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On-Vehicle Inspection

  1. INSPECT VALVE LASH ADJUSTER NOISE 
    1. Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the inspection above again.

      If any defects or problems are found during the inspection above, perform a lash adjuster inspection.

  2. INSPECT IGNITION TIMING 
    1. Warm up and stop the engine.
      NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
    2. When using the intelligent tester:
      1. Connect the intelligent tester to the DLC3.
      2. Start the engine and idle it.
      3. Push the intelligent tester main switch ON.
      4. Enter the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / IGN ADVANCE.

        Standard ignition timing: 8 to 18° BTDC @idle 

        HINT:

        Refer to the intelligent tester operator's manual for further details.

        Fig 1: Connecting Intelligent Tester To DLC3
        G05302628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. When not using the intelligent tester:
      1. Remove the V-bank cover.
      2. Connect the tester probe of a timing light to the wire of the ignition connector for No. 1 cylinder.
        NOTE: Use a timing light which can detect the primary current.
        Fig 2: Connecting Tester Probe Of Timing Light To Wire Of Ignition Connector
        G05302629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST 09843-18040 

        NOTE:
        • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
        • When checking the ignition timing, the transmission should be in neutral.
          Fig 3: Identifying DLC3 Connector Terminal
          G05302630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Using a timing light, check the ignition timing.

        Standard ignition timing: 8 to 12 BTDC @ idle 

      5. Remove the SST from the DLC3.
      6. Check the ignition timing.

        Standard ignition timing: 8 to 18 BTDC @ idle 

        Fig 4: Checking Ignition Timing
        G05302631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Check that the ignition timing advances immediately when the engine speed is increased.
      8. Disconnect the timing light from the engine.
      9. Install the V-bank cover.
  3. INSPECT ENGINE IDLE SPEED 
    1. Warm up and stop the engine.
      NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
    2. When using the intelligent tester:
      1. Connect the intelligent tester to the DLC3.
        NOTE: Switch off all accessories and A/C before connecting the intelligent tester.
        Fig 5: Connecting Intelligent Tester To DLC3
        G05302632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Race the engine speed at 2,500 rpm for approximately 90 seconds.
      3. Push the intelligent tester main switch ON.
      4. Enter the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD.

        Standard idle speed: 950 to 1,050 rpm 

        NOTE: When checking the idle speed, the transmission should be in the neutral.

        HINT:

        Refer to the intelligent tester operator's manual for further details.

        If the idle speed is not as specified, check the air intake system.

      5. Disconnect the intelligent tester from the DLC3.
    3. When not using the intelligent tester:
      1. Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3.

        SST 09843-18040 

        NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
        Fig 6: Identifying DLC3 Connector Terminal
        G05302633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Race the engine speed at 2,500 rpm for approximately 90 seconds.
      3. Check the idle speed.

        Idle speed (Transmission neutral position): 950 to 1,050 rpm 

        If the speed is not as specified, check the air intake system.

      4. Disconnect the tachometer from the DLC3.
  4. INSPECT COMPRESSION 
    1. Warm up and stop the engine.
      NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
    2. Remove the cool air intake duct seal.
    3. Remove the engine room side cover LH.
    4. Remove the engine room side cover RH.
    5. Remove the V-bank cover.
    6. Disconnect the No. 2 ventilation hose.
    7. Remove the air cleaner cap with the air cleaner hose.
    8. Remove the nut.
    9. Detach the protector from the bracket.
      Fig 7: Locating Bracket Nuts
      G05302634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 2 nuts and inverter motor cable bracket.
      Fig 8: Locating Inverter Motor Cable Bracket Nuts
      G05302635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the bolt and water filler.
      Fig 9: Locating Water Filler With Bolts
      G05302636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the clamp and plug.
      Fig 10: Locating Clamp And Plug
      G05302637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Disconnect the 3 clamps and connector.
      Fig 11: Locating Connector Clamps
      G05302638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Disconnect the 4 connectors.
    15. Disconnect the throttle body connector.
    16. Disconnect the 6 injector connectors.
    17. Remove the 6 ignition coils.
    18. Remove the 6 spark plugs.
      Fig 12: Locating Connectors
      G05302639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    19. Disconnect the 2 injector driver connectors as shown in the illustration.
      Fig 13: Locating Injector Driver Connectors
      G05302640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    20. Inspect the compression pressure.
      1. Insert a compression gauge into the spark plug hole.
        Fig 14: Inserting Compression Gauge Into Spark Plug Hole
        G05302641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the intelligent tester to the DLC3.
        Fig 15: Connecting Intelligent Tester To DLC3
        G05302642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Turn the power switch ON (IG).
      4. Push the intelligent tester main switch ON.
      5. To check the HV battery voltage, enter the following items: DIAGNOSIS / OBD / MOBD / HV ECU / DATA LIST / +B.

        Standard voltage: 10 to 14 V 

      6. Enter the following items: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST.
      7. Depress and hold the brake pedal, and turn the power switch ON (READY). Then check the compression pressure.

        HINT:

        • Noise may emit from the transmission. However, this is not a malfunction.
        • Always use a fully charged battery to obtain engine speed of 200 rpm or more.
        NOTE: The measurement must be done as quickly as possible.

        Standard compression pressure: 1.0 MPa (10 kgf/cm 2  , 143 psi) or more 

        Minimum pressure: 0.7 MPa (7.1 kgf/cm 2  , 101 psi) 

      8. Turn the power switch OFF and the intelligent tester main switch off.
    21. Perform the following inspection procedures for the other cylinders.

      HINT:

      Make sure to turn the power switch OFF and the intelligent tester main switch off between each pressure inspection. If not, the compression pressure cannot be inspected.

      1. Insert a compression gauge into the spark plug hole.
      2. Turn the power switch ON (IG).
      3. Push the intelligent tester main switch on.
      4. Enter the following items: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST.
      5. Depress and hold the brake pedal, and turn the power switch ON (READY). Then check the compression pressure.

        HINT:

        • Noise may emit from the transmission. However, this is not a malfunction.
        • Always use a fully charged battery to obtain engine speed of 200 rpm or more.
        NOTE: The measurement must be done as quickly as possible.

        Standard compression pressure: 1.0 MPa (10 kgf/cm 2  , 143 psi) or more 

        Minimum compression pressure: 0.7 MPa (7.1 kgf/cm 2  , 101 psi) 

      6. Turn the power switch OFF and the intelligent tester main switch off.
    22. Check the pressure difference between each compression pressure.

      Pressure difference: 0.1 MPa (1.0 kgf/cm 2  , 15 psi) or less 

    23. If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole. Then perform the first 3 steps under "inspect the cylinder compression pressure" for the cylinders with low compression.

      HINT:

      • If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
      • If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
    24. Connect the 2 injector driver connectors as shown in the illustration.
      Fig 16: Locating Injector Driver Connectors
      G05302643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    25. Install the 6 spark plugs.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    26. Install the 6 ignition coils.

    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    1. (aa) Connect the 6 injector connectors.
    2. (ab) Connect the throttle body connector.
    3. (ac) Connect the 4 connectors.
      Fig 17: Locating Connectors
      G05302644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. (ad) Connect the 3 clamps and connector.
      Fig 18: Locating Connector Clamps
      G05302645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. (ae) Install the clamp and plug.
      Fig 19: Locating Clamp And Plug
      G05302646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. (af) Install the water filler with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 20: Locating Water Filler With Bolt
      G05302647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. (ag) Install the inverter motor cable bracket with the 2 nuts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 21: Locating Inverter Motor Cable Bracket With Nuts
      G05302648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. (ah) Attach the protector to the bracket.
    9. (ai) Install the nut.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    10. (aj) Install the air cleaner cap with the air cleaner hose.
    11. (ak) Connect the No. 2 ventilation hose.
    12. (ai) Install the V-bank cover.
    13. (am) Install the engine room side cover LH.
    14. (an) Install the engine room side cover RH.
    15. (ao) Install the cool air intake duct seal.
  5. INSPECT CO/HC 

    HINT:

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

    1. Start the engine.
    2. Keep the engine speed at 2,500 rpm for approximately 180 seconds.
    3. Insert the CO / HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
      Fig 22: Checking CO/HC
      G05302649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Immediately check CO / HC concentration at idle and 2,500 rpm.

      HINT:

      • When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
      • If the CO / HC concentration does not comply with regulations, troubleshoot in the order given below.
      1. Check the A/F sensor and heated oxygen sensor operation.
      2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.
        SYMPTOM CHART

        CO HC Symptom Causes
        Normal High Rough idle
        1. Faulty ignitions
          • Incorrect timing
          • Plugs are contaminated, shorted, or gaps are defective.
        2. Leaky intake and exhaust valves
        3. Leaky cylinder
        Low High Rough idle (Fluctuating HC reading)
        1. Vacuum leaks
          • PCV hose
          • Intake manifold
          • Throttle body
        2. Lean mixture causing misfire
        High High Rough idle (Black smoke from exhaust)
        1. Restricted air filter
        2. Faulty SFI system
          • Faulty pressure
          • Defective ECT sensor
          • Faulty ECM
          • Faulty injector
          • Faulty throttle position sensor
          • Faulty MAF sensor
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