Toyota Camry 2007-2009 Service Manual - 2GR-FE_Engine_Control_System

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).

ES–1

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.

Typical Enabling Condition Preconditions that allow ECM to detect malfunctions.

With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s).

Sequence of Operation Order of monitor priority, applied if multiple sensors and components are involved in single

malfunction detection process. Each sensor and component monitored in turn and not monitored until previous detection

operation is completed. Required Sensor/Components Sensors and components used by ECM to detect each malfunction. Frequency of Operation Number of times ECM checks for each malfunction during each driving cycle.

"Once per driving cycle" means that ECM checks for malfunctions only once in single

driving cycle.

"Continuous" means that ECM checks for malfunctions whenever enabling conditions are

met. Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in

order to set DTC. Timing begins when Typical Enabling Conditions are met. Malfunction Thresholds Value, beyond which, ECM determines malfunctions exist and sets DTCs. MIL Operation Timing of MIL illumination after a malfunction is detected.

"Immediate" means that ECM illuminates MIL as soon as a malfunction is detected.

"2 driving cycle" means that ECM illuminates MIL if the same malfunction is detected twice

during next sequential driving cycle.

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

PARTS LOCATION

ES–3

ECM

MASS AIR FLOW METER

ENGINE ROOM R/B

- EFI RELAY

- A/F RELAY

- C/OPN RELAY

- ST RELAY

ACTIVE MOUNT CONTROL VSV

PURGE VSV

HEATED OXYGEN SENSOR (BANK 1 SENSOR 2)

- ST CUT RELAY

- IG2 RELAY

CANISTER

FUEL PUMP

HEATED OXYGEN SENSOR (BANK 2 SENSOR 2)

A134870E01

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

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

VVT SENSOR FOR INTAKE CAMSHAFT (BANK 2)

CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(BANK 2 INTAKE SIDE)

ES–5

VVT SENSOR (BANK 1 INTAKE SIDE)

CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(BANK 1 INTAKE SIDE)

IGNITION COIL WITH IGNITER

FUEL INJECTOR

AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1)

ENGINE COOLANT TEMPERATURE SENSOR

VVT SENSOR FOR EXHAUST CAMSHAFT (BANK 2)

CRANKSHAFT POSITION SENSOR

VVT SENSOR FOR EXHAUST CAMSHAFT (BANK 1)

AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1)

CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(BANK 2 EXHAUST SIDE)

A114586E05

ES–6

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

THROTTLE BODY (THROTTLE POSITION SENSOR)

ACIS ACTUATOR

KNOCK SENSOR

(BANK 1)

(BANK 2)

A114543E04

ST/AM2

AM2

AM1

IG2

IG SW

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

SYSTEM DIAGRAM

1. Without Smart Key System:

IG2

ECM

IG2

ST2

IG1

ST1

PNP SW

NSW

IGSW

STA

ES–7

GAUGE No. 2

IGN

Combination Meter

AM1

ALT

FL MAIN

Fuel Pump

EFI MAIN

C/OPN

ETCS

EFI No. 1

EFI

+BM

BATT

MREL

SPD

OC1+

OC1-

OC2+

OC2-

OE1+

OE1-

OE2+

OE2-

MIL

VVT OCV (Intake Side RH)

VVT OCV (Intake Side LH)

VVT OCV (Exhaust Side RH)

VVT OCV (Exhaust Side LH)

Battery

Starter

E02

E05

A137635E02

ES–8

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

EFI No. 3

EFI No. 2

VSV for ACIS

VSV for EVAP System

VSV for ACIS

VSV for Active Control Mount System

+B2

AICV

PRG

ACIS

ACM

ECM

VCP2

VPA2

EPA2

VCPA

VPA

EPA

CAN+

CAN-

IMO

IMI

APP Sensor

Transmission Control ECU

Transponder Key ECU

THA

MAF Meter

HO2 Sensor (Bank 1 Sensor 2)

HO2 Sensor (Bank 2 Sensor 2)

E2G

VG ETHA

HT1B

EX1B

OX1B

HT2B

EX2B

OX2B

STP

ST1-

Power Steering Oil Pressure SW

PSW

E04

E01

E03

ME01

Stop Light SW

STOP

IGN

A137631E02

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

ES–9

Canister Pump Module

VVT Sensor (Bank 1 Intake Side)

ECM

VPMP

EPPM

PPMP

VCPP

MPMP

VV1+

VV1-

VCV1

KNK1

EKNK

KNK2

EKN2

#10

Knock Sensor (Bank 1)

Knock Sensor (Bank 2)

No. 1 Fuel Injector

VVT Sensor (Bank 2 Intake Side)

VVT Sensor (Bank 1 Exhaust Side)

VVT Sensor (Bank 2 Exhaust Side)

To Main Body ECU

VV2+

VV2-

VCV2

EV1+

EV1-

VCE1

EV2+

EV2-

VCE2

CANH

CANL

#20

No. 2 Fuel Injector

#30

No. 3 Fuel Injector

#40

No. 4 Fuel Injector

#50

No. 5 Fuel Injector

#60

No. 6 Fuel Injector

To IG2 Relay

A137632E02

ES–10

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

ECM

VTA1

NE+

Crankshaft Position Sensor

Throttle Body Assembly

A/F Sensor (Bank 1 Sensor 1)

ECT Sensor

VCTA

VTA2

ETA

M+

M-

GE01

THW

ETHW

HA1A

A1A+

A1A-

NE-

IGT1 IGF1

IGT2

IGT3

DLC3

Ignition Coil (No. 1)

Ignition Coil (No. 2)

Ignition Coil (No. 3)

Ignition Coil (No. 4)

A/F

A/F Sensor (Bank 2 Sensor 1)

A/F

To EFI Relay

To Battery

HA2A

A2A+

A2A-

IGT4

Ignition Coil (No. 5)

IGT5

Ignition Coil (No. 6)

IGT6

To IG2 Relay

Noise Filter (RH Side)

Noise Filter (LH Side)

A137633E02

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

ES–11

GAUGE No. 1

To IG1 Relay

Park / Neutral Position SW

Transmission Control ECU

ECM

SFTD

SFTU

Transmission Control SW

ECU IG No. 2

Spiral Cable

Cruise Control SW

To IG1 Relay

CCS

A137634E02

ES–12

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

2. With Smart Key System:

Main Body ECU

ACC

STSW

ACCR

IG2D

STR

STR2

IG2

IGN

ST/AM2

To ECU-ACC Fuse

To IG2 Fuse

ST CUT

ETCS

PNP SW

STSW

ACCR

STAR

+BM

NSW

STA IGSW

ECM

SPD

OC1+

OC1-

OC2+

OC2-

GAUGE No. 2

Combinatiion Meter

MIL

VVT OCV (Intake Side RH)

VVT OCV (Intake Side LH)

VVT OCV (Exhaust Side RH)

FL MAIN

Battery

To IGN Fuse

Fuel Pump

Starter

EFI No. 1

EFI MAIN

C/OPN

EFI

OE1+

BATT

MREL

OE1-

VVT OCV (Exhaust Side LH)

OE2+

OE2-

E02

E05

A137630E02

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

ES–13

EFI No. 3

EFI No. 2

VSV for ACIS

VSV for EVAP System

VSV for ACIS

VSV for Active Control Mount System

+B2

AICV

PRG

ACIS

ACM

ECM

VCP2

VPA2

EPA2

VCPA

VPA

EPA

CAN+

CAN-

IMO

IMI

APP Sensor

Transmission Control ECU

Transponder Key ECU

THA

MAF Meter

HO2 Sensor (Bank 1 Sensor 2)

HO2 Sensor (Bank 2 Sensor 2)

E2G

VG ETHA

HT1B

EX1B

OX1B

HT2B

EX2B

OX2B

STP

ST1-

Power Steering Oil Pressure SW

PSW

E04

E01

E03

ME01

Stop Light SW

STOP

IGN

A137631E02

ES–14

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

Canister Pump Module

VVT Sensor (Bank 1 Intake Side)

ECM

VPMP

EPPM

PPMP

VCPP

MPMP

VV1+

VV1-

VCV1

KNK1

EKNK

Knock Sensor (Bank 1)

KNK2

EKN2

Knock Sensor (Bank 2)

#10

No. 1 Fuel Injector

VVT Sensor (Bank 2 Intake Side)

VVT Sensor (Bank 1 Exhaust Side)

VVT Sensor (Bank 2 Exhaust Side)

To Main Body ECU

VV2+

VV2-

VCV2

EV1+

EV1-

VCE1

EV2+

EV2-

VCE2

CANH

CANL

#20

No. 2 Fuel Injector

#30

No. 3 Fuel Injector

#40

No. 4 Fuel Injector

#50

No. 5 Fuel Injector

#60

No. 6 Fuel Injector

To IG2 Relay

A137632E02

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

Crankshaft Position Sensor

ECM

VTA1

NE+

ES–15

Throttle Body Assembly

A/F Sensor (Bank 1 Sensor 1)

ECT Sensor

VCTA

VTA2

ETA

M+

M-

GE01

THW

ETHW

HA1A

A1A+

A1A-

NE-

IGT1 IGF1

IGT2

IGT3

DLC3

Ignition Coil (No. 1)

Ignition Coil (No. 2)

Ignition Coil (No. 3)

Ignition Coil (No. 4)

A/F

A/F Sensor (Bank 2 Sensor 1)

A/F

To EFI Relay

To Battery

HA2A

A2A+

A2A-

IGT4

Ignition Coil (No. 5)

IGT5

Ignition Coil (No. 6)

IGT6

To IG2 Relay

Noise Filter (RH Side)

Noise Filter (LH Side)

A137633E02

ES–16

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

GAUGE No. 1

To IG1 Relay

Park / Neutral Position SW

Transmission Control ECU

ECM

SFTD

SFTU

CCS

Transmission Control SW

ECU IG No. 2

Spiral Cable

Cruise Control SW

To IG1 Relay

A137634E02

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING

HINT: *: Use the intelligent tester.

VEHICLE BROUGHT TO WORKSHOP

CUSTOMER PROBLEM ANALYSIS

ES–17

CONNECT INTELLIGENT TESTER TO DLC3*

HINT: If the display indicates a communication fault in the tester, inspect the DLC3.

CHECK DTC AND FREEZE FRAME DATA*

HINT: Record or print DTCs and freeze frame data, if necessary.

CLEAR DTC AND FREEZE FRAME DATA*

CONDUCT VISUAL INSPECTION

SET CHECK MODE DIAGNOSIS*

CONFIRM PROBLEM SYMPTOMS

HINT: If the engine does not start, perform steps 10 and 12 first.

ES–18

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

Result

Result Proceed to

Malfunction does not occur A

Malfunction occurs B

SIMULATE SYMPTOMS

CHECK FOR DTCS*

REFER TO DTC CHART

Result

GO TO STEP 10

Result Proceed to

Trouble code A

No code B

GO TO STEP 12

GO TO STEP 14

CONDUCT BASIC INSPECTION

REFER TO PROBLEM SYMPTOMS TABLE

Result

Result Proceed to

Malfunctioning parts not confirmed A

Malfunctioning parts confirmed B

GO TO STEP 17

Result

Result Proceed to

Malfunctioning circuit confirmed A

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

Result Proceed to

Malfunctioning parts confirmed B

ES–19

CHECK ECM POWER SOURCE CIRCUIT

CONDUCT CIRCUIT INSPECTION

Result

Malfunction not confirmed A

Malfunction confirmed B

CHECK FOR INTERMITTENT PROBLEMS

GO TO STEP 17

Result Proceed to

GO TO STEP 18

CONDUCT PARTS INSPECTION

IDENTIFY PROBLEM

ADJUST AND/OR REPAIR

ES–20

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

END

CONDUCT CONFIRMATION TEST

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.

1. Clear the DTCs.

2. Switch the ECM from normal mode to check mode using an intelligent tester (See page ES-49).

3. Perform a simulation test (See page IN-40).

4. Check and wiggle the harness(es), connector(s) and terminal(s) (See page IN-45).

ES–21

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. Therefore, using this check is essential when troubleshooting the engine.

CHECK BATTERY VOLTAGE

NOTICE: Carry out this check with the engine stopped and the engine switch off. Result

Result Proceed to

11 V or more OK

Below 11 V NG

CHECK WHETHER ENGINE CRANKS

CHECK WHETHER ENGINE STARTS

CHECK AIR FILTER

(a) Visually check that the air filter is not excessively

contaminated with dirt or oil.

CHARGE OR REPLACE BATTERY

PROCEED TO PROBLEM SYMPTOMS TABLE

GO TO STEP 6

CHECK IDLING SPEED

REPLACE AIR FILTER

TROUBLESHOOT IDLING SPEED AND PROCEED TO NEXT STEP

CHECK FUEL PRESSURE

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

ES–23

CHECK FOR SPARKS

PROCEED TO PROBLEM SYMPTOMS TABLE

TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP

TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP

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.

1. INPUT INSTRUCTIONS

(a) The general VIN input instructions using an

intelligent tester are explained below:

(b) The arrow buttons (UP, DOWN, RIGHT and LEFT)

and numerical buttons (0 to 9) are used, in order to input the VIN.

To move the cursor around the tester screen, press the RIGHT and LEFT buttons.

(d) Alphabetical Character Input

(1) Press the UP and DOWN buttons to select the

desired alphabetical character.

(e) Numeric Character Input

(1) Press the numerical button corresponding to

the number that you want to input. HINT: Numerical characters can be selected by using the UP and DOWN buttons.

(f) Correction

(1) When correcting the input character(s), put the

cursor onto the character using the RIGHT or LEFT button.

(2) Select or input the correct character using the

UP and DOWN buttons, or the numerical buttons.

(g) Finishing Input Operation

(1) Make sure that the input VIN matches the

vehicle VIN after input.

(2) Press the ENTER button on the tester.

2. READ VIN (Vehicle Identification Number)

(a) The flowchart of the VIN reading process is shown.

This process allows the VIN stored in the ECM to be read, in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle's ECM, are

the same. (b) Read VIN using an intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch on (IG). (f) Turn the tester on.

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

(g) Enter the following menus: DIAGNOSIS /

ENHANCED OBD ll / VIN.

Menu Screen:

Select VIN READ

ES–25

DTC P0630 Set

[EXIT]

VIN Previously Stored

[EXIT]

To Menu Screen

VIN Not Stored

17-digit VIN displayed

[EXIT]

A103812E03

3. WRITE VIN

(a) The flowchart of the VIN writing process is shown.

This process allows the VIN to be input into the ECM. If the ECM is changed, or the VINs do not match, the VIN can be registered, or overwritten in

the ECM by following this procedure. (b) Write VIN using the intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch on (IG). (f) Turn the tester on.

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

To Menu Screen

[YES][NO]

[YES]

Continue to next illustration

[YES]

17-digit VIN displayed

[NO]

To Menu Screen

A103813E01

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

New Registration

ES–27

Input Instructions

[ENTER]

Continue to next illustration

[ENTER]

Input Error

[EXIT]

A103814E03

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

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

CHECKING MONITOR STATUS

The purpose of the monitor result (mode 06) is to allow access to the results for on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Examples are catalyst, evaporative emission (EVAP) and thermostat. The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit. These data are displayed after the vehicle has been driven to run the monitor. When the test value is not between the minimum test limit and maximum test limit, the ECM (PCM) interprets this as a malfunction. When the component is not malfunctioning, if the difference of the test value and test limit is very small, the component will malfunction in the near future. 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.

1. PERFORM MONITOR DRIVE PATTERN

The monitor results and test values can be checked with the OBD II scan tool or the intelligent tester. The engine control module (ECM) monitors the emissions-related components such as the thermostat, catalyst converter and evaporative emissions (EVAP), and determines whether they are functioning normally or not. When monitoring is finished, the ECM stores the monitor results and the test values. The monitor result indicates whether the component is functioning normally or not. The test value is the value that was used to determine the monitor result. If the test value is outside of the test limit (malfunction criterion), the ECM determines the component is malfunctioning. Some emissions-related components have multiple test values to determine monitor result. If one of these test values is outside of the test limit, the ECM determines the component is malfunctioning. (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Clear the DTCs. (d) Run the vehicle in accordance with the applicable

drive pattern described in READINESS MONITOR

DRIVE PATTERN (See page ES-28). DO NOT turn

the engine switch off.

NOTICE:

The test results will be lost if the engine switch

is turned off.

ES–29

ES–30

2GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM

2. 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.

• PASS: The component is functioning normally.

• FAIL: The component is malfunctioning.

(b) Confirm that the component is either PASS or FAIL. (c) Select the component and press ENTER. The

accuracy test value appears if the monitor status is either PASS or FAIL. HINT: The monitor result might be PASS on rare occasions even if the Malfunction Indicator Lamp (MIL) is illuminated. This indicates that the system was malfunctioning in the previous driving cycle. This might be caused by an intermittent problem.

3. CHECK COMPONENT STATUS

(a) Compare the test value with the minimum test limit

(MIN LIMIT) and maximum test limit (MAX LIMIT).

(b) If the test value is between the minimum test limit

and maximum test limit, the component is functioning normally. If not, the component is malfunctioning. The test value is usually significantly higher or lower than the test limit. If the test value is on the borderline of the test limit, the component will

malfunction in the near future. HINT: The monitor result might be PASS on rare occasions even if the Malfunction Indicator Lamp (MIL) is illuminated. This indicates that the system was malfunctioning in the previous driving cycle. This might be caused by an intermittent problem.

4. MONITOR RESULT INFORMATION

If you use a generic scan tool, multiply the test value by the scaling value listed below.

A/F Sensor Bank 1:

Monitor ID Test ID Scaling Unit Description

$01 $8E Multiply by 0.0003 No dimension A/F sensor deterioration level $01 $91 Multiply by 0.004 mA A/F sensor current

HO2S Bank 1 Sensor 2:

Monitor ID Test ID Scaling Unit Description

$02 $07 Multiply by 0.001 V Minimum sensor voltage $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.003 g Maximum oxygen storage capacity

A/F Sensor Bank 2:

Monitor ID Test ID Scaling Unit Description

$05 $8E Multiply by 0.0003 No dimension A/F sensor deterioration level $05 $91 Multiply by 0.004 mA A/F sensor current

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Toyota Camry 2007-2009 Service Manual - 2GR-FE_Engine_Control_System

Specifications and Main Features

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