11 2005 2006 toyota hilux factory service manual ignition system he thong danh lua

IG–4

1GR-FE IGNITION – IGNITION SYSTEM

ON-VEHICLE INSPECTION
1.

CHECK IGNITION COIL ASSEMBLY AND PERFORM
SPARK TEST
(a) Check for DTCs.
NOTICE:
If any DTC is present, perform troubleshooting
in accordance with a procedure for that DTC.
(b) Check that sparks occur.
(1) Remove the ignition coils.
(2) Using a 16 mm plug wrench, remove the spark
plugs.
(3) Install the spark plugs to each ignition coil, and
connect the ignition coil connectors.
(4) Disconnect the 6 injector connectors.
(5) Ground the spark plugs.
(6) Check if sparks occur at each spark plug while
the engine is being cranked.
NOTICE:
• Be sure to ground the spark plug when
checking.
• Replace the ignition coil if it receives an
impact.
• Do not crank the engine for more than 2
seconds.
If sparks do not occur, perform the following

test:
(c) Spark test flow chart.
(1) Check that the wire harness side connector of
ignition coil with igniter is securely connector.
Result

Result

Proceed to

NG

Connect securely.

OK

Go to next step.

(2) Perform spark test on each ignition coil with
igniter.
1.Replace ignition coil with igniter with a normal
one.
2.Perform spark test again.
Result

IG
Result

Proceed to

NG

Replace ignition coil with igniter.

OK

Go to next step.

(3) Check power supply to ignition coil.
1.Turn ignition switch ON.
2.Check that there is battery positive (+)
voltage at ignition coil positive (+) terminal.
Result
Result

Proceed to

NG

Check wiring between ignition
switch and ignition coil assembly.

OK

Go to next step.


IG–5

1GR-FE IGNITION – IGNITION SYSTEM

(4) Check resistance in VVT sensor out put voltage
(see step 2).
Result
Result

Proceed to

NG

Following test 1 and 2.

OK

Go to next step.

1. Check that the wiring between VVT sensor
and ECM.
Result
Result

Proceed to

NG

Repair wiring between VVT sensor
and ECM.

OK

Repair VVT sensor

(5) Check resistance in crankshaft position sensor.
Standard resistance
Standard condition

Specified condition

at 20°C (68°F)

1850 to 2450 Ω

Result
Result

Proceed to

NG

Replace the crankshaft position
sensor.

OK

Go to next step.

(6) Check IGT signal from ECM.
Result
Result

Proceed to

NG

Check ECM

OK

Repair wiring between ignition coil
and ECM.

(d) Using a 16 mm plug wrench, install the spark plugs.
(e) Install the ignition coils.
2.

CHECK SPARK PLUG
NOTICE:
• Never use a wire brush for cleaning.
• Never attempt to adjust the electrode gap on a
used spark plug.
• The spark plug should be replaced every 200,000
km (120,000 miles).
(a) Remove the engine cover.
(b) Remove the air cleaner.
(c) Remove the ignition coil.
(d) Remove the spark plug.

IG

IG–6

1GR-FE IGNITION – IGNITION SYSTEM

(e) Check the electrode.
(1) Using an ohmmeter, measure the insulation
resistance.
Correct insulation resistance:
10 MΩ or more
If the resistance is below the specified range,
remove the spark plug.
HINT:
If an ohmmeter is not available, perform the
following simple inspection.

OHMMETER

GROUND
A110413E04

(f)

Alternative inspection method:
(1) Quickly accelerate the engine to 4,000 rpm 5
times.
(2) Remove the spark plug.
(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.

(g) Check the spark plug for any damage on its threads
and insulator.
If there is damage, replace the spark plug. If not,
reinstall the spark plug.
Recommended spark plug

B001301E01

Manufacturer

Spark Plug Type

DENSO

K20HR-U11

NGK

LFR6C11

(h) Check the spark plug electrode gap.
Standard electrode gap:
1.0 to 1.1 mm (0.039 to 0.043 in.)
If the electrode gap is larger than the standard,
replace the spark plug.

IG
Electrode Gap
A088861E02

IG–3

2TR-FE IGNITION – IGNITION SYSTEM

ON-VEHICLE INSPECTION
NOTICE:
In this section, the terms "cold" and "hot" refer to the
temperature of the coils. "Cold" means approximately 10 to 50°C (14 to 122°F). "Hot" means approximately 50 to
100°C (122 to 212°F).
1.

PERFORM SPARK TEST
(a) Check for DTCs.
NOTICE:
If a DTC is present, perform troubleshooting
procedures for that DTC.
(b) Check if sparks occur.
(1) Remove the ignition coil.
(2) Remove the spark plug.
(3) Install the spark plug to the ignition coil and
connect the ignition coil connector.
(4) Disconnect the 4 injector connectors.
(5) Ground the spark plug.
(6) Visually check that sparks occur while the
engine is being cranked.
NOTICE:
• Be sure to ground the spark plug when
checking.
• If the ignition coil has been struck or

dropped, replace it.
• Do not crank the engine for more than 2
seconds.
(c) Spark test flow chart.
(1) Check that the wire harness side connector of
the ignition coil with igniter is securely
connected.
Result

Result

Proceed to

NG

Connect securely

OK

Go to next step

(2) Perform spark test on each ignition coil with
igniter.
1. Replace ignition coil with igniter with a
normal one.
2. Perform spark test again.
Result
Result

Proceed to

OK

Replace ignition coil with igniter

NG

Go to next step

(3) Check power supply to ignition coil with igniter.
1. Turn the ignition switch ON.

IG


IG–4

2TR-FE IGNITION – IGNITION SYSTEM

2. Check that there is battery voltage at ignition
coil positive (+) terminal.
Result
Result

Proceed to

NG

Check wiring between engine switch
and ignition coil with igniter

OK

Go to next step

(4) Check resistance of camshaft position sensor.
Standard resistance
Temperature

Specified Condition

Cold

835 to 1,400 Ω

Hot

1,060 to 1,645 Ω

Result
Result

Proceed to

NG

Replace camshaft position sensor

OK

Go to next step

(5) Check resistance of crankshaft position sensor.
Standard resistance
Temperature

Specified Condition

Cold

1,690 to 2,740 Ω

Hot

2,065 to 3,225 Ω

Result
Result

Proceed to

NG

Replace crankshaft position sensor.

OK

Go to next step

(6) Check IGT signal from ECM.

Result

IG

Result

Proceed to

NG

Check ECM

OK

Repair wiring between ignition coil
and ECM

(d) Using a 16 mm plug wrench, install the spark plug.
Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf)
(e) Install the ignition coil.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2.

CHECK SPARK PLUG
NOTICE:
• Do not use a wire brush for cleaning.
• Do not attempt to adjust the electrode gap of a
used spark plug.

IG–5

2TR-FE IGNITION – IGNITION SYSTEM

Megaohmmeter

(a) Check the electrode.
(1) Using a megohmmeter, measure the insulation
resistance.
Insulation resistance:
10 MΩ or more
HINT:
If a megohmmeter is not available, perform the
following simple inspection instead.

Ground

A120009E01

P003783E01

1.1 mm
G037848E01

(b) Alternative inspection method:
(1) Quickly accelerate the engine to 4,000 rpm 5
times.
(2) Remove the spark plug.
(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.
(c) Check the spark plug for any damage on its thread
and insulator.
If there is damage, replace the spark plug. If not,
reinstall the spark plug.
Recommended spark plug
Manufacturer

Spark Plug Type

DENSO made

SK20R11

NGK made

ILFR6C11

(d) Check the spark plug electrode gap.
Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than the maximum, replace
the spark plug.
Electrode gap for new spark plug:
1.1 mm (0.043 in.)
NOTICE:
When adjusting the gap of a new spark plug,
bend only the base of the ground electrode. Do
not touch the tip. Never attempt to adjust the

gap of a used plug.

IG


IG–6

2TR-FE IGNITION – IGNITION SYSTEM

A050033E01

IG

(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the
electrode with a spark plug cleaner and then dry it.
Air pressure:
588 kPa (6 kgf/cm2, 85 psi)
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.


1GR-FE IGNITION – IGNITION SYSTEM

IG–1

IGNITION SYSTEM
1GR-FE IGNITION
ENGINE

PARTS LOCATION

CAMSHAFT TIMING OIL
CONTROL VALUVE

VVT SENSOR

IGNITION COIL

CAMSHAFT TIMING OIL
CONTROL VALVE

VVT SENSOR

CRANK POSITION SENSOR

IG
A113581E01


IG–2

1GR-FE IGNITION – IGNITION SYSTEM

SYSTEM DIAGRAM

5 AM2

IG2

6

9
1B

10
1B

IGNITION
SWITCH

ECM

2A

4
2

GND

+B

IGF

IGT1

1
3

8
B16 IGT1

IGNITION COIL
4
2
NOISE
FILTER

GND
IGF

+B
IGT2

1
3

9
B16 IGT2

IGNITION COIL
4
2

2

GND
IGF

+B
IGT3

1
3

10
B16 IGT3

IGNITION COIL

30 A
AM2

4
2

2

GND

+B

IGF

IGT4

1
3

11
B16 IGT4

IGNITION COIL
4
2

IG

IGF

+B
IGT5

1
3

12
B16 IGT5

IGNITION COIL

J/C
4
BATTERY

GND

2

GND
IGF

+B
IGT6

IGNITION COIL

1
3

13
B16 IGT6
24
B16 IGF
G036237E01


IG–3

1GR-FE IGNITION – IGNITION SYSTEM

7
W1

3

VC

VVL+
VVL-

1

18
B18 VV2+

3

28
B18 VV2-

1

19
B18 VV1+

3

29
B18 VV1-

VVT SENSOR
6
W1

3

VC

VVR+
VVR-

VVT SENSOR

1
W1

1

23
B18 VC
20
B18 NE-

2

CRANKSHAFT POSITION SENSOR

21
B18 NE+
(SHIELD)
7

J/C

6

IG
ECM

G036238E01


1GR-FE IGNITION – IGNITION COIL

IG–7

IGNITION COIL
REMOVAL
1.

DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL

2.

REMOVE V-BANK COVER (See page ES-414)

3.

REMOVE AIR CLEANER ASSEMBLY (See page ES415)

4.

DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose from the intake air
surge tank.

5.

REMOVE IGNITION COIL ASSEMBLY
(a) Disconnect the 6 connectors.
(b) Remove the 6 bolts, then remove the 6 ignition
coils.

A075645E01

G036133E01

IG


IG–8

1GR-FE IGNITION – IGNITION COIL

INSTALLATION

IG

1.

INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)

(b) Connect the 6 ignition coil connectors.

2.

CONNECT VENTILATION HOSE

3.

INSTALL AIR CLEANER ASSEMBLY (See page ES416)

4.

INSTALL V-BANK COVER (See page ES-416)

5.

CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

6.

INSPECT IGNITION TIMING (See page EM-1)

7.

INSPECT ENGINE IDLING SPEED (See page EM-2)


IG–8

1GR-FE IGNITION – VVT SENSOR

VVT SENSOR
REMOVAL
1.

DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL

2.

DRAIN ENGINE COOLANT (See page CO-3)

3.

REMOVE V-BANK COVER (See page ES-414)

4.

REMOVE AIR CLEANER ASSEMBLY (See page ES415)

5.

REMOVE VVT SENSOR
(a) RH bank side VVT sensor:
(1) Disconnect the VVT sensor connector.
(2) Remove the bolt and VVT sensor.

A076413E01

(b) LH bank side VVT sensor:
(1) Disconnect the water by-pass hoses No. 4 and
No. 5 .
(2) Disconnect the VVT sensor connector.

A076414E01

(3) Remove the bolt and VVT sensor.

IG
A076415E01


1GR-FE IGNITION – VVT SENSOR

IG–9

INSTALLATION
1.

INSTALL VVT SENSOR
(a) LH bank side VVT sensor:
(1) Apply a light coat of engine oil to the O-ring of
the VVT sensor.
(2) Install the VVT sensor with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(3) Connect the VVT sensor connector.
(4) Connect the water by-pass hoses No. 4 and
No. 5.

(b) RH bank side VVT sensor:
(1) Apply a light coat of engine oil to the O-ring of
the VVT sensor.
(2) Install the VVT sensor with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(3) Connect the VVT sensor connector.

2.

INSTALL AIR CLEANER ASSEMBLY (See page ES416)

3.

CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

4.

ADD ENGINE COOLANT (See page CO-3)

5.

CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-4)

6.

INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

IG


IG–1

2TR-FE IGNITION – IGNITION SYSTEM

IGNITION SYSTEM
2TR-FE IGNITION
ENGINE

PARTS LOCATION

ECM

IGNITION COIL
CAMSHAFT POSITION SENSOR

SPARK PLUG

IG

CRANKSHAFT POSITION SENSOR

A113627E01


IG–2

2TR-FE IGNITION – IGNITION SYSTEM

SYSTEM DIAGRAM
Ignition Coil
AM2

IG2

+B

IGT1

Spark Plug

Ignition SW

IGF

IGT1
IGF1

GND
Ignition Coil
+B

AM2

IGT2

Spark Plug

IGT2

IGF
GND
Ignition Coil

+B

IGT3

Spark Plug

IGT3

IGF
GND
Ignition Coil

+B

IGT4

Spark Plug

Noise Filter

IGT4

IGF
GND

Comshaft Position Sensor
Rotor of
Comshaft

G2

G2

NE-

IG
Battery

Crankshaft Position
Sensor Sensor
Plate

NE+
NE-

NE+
NE-

E1
Crankshaft Position Sensor

E1

G038229E01