engine (2gr−fe) - Frankenstein Motorworks

engine (2gr−fe) - Frankenstein Motorworks
14−1
ENGINE MECHANICAL
−
ENGINE (2GR−FE)
ENGINE (2GR−FE)
1404Q−13
INSPECTION
1.
2.
3.
4.
(a)
(b)
5.
INSPECT ENGINE COOLANT (SEE PAGE 16−1)
INSPECT ENGINE OIL (SEE PAGE 17−1)
INSPECT BATTERY (SEE PAGE 19−20)
INSPECT AIR CLEANER FILTER ELEMENT SUB−ASSY
Remove the air filter.
Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter.
INSPECT SPARK PLUG (SEE PAGE 18−4)
6.
(a)
INSPECT V−RIBBED BELT
Visually check the drive belt for excessive wear, frayed
cords, etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the drive belt has chunks missing from the ribs, it should be
replaced.
REPLACE
G42362
HINT:
After installing the drive belt, check that it fits properly in
the ribbed grooves. Check to confirm that the belt has not
slipped out of the groove on the bottom of the crank pulley
by hand.
S
A ”new belt” is a belt which has been used for less than
5 minutes with the engine running.
INCORRECT
CORRECT
S
A ”used belt” is a belt which has been used for 5 minutes
or more with the engine running.
G42363
S
After installing a new belt, run the engine for approximately 5 minutes and then recheck the belt.
7.
INSPECT V−RIBBED BELT TENSIONER ASSY (SEE PAGE 14−6)
8.
INSPECT VALVE LASH ADJUSTER NOISE
(a) 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 repeat step (a).
HINT:
If any defects or problems are found during the inspection above, perform lash adjuster inspection (see page
14−188)
S
2005 AVALON REPAIR MANUAL (RM1169U)
Author:
Date:
2870
14−2
ENGINE MECHANICAL
−
ENGINE (2GR−FE)
9.
(a)
INSPECT IGNITION TIMING
Warm up the engine.
(b)
When using the hand−held tester:
Check the ignition timing.
(1) Connect the hand−held tester to the DLC3.
(2) Enter DATA LIST MODE with the hand−held tester.
Ignition timing : 8 to 12_ BTDC at idle
Hand−held Tester
HINT:
Refer to the hand−held tester operator’s manual for help on selecting the DATA LIST.
CAN VIM
DLC3
G41046
(c)
CG
DLC3
1 2 3 4 5 6 7 8
9 10 11 1213141516
TC
A82779
Red Lead Wire
Tester Terminal
G40663
When not using the hand−held tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843−18040
NOTICE:
S
Confirm the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.
S
Turn off all electrical systems before connecting the
terminals.
S
Perform this inspection after the cooling fan motor is
turned off.
(2) Remove the V−bank cover.
(3)
(4)
Pull out the red lead wire harness.
Connect the tester terminal of the timing light to the
red lead wire as shown in the illustration.
NOTICE:
Use a timing light which detects the first signal.
(5) Check the ignition timing at idle.
Ignition timing: 8 to 12_ BTDC at idle
NOTICE:
When checking the ignition timing, the transmission
should be in the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, and then
check that the engine rpm returns to idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Check the ignition timing at idle.
Ignition timing: 5 to 15_ BTDC at idle
(8) Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased.
2005 AVALON REPAIR MANUAL (RM1169U)
Author:
Date:
2871
14−3
ENGINE MECHANICAL
10.
(a)
−
ENGINE (2GR−FE)
(9) Remove the timing light.
INSPECT ENGINE IDLE SPEED
Warm up the engine.
(b)
Hand−held Tester
CAN VIM
DLC3
G41046
When using the hand−held tester:
Check the idle speed.
(1) Connect the hand−held tester to the DLC3.
(2) Enter DATA LIST MODE with the hand−held tester.
Idle speed: 600 to 700 rpm
NOTICE:
S
When checking the idle speed, the transmission
should be in the neutral position.
S
Check the idle speed with the cooling fan off.
S
Switch off all accessories and air conditioning before
connecting the hand−held tester.
HINT:
Refer to the hand−held tester operator’s manual for further details.
(c)
DLC3
1 2 3 4 5 6 7 8
9 10 11 1213141516
TAC
A82779
11.
(a)
(b)
(c)
(d)
(e)
(f)
When not using the hand−held tester:
Check the idle speed.
(1) Using SST, connect tachometer test probe to terminal 9 (TAC) of the DLC3.
SST 09843−18030
(2) Check the idle speed.
Idle speed: 600 to 700 rpm
INSPECT COMPRESSION
Warm up and stop the engine.
Disconnect the injector connectors.
Remove the intake air surge tank (see page 11−15).
Remove the 6 ignition coils.
Remove the 6 spark plugs.
Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
G41852
2005 AVALON REPAIR MANUAL (RM1169U)
Author:
Date:
2872
14−4
ENGINE MECHANICAL
−
ENGINE (2GR−FE)
(2)
While cranking the engine, measure the compression pressure.
Compression pressure:
1.4 MPa (14 kgf/cm2, 199 psi)
Minimum pressure:
0.98 MPa (10 kgf/cm2, 142 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm2, 15 psi)
NOTICE:
S
Always use a fully charged battery to obtain an engine speed of 250 rpm or more.
S
Check the other cylinders’ compression pressure in
the same way.
S
This measurement must be done as quickly as possible.
(3) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole and inspect again.
HINT:
S
If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.
S
If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
12. INSPECT CO/HC
(a) Start the engine.
(b) Rev the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check CO/HC concentration at idle and/or 2,500 rpm.
HINT:
Check regulations and restrictions in your area when performing 2 mode CO/CH concentration testing (engine check at both idle speed and at 2,500 rpm).
If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
(1) Check A/F sensor and heated oxygen sensor operation (see page 05−159 and 05−327).
(2) See the table below for possible causes, and then inspect and repair.
2005 AVALON REPAIR MANUAL (RM1169U)
Author:
Date:
2873
14−5
ENGINE MECHANICAL
CO
Normal
Low
High
HC
High
High
High
−
ENGINE (2GR−FE)
Problems
Causes
Rough idle
1. Faulty ignitions:
S Incorrect timing
S Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Rough idle
(fluctuating HC reading)
1. Vacuum leaks:
S PCV hoses
S Intake manifold
S Throttle body
S Brake booster line
2. Lean mixture causing misfire
Rough idle
(black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
S Faulty fuel pressure regulator
S Defective ECT sensor
S Defective MAF meter
S Faulty ECM
S Faulty injectors
S Faulty throttle position sensor
2005 AVALON REPAIR MANUAL (RM1169U)
Author:
Date:
2874
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