Canada - Engine - MIL ON/DTC's P0171/P0300/P0133

Bulletin
2909

Issue Date
October 5, 2007

Market
Canada

Title:
M.I.L. "ON" DTC P0171, P030#, AND/OR P0133 ENGINE RUNNING LEAN IN SUBFREEZING AMBIENT TEMPERATURES

Component
FUEL

Models
'00 - '05 Celica and '03 - '08 Corolla & Matrix (1ZZ-FE)

INTRODUCTION:
Following a cold soak in sub-freezing ambient temperatures, some 2003 - 2008 model year Corolla and Matrix or 2000 - 2005 model year Celica vehicles equipped with a 1ZZ-FE engine may exhibit a M.I.L. "ON" with one or more of the following Diagnostic Trouble Codes (DTCs) as the result of a vacuum leak at the intake manifold.
- P0171 - System Too Lean (Bank 1)
- P0300 - Random Multiple Cylinder Misfire Detected
- P030# - Cylinder (1-4) Misfire Detected
- P0133 - Oxygen Sensor Slow Response (Bank 1 Sensor 1)
Please use the following procedure to repair the vehicle.

APPLICABLE VEHICLES:
- 2003 - 2008 model year Corolla and Matrix vehicles equipped with the 1ZZ-FE engine.
- 2000 - 2005 model year Celica vehicles equipped with the 1ZZ-FE engine.







PARTS INFORMATION:







WARRANTY INFORMATION:







REQUIRED SSTS:

NOTE:
- Please contact your zone Area Parts & Service Managers to order additional Techstream units.
- The Toyota Diagnostic Tester (TDT) and CAN Interface Module may also be used to perform the service procedures listed in this bulletin.

INSPECTION PROCEDURE:

NOTE:
The vehicle MUST be diagnosed following a cold soak. If the vehicle is at operating temperature, the condition will not be present.

1. Monitor the following Data List parameter: Short FT #1 (Short Term Fuel Trim for Bank 1). Using Techstream, select: Connect to Vehicle / Engine and ECT / Data List / Short FT #1.







2. Following conventional diagnostic procedure, confirm if there is a leak where the intake manifold and cylinder head meet between each intake runner.

3. Did the short term fuel trim change to a rich reading (negative fuel trim) in step 2? If YES: Replace the intake manifold gasket.
If NO: Check for other vacuum leaks or lean running conditions per the ETAS/TIS.

REPAIR PROCEDURE:

2003 - 2008 model year Corolla and Matrix vehicles.

1. Drain the engine coolant.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Corolla
- Year: 2003 or 2004
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: Coolant: Replacement

- Division: Toyota
- Model: Corolla
- Year: 2005
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: Engine Coolant (1ZZ-FE): Replacement

- Division: Toyota
- Model: Corolla
- Year: 2006, 2007, or 2008
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 1ZZ-FE Cooling: Coolant: On-Vehicle Inspection







2. Remove the air cleaner hose No. 1.

A. Disconnect the VSV connector.
B. Remove the clamp of the engine wire.
C. Disconnect the fuel vapor feed hose No. 1 from the VSV.
D. Disconnect the fuel vapor feed hose No. 3 from the VSV.







E. Loosen the 2 hose clamp bolts, then remove the air cleaner hose No. 1.







3. Remove the intake manifold.

A. Remove the 2 clamps of the engine wire from the clamp bracket.







B. Disconnect the throttle control motor connector or accelerator cable (if equipped).







C. Disconnect the water by-pass hose from the throttle body.
D. Disconnect the water by-pass hose No. 2 from the throttle body.







E. Disconnect the union to check valve hose from the intake manifold.







F. Remove the 4 bolts, 2 nuts, and 2 clamp brackets.
G. Remove the intake manifold and throttle body.
H. Remove the gasket from the intake manifold.

4. Clean the mounting surface of the intake manifold.

5. Install the intake manifold.

A. Install a NEW gasket onto the intake manifold.
B. Install the intake manifold and throttle body assembly with the 2 brackets, 4 bolts, and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
C. Torque: 30 N-m (306 kgf-cm, 22 ft-lbf)
D. Connect the union to check valve hose to the intake manifold.
E. Connect the water by-pass hose No. 2 to the throttle body.
F. Connect the water by-pass hose to the throttle body.
G. Connect the throttle control motor connector.
H. Install the 2 clamps of the engine wire onto the clamp bracket.

6. Reinstall the air cleaner hose No. 1.

A. Install the air cleaner hose No. 1 with the 2 hose clamp bolts.
B. Connect the fuel vapor feed hose No. 3 to the VSV.
C. Connect the fuel vapor feed hose No. 1 to the VSV.
D. Install the clamp of the engine wire.
E. Connect the VSV connector.

7. Fill and check the engine coolant.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Corolla
- Year: 2003 or 2004
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: Coolant: Replacement

- Division: Toyota
- Model: Corolla
- Year: 2005
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: Engine Coolant (1ZZ-FE): Replacement

- Division: Toyota
- Model: Corolla
- Year: 2006 or 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 1ZZ-FE Cooling: Coolant: On-Vehicle Inspection

8. Clear the fuel trim values by disconnecting the negative (-) battery cable for 90 seconds.
9. Test drive the vehicle and confirm normal operation.

REPAIR PROCEDURE:

2000 - 2005 model year Celica vehicles.

1. Drain the engine coolant.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Celica
- Year: 2000, 2001, or 2002
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 1ZZ-FE 2ZZ-GE Coolant: Replacement

- Division: Toyota
- Model: Celica
- Year: 2003, 2004, or 2005
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: Coolant Replacement

2. Remove the air cleaner assembly.
3. Disconnect the accelerator cable.







4. Remove the intake manifold.
A. Disconnect the throttle position sensor connector.
B. Disconnect the IAC valve connector.
C. Disconnect the PCV hose from the throttle body.







D. Disconnect the 2 water by-pass hoses.







E. Disconnect the EVAP hose for ORVR.
F. Disconnect the brake booster vacuum hose.
G. Remove the 4 bolts, 2 nuts, intake manifold, 2 wire harness stays, and gasket.

5. Clean the mounting surface of the intake manifold.
6. Install the intake manifold.

A. Install a NEW gasket, 2 wire harness stays and the intake manifold with the 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
B. Torque: 30 N-m (306 kgf-cm, 22 ft-lbf)
C. Connect the brake booster vacuum hose.
D. Connect the EVAP hose for ORVR.
E. Connect the 2 water by-pass hoses to the throttle body.
F. Connect the IAC connector.
G. Connect the throttle position sensor connector.
H. Connect the PCF hose to the throttle body.

7. Reconnect the accelerator cable.
8. Reinstall the air cleaner assembly.

9. Fill and check the engine coolant.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Celica
- Year: 2000, 2001, or 2002
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 1ZZ-FE 2ZZ-GE Coolant: Replacement

- Division: Toyota
- Model: Celica
- Year: 2003, 2004, or 2005
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: Coolant Replacement

10. Clear the fuel trim values by disconnecting the negative (-) battery cable for 90 seconds.
11. Test drive the vehicle and confirm normal operation.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.