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Introduction IMPORTANT It is mandatory that the VVT-i gear actuator bolts, actuator center section alignment, and actuator body be inspected BEFORE performing this TSB. If no concerns are noted with these parts, this TSB does NOT apply. Some 2005 – 2009 model year vehicles with 2GR-FE engines may exhibit a ticking/clicking type noise from the cylinder head cover area which may be accompanied by a MIL “ON” and one or more VVT-i related Diagnostic Trouble Codes (DTCs). Please use the following repair procedure to address customer concerns. Inspection Procedure 1. Start the engine and listen for any ticking/clicking type noises coming from the VVT-i gear area of the engine. NOTE This condition may or may not be accompanied by one or more of the following DTCs stored in the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM): • P0014: Camshaft Position “B” – Timing Advanced or System Performance (Bank 1) • P0015: Camshaft Position “B” Timing Over Retarded (Bank 1) • P0017: Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor B) • P0018: Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor A) • P0024: Camshaft Position “B” – Timing Over-Advanced or System Performance (Bank 2) • P0025: Camshaft Position “B” – Timing Over-Retarded (Bank 2) 2. Remove the cylinder head cover and inspect the exhaust VVT-i gear assembly on the affected cylinder bank. NOTE If NO concerns are found with the VVT-i gear actuator bolts, the actuator center section alignment, or actuator body, this TSB does NOT apply. Refer to Repair Manual procedures for further diagnosis. Repair Procedure 1. If any concerns are noted with the exhaust VVT-i gear bolts or actuator follow the four steps below: A. Replace the camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly on the affected bank. B. Inspect the intake VVT-i gear assembly and bolts on the affected bank. Replace the intake VVT-i gear assembly if necessary. C. Inspect the opposite bank exhaust VVT-i gear actuator and bolts. If any concerns are noted replace the opposite bank camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly. D. Inspect the opposite bank intake gear actuator assembly and bolts. Replace the intake VVT-i gear assembly if necessary. For complete disassembly procedures refer to the Technical Information System (TIS), applicable model and model year Repair Manual: • 2005 Avalon: Engine/Hybrid System – Engine Mechanical – “Engine Mechanical: Camshaft (LH Bank) / (RH Bank) (2GR-FE): Replacement” • 2006 / 2007 / 2008 / 2009 Avalon: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2008 / 2009 Highlander: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2006 / 2007 / 2008 / 2009 RAV4: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly”

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Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106 and P2135 diagnostic trouble codes (DTCs). ACTION: Replace the throttle position sensor (TPS) following the instruction sheet included in the TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the B37 CD. Calibration files are also available at www.motorcraft.com. CAUTION: FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT IN DAMAGE TO THE TPS SCREWS.

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ISSUE Some 2006 Explorer, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 8/8/2006 and equipped with a 4.0L engine may experience coolant leaking from the radiator. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Replace the radiator with the updated radiator following Workshop Manual (WSM), Section 303-03. NOTE NOTE: A REVISED FAN STRATEGY IS ALSO AVAILABLE FOR THESE APPLICATIONS 2. Reprogram the Powertrain Control Module (PCM) to the latest calibration using IDS release 58.2 and higher. This new calibration is not included in the VCM 2008.11 Calibration files may also be obtained at www.motorcraft.com.

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ISSUE Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2010 E-Series vehicles equipped with a 6.0L engine may exhibit a runs rough, lacks power, hard start, no start concern with or without diagnostic trouble code (DTC) P0611 code or various injector circuit codes. This concern may be caused by a DC-DC converter located in one half of the Fuel Injector Control Module (FICM) or by the main circuit board in the other half of the FICM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE FICM Information: The FICM contains two major internal components, the main circuit board and a DC-DC converter. The DC-DC converter is the device that amplifies battery voltage to 48 volts to operate the injectors. Low FICM supply voltage results in increased FICM operating loads, potentially damaging or shortening the life of the FICM. For contribution codes without circuit codes, go to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test P. Do not continue with this procedure. 1. Connect Integrated Diagnostic System (IDS) scan tool and confirm battery voltage is greater then 11.5 volts key on engine off (KOEO). a. If battery voltage is less then 11.5 volts KOEO, do not continue with this article. Refer to Workshop Manual (WSM), Section 414-00. b. If battery voltage is 11.5 volts KOEO or higher, continue to Step 2. 2. Remove the FICM relay.

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Customer Concern: Tests/Procedures: Potential Causes: The battery light is on, but the alternator is charging. Has a code P1246. 1. Disconnect the alternator and the Powertrain Control Module (PCM). Check the Violet (VT) (GENerator MONitor or GENMON) wire from the alternator to pin 20 of the PCM connector and the Red/Pink (RD/PK) (GENerator COMmand or GENCOM) wire from the alternator to pin 45 of the PCM for high resistance, an open, or a short to ground. Repair the wiring as needed. 2. If the wiring checks OK, reconnect the PCM and alternator. Start the engine and monitor the VT wire for a roughly 0-10v square wave signal. The signal will be around 40-50% normally with no loads on the system and minimal charging system output. As the load increases, the duty cycle should increase (NOTE: the duty cycle is a positive duty cycle so as the duty cycle increases, the voltage high time increases). 3. If there is no signal on the wire, disconnect the alternator and with key on check the VT wire for roughly 9-10v from the PCM. If OK, jump the Orange/Light Blue (OG/LB) wire to battery voltage and recheck operation with everything connected. This wire should be battery voltage at all time. If the OG/LB wire has battery voltage, the VT wire shows voltage from the PCM but there is no signal on it with the alternator charging, suspect a faulty, defective or incorrect alternator. Alternator Harness