Gasoline engine

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Me Majid.
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1. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
General Description General Description
(1/1)
Basic principle of four-stroke engine

2. 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
Theoretical
air-fuel ratio
1510 20
Air-fuel ratioRicher Leaner
1

3. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Three Elements of Gasoline Engines Good Air-fuel Mixture
(1/2)
2.Air-fuel ratio
Air
Fuel
15
Theoretical
air-fuel ratio
1510 20
Air-fuel ratioRicher Leaner
1

4. 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
Theoretical
air-fuel ratio
1510 20
Air-fuel ratioRicher Leaner
1

5. 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)
=

6. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Three Elements of Gasoline Engines Good Spark
(1/1)
1 2
Spark plug
Air-fuel
mixture

7. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Three Elements of Gasoline Engines Good Spark
(1/1)
1 2
Spark plug
Air-fuel
mixture
1.Conditions for a good spark

8. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Three Elements of Gasoline Engines Good Spark
(1/1)
1 2
Spark plug
Air-fuel
mixture

9. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)

10. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)
Cylinder head
Cylinder head gasket

11. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)
Cylinder block

12. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)
Crankshaft
Bearing cap

13. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)
Connecting rod
Bearing cap

14. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)
Crankshaft
bearing
Thrust
washer
Connecting
rod bearing

15. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Description
(1/1)
Piston
Piston pin
Piston
rings

16. 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

17. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Cylinder Head
(1/1)
Cylinder head
Spark plug
Intake port
Water jacket
Exhaust port
Cylinder head gasket
Combustion
chamber
Oil hole

18. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Plastic Region Bolt
(1/1)
Elastic regionPlastic region
Smaller
Larger
B
o
lt

t
e
n
s
io
n
Yield
point
Fracture
point
Bolt’s rotational angle
Plastic region bolt
Cylinder head
Bolt’s rotational angle
Bolt
tension

19. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Cylinder Block
(1/3)
Cylinder block
Cylinder liner
Combustion strokeCompression stroke
Ridge
Cylinder wear
Thrust force

20. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Cylinder Block
(2/3)
1.Cylinder bore size
Location of cylinder bore STD size codes
(5VZ-FE engine)
Front
Bore size code
1
2
3
Small
Large
Cylinder bore size

21. 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 main
journal bore size

22. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Crankshaft
(1/3)
REFERENCE:
Crankshaft Offset
Crankshaft
Crank pin
Crank journal Balance weight
Oil hole

23. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Crankshaft
(2/3)
Example
Bearing cap
Bearing cap unit with ladder-frame construction

24. 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

25. 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 groove
Lower half-bearing
Locking lip
Bearing size code Bearing size
1
2
Thin
Thick

26. 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

27. 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

28. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Bearing Selection
(1/2)
Oil clearance
Bearing Oil film
Oil clearance

29. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Bearing Selection
(2/2)
1.Bearing selection method
No.2
No.1
No.3
No.5
No.1No.2No.3No.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 - 56 - 89 - 11
7
1 2 3 4
Bearing size cord
No.4

30. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Piston
(1/4)
1.Description
B
A
Oval
Circle
Small
Piston pin boss
Piston
skirt
Large
Truncated cone
Cold
True cylinder
Hot

31. 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)

32. 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

33. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Piston
(3/4)
3.Piston slap (Side knocking)/
4.Operation of offset pistons

34. 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

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Valve Mechanism
(1/1)
1.Valve opening and closing system

42. 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 valve
Combustion chamber
Intake valve

43. 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

44. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Valve and Related Parts
(3/4)
4.Valve seat
Valve contact face
6
0
°
4
5
°
3
0
°

45. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Valve and Related Parts
(4/4)
5.Valve guide bushing and
oil seal
Oil seal
Valve quide bushing
Valve stem
Engine oil

46. 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.
TDC
Valve overlap
Intake valve
opens
Intake
valve
closes
Exhaust
valve closes
Exhaust
valve
opens
BDC
43°
2° 2°
34°

47. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Valve Timing
(2/2)
Valve overlap

48. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Valve Clearance
(1/1)

49. 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

50. 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 screw
Rocker arm
Valve lifer

51. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper
Scissors Gear Mechanism
(Sub-gear Mechanism)
(1/1)
Backlash
Sub gear
Driven gear
Sub gear
Driven gear
Drive gear
Drive gear
Sub gear
Scissors spring
Driven gear
Drive gear

52. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Balance Shaft
(1/1)
va, vb: Crankshaft rotational speed
Va, Vb: Piston movable speed
La, Lb: Piston movable distance
va = vb
Va<Vb
La<Lb
Lb Vb
La Va
va
vb
A B
Counterweight
Balance shaft
Inertial forces

53. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Timing Chain Auto-tensioner
(1/1)
Chain damper
Timing chain
auto-tensioner
Chain slipper
Chain
Engine
oil
Plunger
Spring
Check ball
Cam
Spring
Chain auto-tensioner (1NZ-FE engine)

54. 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

55. 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

56. 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.

57. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Lubrication System Oil Pump
(1/1)
Drive roter
Driven roter
Relief valve

58. 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

59. 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/cm
2
) or lower]/
2.When the oil pressure is high
[19.6 ± 4.9 kPa (0.2 ± 0.05
kgf/cm
2
) 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 sensor
Oil pan
Oil level
(Normal)
Warning lamp
Oil

60. 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/cm
2
) or lower]/
2.When the oil pressure is high
[19.6 ± 4.9 kPa (0.2 ± 0.05
kgf/cm
2
) 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 sensor
Oil pan
Oil level
(Low)
Oil

61. 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

62. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Lubrication System Oil Consumption
(1/1)The gap between the cylinder and the piston
The gap between the valve guide bushing and valve stem
Loss due to oil contained in blow-by gas
PCV
valve

63. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Description
(1/1)
1.Cooling system
to Radiator
from Heater core
from Radiator
Bypass passage Cylinder head
Water pump
Thermostat
Cylinder block
Throttle body
Radiator
Heater core
to Heater core
to Throttle body

64. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Flow of Engine Coolant
(1/1)
1.Thermostat in water inlet
type (With bypass valve)

65. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Thermostat
(1/1)
With bypass valve Without bypass valve
Main valve
Cylinder
Bypass valve
Wax
Main valve
Jiggle valve
Jiggle valve
WaxCylinder

66. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Water Pump
(1/1)
V-ribbed beltBearing Mechanical seal
Cylinder
block
Swirl
chamber
Rotor
Water pump pully Water drain hole

67. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Electric Motor-driven Cooling Fan
(1/2)
1.Outline
Cooling fan
Fan motor
Water temperature switch

68. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Electric Motor-driven Cooling Fan
(2/2)
2.Operation
Fan relay
Ignition switch
Coolant
temp. switch
Coolant temperature

69. 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

70. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Cooling System Temperature-controlled Fluid Coupling
(2/2)
2.Operation
Without coupling
F
a
n

s
p
e
e
d
Air hot
Air warm
Air cold
0
Air Temperature (HOT) during low speed driving
Air temperature (HOT) during high speed driving
Air temperature (WARM) during high speed driving
Air temperature (COLD) during high speed driving
Fluid coupling shaft speed

71. 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

72. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Inspection Compression Pressure
(1/1)
1.Check compression pressure

73. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

74. 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

75. Diagnosis Technician >> Gasoline Engine >> Gasoline Engine
Engine Proper Striations on the Piston Skirt
(1/1)
Resin coating
Striation finish