Toyota Camry 2007-2009 Service Manual - 2AZ-FE_Emission_Control

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM

ENGINE2AZ-FE EMISSION CONTROL

EMISSION CONTROL SYSTEM

PARTS LOCATION

VENTILATION VALVE

VACUUM SWITCHING VALVE

EC–1

HEATED OXYGEN SENSOR

AIR FUEL RATIO SENSOR

EC

CANISTER

FUEL TANK CAP

A135646E03

EC–2

For PZEV :

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM

SYSTEM DIAGRAM

Air Cleaner

ECM

EC

Intake Manifold

EVAP VSV

Service Port

Canister

Soak Timer

Air Filter

Fuel Cap

Pump Module

Roll-over Valve

Cut-off Valve

Fuel Tank

A128935E01

Except PZEV :

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM

Air Cleaner

ECM

EC–3

Intake Manifold

EVAP VSV

Service Port

Canister

Pump Module

Roll-over Valve

Cut-off Valve

Fuel Tank

Soak Timer

Air Filter

Fuel Cap

EC

A128936E01

EC–4

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM

N17
Canister Pump Module

ECM

EC

MGND MTRB

6

Leak Detection Pump

Canister
Pressure
Sensor

Vent Valve

VLVB

9

C6 VSV (Purge)

12

1

VCC

4

VOUT

3

SGND

2

VGND

8

C22
Heated Oxgen Sensor

34
A24

70
C24

71
C24

94
C24

42
A24

49
C24

VCPP

PPMP

EPPM

VPMP

PRG

EFI-MAIN

From Battery

EFI No. 3

EFI

C15
Air Fuel Ratio Sensor

2

1

+B

HA1A

A1A-

A1A+

87
C24

64
C24

47
C24

113
C24

112
C24

109
C24

44
A24

EX1B

OX1B

HT1B

A1A-

A1A+

HA1A

MREL

A135723E01

+B

2

HT1B

1

4

3

E2

OX1B

4

3

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM

ON-VEHICLE INSPECTION

1. VISUALLY INSPECT HOSE, CONNECTIONS AND
GASKETS

(a) Check that there are no cracks, leaks or damage.

HINT:

• Detachment or other problems with the engine oil
dipstick, filler cap, PCV hose and other
components may cause the engine to run

B000412

2. INSPECT FUEL CUT RPM

(a) Start and warm up the engine.
(b) Open the throttle valve and keep the engine speed

(c) Use a sound scope to check for injector operating
(d) Check that when the accelerator pedal is released,

improperly.

• Disconnection, looseness or cracks in the parts
of the air induction system between the throttle
body and cylinder head will allow air suction and
cause an engine failure or engine malfunctions.

If the result is not as specified, replace the parts as
necessary.

at 3,000 rpm.
sounds.
injector operating sounds stop momentarily (at

2,500 rpm) and then resume (at 1400 rpm).

Standard

Item Specified condition

Fuel cut off rpm 2,500 rpm
Fuel return rpm 1,400 rpm

EC–5

EC

A128092

If the result is not specified, check the injectors,
wiring and ECM.

3. INSPECT LINE AND CONNECTORS

(a) Visually check for loose connections, sharp bends

or damage.

4. CHECK AIR TIGHTNESS IN FUEL T ANK AND FILLER
PIPE

(a) Disconnect the vent line hose from the fuel tank.
(b) Connect the pressure gauge to the fuel tank.
(c) Apply pressure to the fuel tank to create an internal

pressure of 4 kPa (41 gf/cm

2

, 0.58 psi).

(d) Check that the internal pressure of the fuel tank is

maintained for 1 minute.

(e) Check the connected portions of each hose and

pipe.

(f) Check the installed parts on the fuel tank.

If any malfunctions, damage or other problems are
found, replace the fuel tank and filler pipe.

(g) Reconnect the vent line hose to the fuel tank.

EC–6

Fuel Tank Cap

2AZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM

5. REMOVE FUEL TANK ASSEMBLY

(a) Disconnect the vent line hose from the fuel tank.
(b) Connect the pressure gauge to the fuel tank.
(c) Fill the fuel tank with fuel.

(d) Apply pressure of 4 kPa (41 gf/cm

vent port of the fuel tank.
HINT:
Check the amount of fuel in the fuel tank. When the
fuel tank is full, the float valve of the fill check valve
is closed and no air can pass through.

(e) Remove the fuel tank cap, and check that the

pressure drops.
If the pressure does not drop, replace the fuel tank
assembly.

(f) Reconnect the vent line hose to the fuel tank.

A126204E01

2

, 0.58 psi) to the

EC

Air

Air Inlet Hose

6. REMOVE AIR INLET LINE

(a) Disconnect the air inlet line hose from the charcoal

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.

(c) Reconnect the air inlet line hose to the charcoal

canister.

A128093E02

ENGINE2AZ-FE EMISSION CONTROL

CANISTER

COMPONENTS

for PZEV:

2AZ-FE EMISSION CONTROL – CANISTER

EC–7

39 (398, 29)

EC

CHARCOAL CANISTER ASSEMBLY

N*m (kgf*cm, ft.*lbf)

: Specified torque

A135649E03

EC–8

except PZEV:

2AZ-FE EMISSION CONTROL – CANISTER

EC

CHARCOAL CANISTER ASSEMBLY

39 (398, 29)

N*m (kgf*cm, ft.*lbf)

: Specified torque

A135648E06

Pinch A

2AZ-FE EMISSION CONTROL – CANISTER

REMOVAL

1. REMOVE FUEL TANK ASSEMBLY

HINT:
(See page FU-34)

2. REMOVE CHARCOAL CANISTER ASSEMBLY

(a) Disconnect the fuel tank vent hose from the

charcoal canister.

A

(1) Push the connector deep inside.
(2) Pinch portion A.
(3) Pull out the connector.

EC–9

Pinch A

Pinch

Pinch

Push

Push

A

A132954E01

(b) Disconnect the charcoal canister filter sub-assembly

from the charcoal canister.
(1) Push the connector deep inside.

A

(2) Pinch portion A.
(3) Pull out the connector.

(c) Disconnect the vapor pressure sensor connector.

A

(d) Disconnect the wire harness clamp.
(e) Disconnect the purge line hose from the charcoal

canister.

A128095E01

EC

(f) Remove the 2 bolts, clip and charcoal canister.

A128096

A112883E01

INSPECTION

1. INSPECT CHARCOAL CANISTER ASSEMBLY

(a) Visually check the charcoal canister for cracks or

damage.
If cracks or damage are found, replace the charcoal
canister assembly.

EC–10

Vent Port

Purge Port

Air

2AZ-FE EMISSION CONTROL – CANISTER

(b) Check charcoal canister operation.

(1) With the purge port closed, blow 1.10 kPa (1 1.2

2

gf/cm

, 0.16 psi) of air into the vent port, and
check that air flows from the air inlet port.
If the result is not as specified, replace the
charcoal canister assembly.

Air Inlet Port

A111044E02

EC

Purge Port

Vent Port

Purge Port

Air Inlet Port

Air Inlet Port

Pressure Gauge

Air

A111043E02

(2) With the vent port closed, blow 1.10 kPa (11.2

2

gf/cm

, 0.16 psi) of air into the air inlet port, and
check that air flows from the purge port.
If the result is not as specified, replace the
charcoal canister assembly.

(c) Check for air leakage.

(1) With the purge port and air inlet port closed,

apply 19.6 kPa (0.2 kgf/cm

2

, 2.81 psi) of
pressurized air into the vent port, then confirm
that pressure is retained for 1 minute.
If the result is not as specified, replace the
charcoal canister assembly.

Vent Port

Air

SST

A

A111042E02

(d) Check the leak detection pump.

(1) Remove the detection pump from the charcoal

canister.

(2) Check that air flows from port A to B.

If the result is not as specified, replace the
charcoal canister assembly.

B

A112886E01

2AZ-FE EMISSION CONTROL – CANISTER

EC–11

(3) Connect the positive (+) lead of the battery to

Valve

Closed

terminal 7 and the negative (-) lead to terminal

6.

6

7

(4) Check that the valve is closed.

If the result is not as specified, replace the
charcoal canister assembly.

(5) Install the detection pump.

A111047E01

INSTALLATION

1. INSTALL CHARCOAL CANISTER ASSEMBLY

(a) Install the 2 bolts, clip and charcoal canister.

Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)

(b) Connect the purge line hose to the charcoal

canister.
(c) Connect the wire harness clamp.
(d) Connect the vapor pressure sensor connector.
(e) Connect the charcoal canister filter sub-assembly to

the charcoal canister.
(f) Connect the fuel tank vent hose to the charcoal

canister.

A128096

2. INSTALL FUEL TANK ASSEMBLY

HINT:
(See page FU-39)

3. CHECK FOR EXHAUST GAS LEAKS

EC

EC–12

ENGINE2AZ-FE EMISSION CONTROL

2AZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE

VACUUM SWITCHING VALVE

COMPONENTS

VACUUM SWITCHING VALVE CONNECTOR

VACUUM SWITCHING VALVE

PURGE LINE HOSE

PURGE LINE HOSE

EC

A135652E03

2AZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE

23 to 26 Ω

1

A135666

REMOVAL

1. REMOVE VACUUM SWITCHING VALVE

(a) Disconnect the vacuum switching valve connector.
(b) Disconnect the wire harness clamp.
(c) Disconnect the 2 purge line hoses from the purge

VSV.
(d) Remove the vacuum switching valve.

INSPECTION

1. INSPECT VACUUM SWITCHING VALVE

(a) Measure the resistance of the purge VSV.

Standard resistance

Tester Connection Specified Condition

1 - 2 23 to 26 Ω at 20°C (68°F)

1 - Body ground
2 - Body ground

10 MΩ or higher

EC–13

2

10 MΩ or higher

F

E

If the result is not as specified, replace the purge

VSV.

EC

A124791E01

(b) Check the operation of the purge VSV.

(1) Check that air does not flow from port E to port

F.

Air

A124792E01

(2) Apply battery voltage across the terminals.

(3) Check that air flows from port E to port F.

If the result is not as specified, replace the
purge VSV.

F

E

Air

A124793E01

EC–14

2AZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE

INSTALLATION

1. REMOVE VACUUM SWITCHING VALVE

(a) Install the vacuum switching valve onto the air

cleaner hose.

(b) Connect the 2 purge line hoses to the vacuum

switching valve.

(c) Connect the vacuum switching valve connector.

A135666

EC

2AZ-FE EMISSION CONTROL – VENTILATION VALVE

ENGINE2AZ-FE EMISSION CONTROL

VENTILATION VALVE

COMPONENTS

NO. 1 ENGINE COVER SUB-ASSEMBLY

VENTILATION VALVE SUB-ASSEMBLY

EC–15

7.0 (71, 62 in.*lbf)

VENTILATION HOSE

EC

N*m (kgf*cm, ft.*lbf)

: Specified torque

Precoated part

A135650E03

EC–16

2AZ-FE EMISSION CONTROL – VENTILATION VAL VE

REMOVAL

1. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

2. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Disconnect the ventilation hose from the ventilation

valve sub-assmbly.

A097786E01

EC

22 mm Deep Socket Wrench

Cylinder Head Side

Clean Hose

Intake Manifold Side

A098067E01

A059511E02

(b) Using a 22 mm deep socket wrench, remove the

ventilation valve sub-assembly.

INSPECTION

1. INSPECT VENTILATION VALVE SUB-ASSEMBLY

(a) Install a clean hose to the ventilation valve.
(b) Inspect the ventilation valve operation.

(1) Blow air into the cylinder head side, and check

that air passes through easily.

NOTICE:
Do not suck air through the valve.
Petroleum substances inside the valve are
hazardous to your health.

(2) Blow air into the intake manifold side, and

check that air passes through with difficulty.
If the result is not as specified, replace the
ventilation valve.

(c) Remove the clean hose from the ventilation valve.

Clean Hose

A059512E11

2AZ-FE EMISSION CONTROL – VENTILATION VALVE

EC–17

Adhesive

22 mm Deep Socket Wrench

INSTALLATION

1. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the ventilation

valve.

Adhesive:

Toyota genuine adhesive 1324, three bond
1324 or equivalent

A092670E03

(b) Using a 22 mm deep socket wrench, install the

ventilation valve.

Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)

(c) Connect the ventilation hose.

2. INSTALL ENGINE COVER SUB-ASSEMBLY

3. CHECK FOR ENGINE OIL LEAKS

A098067E01

EC

EC–18

ENGINE2AZ-FE EMISSION CONTROL

2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR

AIR FUEL RATIO SENSOR

COMPONENTS

except PZEV :

EC

x4

NO. 1 EXHAUST MANIFOLD
HEAT INSULATOR

12 (122, 9)

44 (449, 33)

AIR FUEL RATIO SENSOR

N*m (kgf*cm, ft.*lbf)

: Specified torque

A135654E03

for PZEV :

AIR FUEL RATIO SENSOR

2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR

44 (449, 33)

EC–19

EC

N*m (kgf*cm, ft.*lbf)

: Specified torque

A132950E02

EC–20

2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR

REMOVAL

1. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR (except PZEV)

(a) Remove the 4 bolts and No. 1 exhaust manifold

heat insulator.

A135682

2. REMOVE AIR FUEL RATIO SENSOR (except PZEV)

(a) Disconnect the air fuel ratio sensor connector and

clamp.

A135681E01

EC

(b) Using SST, remove the air fuel ratio sensor from the

exhaust manifold converter sub-assembly No. 2.

SST 09224-00010
NOTICE:
Do not damage the air fuel ratio sensor.

SST

A135683E01

3. REMOVE AIR FUEL RATIO SENSOR (for PZEV)

(a) Disconnect the air fuel ratio sensor connector.

A135685E01

(b) Using SST, remove the air fuel ratio sensor.

SST 09224-00010
NOTICE:
Do not damage the air fuel ratio sensor.

SST

A135686E01

2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR

INSPECTION

EC–21

+B

AF-

SST

HT

AF+

A075325E01

A135687E01

1. INSPECT AIR FUEL RATIO SENSOR

(a) Using an ohmmeter, measure the resistance

between terminals 1 (HT) and 2 (+B).

Standard resistance

Condition Specified Condition

20°C (68°F) 1.8 to 3.4 Ω

If the result is not as specified, replace the sensor.

INSTALLATION

1. INSTALL AIR FUEL RATIO SENSOR (for PZEV)

(a) Temporarily tighten the air fuel ratio sensor.

NOTICE:
Do not damage the air fuel ratio sensor.

(b) Using SST, fully tighten the air fuel ratio sensor.

SST 09224-00010
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)

(c) Connect the air fuel ratio sensor connector and

clamp.

2. INSTALL AIR FUEL RATIO SENSOR (except PZEV)

(a) Temporarily tighten the air fuel ratio sensor.

NOTICE:
Do not damage the air fuel ratio sensor.

EC

SST

A135685E01

(b) Using SST, fully tighten the air fuel ratio sensor.

SST 09224-00010
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)

A135684E01

(c) Connect the air fuel ratio sensor connector and

clamp.

A135681E01

EC–22

2AZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR

3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR (except PZEV)

(a) Install the exhaust manifold heat insulator with the 4

bolts.

Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

A135682

EC

2AZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR

ENGINE2AZ-FE EMISSION CONTROL

HEATED OXYGEN SENSOR

COMPONENTS

EC–23

N*m (kgf*cm, ft.*lbf)

EC

HEATED OXYGEN SENSOR

44 (449, 33)

: Specified torque

A135656E02

EC–24

2AZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR

REMOVAL

1. REMOVE HEATED OXYGEN SENSOR

(a) Disconnect the heated oxygen sensor connector.

A135678E01

(b) Using SST, remove the heated oxygen sensor from

SST

A135679E01

the exhaust pipe assembly front No. 3.

SST 09224-00010
NOTICE:
Do not damage the heated oxygen sensor.

EC

INSPECTION

HT+B

A104021E01

1. INSPECT HEATED OXYGEN SENSOR

(a) Measure the resistance between terminals 1 (HT)

and 2 (+B).

Standard resistance

Condition Specified Condition

20°C (68°F) 11 to 16 Ω

If the resistance is not as specified, replace the
sensor.

SST

2AZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR

INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR

(a) Temporarily tighten the heated oxygen sensor.

NOTICE:
Do not damage the heated oxygen sensor.

(b) Using SST, fully tighten the heated oxygen sensor.

SST 09224-00010
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)

A135680E01

(c) Connect the heated oxygen sensor connector.

EC–25

A135678E01

EC