltage according to the value(s) in the table below. Standard voltage...
  • Page 983 ST–121 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Disconnect the IF and IM ECU connectors. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below. Standard resistance...
  • Page 984 ST–122 2GR-FE STARTING – SMART KEY SYSTEM MAIN BODY: Measurement Item/Display Item Normal Condition Diagnostic Note (Range) ON: Engine switch on (IG) STSW1 Start Switch 1/ON or OFF OFF: Engine switch off ON: Engine switch on (IG) START SW2 Start Switch 2/ON or OFF...
  • Page 985 ST–123 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Main Body ECU Engine Switch SSW1 SSW2 B137980E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition (Symbols) E52-7 (SS1) - E7-17 Below 1 Ω...
  • Page 986 ST–124 2GR-FE STARTING – SMART KEY SYSTEM Power Source Mode does not Change to ON (IG) DESCRIPTION When the engine switch is pushed with the electrical key in the cabin, the main body ECU receives signals to switch the power source mode.
  • Page 987 ST–125 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Room J/B From Battery Engine Room R/B From IG2 Fuse To Each System IG2D Instrument Panel J/B GND1 GND2 From ALT Fuse To Each System IG1D B137993E01...
  • Page 988 ST–126 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω REPLACE FUSE CHECK CONNECTORS (a) Check that the connectors are securely connected and the terminals are not deformed or loose.
  • Page 989 ST–127 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. Wire Harness Side: (b) Measure the voltage according to the value(s) in the table below. Standard voltage...
  • Page 990 ST–128 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Disconnect the IF and IM ECU connectors. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below. Standard resistance...
  • Page 991 ST–129 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Main Body ECU Engine Room R/B IG2D IG2 Relay Terminal B138002E01 (b) Disconnect the E6 ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No.
  • Page 992 ST–130 2GR-FE STARTING – SMART KEY SYSTEM INSPECT RELAY (IG1 RELAY) (a) Remove the IG1 relay from the instrument panel J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3 - 5 10 kΩ...
  • Page 993 ST–131 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (INSTRUMENT PANEL J/B - BATTERY AND BODY GROUND) (a) Disconnect the IF and IA J/B connectors. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below.
  • Page 994 ST–132 2GR-FE STARTING – SMART KEY SYSTEM Standard resistance Terminal No. Condition Specified Condition IF-10 - IG1 relay Below 1 Ω Always terminal-1 II-9 - IG1 relay terminal- Below 1 Ω Always IF-10 - Body ground Always 10 kΩ or higher...
  • Page 995 ST–133 2GR-FE STARTING – SMART KEY SYSTEM Power Source Mode does not Change to ON (ACC) DESCRIPTION When the engine switch is pushed with the electrical key in the cabin, the main body ECU receives signals to switch the power source mode.
  • Page 996 ST–134 2GR-FE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Main Body ECU Engine Room J/B From Battery Instrument Panel J/B GND1 GND2 From ALT Fuse To Each System ACCD B137994E01...
  • Page 997 ST–135 2GR-FE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE INSPECT FUSE (AM2) (a) Remove the AM2 fuse from the engine room J/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω REPLACE FUSE CHECK CONNECTORS (a) Check that the connectors are securely connected and the terminals are not deformed or loose.
  • Page 998 ST–136 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BATTERY) (a) Disconnect the E6 and E7 ECU connectors. Wire Harness Side: (b) Measure the voltage according to the value(s) in the table below. Standard voltage...
  • Page 999 ST–137 2GR-FE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (MAIN BODY ECU - BODY GROUND) (a) Disconnect the IF and IM ECU connectors. Wire Harness Side: (b) Measure the resistance according to the value(s) in the table below. Standard resistance...
  • Page 1000 ST–138 2GR-FE STARTING – SMART KEY SYSTEM Wire Harness Side: Main Body ECU ACCD B138001E02 (b) Disconnect the II J/B connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. (Symbol) Condition Specified Condition Below 1 Ω...

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