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On-Vehicle Inspection

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  1. INSPECT VALVE LASH ADJUSTER NOISE 
    1. Put the engine in inspection mode (see INSPECTION MODE PROCEDURE ).
    2. 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 above inspection again.

      If any defects or problems are found during the inspection above, perform the lash adjuster inspection (see INSPECTION ).

  2. INSPECT IGNITION TIMING 
    1. Put the engine in inspection mode (see INSPECTION MODE PROCEDURE ).
    2. Warm up and stop the engine
    3. When using the Intelligent tester or Techstream:
      1. Connect the Intelligent tester or Techstream to the DLC3.
      2. Start the engine and idle it
      3. Push the Intelligent tester or Techstream main switch ON.
      4. Enter the following menus:

        Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / IGN ADVANCE

        Techstream - Select: Powertrain / Engine and ECT / Data List / Primary / IGN Advance

        HINT.

        Refer to the Intelligent tester or Techstream operator's manual for further details.

        Standard ignition timing: 

        5 to 15° BTDC @ idle (Transmission neutral position and A/C switch OFF) 

    4. When not using the Intelligent tester or Techstream:
      1. Remove the V-bank cover.
      2. Remove the 5 clips and air cleaner inlet cover.
      3. Remove the 4 clips and engine room side cover LH.
      4. Remove the 2 bolts and No 1 air cleaner inlet.
      5. Disconnect the air cleaner cap LH.
      6. Remove the element, 2 nuts and air cleaner case LH
      7. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No 1 cylinder
        NOTE: Use a timing light that detects primary signals.
        Fig 1: Connecting Tester Probe Of Timing Light To Wire Of Ignition Coil Connector
        G05771289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      8. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST 09843-18040 

        NOTE:
        • Confirm the terminal numbers before connecting the probes. Connecting the probe to the wrong terminal can damage the engine.
        • When checking the ignition timing, the transmission should be in neutral.
          Fig 2: Identifying DLC3 Connector Terminals
          G04944121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      9. Using a timing light, check the ignition timing.

        Standard ignition timing: 

        8 to 12° BTDC @ idle (Transmission neutral position and A/C switch OFF) 

      10. Remove SST from the DLC3.
      11. Check the ignition timing.

        Standard ignition timing: 

        5 to 15° BTDC @ idle (Transmission neutral position and A/C switch OFF) 

        Fig 3: Checking Ignition Timing
        G05771291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      12. Check that the ignition timing advances immediately when the engine speed is increased.
      13. Disconnect the timing light from the engine.
      14. Install the air cleaner case LH with the 2 nuts.

        Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

      15. Install the element
      16. Connect the air cleaner cap LH.
      17. Install the No. 1 air cleaner inlet with the 2 bolts

        Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

      18. Install the engine room side cover LH with the 4 clips.
      19. Install the air cleaner inlet cover with the 5 clips.
      20. Install the V-bank cover.
  3. INSPECT ENGINE IDLE SPEED 
    1. Put the engine in inspection mode (see INSPECTION MODE PROCEDURE ).
    2. Warm up and stop the engine.
    3. When using the Intelligent tester or Techstream:
      1. Connect the Intelligent tester or Techstream to the DLC3.
        NOTE: Switch off all accessories and the A/C before connecting the Intelligent tester or Techstream.
      2. Race the engine at 2500 RPM for approximately 90 seconds.
      3. Push the Intelligent tester or Techstream main switch ON.
      4. Enter the following menus: Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD.

        INTELLIGENT TESTER 

        DATA LIST

        Tester Display Measurement Item/Range Normal Condition Diagnostic Note
        ENGINE SPD Engine speed:
        Min.: 0 rpm, Max.: 16383.75 rpm        		 800 to 900 rpm: Idling
        • Shift lever on P
        • When TC and CG terminals not connected
        950 to 1050 rpm: Idling
        • Shift lever on N
        • When TC and CG terminals not connected
        950 to 1050 rpm: Idling
        • Shift lever on P
        • When TC and CG terminals connected
        950 to 1050 rpm: Idling
        • Shift lever on N
        • When TC and CG terminals connected

        Techstream - Select: Powertrain / Engine and ECT / Data List / Primary / Engine Speed.

        TECHSTREAM 

        DATA LIST

        Tester Display Measurement Item/Range Normal Condition Diagnostic Note
        Engine speed Engine speed:
        Min.: 0 rpm, Max.: 16383.75 rpm        		 800 to 900 rpm: Idling
        • Shift lever on P
        • When TC and CG terminals not connected
        950 to 1050 rpm: Idling
        • Shift lever on N
        • When TC and CG terminals not connected
        950 to 1050 rpm: Idling
        • Shift lever on P
        • When TC and CG terminals connected
        950 to 1050 rpm: Idling
        • Shift lever on N
        • When TC and CG terminals connected

        HINT:

        Refer to the Intelligent tester or Techstream operator's manual for further details.

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

      5. Disconnect the Intelligent tester or Techstream from the DLC3.
    4. When not using the Intelligent tester or Techstream:
      1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

        SST 09843-18030 

        NOTE: Confirm the terminal number before connecting the probe. Connecting the probe to the wrong terminal can damage the engine.
        Fig 4: Identifying DLC3 Connector Terminals
        G05150491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST 09843-18040 

        NOTE: Confirm the terminal numbers before connecting the probes. Connecting the probe to the wrong terminal can damage the engine.
      3. Race the engine at 2500 RPM for approximately 90 seconds.
        Fig 5: Identifying DLC3 Connector Terminals
        G04944121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Check the idle speed.

        STANDARD IDLE SPEED 

        IDLE SPEED SPECIFICATION

        Tester Connection Condition Specified Condition
        13 (TC)-4 (CG)
        • Shift lever on P
        • When TC and CG terminals connected
        		 950 to 1050 rpm
        • Shift lever on N
        • When TC and CG terminals connected
        		 950 to 1050 rpm

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

      5. Remove SST that is connecting terminals 13 (TC) and 4 (CG) from the DLC3.
      6. Check the idle speed.

        STANDARD IDLE SPEED 

        IDLE SPEED SPECIFICATION

        Tester Connection Condition Specified Condition
        13 (TC)-4 (CG)
        • Shift lever on P
        • When TC and CG terminals not connected
        		 800 to 900 rpm
        • Shift lever on N
        • When TC and CG terminals not connected
        		 950 to 1050 rpm

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

      7. Disconnect the tachometer from the DLC3.
  4. INSPECT COMPRESSION 
    1. Warm up and stop the engine.
    2. Remove the luggage compartment mat and battery service hole cover LH.
    3. Disconnect the cable from the negative (-) battery terminal (see REMOVAL ).
    4. Remove the service plug grip (see REMOVAL ).
    5. Remove the 8 spark plugs (See REMOVAL ).
    6. Connect the frame wire (see INSTALLATION ).
    7. Connect the generator cable (See INSTALLATION ).
    8. Connect the motor cable (See INSTALLATION ).
    9. Install the skid control ECU bracket with the 2 nuts and bolt.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

    10. Connect the 3 skid control ECU connectors.

      HINT

      If a DTC for the hybrid control system is output, the Active Test cannot be performed. Therefore, it is necessary to install the skid control ECU

    11. Install the skid control ECU with the 2 bolts and nut.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

    12. Install the service plug grip (see INSPECTION )
    13. Connect the cable to the negative (-) battery terminal.
    14. Temporarily install the engine oil level dipstick guide with the bolt and insert the dipstick.
      NOTE: Engine oil will overflow if the compression test is performed with the engine oil level dipstick guide uninstalled.
    15. Disconnect the 4 injector driver connectors as shown in the illustration.

      HINT:

      To release each connector lock, push the claw downward ("Release" in the illustration) and move the lock lever ("Move" in the illustration).

      Fig 6: Disconnecting Injector Driver Connectors
      G05771294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. Disconnect the 2 injector connectors shown in the illustration
      Fig 7: Locating Injector Connectors
      G05771295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Insert a compression gauge into the spark plug hole.
    18. Connect the Intelligent tester or Techstream to the DLC3.
      NOTE: Check the HV battery voltage in the data list to ensure that the battery is fully charged.
    19. Turn the power switch ON (IG).
    20. Push the Intelligent tester or Techstream main switch ON
    21. Enter the following menus:

      Intelligent tester - Select: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST / ON.

      Fig 8: Checking Compression Pressure
      G05771296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      22. Techstream - Select: Powertrain / Hybrid Control / Active Test / Compress Test / On.

    22. Fully depress the acceleration pedal.
    23. 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 an engine speed of 200 RPM or more.
      NOTE: The measurement must be done as quickly as possible.

      Standard compression pressure: 

      1400 kPa (14.2 kgf/cm 2  , 203 psi) or more 

      Minimum pressure: 

      980 kPa (9.9 kgf/cm 2  , 142 psi) 

    24. Remove the compression gauge.
    25. Perform the inspection above for each cylinder.
    26. Check the pressure difference between each compression pressure.

      Pressure difference: 

      100 kPa (1.0 kgf/cm 2  , 15 psi) or less 

    1. (aa) If the cylinder compression is low in one or more cylinders, pour a small amount of engine oil into the cylinder with low compression through its spark plug hole. Then inspect the cylinder compression pressure again.

      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.

    2. (ab) Disconnect the cable from the negative (-) battery terminal.
    3. (ac) Remove the service plug grip.
    4. (ad) Remove the 2 bolts, nut and skid control ECU.
    5. (ae) Disconnect the 3 skid control ECU connectors.
    6. (af) Remove the 2 nuts, bolt and skid control ECU bracket.
    7. (ag) Disconnect the motor cable
    8. (ah) Disconnect the generator cable.
    9. (ai) Disconnect the frame wire.
    10. (aj) Connect the 4 injector driver connectors as shown in the illustration.
      NOTE: Connect the connector securely.

      HINT

      Move the lock lever in the direction indicated by the arrow to lock the connector.

      Fig 9: Connecting Injector Driver Connectors
      G05771297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. (ak) Connect the 2 injector connectors as shown in the illustration, (al) Remove the dipstick, engine oil level dipstick guide and bolt.
    12. (am) Install the 8 spark plugs (see INSTALLATION ).
    13. (an) Install the service plug grip.
    14. (ao) Connect the cable to the negative (-) battery terminal (see INSTALLATION ).
    15. (ap) Install the luggage compartment mat and battery service hole cover LH.
    16. (aq) Clear the DTCs (see DTC CHECK/CLEAR ).
  5. INSPECT CO/HC 

    HINT:

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

    Fig 10: Locating Injector Connectors
    G05771295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Put the engine in inspection mode (see INSPECTION MODE PROCEDURE ).
    2. Warm up the engine
    3. Keep the engine speed at 2500 RPM for approximately 180 seconds.
    4. Insert the CO / HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling.
    5. Immediately check CO / HC concentration at idle and 2500 RPM.

      HINT:

      • When performing the 2 mode (2500 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
        Fig 11: Inspecting CO/HC
        G04943162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check the A/F sensor (see INSPECTION ) and heated oxygen sensor (see INSPECTION ) operation.
      2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.
        CO/HC INSPECTION CHART

        CO HC Symptom Causes
        Normal High Rough idle
        1. Faulty ignitions
          • Incorrect timing
          • Plugs (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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