Subject: 2AD-FHV Oil consumptionfiles.vetosfiles.nl/bulletin/EG-0031T-0808-EN_AD.pdf · 2013. 2....

QUALITY SERVICE TOYOTA MOTOR EUROPE NV / SA

INTRODUCTION

This Technical Service Bulletin is to inform you of the production improvement and repair method for the subject concern. Applicable to vehicles produced before the production change effective engine numbers shown below and equipped with 2AD-FHV engine. DESCRIPTION OF PHENOMENON

The customer may complain of excessive oil consumption. PRODUCTION IMPROVEMENT

The tension of the piston top ring and piston oil ring has been increased. PRODUCTION CHANGE INFORMATION

Model code Engine Production change effective engine number

Production change effective VIN

Implementation date

ADT251 2AD-FHV 5405300 SB1EB56L40E094812 June, 2008 PARTS INFORMATION

Previous part number Current part number Part name Quantity 13011-0R020 13011-0R030 Ring set, piston 1

11115-26052-A0 or B0 or C0 or D0 or E0

11115-26052-A0 or B0 or C0 or D0 or E0 Gasket, cylinder head 1

04111-0R042 04111-0R042 Gasket Kit, Engine overhaul 1

1 Check Exhaust Fuel Addition FB with IT2.

(a) Connect the intelligent tester to the DLC3. (b) Turn the IG and tester on. (c) Enter the following menus: Power train / Engine /

Data list / Exhaust Fuel Addition FB. (d) Result should be less than 1.45 in normal condition. Result:

Result Injector condition Less than 1.45 OK

More than 1.45 Replace injector assy, exhaust fuel addition

20/08/2008 Technical Service Bulletin Subject:

2AD-FHV Oil consumption Models:

AVENSIS Model codes:

ADT251

EN

GIN

E

35 pages

EG-0031T-0808-EN

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A

2 Check DPNR Catalytic Converter System

1. Check blockage of vacuum pipes and vacuum transmitting hoses. (Differential Pressure Sensor)

Caution: Be careful of being burned by exhaust gases during the following inspection. Notice: 刷Confirm the paint marks on the vacuum hoses before disconnecting them. 刷Check that the vacuum hose connections are on the correct side of the DPNR catalytic converter.

(a) Disconnect both vacuum transmitting hoses (both upstream and downstream) on the differential pressure sensor side.

(b) Start the engine. (c) Check if there is exhaust gas pulsation from both

vacuum hoses while the engine is idling.

Result:

Hint: It is better to check and clean the pipe whether or not there is deposit in side of the pipe.

Result Proceed to No exhaust gas pulsation A

Exhaust gas pulsation exists B

Remove the vacuum pipe No,1 at union of converter and clean the end of the pipe. Vacuum pipe No1

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B

Previous Type Current Type

2. Read value of the DPF differential pressure and MAF using IT2.

(a) Start the engine and warm it up. (b) Connect the IT2 to the DLC3. (c) Switch the IT2 on. (d) Enter the following menus: Power train / Engine

and ECT / Data list / DPF Differential pressure and MAF.

(e) Check the differential pressure and MAF at 3000 rpm.

Standard: DPF Differential pressure is less than MAF X 0.25

Example of good DPNR condition (EX.2AD @ 3000rpm)

MAF (g/s) X 0.25 =

Calculated value

DPF Differential pressure (kPa) Result

54.5 X 0.25 = 13.6 6.5 The DPF Differential Pressure (6.5) is less than the calculated value (13.6) Result:

Result DPNR condition

Less than MAF X 0.25 Go to step 4 More than MAF X

0.25 Replace DPNR

Converter

Hint: 1) Make sure to read the value of the correct parameter: - select “DPF Differential Pressure (kPa)” available in the “All data” data list - don’t select “Diff. Press. Sensor Corr. (kPa)” in the “Primary” data list 2) Although your vehicle is equipped with DPNR, datalist always mentions “DPF Differential Pressure” Notice: If the DPNR is replaced the catalyst record of the DPNR thermal deterioration stored in the engine ECU must be cleared.

Converter Union

Vacuum Pipe

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3 Check whether the engine ECU has the latest calibration ID

Engine Minimum Calibration ID 2AD-FHV 30551800

Result:

Result Reprogram engine ECU required Latest calibration ID NO

Previous calibration ID YES

Hint: Refer to TSB: EG-6006R2 for the procedure how to reprogram the ECU.

4 Inspect EGR Valve Operation.

(a) Connect the IT2 to the DLC3. (b) Turn IG and IT2 ON. (c) Enter the following menus: Power train / Engine

and ECT / DTC. (d) Record the stored DTC and Freeze Frame Data. (e) Clear the DTC. (f) Enter the following menus: Power train / Engine

and ECT / Active test / Control the EGR Step Position / Data List / EGR Lift Sensor Output.

(g) Record the value of EGR Lift Sensor Output. (h) Start the engine and warm it up. (Coolant temp.

>40し) (i) After the engine warmed up, check that the value

of EGR Lift Sensor Output has changed compared to that before the engine started.

Hint: Under normal conditions, the EGR Lift Sensor Output is indicated on the IT2 as follows.

Engine condition EGR Valve Condition EGR Lift Sensor Output Stopped Fully closed 80.0 +/- 10%

Idling (After warming up)

Opened Approx. 60%

Hint: If the EGR valve operation has failed (ex. Deposit adhesion) the valve does not open and the MIL (DTC P0400) is on even when the engine is warmed up. If the engine has idled for more than 20 minutes, the EGR valve does not open. Restart the engine and check the value of the EGR Lift Sensor.

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OK

(a) Remove the EGR valve assembly. (b) Check that the EGR valve is fully closed OK: The EGR valve fully closes.

Hint: Hold the EGR valve to a light and confirm that the valve contacts with the valve seat securely. If the light is visible through the valve, the EGR valve is not fully closed. If the EGR valve cannot close fully, hesitation or poor acceleration might occur during driving. Notice: When replacing the injector assy, exhaust fuel addition or EGR valve, remove EFI fuse for more than 1 minute in order to reset learning value in ECU. Alternatively, the cable from the negative (-) battery terminal can be disconnected for more than 1 minute.

5 Remove the engine according to the repair manual.

NG Replace EGR Valve

NG Replace EGR Valve

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6 Check for the amount of carbon deposits.

Result:

Result Clean

No deposits No need to clean

Some deposits Intake manifold, EGR valve

Notice: When cleaning the EGR valve, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly on to this part or soaking the parts in the solvent may damage the part. Extreme care must be taken to prevent the removed deposits from falling into the engine unit during cleaning. Hint: Remove the intake manifold from the cylinder head when it has to be cleaned. Do not leave any deposits in the EGR valve assembly when cleaning the valve.

7 Replace the piston rings

8 Reassemble the engine and reinstall to the vehicle

9 Check wheel alignment

EGR Valve Assembly

Intake Manifold

EGR Passage of Intake Manifold

Carbon Deposit

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2AD-FHV

A111386E01

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2AD-FHV

A111398E01

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2AD-FHV

A111397E01

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2AD-FHV

A111396E01

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2AD-FHV

A113473E01

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2AD-FHV

A114795E01

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2AD-FHV

A110860E01

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2AD-FHV

A116707E01

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2AD-FHV

A111393E01

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2AD-FHV

A111223E02

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2AD-FHV

A111224E02

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2AD-FHV

A111225E02

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(a) Remove camshafts Remove the 2 union bolts. Using several steps, loosen and remove the 20 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 8 bearing caps, No. 1 bearing cap and 2 oil delivery pipes. Hint: Do not remove the No. 4 bearing cap.

Remove the camshaft and No. 2 camshaft. Remove the No. 2 bearing cap.

(b) Remove cylinder head sub-assembly a. Uniformly loosen the 10 bolts in the sequence

shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

Notice: • Do not drop washers into the cylinder head. • Head warpage or cracking could result from

removing bolts in the incorrect order. b. Remove the cylinder head and gasket.

10 Remove cylinder head sub-assembly

No. 4 Bearing Cap

Union Bolt

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11 Procedure to clean soot from cylinder head, valves and EGR port

(c) Soot thickness measurement

Measure the soot thickness in each intake channel and in the EGR port.

Soot thickness Result

Less than 3 mm OK

Proceed with short block disassembly

More than 3 mm Clean and proceed with step (d)

(d) Remove all 16 valves from the cylinder head

Intake channels

EGR port

Non-reusable part

A111225E05

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(e) Clean the soot from the valves seats

(f) Clean the soot from the intake channels and EGR port Use cleaning solvent and a scotch brite or equivalent

Intake channels

EGR port

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12 Reassemble the cylinder head and replace all seals with new ones

(g) Clean the soot from the valves Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.

(h) Hand lap the valves and the valves seats with an abrasive compound

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13 Disassemble the short block

Hint: When removing the balancer shaft, make sure that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.

1. Remove the Balancer Shaft Align the driver and driven gear’s timing marks (1 dot mark each) by turning the crankshaft with a wrench. Install the service bolt. Recommended service bolt:

Item Specified Condition

Thread diameter 6 mm (0.24 in.) Thread pitch 1 mm (0.04 in.) Bolt length 16 to 18 mm (0.63 to 0.71 in.)

Torque: 1.5 N*m 15 kgf*cm, 13 in.*lbf

2. Remove the piston with connecting rod assembly from the block Remove all the carbon from the top of the cylinder by using a scotch brite and cleaning solvent or equivalent.

Service Bolt

Align

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3. Inspect the cylinder bore wear condition.

This drawing shows a GOOD condition. Check the cylinder bore for vertical scratches. If the scratch depth is more than 10µm, which can be felt by fingernail, the cylinder block MUST be replaced. Check the cylinder bore for mirrored surfaces If any mirrored surfaces larger than 0.5 cm² is found within 70mm from the cylinder block top, The cylinder block MUST be replaced.

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14 Remove the piston with connecting rod only

A111226E01

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Remove the piston rings. Using a piston ring expander, remove the 2 compression rings. Using a piston ring expander, remove the oil ring rail. Remove the oil ring expander by hand.

Clean the piston. Using a gasket scraper, remove the carbon from the piston top.

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

Using solvent and a brush, thoroughly clean the piston. Notice: Do not use a wire brush.

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15 Install the new piston rings

Install the oil ring expander by hand.

Using a piston ring expander, install the oil ring rail.

Coil Joint

Oil Ring Ends

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Notice: When installing piston rings on the piston by using a piston ring compressor, take extreme care in order that the ring does not come of or does not brake.

Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration. Hint: • Install the No. 1 compression ring with the

code mark (1T) facing upward. • Install the No. 2 compression ring with the

code mark (2FTE) facing upward.

Position the piston rings so that the ring ends are as shown in the illustration. Notice: Do not align the ring ends.

Re-install the pistons with conrods. Using a piston ring compressor, push the correctly numbered * piston and connecting rod into the cylinder with the front mark of the piston facing forward. * Install the pistons back in there original order.

Upward

Coil No. 1

Code Mark (1T) Code Mark (2FTE)

Front Mark

No. 2 Oil

Front Mark

Front

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Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m 408 kgf*cm, 30 ft.*lbf

Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts by 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.

Front Mark

Painted Mark

Front

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Reinstall the engine balancer shaft. Align the driver and driven gear’s timing marks (1 dot mark each) by turning the crankshaft with a wrench. Set the engine balancer. Install the engine balancer bolts. Hint: The engine balancer bolts are tightened in 2 progressive steps

Step 1 Install and uniformly tighten the 8 bolts in several passes in the sequence shown Torque: 50 N*m 510 kgf*cm, 37 ft.*lbf

Service Bolt

Align

Painted Mark

Front

Step 2 Mark the front side of each connecting cap bolt with paint. Retighten the engine balancer bolts by 90° as shown. Check that the painted mark is now at a 90° angle to the front. Install the oil baffle plate with 2 bolts. Torque: 9.0 N*m 92 kgf*cm, 80 in.*lbf

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Select cylinder head gasket. Check the piston protrusions for each cylinder. i. Clean the cylinder block with solvent. ii. Set the piston of the cylinder to be

measured to slightly before TDC.

iii. Place a dial indicator on the cylinder block, and set the measuring tip as shown in the illustration.

iv. Set the dial indicator at 0 mm (0 in.).

Hint: Make sure that the measuring tip is square to the cylinder block gasket surface and piston head when taking the measurements.

v. Find where the piston head protrudes most

by slowly turning the crankshaft clockwise and counter clockwise.

vi. Measure each cylinder at 2 places as

shown in the illustration, making a total of 8 measurements.

vii. For the piston protrusion value of each

cylinder, use the average of the 2 measurements of each cylinder. If the protrusion is not as specified, remove the piston and connecting rod and reinstall it.

Standard piston protrusion: 0.300 to 0.560 mm (0.01181 to 0.02205 in.)

Hint: In case you only replace piston rings, it is not necessary to measure again the piston protrusion: replace the cylinder head gasket with the same gasket size as originally installed (A, B, C, D or E). See next page for details. In case except for the piston rings, also other parts are replaced (e.g. bearings, pistons…), it is necessary to measure again the piston protrusion.

Front

X: Measuring Point

Measuring Tip

Protrusion

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Select a new cylinder head gasket. Hint: Cylinder head gaskets are marked A, B, C, D or E accordingly. New installed cylinder head gasket thickness:

Cutout mark Specified Condition

A 1.00 to 1.10 mm (0.0394 to 0.0433 in.) B 1.05 to 1.15 mm (0.0413 to 0.0453 in.) C 1.10 to 1.20 mm (0.0433 to 0.0472 in.) D 1.15 to 1.25 mm (0.0453 to 0.0492 in.) E 1.20 to 1.30 mm (0.0472 to 0.0512 in.)

Select the largest piston protrusion value from the measurements and then select a new appropriate gasket according to the table below. Piston protrusion:

Gasket size Specified Condition

Use A 0.300 to 0.355 mm (0.01181 to 0.01398 in.) Use B 0.355 to 0.405 mm (0.01398 to 0.0159 in.) Use C 0.405 to 0.455 mm (0.0159 to 0.01791 in.) Use D 0.455 to 0.505 mm (0.01791 to 0.01988 in.) Use E 0.505 to 0.560 mm (0.01988 to 0.02205 in.)

Front

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Re-install cylinder head. i. Install and uniformly tighten the 10 cylinder

head bolts, in several steps in the sequence shown in the illustration. Torque: 50 N*m 510 kgf*cm, 37 ft.*lbf

ii. Mark the front of the cylinder head bolt

with paint. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.

Check that the painted mark is positioned as shown in the illustration. Hint: • If any of the cylinder head bolts does

not meet the torque specification, replace the cylinder head bolt.

• This tightening procedure is only applicable for used bolts. In case of new bolts, refer to the repair manual for correct tightening procedure.

Used bolt tightening procedure 1st: 50 N*m 510 kgf*cm, 37 ft.*lbf 2nd: Turn 90 3rd: Turn 90 4th: Turn 90

Reinstall the camshafts. Set the camshaft bearing caps as shown in the illustration. Hint: Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Set the oil delivery pipe, bolts and union bolts. Temporarily tighten the 2 union bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 10 N*m 102 kgf*cm, 7 ft.*lbf for 1 to 16 25 N*m 255 kgf*cm, 18 ft.*lbf for 17 to 20 Tighten the 2 union bolts. Torque: 17 N*m 173 kgf*cm, 13 ft.*lbf

Front

Paint Mark

Front

Union Bolt

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Install the timing chain. a. Install the crankshaft timing sprocket,

camshaft timing sprocket and chain. b. Install the camshaft timing sprocket by

fitting the straight pin of the No. 2 camshaft into the hole on the camshaft timing sprocket.

c. Make sure that the timing mark of the

timing sprocket and the paint mark of the timing chain align.

d. While holding the hexagon portion of the

No. 2 camshaft, tighten the 4 bolts uniformly to install the camshaft timing sprocket to the no. 2 camshaft.

Torque:

20 N*m 204 kgf*cm, 15 ft.*lbf

Paint Mark (Yellow)

Paint Mark (Yellow)

Timing Mark

Timing Mark

Straight Pin

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16 Catalyst record of DPNR thermal deterioration clear function.

Hint: When a DPNR catalyst is replaced, the catalyst record of DPNR thermal deterioration stored in the engine ECU must be cleared.

a. Connect the intelligent tester to the DLC3. b. Turn the ignition switch on (IG) and turn

the tester ON.

c. Enter the following menus: Powertrain / Engine and ECT / Utility / Catalyst Record Clear.

d. Press “Next”.

e. Press “Exit”.

EG-0031T-0808

WARRANTY INFORMATION

Warranty application is limited to correction of a problem based upon a customer's specific complaint.

OP code Operation Time OFP T1 T2132021 R&R piston ring set (all) 14.4 13011-0R020 11 41

132021K Add: air conditioning 0.8 13011-0R020 11 41889001 R&R refrigerant recovery & recycling unit 0.2 13011-0R020 11 41

132021Z Comb: cylinder head cleaning, valve cleaning and re-lappingvalves

6.9 13011-0R020 11 41

132021Z Comb: EGR valve, intake manifold cleaning 1.2 13011-0R020 11 41132021Z Comb: 5th injector replacement 0.1 13011-0R020 11 41132021Z Comb: DPNR replacement 0.3 13011-0R020 11 41801013 Insp IT2 0.2 13011-0R020 11 4189599 E.C.M reprogramming+Sticker application 0.3 13011-0R020 11 41

132021Z Comb: EGR valve replacement 0.2 13011-0R020 11 41

QUALITY

SERVICE TOYOTA MOTOR EUROPE NV / SA

INTRODUCTIONThis Technical Service Bulletin is to inform you of the production improvement and repair method for the subject concern. Applicable to vehicles produced before the production change effective engine numbers shown below and equipped with 2AD-FHV engine.DESCRIPTION OF PHENOMENONPRODUCTION IMPROVEMENTPRODUCTION CHANGE INFORMATIONPARTS INFORMATION2AD-FHV Oil consumptionTechnical Service Bulletin

20/08/2008

Subject: 2AD-FHV Oil consumptionfiles.vetosfiles.nl/bulletin/EG-0031T-0808-EN_AD.pdf · 2013. 2....

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Transcript of Subject: 2AD-FHV Oil consumptionfiles.vetosfiles.nl/bulletin/EG-0031T-0808-EN_AD.pdf · 2013. 2....