Inspection Procedure

HINT:

If any DTCs other than misfire DTCs are output, troubleshoot those DTCs first.
Read freeze frame data using Techstream. The ECM (Included in HV control ECU) records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was LEAN or RICH, and other data from the time the malfunction occurred.
If the misfire does not recur when the vehicle is brought to the workshop, reproduce the conditions stored in the freeze frame data.
The misfire still cannot be reproduced even though the conditions stored in the freeze frame data have been duplicated, one of the following factors is considered to be a possible cause of the problem:
1. The fuel tank is low full.
2. Improper fuel is used.
3. The spark plugs have been contaminated.
4. The problem is complex.
After finishing repairs, check the misfire counts of the cylinders (Cylinder #1 Misfire Count to Cylinder #6 Misfire Count).
Be sure to confirm that no misfiring cylinder DTCs are set again by conducting the confirmation driving pattern, after repairs.
For 6 and 8 cylinder engines, the ECM (Included in HV control ECU) intentionally does not set the specific misfiring cylinder DTCs at high engine RPM. If misfires occur only in high engine RPM areas, only DTC P0300 is set.
In the event of DTC P0300 being present, perform the following operations:
1. Clear the DTCs (See DTC CHECK / CLEAR ).
2. Start the engine and conduct the confirmation driving pattern.
3. Read the misfiring rates of each cylinder or DTC (s) using the tester.
4. Repair the cylinder(s) that has a high misfiring rate or is indicated by the DTC.
5. After finishing repairs, conduct the confirmation driving pattern again, in order to verify that DTC P0300 is not set.
When one of Short FT #1, Long FT #1, Short FT #2 or Long FT #2 in the freeze frame data is outside the range of +-20%, the air-fuel ratio may be RICH (-20% or less) or LEAN (+20% or more).
When the Coolant Temp in the freeze frame data is less than 75°C (167°F), misfires have occurred only while warming up the engine.
An extremely imbalanced drive wheel which causes body vibration may cause misfire DTCs to be detected.

CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO MISFIRE DTCS)

Connect Techstream to the DLC3.
Turn the ignition switch to the ON position.
Turn the tester ON.
Enter the following menus: Powertrain / Engine and ECT / Trouble Code.

Read the DTCs.

Result

RESULT CHART

Display (DTC output)	Proceed to
P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306	A
P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306 and other DTCs	B

HINT:

If any DTCs other than P0300, P0301, P0302, P0303, P0304, P0305 and P0306 are output, troubleshoot those DTCs first.

B: GO TO DTC CHART

A: Go to next step

READ VALUE USING TECHSTREAM (MISFIRE RPM AND MISFIRE LOAD)
1. Connect Techstream to the DLC3.
2. Put the engine in inspection mode (See CHECK MODE PROCEDURE ).
3. Turn the ignition switch to the ON position and turn the tester ON.
4. Enter the following menus: Powertrain / Engine and ECT / Data List / Misfire / Misfire RPM and Misfire Load.
5. Read and note the Misfire RPM and Misfire Load (engine load) values.
  HINT:
  
  The Misfire RPM and Misfire Load indicate the vehicle conditions under which the misfire occurred.
CHECK PCV HOSE CONNECTIONS
OK: PCV hose is connected correctly and is not damaged.

NG: REPAIR OR REPLACE PCV HOSE

OK: Go to next step

READ VALUE OF TECHSTREAM

Connect Techstream to the DLC3.
Put the engine in inspection mode (See CHECK MODE PROCEDURE ).
Turn the tester ON.
Clear the DTCs.
Enter the following menus: Powertrain / Engine and ECT / Data List / Misfire / Cylinder #1 Misfire Count, #1, #2, #3, #4, #5 and #6.
Start the engine.
Read each value of Cylinder #1 Misfire Count to #6 displayed on the tester. If no misfire counts occur in any cylinders, perform the following conditions:
1. Shift the gear selector lever to the D position.
2. Repeat steps ( e) to ( g) above.
3. Check the Cylinder #1 Misfire Count to #6.
4. If misfire counts are still not displayed, perform steps ( h) and ( i) and then check the misfire counts again.
Drive the vehicle with Misfire RPM and Misfire Load noted in step 2.

Read the Cylinder #1 Misfire Count to #6 or DTCs displayed on the tester.

Result

RESULT CHART

Misfire count	Proceed to
1 or 2 cylinders have misfire counts	A
3 cylinders or more have misfire counts	B

B: Go to step 17

A: Go to next step

CHECK SPARK PLUG

Remove the ignition coil and the spark plug of the misfiring cylinder.
Measure the spark plug electrode gap.
Standard:

Between 1.0 mm and 1.1 mm (0.039 in. and 0.043 in.)

Check the electrode for carbon deposits.

Recommended spark plug:

SPARK PLUG SPECIFICATION

Manufacture	Product
DENSO	SK20R11
NGK	IFR6A11

NOTE: If the electrode gap is larger than standard, replace the spark plug. Do not adjust the electrode gap.

NG: REPLACE SPARK PLUG

OK: Go to next step

CHECK FOR SPARKS AND IGNITION
1. Disconnect the injector connectors, in order to prevent the engine from starting.
  CAUTION: Always disconnect all injector connectors.
2. Install the spark plug to the ignition coil.
3. Attach the spark plug assembly to the cylinder head cover.
4. Crank the engine for less than 2 seconds and check the spark.
  OK: Sparks jump across electrode gap.
5. Reconnect the injector connectors.
NG: Go to step 29

OK: Go to next step
CHECK CYLINDER COMPRESSION PRESSURE OF MISFIRING CYLINDER
1. Measure the cylinder compression pressure of the misfiring cylinder (See ON-VEHICLE INSPECTION ).
  Minimum pressure:
  
  0.74 MPa (7.5 kgf/cm ² , 107 psi)
  
  Difference between each cylinder:
  
  100 kPa (1.0 kgf/cm ² , 15 psi)
NG: CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

OK: Go to next step

CHECK HARNESS AND CONNECTOR (INJECTOR OF MISFIRING CYLINDER POWER SOURCE)

Disconnect the I8 to I13 injector connectors (of the misfiring cylinder).

Measure the voltage according to the value(s) in the table below.

Standard voltage

TESTER CONNECTION SPECIFIED CONDITION CHART

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	I8-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 2	I9-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 3	I10-2-Body ground	Ignition switch to the ON position	9 to 14 V
No. 4	I11-2-Body ground	Ignition switch to the ON position	9 to 14 V
No. 5	I12-2-Body ground	Ignition switch to the ON position	9 to 14 V
No. 6	I13-2-Body ground	Ignition switch to the ON position	9 to 14 V

Fig 1: Identifying Terminals Of I8 To I13 Injector Connectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HARNESS AND CONNECTOR

Disconnect the I8 to I13 injector connectors.
Disconnect the H32 and H33 HV control ECU connector.

Measure the resistance according to the value(s) in the table below.

Standard resistance:

Check for open

TESTER CONNECTION SPECIFIED CONDITION CHART

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	I8-1 - H32-1 (#10)	Always	Below 1Ω
No. 2	I9-1 - H32-2 (#20)	Always	Below 1Ω
No. 3	I10-1 - H32-3 (#30)	Always	Below 1Ω
No. 4	I11-1 - H32-4 (#40)	Always	Below 1Ω
No. 5	I12-1 - H32-5 (#50)	Always	Below 1Ω
No. 6	I13-1 - H33-7 (#60)	Always	Below 1Ω

Check for short

TESTER CONNECTION SPECIFIED CONDITION CHART

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	I8-1 - Body ground	Always	10 kΩ or higher
No. 2	I9-1 - Body ground	Always	10 kΩ or higher
No. 3	I10-1 - Body ground	Always	10 kΩ or higher
No. 4	I11-1 -Body ground	Always	10 kΩ or higher
No. 5	I12-1 - Body ground	Always	10 kΩ or higher
No. 6	I13-1 -Body ground	Always	10 kΩ or higher

Fig 2: Identifying Terminals Of H32 And H33 HV Control ECU Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Reconnect the injector connectors.
Reconnect the HV control ECU connectors.

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK FUEL INJECTOR OF MISFIRING CYLINDER
1. Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor).
  Standard:
  
  13 cm ³ (0.8 cu in.) or less
NG: REPLACE FUEL INJECTOR ASSEMBLY

OK: Go to next step
CHECK VALVE CLEARANCE OF MISFIRING CYLINDER
1. Check the valve clearance of the misfiring cylinder (See VALVE CLEARANCE ).
NG: ADJUST VALVE CLEARANCE

OK: Go to next step
CHECK AIR INDUCTION SYSTEM
1. Check the air induction system for vacuum leakage.
  OK: No leakage from air induction system.
NG: REPAIR OR REPLACE AIR INDUCTION SYSTEM

OK: Go to next step
CHECK VALVE TIMING
1. Remove the cylinder head cover.
2. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
3. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration.
  If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
  
  OK: The timing marks on the camshaft timing gears are aligned as shown in illustration.
4. Reinstall the cylinder head cover.
NG: ADJUST VALVE TIMING

OK: Go to next step
CHECK FUEL PRESSURE
1. Check the fuel pressure (See ON-VEHICLE INSPECTION ).
  Standard:
  
  304 to 343 kPa (3.1 to 3.5 kgf/cm ² , 44.1 to 49.7 psi)
NG: CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER

OK: Go to next step
READ VALUE USING TECHSTREAM (COOLANT TEMP)
1. Connect Techstream to the DLC3.
2. Put the engine in inspection mode (See CHECK MODE PROCEDURE ).
3. Start the engine.
4. Turn the tester ON.
5. Enter the following menus: Powertrain / Engine and ECT / Data List / Coolant Temp.
6. Read the Coolant Temp twice, when the engine is both cold and warmed up.
  Standard:
  
  With cold engine:
  
  Same as ambient air temperature.
  
  With warm engine:
  
  Between 75°C and 95°C (167°F and 203°F).
NG: REPLACE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR

OK: Go to next step
READ VALUE USING TECHSTREAM (MAF)
1. Connect Techstream to the DLC3.
2. Turn the tester ON.
3. Enter the following menus: Powertrain / Engine and ECT /Data List/All Data/MAF.
4. Read the MAF with the engine stopped.
  Standard:
  
  MAF while engine stopped:
  
  0.54 g/s or less
5. Put the engine in inspection mode (See CHECK MODE PROCEDURE ).
6. Enter the following menus: Powertrain / Engine and ECT / Data List / MAF and Coolant Temp.
7. Allow the engine to idle until the Coolant Temp reaches 75°C (167°F) or more.
8. Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm.
  Standard:
  
  MAF while engine idling:
  
  Between 2.0 g/s and 4.3 g/s (shift position: N, A/C: OFF).
  
  MAF at an engine speed of 2,500 rpm:
  
  Between 12.1 g/s and 18.2 g/s (shift position: N, A/C: OFF).
NG: REPLACE MASS AIR FLOW METER

OK: REPLACE ECM
CHECK AIR INDUCTION SYSTEM
1. Check the air induction system for vacuum leakage.
  OK: No leakage from air induction system.
NG: REPAIR OR REPLACE AIR INDUCTION SYSTEM

OK: Go to next step
CHECK VALVE TIMING
1. Remove the cylinder head cover.
2. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
3. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration.
  If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
  
  OK: The timing marks on the camshaft timing gears are aligned as shown in illustration.
4. Reinstall the cylinder head cover.
NG: ADJUST VALVE TIMING

OK: Go to next step
CHECK FUEL PRESSURE
1. Check the fuel pressure (See ON-VEHICLE INSPECTION ).
  Standard:
  
  304 to 343 kPa (3.1 to 3.5 kgf/cm ² , 44.1 to 49.7 psi)
NG: CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER

OK: Go to next step
READ VALUE OF TECHSTREAM (COOLANT TEMP)
1. Connect Techstream to the DLC3.
2. Put the engine in inspection mode (See CHECK MODE PROCEDURE ).
3. Start the engine.
4. Turn the tester ON.
5. Enter the following menus: Powertrain / Engine and ECT / Data List / Coolant Temp.
6. Read the Coolant Temp twice, when the engine is both cold and warmed up.
  Standard:
  
  With cold engine:
  
  Same as ambient air temperature.
  
  With warm engine:
  
  Between 75°C and 95°C (167°F and 203°F).
NG: REPLACE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR

OK: Go to next step
READ VALUE OF TECHSTREAM (MAF)
1. Connect Techstream to the DLC3.
2. Turn the tester ON.
3. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAF.
4. Read the MAF with the engine stopped.
  Standard:
  
  MAF while engine stopped:
  
  0.54 g/s or less
5. Put the engine in inspection mode (See CHECK MODE PROCEDURE ).
6. Enter the following menus: Powertrain / Engine and ECT / Data List / MAF and Coolant Temp.
7. Allow the engine to idle until the Coolant Temp reaches 75°C (167°F) or more.
8. Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm.
  Standard:
  
  MAF while engine idling:
  
  Between 2.0 g/s and 4.3 g/s (shift position: N, A/C: OFF).
  
  MAF at an engine speed of 2,500 rpm:
  
  Between 12.1 g/s and 18.2 g/s (shift position: N, A/C: OFF).
NG: REPLACE MASS AIR FLOW METER

OK: Go to next step

CHECK SPARK PLUG

Remove the ignition coil and the spark plug of the misfiring cylinder.
Measure the spark plug electrode gap.
Standard:

Between 1.0 mm and 1.1 mm (0.039 in. and 0.043 in.)

Check the electrode for carbon deposits.

Recommended spark plug:

SPARK PLUG SPECIFICATION

Manufacture	Product
DENSO	SK20R11
NGK	IFR6A11

NOTE: If the electrode gap is larger than standard, replace the spark plug. Do not adjust the electrode gap.

NG: REPLACE SPARK PLUG

OK: Go to next step

CHECK SPARKS AND IGNITION
1. Disconnect the injector connectors, in order to prevent the engine from starting.
  CAUTION: Always disconnect all injector connectors.
2. Install the spark plug to the ignition coil.
3. Attach the spark plug assembly to the cylinder head cover.
4. Crank the engine for less than 2 seconds and check the spark.
  OK: Sparks jump across electrode gap.
5. Reconnect the injector connectors.
NG: Go to step 29

OK: Go to next step
CHECK CYLINDER COMPRESSION PRESSURE
1. Measure the cylinder compression pressure of the misfiring cylinder (See ON-VEHICLE INSPECTION ).
  Minimum pressure:
  
  0.74 MPa (7.5 kgf/cm ² , 107 psi)
  
  Difference between each cylinder:
  
  100 kPa (1.0 kgf/cm ² , 15 psi)
NG: CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

OK: Go to next step

CHECK HARNESS AND CONNECTOR (INJECTOR OF MISFIRING CYLINDER POWER SOURCE)

Disconnect the I8 to I13 injector connectors (of the misfiring cylinder).

Measure the voltage according to the value(s) in the table below.

Standard voltage

TESTER CONNECTION SPECIFIED CONDITION CHART

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	I8-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 2	I9-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 3	I10-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 4	I11-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 5	I12-2 - Body ground	Ignition switch to the ON position	9 to 14 V
No. 6	I13-2 - Body ground	Ignition switch to the ON position	9 to 14 V

Fig 5: Identifying Terminals Of I8 To I13 Injector Connectors

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HARNESS AND CONNECTOR

Disconnect the I8 to I13 injector connectors.
Disconnect the H32 and H33 HV control ECU connector.

Measure the resistance according to the value(s) in the table below.

Standard resistance

Check for open

TESTER CONNECTION SPECIFIED CONDITION CHART

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	I8-1 - H32-1 (#10)	Always	Below 1Ω
No. 2	I9-1 - H32-2 (#20)	Always	Below 1Ω
No. 3	I10-1 - H32-3 (#30)	Always	Below 1Ω
No. 4	I11-1 - H32-4 (#40)	Always	Below 1Ω
No. 5	I12-1 - H32-5 (#50)	Always	Below 1Ω
No. 6	I13-1 - H33-7 (#60)	Always	Below 1Ω

Check for short

TESTER CONNECTION SPECIFIED CONDITION CHART

Cylinder	Tester Connection	Condition	Specified Condition
No. 1	I8-1 - Body ground	Always	10 kΩ or higher
No. 2	I9-1 - Body ground	Always	10 kΩ or higher
No. 3	I10-1 - Body ground	Always	10 kΩ or higher
No. 4	I11-1 -Body ground	Always	10 kΩ or higher
No. 5	I12-1 -Body ground	Always	10 kΩ or higher
No. 6	I13-1 -Body ground	Always	10 kΩ or higher

Fig 6: Identifying Terminals Of I8 To I13 Injector Connectors

Reconnect the injector connectors.
Reconnect the HV control ECU connectors.

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK FUEL INJECTOR OF MISFIRING CYLINDER
1. Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor).
  Standard:
  
  13 cm ³ (0.8 cu in.) or less
NG: REPLACE FUEL INJECTOR ASSEMBLY

OK: Go to next step
CHECK VALVE CLEARANCE OF MISFIRING CYLINDER
1. Check the valve clearance of the misfiring cylinder (See REASSEMBLY ).
NG: ADJUST VALVE CLEARANCE

OK: REPLACE ECM
CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER
1. Change the installed spark plug to a spark plug that functions normally.
2. Perform a spark test.
  CAUTION: Always disconnect all injector connectors.
  
  NOTE: Do not crank the engine for more than 2 seconds.
  1. Install the spark plug to the ignition coil and connect the ignition coil connector.
  2. Disconnect the injector connector.
  3. Ground the spark plug.
  4. Check if sparks occur while the engine is being cranked.
    OK: Sparks jump across electrode gap.
NG: Go to step 30

OK: REPLACE SPARK PLUG
CHANGE TO NORMAL IGNITION COIL AND SPARK OF MISFIRING CYLINDER
NG: REPLACE ECM

OK: REPLACE IGNITION COIL ASSEMBLY