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Home >> Toyota >> 2009 >> Highlander Limited, FWD >> Repair and Diagnosis >> Engine Performance >> Tune-Up >> Engine Ignition System (2GR-FE) >> Ignition Coil And Spark Plug >> On-Vehicle Inspection

On-Vehicle Inspection

  1. INSPECT IGNITION COIL ASSEMBLY 
    1. Check for DTCs.
      NOTE: If any DTC is present, perform troubleshooting in accordance with the procedure for that DTC.
    2. Remove the ignition coil assembly and spark plug (See REMOVAL ).
    3. Check that sparks occur.
      1. Disconnect the 6 fuel injector connectors.
        2. Fig 1: Locating Fuel Injector Connectors
        G04975488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the spark plug to ignition coil, and connect the ignition coil connector.
      3. Ground the spark plug.
      4. Check if spark occurs at each spark plug while the engine is being cranked.
      NOTE:
      • Be sure to ground the spark plugs during the inspection.
      • Replace the ignition coil if it receives an impact.
      • Do not crank the engine for more than 2 seconds.
      Fig 2: Checking Spark Occurs At Each Spark Plug While Engine Is Being Cranked
      G04975489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Perform the spark test according to the flowchart below:
      1. Check that the ignition coil connector is securely connected.

        Result 

        RESULT REFERENCE CHART

        Result Action
        NG Connect securely
        OK Go to next step
      2. Perform a spark test on each ignition coil.
        1. Replace the ignition coil with a known good one.
        2. Perform the spark test again.

          Result 

        RESULT REFERENCE CHART

        Result Action
        NG Go to next step
        OK Replace ignition coil
      3. Check the spark plug (to INSPECT SPARK PLUG).

        Result 

        RESULT REFERENCE CHART

        Result Action
        NG Replace spark plug
        OK Go to next step
      4. Check the power supply to the ignition coil.
        1. Turn the ignition switch on (IG).
        2. Check that there is battery voltage at the ignition coil positive (+) terminal.

          Result 

        RESULT REFERENCE CHART

        Result Action
        NG Check wiring between ignition switch and ignition coil
        OK Go to next step
      5. Measure the resistance of the crankshaft position sensor (See INSPECTION ).

        Result 

        RESULT REFERENCE CHART

        Result Action
        NG Replace crankshaft position sensor
        OK Go to next step
      6. Check the IGT signal from the ECM (See TERMINALS OF ECM ).

        Result 

      RESULT REFERENCE CHART

      Result Proceed to Action
      NG Check ECM
      OK Repair wiring between ignition coil and ECM
    5. Using a 16 mm plug wrench, install the spark plugs.

      Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) 

    6. Connect the 6 fuel injector connectors.
    7. Install the ignition coil assembly (See INSTALLATION ).
  2. INSPECT SPARK PLUG 
    NOTE:
    • Never use a wire brush for cleaning.
    • Never attempt to adjust the electrode gap on a used spark plug.
    1. Check the electrode.
      1. Using a megohmmeter, measure the insulation resistance.

        Standard insulation resistance: 

        10 MΩ or higher 

        HINT:

        • If the result is below 10 MΩ, clean the plug and measure the resistance again.
        • If a megohmmeter is not available, perform the following inspection instead.
        Fig 3: Measuring Insulation Resistance
        G04975477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Alternative inspection method:
      1. Quickly accelerate the engine to 4000 rpm 5 times.
      2. Remove the spark plugs.
      3. Visually check the spark plug.

        If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step.

    3. Check the spark plug for any damage to its threads and insulator. If there is damage, replace the spark plug.

      Recommended spark plug 

      RECOMMENDED SPARK PLUG

      Manufacturer Spark Plug Type
      DENSO FK20HR11
      NOTE: Use only the listed spark plug or equivalent to ensure engine performance and smooth driveability.
    4. Check the spark plug electrode gap.

      Maximum electrode gap for a used spark plug: 1.4 mm (0.055 in.) 

      If the gap is greater than the maximum, replace the spark plug.

      Fig 4: Checking Spark Plug Electrode Gap
      G05415252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Clean the spark plugs.

      Electrode gap for a new spark plug (for reference): 

      1.0 to 1.1 mm (0.039 to 0.043 in.) 

      If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it.

      Standard air pressure: 

      588 kPa (6 kgf/cm 2  , 85 psi) 

      Standard duration: 

      20 seconds or less 

      Fig 5: Cleaning Spark Plugs
      G04962921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner.

    6. Install the ignition coil assembly and spark plug. (See INSTALLATION ).
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