Technical Service BULLETIN July 4, 2007 Title: Models: 07 Avalon, Camry (NAP), Camry HV (NAP), & Solara EG035-07 ENGINE TSB REVISION NOTICE: August 22, 2007: Two parts have been added to the Parts Information table for Camry (PZEV) and Camry HV (P/N 77730 33090 and 7770 3300). Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. EG036 06. TSB No. EG036 06 is now obsolete and should be discarded. Introduction Some 2007 model year Avalon, Camry, Camry HV, and Solara vehicles may exhibit one of the following conditions: Intermittent stalling at idle when at operating temperature. Intermittent rough idle when at operating temperature. M.I.L. ON with at least one of the following DTCs stored: P044 (Evaporative Emission Control System Incorrect Purge Flow) P043E (Evaporative Emission System Reference Orifice Clog Up) P043F (Evaporative Emission System Reference Orifice High Flow) P240 (Evaporative Emission System Leak Detection Pump Control Circuit Low) P2402 (Evaporative Emission System Leak Detection Pump Control Circuit High) P249 (Evaporative Emission System Switching Valve Control Circuit Low) Follow the repair procedure below to address customer concerns. Applicable Vehicles 2007 model year Avalon vehicles produced BEFORE the Production Change Effective VIN shown in this TSB. 2007 model year Camry (North American produced) vehicles produced at TMMK and SIA BEFORE the Production Change Effective VINs shown in this TSB. 2007 model year Camry HV (North American produced) vehicles produced at TMMK BEFORE the Production Change Effective VINs shown in this TSB. 2007 model year Solara vehicles produced BEFORE the Production Change Effective VINs shown in this TSB. NOTE: This condition is a production caused issue and will be present from the first fill of the fuel tank. Vehicles with more than 0,000 miles of use with NO prior complaints about this condition should NOT need this repair. Refer to the Repair Manual to diagnose this issue on vehicles with greater than 0,000 miles and NO prior complaints. Toyota Supports ASE Certification Page of 6
Warranty Information OP CODE DESCRIPTION MODEL TIME OFP T T2 Avalon 2.0 7700 06 2370 R & R Charcoal Canister Camry 2. 7700 06 and dfuel ltank Camry HV 2.4 7700 0620 08 3 Solara 2.0 7700 06 Applicable Warranty*: This repair is covered under the Toyota Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle s in-service date. For California specification vehicles sold, registered, and operated in California, Maine, Massachusetts, and Vermont, this repair is covered under the California Emission Warranty, which is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle s in service date. For California specification Camry HV and 4 cylinder Camry PZEV vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Hampshire, New Jersey, New York, Rhode Island, and Vermont, this repair is covered under the California Emission Warranty, which is in effect for 80 months or 50,000 miles, whichever occurs first, from the vehicle s in service date. * Warranty application is limited to correction of a problem based upon a customer s specific complaint. Production Change Information MODEL ENGINE PLANT PRODUCTION CHANGE EFFECTIVE VIN Avalon 2GR FE TMMK 4TBK36B*7U237983 SIA 4T4BE46K*7R004774 2AZ FE Line 4TBE46K*7U50555 Camry Line 2 4TBE46K*7U687923 TMMK Line 4TBK46K*7U040384 2GR FE Line 2 4TBK46K*7U54747 Camry HV 2AZ FE 4TBB46K*7U08802 Solara 2AZ FE TMMK 4TCE3#P*7U760255 2GR FE 4T*A3#P*7U30607 NOTE: Camry vehicles produced at SIA can be identified with an R as the th digit in the VIN. For example: 4T4BE46K*7R######. Camry vehicles produced at TMMK Line can be identified with a 0,, 2, 3, or 4 as the 2th digit in the VIN. For Example: 4TB*46K*7U0#####. Camry vehicles produced at TMMK Line 2 can be identified with a 5, 6, 7, 8, or 9 as the 2th digit in the VIN. For example: 4TB*46K*7U5#####. Page 2 of 6
Parts Information MODEL Camry Camry (4 Cylinder PZEV) Camry HV PREVIOUS PART NUMBER 7700 060 7700 06 CURRENT PART NUMBER 7700 06 PART NAME Fuel Tank Assembly (Federal Specification Emission System) 77740 07020 Same Charcoal Canister Assembly 7700 06080 7700 0608 Avalon 7700 060 060 Solara 7700 06 Avalon Solara 7700 0608 Fuel Tank Assembly (California Emission [PZEV] System) 77740 0620 Same Charcoal Canister Assembly N/A 77730 33090 Canister Assembly, Trap w/outlet Valve N/A 7700 0620 Fuel Tank Assembly N/A 77740 3390 Charcoal Canister Assembly N/A 7770 3300 Valve Assembly, Fuel Tank Solenoid Main 7700 0606 Fuel Tank Assembly 77740 0702007020 Same Charcoal Canister Assembly QTY Required Tools & Material REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY TIS Techstream* NOTE: Software version 2.0.06 or later is required. * Essential SSTs. ADE TSUNT NOTE: Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 800 368 6787. The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Page 3 of 6
Repair Procedure. Duplicate customer complaint (stalling or rough idle) or confirm if EVAP system DTCs are stored using TIS Techstream. 2. Confirm if the condition (stalling or rough idle) occurs when Purge VSV is turned ON with engine running at idle. A. Connect the Techstream unit to the vehicle. B. Enter the following menus: Powertrain / Engine / Active Test / VSV for EVAP Control C. Select Activate the VSV for Evap Control. D. Use the toggle buttons to turn Active Test ON or OFF and confirm if the vehicle stalls or runs rough when Active Test is ON. If the vehicle stalls or runs rough when Active Test is ON, go to step 3. If NOT, this TSB does NOT apply. Continue diagnostics per the Repair Manual. 3. Check for fuel in the EVAP system by disconnecting the vent line from the charcoal canister at the trap filter. Is liquid fuel present in the EVAP system? If YES Go to step 4. If NO This TSB does NOT apply. Continue diagnostics per the Repair Manual. 4. Remove the fuel tank assembly and the charcoal canister assembly. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual: 2007 model year Avalon Repair Manual: Engine/Hybrid System Fuel System 2GR FE Fuel: Fuel Tank: Removal Engine/Hybrid System Emission Control 2GR FE Emission Control: Canister: Removal 2007 model year Camry Repair Manual: Engine/Hybrid System Fuel System 2AZ FE / 2GR FE Fuel: Fuel Tank: Removal Engine/Hybrid System Emission Control 2AZ FE / 2GR FE Emission Control: Canister: Removal 2007 model year Camry HV Repair Manual: Engine/Hybrid System Fuel System 2AZ FXE Fuel: Fuel Tank: Removal Engine/Hybrid System Emission Control 2AZ FXE Emission Control: Canister: Removal 2007 model year Solara Repair Manual: Engine/Hybrid System Fuel System 2AZ FE / 3MZ FE Fuel: Fuel Tank: Removal Engine/Hybrid System Emission Control 2AZ FE / 3MZ FE Emission Control: Canister: Removal Page 4 of 6
Repair Procedure (Continued) 5. Drain all remaining fuel in the EVAP system lines (including the trap filter assembly). Air Cleaner Case Throttle Valve Intake Air Intake Manifold Charcoal Filter Air Cleaner Filter When EVAP VSV is Opened, Partial Vacuum is Created Purge Line Leak Detection Area ECM EVAP VSV (Purge Valve) Fuel Tank Cap Vapor Pressure Sensor EVAP Line* Diaphragm (Atmospheric Pressure) Restrictor Passage EVAP Service Port Fuel Tank Purge Line* Charcoal Canister When CCV is Opened, Air is Drawn or Released Charcoal Canister Filter* (Trap Filter) CCV Air Inlet Line* * Check These Lines for Liquid Fuel Page 5 of 6
Repair Procedure (Continued) 6. Install the NEW fuel tank assembly and the NEW charcoal canister assembly. Refer to TIS, applicable model and model year Repair Manual: 2007 model year Avalon Repair Manual: Engine/Hybrid System Emission Control 2GR FE Emission Control: Canister: Installation Engine/Hybrid System Fuel System 2GR FE Fuel: 2007 model year Camry Repair Manual: Engine/Hybrid System Emission Control 2AZ FE / 2GR FE Emission Control: Canister: Installation Engine/Hybrid System Fuel System 2AZ FE / 2GR FE Fuel: 2007 model year Camry HV Repair Manual: Engine/Hybrid System Emission Control 2AZ FXE Emission Control: Canister: Installation Engine/Hybrid System Fuel System 2AZ FXE Fuel: 2007 model year Solara Repair Manual: Engine/Hybrid System Emission Control 2AZ FE / 3MZ FE Emission Control: Canister: Installation Engine/Hybrid System Fuel System 2AZ FE / 3MZ FE Fuel: 7. Clear all stored DTCs. Page 6 of 6