2NZ-FE ENGINE MECHANICAL ENGINE ON-VEHICLE INSPECTION

PROCEDURE

Hide Display 1.INSPECT ENGINE COOLANT

Click hereEngine / Hybrid System>2NZ-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide Display 2.INSPECT ENGINE OIL

Click hereEngine / Hybrid System>2NZ-FE LUBRICATION>LUBRICATION SYSTEM>ON-VEHICLE INSPECTION

Hide Display 3.INSPECT BATTERY

Click herePower Source / Network>2NZ-FE BATTERY / CHARGING>CHARGING SYSTEM>ON-VEHICLE INSPECTION

Hide Display 17801 4.INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Remove the air cleaner cap with air cleaner hose.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>THROTTLE BODY>REMOVAL

Remove the air cleaner filter element sub-assembly.

Visually check that the air cleaner filter element sub-assembly is not excessively damaged or oily.

If necessary, replace the air cleaner filter element sub-assembly.

HINT:: ·

If there is any foreign matter or clogs in the air cleaner filter element sub-assembly, clean it with compressed air.

·

If any foreign matter or clogs remain even after cleaning the air cleaner filter element sub-assembly with compressed air, replace it.

Install the air cleaner filter element sub-assembly.

Install the air cleaner cap with air cleaner hose.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>THROTTLE BODY>INSTALLATION

Hide Display 19100P 5.INSPECT SPARK PLUG

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>IGNITION SYSTEM>ON-VEHICLE INSPECTION

Hide Display 16361A 6.INSPECT V-RIBBED BELT

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

Hide Display 7.INSPECT VALVE CLEARANCE

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>VALVE CLEARANCE>ON-VEHICLE INSPECTION

Hide Display 8.INSPECT IGNITION TIMING

Warm up and stop the engine.

When using the GTS:

Connect the GTS to the DLC3.

ii.

Start the engine and run it at idle.

iii.

Turn the GTS on.

iv.

Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance.

Powertrain > Engine and ECT > Data List

Tester Display
IGN Advance

50003 234 29

Standard Ignition Timing:: 0 to 14 degrees BTDC

NOTICE:: ·

Check the ignition timing with the cooling fan off.

·

Turn off all electrical systems and the A/C.

·

When checking the ignition timing, the transaxle should be in neutral or park.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON.

Powertrain > Engine and ECT > Active Test

Active Test Display
Connect the TC and TE1

Data List Display
IGN Advance

50004 234 13 29

vi.

Monitor IGN Advance of the Data List.

Standard Ignition Timing:: 8 to 12 degrees BTDC

NOTICE:: When checking the ignition timing, the transaxle should be in neutral or park.

vii.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / OFF.

viii.

Check that the ignition timing advances immediately when the engine speed is increased.

ix.

Turn the ignition switch off.

Disconnect the GTS from the DLC3.

When not using the GTS:

1.094,0.604 1.552,1.063 false 1.76,1.656 1.323,1.99 false 0.927,1.063 1.042,1.219 0.115,0.156 10 1 0.927,1.469 1.042,1.625 0.115,0.156 10 9 1.104,1.469 1.281,1.625 0.177,0.156 10 10 1.302,1.469 1.479,1.625 0.177,0.156 10 11 1.51,1.469 1.688,1.625 0.177,0.156 10 12 1.719,1.469 1.896,1.625 0.177,0.156 10 13 1.927,1.469 2.104,1.625 0.177,0.156 10 14 2.125,1.469 2.302,1.625 0.177,0.156 10 15 2.333,1.469 2.51,1.625 0.177,0.156 10 16 1.135,1.063 1.25,1.219 0.115,0.156 10 2 1.344,1.063 1.458,1.219 0.115,0.156 10 3 1.552,1.063 1.667,1.219 0.115,0.156 10 4 1.75,1.063 1.865,1.219 0.115,0.156 10 5 1.958,1.063 2.073,1.219 0.115,0.156 10 6 2.156,1.063 2.271,1.219 0.115,0.156 10 7 2.365,1.063 2.479,1.219 0.115,0.156 10 8 0.792,0.5 1.042,0.656 0.25,0.156 10 CG 1.063,1.927 1.313,2.073 0.25,0.146 10 TC 0.115,0.104 0.427,0.26 0.313,0.156 10 *a

DLC3

Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

SST: 09843-18040

NOTICE:: ·

Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components.

·

Check the ignition timing with the cooling fan off.

·

Turn off all electrical systems and the A/C.

·

When checking the ignition timing, the transaxle should be in neutral or park.

ii.

Remove the No. 2 cylinder head cover.

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL

iii.

Connect the clip of the timing light to the wire harness as shown in the illustration.

NOTICE:: Use a timing light that detects the primary signal.

iv.

Inspect the ignition timing at idle.

Standard Ignition Timing:: 8 to 12 degrees BTDC

NOTICE:: When checking the ignition timing, the transaxle should be in neutral or park.

HINT:: After running the engine at 1000 to 1300 rpm for 5 seconds, check that it returns to idle speed.

Disconnect SST from terminals 13 (TC) and 4 (CG) of the DLC3.

vi.

Inspect the ignition timing at idle.

Standard Ignition Timing:: 0 to 14 degrees BTDC

vii.

Confirm that the ignition timing advances immediately when the engine idle speed is increased.

viii.

Disconnect the clip of the timing light from the wire harness.

ix.

Install the No. 2 cylinder head cover.

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

Hide Display 9.INSPECT ENGINE IDLE SPEED

Warm up and stop the engine.

When using the GTS:

Connect the GTS to the DLC3.

ii.

Start the engine and run it at idle.

iii.

Turn the GTS on.

iv.

Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

Powertrain > Engine and ECT > Data List

Tester Display
Engine Speed

50003 234 9

Inspect the engine idle speed.

Standard Idle Speed:: 650 to 750 rpm

NOTICE:: ·

Turn off all electrical systems and the A/C.

·

Inspect the engine idle speed with the cooling fan off.

·

When checking the engine idle speed, the transaxle should be in neutral or park.

vi.

Turn the ignition switch off.

vii.

Disconnect the GTS from the DLC3.

When not using the GTS:

1.042,1.906 1.042,1.479 false 0.104,0.094 0.417,0.292 0.313,0.198 10 false *a 0.938,1.938 1.396,2.135 0.458,0.198 10 false TAC

DLC3

Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

SST: 09843-18040

NOTICE:: Be sure to connect the tachometer probe to the correct terminal. Connecting the wrong terminals may damage electrical components.

ii.

Start the engine and run it at idle.

iii.

Inspect the engine idle speed.

Standard Idle Speed:: 650 to 750 rpm

NOTICE:: ·

Turn off all electrical systems and the A/C.

·

Inspect the engine idle speed with the cooling fan off.

·

When checking the engine idle speed, the transaxle should be in neutral or park.

iv.

Turn the ignition switch off.

Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.

Hide Display 10.INSPECT COMPRESSION

NOTICE:: Keep the spark plug holes free of foreign matter when measuring the compression pressure.

Check for DTCs.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>SFI SYSTEM>DTC CHECK / CLEAR

Warm up and stop the engine.

Remove the 4 spark plugs.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>IGNITION COIL AND SPARK PLUG>REMOVAL

Disconnect the 4 fuel injector connectors.

NOTICE:: Disable fuel injection in order to prevent catalyst damage due to unburned gasoline.

Inspect the cylinder compression pressure.

Insert a compression gauge into the spark plug hole.

ii.

Fully open the throttle.

iii.

While cranking the engine, measure the compression pressure.

Standard Compression Pressure:: 980 kPa (10.0 kgf/cm², 142 psi)

Minimum Compression Pressure:: 784 kPa (8.0 kgf/cm², 114 psi)

Difference between Each Cylinder:: 98 kPa (1.0 kgf/cm², 14.2 psi) or less

NOTICE:: ·

Use a fully-charged battery so that the engine speed can be increased to 250 rpm or more.

·

Inspect the other cylinders in the same way.

·

Measure the compression pressure as quickly as possible.

iv.

If the cylinder compression pressure is low, pour a small amount of engine oil into the cylinder through the spark plug hole, then inspect it again.

HINT:: ·

If adding oil increases the compression pressure, the piston rings and/or cylinder bore may be worn or damaged.

·

If the compression pressure stays low, a valve may be stuck or seated improperly, or there may be leaks in the gasket.

Connect the 4 fuel injector connectors.

Install the 4 spark plugs.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>IGNITION COIL AND SPARK PLUG>INSTALLATION

Clear the DTCs.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>SFI SYSTEM>DTC CHECK / CLEAR

NOTICE:: After the inspection, clear the DTCs, check for DTCs again and make sure the normal system code is output.

Hide Display 11.INSPECT CO/HC

HINT:: This check determines whether or not the idle CO/HC complies with regulations.

Start the engine.

Keep the engine at 2500 rpm for approximately 180 seconds.

Insert a CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idle.

Immediately check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

HINT:: When doing a 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.; If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below.

Check for DTCs.

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>SFI SYSTEM>DTC CHECK / CLEAR

ii.

See the following table for possible causes, then inspect the applicable parts and repair them if necessary.

CO	HC	Problem	Possible Cause
Normal	High	Rough idle	1. Faulty ignition: · Incorrect timing · Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaks in intake or exhaust valves 4. Leaks in cylinders
Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks: · PCV hoses · Intake manifold · Throttle body assembly · Brake booster line 2. Lean mixture causing misfire
High	High	Rough idle (Black smoke from exhaust)	1. Restricted air cleaner filter element sub-assembly 2. Plugged PCV valve 3. Faulty EFI systems: · Pressure regulator · Engine coolant temperature sensor · Mass air flow meter · ECM · Fuel Injector assemblies · Throttle body assembly