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
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