Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

General Description General Description

(1/1)

Basic principle of four-stroke engine

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Air-fuel Mixture

(1/2)

1.Good air-fuel mixture for automobiles

Air

Fuel

15

Theoreticalair-fuel ratio

1510 20Air-fuel ratioRicher Leaner

1

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Air-fuel Mixture

(1/2)

2.Air-fuel ratio

Air

Fuel

15

Theoreticalair-fuel ratio

1510 20Air-fuel ratioRicher Leaner

1

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Air-fuel Mixture

(2/2)

3.Air fuel ratio and driving conditions

Air

Fuel

15

Theoreticalair-fuel ratio

1510 20Air-fuel ratioRicher Leaner

1

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Compression

(1/1)

1.Necessity of compressing the air-fuel mixture

Compression ratio

Volume of combustion chamber (A) + Volume of cylinder (B)

Volume of combustion chamber (A)=

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Spark

(1/1)

1 2

Spark plug

Air-fuelmixture

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Spark

(1/1)

1 2

Spark plug

Air-fuelmixture

1.Conditions for a good spark

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines Good Spark

(1/1)

1 2

Spark plug

Air-fuelmixture

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

Cylinder head

Cylinder head gasket

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

Cylinder block

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

Crankshaft

Bearing cap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

Connecting rod

Bearing cap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

Crankshaft bearing

Thrust washer

Connectingrod bearing

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

PistonPiston pin

Piston rings

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

(1/1)

(1) Exhaust camshaft (2) Intake camshaft

(3)(4)

(5)(6)

(7)(8)

(9) Valve

(10) Timing chain

(11) Chain tensioner slipper

(13) Timing chain tensioner(14) Crankshaft timing sprocket

(12)Chain vibration damper

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Head

(1/1)

Cylinder head Spark plug

Intake port

Water jacket

Exhaust port

Cylinder head gasketCombustion chamber

Oil hole

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Plastic Region Bolt

(1/1)

Elastic region Plastic region

SmallerLarger

Bol

t ten

sion

Yield point

Fracture point

Bolt’s rotational angle

Plastic region bolt

Cylinder head

Bolt’s rotational angle

Bolt tension

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Block

(1/3)

Cylinder block

Cylinder liner

Combustion stroke Compression stroke

Ridge

Cylinder wear

Thrust force

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Block

(2/3)

1.Cylinder bore sizeLocation of cylinder bore STD size codes (5VZ-FE engine)

Front

Bore size code

1

2

3

Small

Large

Cylinder bore size

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Block

(3/3)

2.Crankshaft main journal bore size Location of main journal bore STD size codes

(1NZ-FE engine)

Bore size code

0

1

6

Small

Large

Crankshaft mainjournal bore size

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft

(1/3)REFERENCE:Crankshaft Offset

Crankshaft

Crank pin

Crank journal Balance weight

Oil hole

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft

(2/3)

Example

Bearing cap

Bearing cap unit with ladder-frame construction

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft

(3/3)

1.Main journal and crank pin size

Location of main journal and crank pin STD size codes

Main journal STD size codes (1NZ-FE engine)

Main journal STD size codes (2JZ-GE engine)

Crank pin STD size codes (2JZ-GE engine)

Main journal or crank pin size codes

1

2

3

Small

Large

Main journal or crank pin size

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft Bearing

(1/1)

1.Bearing size/2.Undersize bearing

Upper halt-bearing

Oil holeOil groove

Thrust washer

Bearing size code

Oil grooveLower half-bearing

Locking lip

Bearing size code Bearing size

1

2

Thin

Thick

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Connecting Rod

(1/1)

1.Big end bore size

Connecting rod

Oil jet

Big end bore size codeFront mark

Big end bore

Big bore size code

1

2

3

Large

Small

Big end bore size

Bearing cap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Connecting Rod Bearing

(1/1)

1.Bearing Size/2.Undersize Bearing

Oil hole

Bearing size code

Bearing size code Bearing size

1

2

Thin

Thick

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Bearing Selection

(1/2)

Oil clearance

Bearing Oil film

Oil clearance

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Bearing Selection

(2/2)

1.Bearing selection method

No.2

No.1No.3No.5

No.1 No.2 No.3 No.4

No.5

Cylinder block main journal bore size code (A)

Crankshaft main journal size code (B)

Example

Use bearing size code

A = 4, B = 3, A + B = 7

0 - 2

3 - 5 6 - 8 9 - 11

7

1 2 3 4

Bearing size cord

No.4

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(1/4)

1.Description

B

A

Oval Circle

SmallPiston pin boss

Piston skirt

Large

Truncated cone

Cold

True cylinder

Hot

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(2/4)

2.Thrust force

Combustion pressure Compression pressure

Major thrust force (Combustion stroke)

Minor thrust force (Compression stroke)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(3/4)

3.Piston slap (Side knocking)/4.Operation of offset pistons

Piston slap

Offset piston

Center of piston pin Center of piston

Piston

Offset

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(3/4)

3.Piston slap (Side knocking)/4.Operation of offset pistons

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(4/4)

5.Piston size

Piston size code

Piston size code and front mark (5VZ-FE engine)

Front mark

REFERENCE:Striations on the Piston Skirt

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(4/4)

Piston size code

Piston size code and front mark (5VZ-FE engine)

Front mark

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

(4/4)

Piston size code

Piston size code and front mark (5VZ-FE engine)

Front mark

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

(1/4)

1.Description

Compression ring No.1

Compression ring No.2

Oil ring side rail (upper)

Oil ring expander

Oil ring side rail (lower)

Oil rings

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

(2/4)

2.Marks of ring

Size

Manufacturer

No.1 code mark

No.2 code mark

No.1 compression ring end gap and oil ring expander end gap Oil ring side rail (lower) end gap

No.2 compression ring end gapOil ring side rail (upper) end gap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

(3/4)

3.Ring end gap

1NZ-FE engine:110mm (4.33 in.)

Ring end gap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

(4/4)

4.Ring pumping effect and ring flutter

Cylinder

Engine oil

Piston

Piston ring

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve Mechanism

(1/1)

1.Valve opening and closing system

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve and Related Parts

(1/4)

2.Valve

Valve stem

Oil seal

Valve face

Camshaft

Valve guide bushing

Valve head

44.5 or 45.5

Exhaust valve

Intake valve

Exhaust valveCombustion chamber

Intake valve

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve and Related Parts

(2/4)

3.Valve spring

Uneven pitch spring (symmetrical)

Uneven pitch spring (asymmetrical)

Double spring

Inner Outer

Top

a

b

c

d

e

a=c<d d>e

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve and Related Parts

(3/4)

4.Valve seat

Valve contact face

60

45

30

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve and Related Parts

(4/4)

5.Valve guide bushing and oil seal

Oil sealValve quide bushing

Valve stem

Engine oil

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve Timing

(1/2)

Valve timing diagram (2NZ-FE engine without VVT-i, leaded gasoline type)

Compression stroke

Exhaust stroke

Intake stroke

Combustion (power) stroke

Ex.In.Ex.In.

Ex.In. Ex.In.

TDCValve overlap

Intake valve opens

Intake valve closes

Exhaust valve closesExhaust valve opens

BDC

43

2 2

34

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve Timing

(2/2)

Valve overlap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Valve Clearance

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Adjustment of Valve Clearance

(1/2)

1. Type requiring replacement of the valve lifter when adjusting valve clearance/2. Type requiring replacement of shim when adjusting valve clearance

1

2-(2)

2-(1)

2-(3)

Valve lifter

Valve lifter

Adjusting shim

Valve lifter

Adjusting shim

Adjusting shim

Rocker arm

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Adjustment of Valve Clearance

(2/2)

3.Type requiring adjustment of the adjusting screw when adjusting valve clearance

Adjusting screwRocker arm

Valve lifer

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Scissors Gear Mechanism (Sub-gear Mechanism)

(1/1)

Backlash

Sub gear

Driven gearSub gear

Driven gear

Drive gear

Drive gear

Sub gear

Scissors spring

Driven gear

Drive gear

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Balance Shaft

(1/1)

va, vb: Crankshaft rotational speedVa, Vb: Piston movable speedLa, Lb: Piston movable distanceva = vbVa<VbLa<Lb

Lb Vb

La Va

va

vb

A B

Counterweight

Balance shaft

Inertial forces

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Timing Chain Auto-tensioner

(1/1)

Chain damper

Timing chain auto-tensioner

Chain slipperChain

Engineoil

Plunger

SpringCheck ball

CamSpring

Chain auto-tensioner (1NZ-FE engine)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Timing Belt Auto-tensioner

(1/1)

Piston rod

Timing belt auto-tensioner (2JZ-GE engine)

Timing belt

Idler pulley

Spring

Check ball

SpringTiming belt auto-tensioner

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Description

(1/2)

Camshaft timing oil control valve

Main oil gallery

Oil return hole

Oil pressure switch

Oil filter

Oil strainer

Oil pump

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Description

(2/2)

Main oil gallery

Oil filter

Oil cooler

Oil pump

Oil strainer

Crankshaft journal

Connecting rod

Oil jet

Piston

Oil jet

Timing chain

Chain tensioner

Cylinder head

Camshaft timing oil control valve filter

Intake camshaft journal

Exhaust camshaft journal

Camshaft timing oil control valve

VVT-i controller

Oil pan

Oil flow circuit for 1NZ-FE engine

The oil cooler, outlined with a dotted line, basically is not used on the 1NZ-FE engine.Here is listed to understand the position of the oil cooler in the flow.

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Oil Pump

(1/1)

Drive roter

Driven roter

Relief valve

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Oil Filter

(1/1)

Check valve

Element

Relief valve

Oil flow (in)

Oil flow (out)

Oil flow if the relief valve open

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Oil Pressure Warning Lamp

(1/1)

1.When the oil pressure is low [19.6 ± 4.9 kPa (0.2 ± 0.05 kgf/cm2) or lower]/2.When the oil pressure is high [19.6 ± 4.9 kPa (0.2 ± 0.05 kgf/cm2) or higher]

Oil pressure warning lamp

Low engine oil level warning lamp

Oil pressure switch

Oil pressure (Normal)

ECU

Warning lamp

Oil temp. switch

Oil level sensorOil pan

Oil level (Normal)

Warning lamp

Oil

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Oil Pressure Warning Lamp

(1/1)

1.When the oil pressure is low [19.6 ± 4.9 kPa (0.2 ± 0.05 kgf/cm2) or lower]/2.When the oil pressure is high [19.6 ± 4.9 kPa (0.2 ± 0.05 kgf/cm2) or higher]

Oil pressure warning lamp

Low engine oil level warning lamp

Warning lamp

Oil pressure switch

Oil pressure (Low)

ECU

Warning lamp

Oil temp. switch

Oil level sensorOil pan

Oil level (Low)

Oil

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Oil Cooler

(1/1)

Water bypass hose

Oil cooler

Oil filter

Engine coolant

Oil cooler

Oil filter

From Oil pump

to Main oil gallery

Relief valve

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System Oil Consumption

(1/1)The gap between the cylinder and the pistonThe gap between the valve guide bushing and valve stemLoss due to oil contained in blow-by gas

PCV valve

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Description

(1/1)

1.Cooling systemto Radiator

from Heater core

from Radiator

Bypass passage Cylinder head

Water pump

Thermostat

Cylinder blockThrottle body

Radiator

Heater core

to Heater coreto Throttle body

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Flow of Engine Coolant

(1/1)

1.Thermostat in water inlet type (With bypass valve)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Thermostat

(1/1)

With bypass valve Without bypass valve

Main valve

Cylinder

Bypass valveWax

Main valve

Jiggle valve

Jiggle valve

WaxCylinder

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Water Pump

(1/1)

V-ribbed belt Bearing Mechanical seal

Cylinder block

Swirl chamber

Rotor

Water pump pully Water drain hole

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Electric Motor-driven Cooling Fan

(1/2)

1.Outline

Cooling fan

Fan motor

Water temperature switch

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Electric Motor-driven Cooling Fan

(2/2)

2.Operation

Fan relayIgnition switch

Coolant temp. switch

Coolant temperature

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Temperature-controlled Fluid Coupling

(1/2)

1.Overview

Pulley

Fluid coupling

Cooling fan

Air hot Air warm Air cold

Bimetal spring

Bimetal plate

Front operating chamber

Rear operating chamber

Silicone oil

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Temperature-controlled Fluid Coupling

(2/2)

2.OperationWithout coupling

Fan

spe

ed

Air hot

Air warm

Air cold

0

Air Temperature (HOT) during low speed drivingAir temperature (HOT) during high speed drivingAir temperature (WARM) during high speed drivingAir temperature (COLD) during high speed driving

Fluid coupling shaft speed

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System Electronically Controlled Hydraulic Cooling Fan System

(1/1)

Condenser

Radiator

Cooling fan

Hydraulic motor

Solenoid valve

Hydraulic pump

Reservoir

Oil cooler

Water pump. sensor signal, Air conditioner signal, Engine speed signal

ECU

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Inspection Compression Pressure

(1/1)

1.Check compression pressure

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft Offset

(1/1)

Combustion pressure Combustion pressure

Piston

Connecting rod

Crankshaft center

Offset

Offset crankshaft Center crankshaft

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Striations on the Piston Skirt

(1/1)

Resin coating

Striation finish