On-Vehicle Inspection

1. Activate inspection mode (See INSPECTION MODE PROCEDURE ).
2. Warm up and stop the engine.
3. Remove the intake air surge tank (See REMOVAL ).
   NOTE: If the throttle body connector is disconnected, a DTC will be set. Therefore, reconnect the throttle body connector before performing spark test.
4. Disconnect the 6 fuel injector connectors.
5. Remove the ignition coils assembly (See REMOVAL ).
   NOTE: If the ignition coil assembly connector is disconnected, a DTC will be set. Therefore, reconnect the ignition coil assembly connector before performing spark test.
   Fig 1: Locating Fuel Injector Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs (See REMOVAL ).
7. Install the spark plug to the ignition coil, and connect the ignition coil connector.
   NOTE: If the ignition coil assembly connector is disconnected, a DTC will be set. Therefore, reconnect the ignition coil assembly connector before performing spark test.
8. Activate inspection mode (See INSPECTION MODE PROCEDURE ).
9. Ground the spark plug.
10. Depress and hold the brake pedal, and turn the power switch on (READY).
11. Visually check that spark occurs while the engine is being cranked.
    NOTE:

    • Turn the power switch off within 2 seconds to stop the engine.
    • Be sure to ground the spark plugs during the inspection.
    • Replace the ignition coil if it receives an impact.
    Fig 2: Testing Spark Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Turning the power switch off will cancel inspection mode. Therefore, activate inspection mode every time a spark test is performed.

1. Check that the ignition coil connector is securely connected.

   Result 

   RESULT 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 CHART
      
      

      Result	Action
      NG	Go to next step
      OK	Replace ignition coil

   3. Check the spark plug (refer to  2INSPECT SPARK PLUG  ).

      Result 

      RESULT CHART
      
      

      Result	Action
      NG	Replace spark plug
      OK	Go to next step

   4. Check the power supply to the ignition coil.
      1. Turn the power switch on (IG).
      2. Check that there is battery voltage at the ignition coil positive (+) terminal.

         Result 

         RESULT CHART
         
         

         Result	Action
         NG	Check wiring between power switch and ignition coil
         OK	Go to next step

   5. Measure the resistance of the crankshaft position sensor (See REMOVAL ).

      Result 

      RESULT CHART
      
      

      Result	Action
      NG	Replace crankshaft position sensor
      OK	Go to next step

   6. Check the IGT signal from the hybrid vehicle control ECU (See DESCRIPTION ).

      Result 

      RESULT CHART
      
      

      Result	Action
      NG	Check ECM
      OK	Repair wiring between ignition coil and ECM

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

1. Using a megohmmeter, measure the insulation resistance.

   Standard insulation resistance: 10 MΩ or higher 

   Fig 3: Measuring Insulation Resistance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.

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.

Recommended spark plug 

Maximum electrode gap for a used spark plug: 1.3 mm (0.051 in.) 

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

Electrode gap for a new spark plug (for reference): 1.0 to 1.1 mm (0.039 to 0.043 in.) 

Fig 4: Checking Spark Plug Electrode Gap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 5: Cleaning Spark Plugs

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard air pressure: 583 kPa (6 kgf/cm ²  , 85 psi) 

Standard duration: 20 seconds or less 

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.