Canada - Engine Controls/Exhaust - Excessive Sulfur Odors

Bulletin
2023

Issue Date
July 26, 2004

Market
Canada

Title:
EXCESSIVE SULPHUR DIOXIDE ODOUR

Component
ENGINE ELECTRICAL

Model
'02 - '04 Camry (2AZ-FE)

TSB REVISION NOTICE:
- May 1, 2007: The OFP in the Warranty Information table has been modified. A new step 3 and Figure 2 have been added to the ECM Reprogram Procedure (regarding removal of 10A ECU-IG fuse). Previous Figure 2 is now Figure 3.
- April 26, 2005: The Op Code for "R & R Catalytic Converter Assembly (MTM Only)" has been updated in Warranty Information. Previous versions of this TSB should be discarded.
Previous versions of this TSB should be discarded.

INTRODUCTION:
Some customers may complain of excessive sulphur dioxide odour on 2002-2004 model year Camry vehicles equipped with the 2AZ-FE engine under the following conditions:
- Stop and go driving.
- Heavy acceleration.
In order to reduce the sulphur dioxide odour, the Electronic Control Module (ECM) (SAE term:
Powertrain Control Module/PCM) fuel cut control logic has been modified and a new catalyst is provided. Follow the repair procedure to reflash the ECM and replace the catalytic converter assembly.

Note:
For more complete understanding of the root cause, refer to TSB1212 "Sulphur Odour from Exhaust" dated March 4, 2003

APPLICABLE VEHICLES:
- 2002 - 2004 model year Camry vehicles equipped with the 2AZ-FE engine produced BEFORE the Production Change Effective VINs shown below.







PRODUCTION CHANGE INFORMATION :







PARTS INFORMATION:






NOTE:
- Authorized Modification Labels may be ordered in packages of 25 from your facing PDC.







REQUIRED SSTS:

NOTE*:
- Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.







WARRANTY INFORMATION:







ECM (PCM) IDENTIFICATION CHART:


NOTE:
All 2002 - 2004 model year vehicles equipped with manual transmissions require replacement of the catalytic converter assembly only. Please refer to the Catalytic Converter Replacement Procedure.

ECM REPROGRAM PROCEDURE:

1. Check for the Authorized Modification Label affixed to the vehicle in the location shown in Figure 3. If there is no label present, proceed to step 2.







2. Connect the Diagnostic Tester to the vehicle and select "CURRENT ECU CAL" from the "ECU REPROGRAM MAIN MENU." To determine the vehicle's current ECM (PCM) calibration, see Figure 1.

3. Remove the 10A ECU-IG fuse from the instrument panel Junction Block (refer to Figure 2 for location). This action prevents possible activation of the ABS relay, resulting in ECM Reprogramming failure.







NOTE:
ECU damage may occur if the 10A fuse is NOT removed.

NOTE:
A battery charger MUST be connected to the battery and set at a medium charge setting during the Flash Reprogram procedure in order to maintain proper battery voltage and prevent damage to the ECM (PCM).

4. Proceed to Flash Reprogram the ECM (PCM) by following the procedures in TSB0941 titled "ECU Flash Reprogramming Process," for 2001 and later applicable models.

NOTE:
Errors during the flash reprogramming process can PERMANENTLY DAMAGE the vehicle's ECM (PCM). In order to minimize this risk follow the steps below:
- Make sure that the current battery voltage is no less than 11.4 volts.
- Install a battery charger and set on a low setting to assure that the battery voltage DOES NOT FALL BELOW 11.4 VOLTS during the reprogramming.
- If battery's state of charge is in question, test with SST No. 00002-MP815-L, "Midtronics Battery Tester."
- Confirm that the engine hood is up, parking brake is set and all accessories are OFF (i.e., audio system, A/C, interior lights, headlights, etc.).
- DO NOT perform the reprogramming process until the engine room temperature is 158�F (70�C) or less.
- Confirm cable connections between the vehicle and the Diagnostic Tester are secured.
- In case of Error Message "Cannot Go To Reprogram Mode," refer to TSB0959 "ECU Flash Reprogramming Error Message."
- Do not interrupt the vehicle during the reprogramming process, keep all doors closed.

5. Select the proper ECM (PCM) calibration file for the model year vehicle and reprogram the ECM (PCM).
6. Start the engine and warm up the vehicle to normal operating temperatures before test driving.
7. Test drive vehicle to confirm proper operation and to readjust the ECM (PCM) "Learned Values."
- Drive the vehicle using light to moderate acceleration in mostly stop and go type driving.
- Allow the vehicle to shift fully through all gears and at various shifter positions.







8. Enter the following information on the Authorized Modification Label shown in Figure 3 using a permanent marker.
- ECM (PCM) part number.
- New ECM (PCM) calibration number.
- Your dealer code. " Reprogramming date.
- This TSB number.

CATALYTIC CONVERTER REPLACEMENT PROCEDURE:
Refer to the Technical Information System (TIS) 2002 or 2004 model year Camry Repair Manual: Exhaust Pipe Assy.

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.