norcalvp

A Friend of mine has a 2002 ES300 that over the last week has developed a stalling problem. Yesterday I had him bring the car over so we could try to diagnose the problem. (He told me it was an 01, not an 02) Anyway, The problem only appears to happen at idle, the engine will be running fine, then studders and dies. If he keeps his foot on the gas to increase the RPM's slightly it won't die. I figured that this might be an issue with the throttle body (Similar issue with my Tacoma) so we got the throttle body off and cleaned it, I cleaned the MAF and put it back together and the problem still remains. I did some searching on the forums and found the IAC valve cleaning (Which I realize that this model year doesn't have now) and I also found threads stating that the EGR valve should be cleaned. Can anyone tell me where the valve is physically located? All of the images and documentation I could find was for the '01 and earlier, but alot of the parts houses show a part for an 02-03 ES300 that I cannot seem to locate on the engine, and I'm hoping that it's not behind the intake manifold.

Something else that I am unsure of is that there is a valve on the side of the intake manifold (At the far left of the manifold closest to the passenger front tire) that has a vacuum pod attached to a lever. I the shaft of the valve is a little loose, and I can pull the shaft out of the manifold pretty easily (I didn't think that I should be able to do this...) I tried to remove the valve assembly from the manifold, but could only get it to come out an 1/4 of an inch before it stopped. I have no idea what this is or how it should function.

Anyway if anyone can point me in the right direction or can point me in the direction of an online FSM I'd appreciate it.

Steve

GS4_Fiend

iTrader: (22)

Clean MAF and TB.

Megafast13

Did he recently disconnect the battery terminals? It resets the RPM's ECU system which tends to idle WAY too low. Same thing will happen on my ES, and on many Camry's. Once it relearns his driving habits it shouldn't idle as low to the point of stalling out.

If he hasn't done anything with the battery recently than it probably is a legitimate engine/trans problem.

norcalvp

We did this yesterday. I removed the entire intake cleaned it out including the MAF, both pieces of the throttle body (the throttle body, and the aluminum piece behind it with the butterfly valves) these pieces were pretty clean for having 140K+ on the clock. after everything was cleaned and reassembled the car started and ran normally for about 45 seconds, then the same old stalling started again.

norcalvp

The battery was disconnected about two weeks ago when the starter was replaced (Not by me) He said that this is when his problem started. The car seems to struggle to start whether it's hot or cold. If he bumps the throttle it'll fire up. Once it is on, it'll go to a normal idle. There were a few times where it was idling just fine, then just cuts out. Every once in a while it will recover and return to a normal idle only to cut out 5-30 seconds later again.

Is there something that he needs to do for this idle re-learn? a certian amount of time or miles? He's been driving it for almost two weeks like this....

Thanks for the help!
Steve

GS4_Fiend

iTrader: (22)

Try changing the PCV. And check for vacuum leaks. Usually, stalling is caused by carbon on throttle butterfly.

norcalvp

Do i need to remove the intake manifold off to change the PCV? I think I saw it on therear valve cover under the manifold. I cleaned the throttle blade and both butterfly valves behind the throttle body pretty good. Is there anything else I should clean or inspect?

Thanks for the tips
Steve

GS4_Fiend

iTrader: (22)

No you dont need to just remove the valve

Hayk

iTrader: (1)

Is there really no IACV on the 2002? The problem you're having is exactly what a dirty IACV would do.

norcalvp

Not one that I could find..... All of the articles I found regarding cleaing the IAC Valve were 2001 and previous. It looks like the throttle body changed in 2002 and is not an electronic TB instead of the cable one from previous years. I'd be more than happy to clean it if someone would mind telling me where it was. The only two components on the TB with electrical hookups were the TB Actuator (some sort of gear reduction housing with safety torx bits) and the TPS sensor.

SC400slide

iTrader: (11)

2002 was the first year with the electric throttle on the ES so there is no IACV on you ES300.

What you can do is spray some intake cleaner on a rag and clean inside the throttle plate do remove dirt and grime out.

If the throttle body is dirty it will cause problems for sure!

Hayk

iTrader: (1)

What if the car is not getting enough gas for the amount of air it's taking in? This would be caused my an unmetered air intake, right? This would only happen if there was a vacuum leak after the MAF sensor. Just throwing some ideas out. I would test for air leaks.

SC400slide

iTrader: (11)

Yes, do a smoke test.

norcalvp

I completely removed and cleaned the throttle body and the aluminum piece behind it that has the two butterfly valves in it. Both of these components were pretty clean before we started, but now both are squeaky clean.

Smoke test? I have never done a smoke test before. How would I go about doing that? Does this car have an EGR Valve? If so does anyone know where it is?

SC400slide

iTrader: (11)

To find the EGR, refer to the vacuum hose routing sticker under the hood, find were it says "EGR", follow the green vacuum hose on the sticker and it will lead to the EGR under the hood.
The EGR is the saucer looking thing to the right of the throttle body, or above the EGR modulator.

A smoke test is when you place a smoke machine into a major vacuum line than smoke.
Look for smoke retreating and locate were it is.
It might be slight but in your case, it would be noticeable.
Smoke machines are around $50 at Pep-Boys, or have an Automotive store do it, (like pep-boys)
From what I know about the ES300, I think the 02 ES does have an EGR valve.
Refer to your vacuum hose sticker.
Cheers