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On-Vehicle Inspection [11/2016 - ]: Procedure

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  1. INSPECT ENGINE COOLANT (for Engine) 

    Refer to ON-VEHICLE INSPECTION [11/2016 - ]

  2. INSPECT ENGINE OIL 

    Refer to ON-VEHICLE INSPECTION [11/2016 - ]

  3. CHECK AUXILIARY BATTERY 

    Refer to ON-VEHICLE INSPECTION [11/2016 - ]

  4. INSPECT SPARK PLUG 

    Refer to ON-VEHICLE INSPECTION [11/2016 - ]

  5. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly.
    2. Visually check that the air cleaner filter element sub-assembly is not damaged or excessively oily.

      HINT: 

      • If there is any dirt or clogs in the air cleaner filter element sub-assembly, clean it with compressed air.
      • If any dirt or clogs remain even after cleaning the air cleaner filter element sub-assembly with compressed air, replace it.
    3. Install the air cleaner filter element sub-assembly.
  6. INSPECT V-RIBBED BELT 

    Refer to ON-VEHICLE INSPECTION [11/2016 - ] 

  7. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOISE 
    1. Put the engine in inspection mode.

      Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

    2. Rev up the engine several times. Check that the engine does not emit unusual noises.
    3. If unusual noises occur, warm up the engine and idle it for 30 minutes or more, then perform the inspection.

      HINT: 

      If any defects or problems are found during the inspection, perform valve lash adjuster assembly inspection.

      Refer to PROCEDURE - Step 2

  8. INSPECT IGNITION TIMING 
    NOTE:
    • Check the ignition timing with the cooling fans off.
    • Turn off all the electrical systems and the A/C.
    • When checking the ignition timing, the transaxle should be in park.
    1. Put the engine in inspection mode.

      Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

    2. Warm up and stop the engine.
    3. When using the Techstream:
      1. Connect the Techstream to the DLC3.
      2. Put the engine in inspection mode.

        Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

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

        Powertrain > Engine and ECT > Data List 

        Tester Display
        IGN Advance

        Standard Ignition Timing

        7 to 24° BTDC at idle

      4. Check that the ignition timing advances immediately when the engine speed is increased.
      5. 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
      6. Monitor IGN Advance of the Data List.

        Standard Ignition Timing

        8 to 12° BTDC at idle

    4. When not using the Techstream:
      1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
        • SST: 09843-18040 
        GTY443141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a DLC3
        NOTE:

        Confirm the terminal numbers before connecting them. Connecting the wrong terminals may damage electrical components.

      2. Remove the windshield wiper motor and link assembly.

        Refer to REMOVAL [02/2014 - ]

      3. Remove the outer cowl top panel sub-assembly.

        Refer to PROCEDURE - Step 3

      4. Remove the V-bank cover sub-assembly.

        See step  22

      5. Separate the brake master cylinder reservoir assembly.

        See step  32

      6. Remove the reservoir bracket.

        See step  33

      7. Disconnect the EGR valve assembly connector.
        GTY644666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      8. Remove the bolt and separate the wire harness protector from the cylinder head cover sub-assembly.
        GTY644667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      9. Disengage the 2 claws and open the wire harness protector.
      10. Pull out the wire harness as shown in the illustration.
        GTY644665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        After checking, wrap the wire harness with tape.

      11. Connect the clip of the timing light to the wire harness.
        NOTE:

        Use a timing light that detects the primary signal.

      12. Connect the brake master cylinder reservoir assembly connector, air conditioner tube and accessory assembly connector and EGR valve assembly connector.
      13. Put the engine in inspection mode.

        Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

      14. Check the ignition timing at idle.

        Standard Ignition Timing

        8 to 12° BTDC at idle

        GTY643032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Cutout
        *b 10° CA BTDC
        *c TDC

        HINT: 

        If the cutout of the crankshaft pulley is approximately aligned the protrusion (10° CA BTDC) of the timing chain cover assembly, the ignition timing meets the standard.

      15. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.
      16. Check the ignition timing at idle.

        Standard Ignition Timing

        7 to 24° BTDC at idle

      17. Confirm that the ignition timing advances immediately when the engine speed is increased.
      18. Disconnect the clip of the timing light from the wire harness.
      19. Disconnect the brake master cylinder reservoir assembly connector, air conditioner tube and accessory assembly connector and EGR valve assembly connector.
      20. Close the wire harness protector and engage the 2 claws.
      21. Install the wire harness protector to the cylinder head cover sub-assembly with the bolt.

        Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      22. Connect the EGR valve assembly connector.
      23. Install the reservoir bracket.

        See step  41

      24. Install the brake master cylinder reservoir assembly.

        See step  42

      25. Install the V-bank cover sub-assembly.

        See step  74

      26. Install the outer cowl top panel sub-assembly.

        Refer to PROCEDURE - Step 10

      27. Install the windshield wiper motor and link assembly.

        Refer to INSTALLATION [02/2014 - ]

  9. INSPECT ENGINE IDLE SPEED 
    NOTE:
    • Check the idle speed with the cooling fans off.
    • Turn off all the electrical systems and the A/C.
    • When checking the idle speed, the transaxle should be in park.
    1. Put the engine in inspection mode.

      Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

    2. Warm up and stop the engine.
    3. When using the Techstream:
      1. Connect the Techstream to the DLC3.
      2. Put the engine in inspection mode.

        Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

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

        Powertrain > Engine and ECT > Data List 

        Tester Display
        Engine Speed
      4. Read the value displayed on the Techstream.

        Standard Idle Speed

        950 to 1050 rpm

    4. When not using the Techstream:
      1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.
        • SST: 09843-18030 
        GTY443142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a DLC3
        NOTE:

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

      2. Put the engine in inspection mode.

        Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

      3. Check the idle speed.

        Standard Idle Speed

        950 to 1050 rpm

      4. Turn the power switch off.
      5. Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.
  10. INSPECT COMPRESSION 
    NOTE:

    Keep the intake manifold and spark plug holes free of foreign matter when measuring the compression pressure.

    1. Put the engine in inspection mode.

      Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

    2. Warm up and stop the engine.
    3. Check for DTCs.

      Refer to DTC CHECK / CLEAR [11/2016 - ]

    4. Remove the 6 spark plugs.

      Refer to REMOVAL [11/2016 - ]

      NOTE:

      DTCs will be stored if the inspection is performed with the ignition coil assembly connectors disconnected. Make sure that the ignition coil assembly connectors are connected during the inspection.

    5. Check the cylinder compression pressure.
      GTY695358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Insert a compression gauge into the spark plug hole.
      2. Connect the Techstream to the DLC3.
      3. Turn the power switch on (IG).
      4. Turn the Techstream on.
        NOTE:

        Check the HV battery voltage in the Data List to ensure that the battery is fully charged.

      5. Enter the following menus: Powertrain / Hybrid Control / Active Test / Compression Test / ON.

        Powertrain > Hybrid Control > Active Test 

        Tester Display
        Compression Test
      6. Depress and hold the brake pedal, and turn the power switch on (READY). Then check the compression pressure.

        Standard Compression Pressure

        1000 kPa (10.2 kgf/cm2 , 145 psi)

        Minimum Compression Pressure

        750 kPa (7.6 kgf/cm2 , 109 psi)

        Pressure Difference between Each Cylinder

        200 kPa (2.0 kgf/cm2 , 29 psi) or less

        NOTE:
        • Inspect all cylinders in the same way.
        • Measure the compression pressure as quickly as possible.
        • Noise may be emitted from the hybrid vehicle transaxle assembly. However, this is not a malfunction.
      7. If the cylinder compression pressure is low, pour a small amount of engine oil into the cylinder through the spark plug hole and 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 cylinder head gasket.
    6. Install the 6 spark plugs.

      Refer to INSTALLATION [11/2016 - ]

    7. Clear the DTCs.

      Refer to DTC CHECK / CLEAR [11/2016 - ]

      NOTE:

      After performing the inspection, clear the DTCs and confirm that DTCs are not stored again or that the normal system code is output if using a check wire.

  11. INSPECT CO/HC 

    HINT: 

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

    1. Put the engine in inspection mode.

      Refer to INSPECTION MODE PROCEDURE [11/2016 - ]

    2. Run the engine speed at 2500 rpm for approximately 180 seconds.
    3. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idle.
    4. Immediately check the CO/HC concentration at idle and then at an engine speed of 2500 rpm.

      HINT: 

      When performing a 2 mode test (with the engine idling/running at 2500 rpm), 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.

      1. Check for DTCs.

        Refer to DTC CHECK / CLEAR [11/2016 - ]

      2. See the following table for possible causes, then inspect the applicable parts and repair them if necessary.
        CO HC Problem Cause
        Normal High Rough idle
        1. Faulty ignition:
          • Incorrect valve timing
          • Fouled, shorted or improperly gapped spark plugs
        2. Incorrect valve clearance (valve lash adjuster assembly)
        3. Leaks in intake or exhaust valves
        4. Leaks in cylinders
        5. Faulty EGR
        Low High Rough idle
        (Fluctuating HC reading)
        1. Vacuum leaks:
          • PCV hoses
          • Intake manifold
          • Throttle with motor body assembly
          • Brake booster line
        2. Lean mixture causing misfire
        3. Faulty EGR
        High High Rough idle
        (Black smoke from exhaust)
        1. Restricted air cleaner filter element sub-assembly
        2. Plugged PCV valve
        3. Faulty SFI system:
          • Fuel pressure regulator assembly
          • Engine coolant temperature sensor
          • Mass air flow meter sub-assembly
          • ECM
          • Fuel injector assemblies
          • Throttle position sensor (built into throttle with motor body assembly)
        4. Faulty EGR
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