Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

General Description

General Description

Basic principle of four-stroke engine

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Air-fuel Mixture

1.Good air-fuel mixture for

automobiles

Air

15

Theoretical
air-fuel ratio
Fuel
10
Richer

1
15
Air-fuel ratio

20
Leaner

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Air-fuel Mixture

2.Air-fuel ratio

Air

15

Theoretical
air-fuel ratio
Fuel
10
Richer

1
15
Air-fuel ratio

20
Leaner

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Air-fuel Mixture

3.Air fuel ratio and driving

conditions

Air

15

Theoretical
air-fuel ratio
Fuel
10
Richer

1
15
Air-fuel ratio

20
Leaner

(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Compression

1.Necessity of compressing the air-fuel mixture

Compression
=
ratio

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

Volume of combustion chamber (A)

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Spark

2
Spark plug

Air-fuel
mixture

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Spark

1.Conditions for a good spark

2
Spark plug

Air-fuel
mixture

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Three Elements of Gasoline Engines

Good Spark

2
Spark plug

Air-fuel
mixture

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

Cylinder head

Cylinder head gasket

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

Cylinder block

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

Crankshaft

Bearing cap

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

Connecting rod

Bearing cap

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

Thrust
washer

Crankshaft
bearing

Connecting
rod bearing

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

Piston pin

Piston

Piston
rings

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Description

(1) Exhaust camshaft

(10) Timing chain

(11) Chain tensioner slipper

(2) Intake camshaft

(3)
(4)
(5)
(6)
(7)
(8)
(9) Valve

(12)Chain
vibration
damper

(13) Timing chain tensioner

(14) Crankshaft timing sprocket

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Cylinder Head

Cylinder head

Exhaust port

Spark plug

Intake port
Water jacket

Oil hole

Cylinder head gasket

Combustion
chamber

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Plastic Region Bolt

Bolts rotational angle

Bolt tension

Elastic region Plastic region

Smaller
Larger
Fracture
point

Yield
point

Bolt
tension

Bolts rotational angle

Plastic region bolt

Cylinder head

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Cylinder Block

Cylinder block

Cylinder liner

Combustion stroke Compression stroke

Ridge

Cylinder wear
Thrust force
(1/3)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Cylinder Block

1.Cylinder bore size

Location of cylinder bore STD size codes
(5VZ-FE engine)
Front

Bore size code

Cylinder bore size

Small

2
3

Large

(2/3)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper
2.Crankshaft main journal
bore size

Cylinder Block

Location of main journal bore STD size codes

(1NZ-FE engine)

Bore size code

Crankshaft main
journal bore size

Small

Large

(3/3)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Crankshaft

Crank pin

Balance weight

Crank journal

Crankshaft
Oil hole

REFERENCE:
Crankshaft Offset

(1/3)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Crankshaft

Example

Bearing cap
Bearing cap unit with ladder-frame construction

(2/3)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper
1.Main journal and crank
pin size

Crankshaft

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

Main journal or
crank pin size
Large

2
3
Small

(3/3)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Crankshaft Bearing

1.Bearing size/
2.Undersize bearing
Upper halt-bearing
Oil groove

Oil hole

Thrust washer

Oil groove

Bearing size code

Locking lip
Lower half-bearing

Bearing size code

1

Bearing size

Thin

2
Thick

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Connecting Rod

1.Big end bore size

Connecting rod
Bearing cap

Oil jet

Front mark

Big end bore

size code

Big end bore

Big bore size
code

Big end bore size

Large

2
3

Small

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Connecting Rod Bearing

1.Bearing Size/
2.Undersize Bearing
Oil hole

Bearing size code

Bearing size code

1

Bearing size

Thin

2
Thick

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Bearing Selection

Oil clearance

Bearing

Oil film

Oil clearance

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Bearing Selection

1.Bearing selection method

No.2

No.1
No.3
No.5

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

No.4

No.5

Bearing size cord

Cylinder block main journal

bore size code (A)
Crankshaft main journal
size code (B)

0-2

3-5

Example
A = 4, B = 3, A + B = 7
Use bearing size code

6 - 8 9 - 11

7
1

4
(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston

1.Description

Oval

Circle

Small
Piston pin boss

Piston
skirt

Large

Truncated cone

True cylinder

Cold

Hot

(1/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston

2.Thrust force

Combustion pressure

Compression pressure

Major thrust force

(Combustion stroke)

Minor thrust force

(Compression stroke)

(2/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

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

Piston

Piston slap

Offset piston
Center of piston pin

Center of piston

Piston

Offset

(3/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston

3.Piston slap (Side knocking)/

4.Operation of offset pistons

(3/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston

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

Piston size code

Front mark

REFERENCE:
Striations on the Piston Skirt

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston

Piston size code and front mark

(5VZ-FE engine)

Piston size code

Front mark

(4/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston

Piston size code and front mark

(5VZ-FE engine)

Piston size code

Front mark

(4/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston Ring

1.Description
Compression ring No.1

Compression ring No.2

Oil ring side rail (upper)

Oil rings

Oil ring expander

Oil ring side rail (lower)

(1/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston Ring

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

Oil ring side rail (upper) end gap

No.2 compression ring end gap

(2/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston Ring

3.Ring end gap

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

Ring end gap

(3/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Piston Ring

4.Ring pumping effect and

ring flutter

Cylinder

Engine oil

Piston

Piston ring

(4/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve Mechanism

1.Valve opening and closing system

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve and Related Parts

2.Valve
Camshaft
Valve stem

Valve guide
bushing

Oil seal
Valve face

Valve head

44.5
or 45.5

Exhaust
valve

Intake
valve

Exhaust valve
Intake valve
Combustion chamber
(1/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve and Related Parts

3.Valve spring

Double spring
Uneven pitch spring
(symmetrical)

Uneven pitch spring

(asymmetrical)
Top

a
d
Inner

Outer

e
c
a=c<d

d>e

(2/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve and Related Parts

4.Valve seat

30

45

60

Valve contact face

(3/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve and Related Parts

5.Valve guide bushing and

oil seal

Oil seal
Valve quide bushing
Valve stem

Engine oil

(4/4)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve Timing

Valve timing diagram

(2NZ-FE engine without VVT-i, leaded gasoline type)
TDC
Valve overlap

Compression stroke

In.

Ex.

Intake valve 2
opens

In.

2
In.

Exhaust
valve closes
Exhaust
valve
opens

Exhaust stroke

Ex.

Intake stroke

Combustion
(power) stroke

In.

Intake
valve
closes
43

Ex.

Ex.

34
BDC

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve Timing

Valve overlap

(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Valve Clearance

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

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

Adjustment of Valve Clearance

2-(1)
Adjusting shim

Valve lifter

2-(2)

Valve lifter

2-(3)

Adjusting shim

Rocker arm

Valve lifter
Adjusting shim

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

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

Adjustment of Valve Clearance

Adjusting screw

Rocker arm

Valve lifer

(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Scissors Gear Mechanism

(Sub-gear Mechanism)

Engine Proper
Backlash
Driven gear

Sub gear

Drive gear

Sub gear
Driven gear

Drive gear

Drive gear

Driven gear
Scissors spring
Sub gear

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Balance Shaft

va, vb: Crankshaft rotational speed

Va, Vb: Piston movable speed
La, Lb: Piston movable distance
va = vb
Va<Vb
La<Lb
Inertial forces

Lb

Vb

La

Va

vb
Balance shaft
va
Counterweight
A

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Timing Chain Auto-tensioner

Chain auto-tensioner (1NZ-FE engine)

Chain damper
Plunger
Spring
Check ball

Engine
oil
Timing chain
auto-tensioner

Chain
Chain slipper
Spring

Cam

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Timing Belt Auto-tensioner

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

Timing belt

Piston rod

Idler pulley
Spring

Check ball

Timing belt auto-tensioner

Spring

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Description

Camshaft timing oil control valve

Main oil gallery

Oil return hole

Oil pressure switch

Oil filter
Oil strainer

Oil pump

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Description

Oil flow circuit for 1NZ-FE engine

Main oil gallery

Crankshaft
journal

Oil jet

Cylinder head

Chain
tensioner

Oil filter
Connecting
rod
Oil cooler

Timing
chain

Camshaft timing
oil control
valve filter

Intake
camshaft
journal

Exhaust
camshaft
journal

Oil jet
Camshaft timing
oil control valve
Piston

Oil pump

VVT-i
controller
Oil strainer

Oil pan
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.

(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Oil Pump

Drive roter

Driven roter

Relief valve

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Oil Filter

Check valve

Element

Relief valve
Oil flow (in)
Oil flow (out)
Oil flow if the relief valve open

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Oil Pressure Warning Lamp

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

Warning lamp

Oil pressure switch

Oil pressure
(Normal)
Low engine oil level warning lamp

ECU
Warning lamp
Oil level
(Normal)

Oil

Oil temp. switch

Oil pan
Oil level sensor

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Oil Pressure Warning Lamp

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

Warning lamp

Oil pressure switch

Oil pressure
(Low)
Low engine oil level warning lamp

ECU
Warning lamp
Oil level
(Low)

Oil

Oil temp. switch

Oil pan
Oil level sensor

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Oil Cooler

Water bypass hose

Oil cooler
Oil filter

Engine coolant

Oil cooler
Oil filter

From Oil pump

to Main oil gallery

Relief valve

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Lubrication System

Oil Consumption

PCV
valve

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

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Description

1.Cooling system
to Radiator
from Heater core

to Heater core
to Throttle body

from Radiator

Bypass passage

Cylinder head

Water pump
Heater core

Thermostat
Cylinder block

Radiator

Throttle body

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Flow of Engine Coolant

1.Thermostat in water inlet

type (With bypass valve)

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Thermostat

With bypass valve

Main valve

Without bypass valve

Jiggle valve
Main valve

Jiggle valve

Cylinder
Wax
Bypass valve

Cylinder

Wax

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Water Pump

V-ribbed belt

Bearing

Mechanical seal
Cylinder
block

Swirl
chamber

Rotor

Water pump pully

Water drain hole

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Electric Motor-driven Cooling Fan

1.Outline

Cooling fan

Water temperature switch

Fan motor

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Electric Motor-driven Cooling Fan

2.Operation

Ignition switch

Fan relay

Coolant
temp. switch
Coolant temperature

(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Temperature-controlled Fluid Coupling

1.Overview

Pulley
Fluid coupling
Cooling fan
Air hot

Air warm

Air cold

Bimetal spring
Bimetal plate
Silicone oil
Front operating chamber
Rear operating chamber

(1/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cooling System

Temperature-controlled Fluid Coupling

2.Operation
Without coupling

Fan speed

Air hot
Air warm
Air cold

Fluid coupling shaft speed

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

(2/2)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Electronically Controlled Hydraulic

Cooling Fan System

Cooling System

Solenoid
valve
Hydraulic
motor

ECU

Hydraulic
pump
Oil cooler
Reservoir

Cooling fan

Water pump. sensor signal,

Air conditioner signal,
Engine speed signal

Condenser
Radiator

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Inspection

Compression Pressure

1.Check compression pressure

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Crankshaft Offset

Combustion pressure

Combustion pressure

Piston

Connecting rod

Crankshaft center

Offset

Offset crankshaft

Center crankshaft

(1/1)

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper

Striations on the Piston Skirt

Striation finish

Resin coating

(1/1)