Toyota Repair: Intermittent engine stall on 95 V6 Camry, blown head gasket, electronic fuel pump


Question
Hi Ted

I have a 95 Camry 3.0l (3VZ-FE) with 140,000 km.  I have had an intermittent stopping issue for the last 6 months that I can't seem to track down.

The details of the signs are:
The vehicle looses power and within a second, the engine cuts out.  Can restart, and will continue to run for only about 1 second before stopping.  Pushing the accelerate to the floor while starting will keep it running (just) but the engine wants to stop. (Lack of air, flooding with fuel ?)
Occurs in moderate to high congestion traffic conditions.  Not on country road or highway driving.
Occurs frequently in warmer weather.  No issues over winter.
Can occur while moving up to 40km/hr, or stationary (at idle) or starting after switching engine off for a few minutes.
Can take up to an hour (in hot weather, less in cooler conditions) before it re-starts.  With the bonnet (hood) up, can restart sooner.

With all of the above, it leads me to believe that it is heat related.

As an aside (and probably unrelated), six months prior to this first occurring, I had a blown head gasket.  Work was done on both heads. New water pump, thermostat, radiator cap, timing belt (+ tensioner), drive belts, PCV valve and spark plugs. Fuel injectors and radiator cleaned.

What I have done is the following.  Removed and cleaned fuel tank and replaced electronic fuel pump. Replaced ignition coil (which is external). Replaced both Engine Coolant Temperature (ECT) sensors (one for hydraulic cooling fan).
Have checked all the fuses and relays.  Also checked the voltages and resistances into the Cooling fan ECU (all within specifications).  Checked resistance of wires from ECU to ECT sensors (5V reference from ECU OK). Checked throttle position sensor, pickup coil resistance, EGR VSV resistance, power steering pump resistance (for cooling fan hydraulics), PCV vacuum, mass airflow (MAF) sensor.  All are within specifications.

I have also cleaned the throttle body, EGR valve, EGR modulator and air filter.

I have had mechanics and auto electricians look at it, and no one has been able to find anything.  They checked the distributor and it came up fine.

The last time it stopped, I was able to verify that the fuel pump was working.  I also poured water on both ECT sensors.  When pouring it over the ECT (right side of engine bay - facing engine), there was a loud click.  Not sure if it was from 2 valves that sit either side of the ECT (BVSV for EGR and EVAP) or elsewhere.  After this, the engine started and continued to run.  I cannot tell if it was the click that allowed the engine to start or if a particular component cooled sufficiently to let the motor run correctly.

The previous engine codes I have been able to extract are (newest) 22 [Coolant temp], 24 [Inlet air temp sensor] and 41 [throttle position sensor].  I don't know if the last 2 codes are valid because of all the trouble shooting and testing I have conducted.

Any advice will be greatly appreciated.

Thanks
Chris

PS. I have seen what sounds like a similar issue on this site [http://experts.about.com/q/832/3876794.htm], but my coil is external.

Answer
There is one more thing that you didn't mention in your question and that is the IAC (idle air control valve)it's located on the throttle body, it's the only thing I can think of at this time that may be causing the problem, try removing the throttle body and the the iac valve and clean out the carbon deposits in it, this is a very common problem on all camry engines but more so on the 4 cylinder than the v-6 but it is a possibility.