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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 48 (Ignition System (A25A-FXS) - Inspection) >> Ignition System >> On-Vehicle Inspection [12/2019 - ] >> Procedure

On-Vehicle Inspection [12/2019 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PERFORM SPARK TEST 
    1. Check for DTCs.

      Powertrain > Engine > Trouble Codes 

      NOTE:

      If any DTCs are present, perform troubleshooting in accordance with the procedure for each DTC.

    2. Remove the 4 ignition coil assemblies and 4 spark plugs.

      Refer to REMOVAL [12/2019 - ]

    3. Remove the front wheel opening extension pad LH.

      Refer to PROCEDURE - Step 7 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 7 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 7 [11/2023 - ]

    4. Remove the front wheel opening extension pad RH.

      Refer to PROCEDURE - Step 8 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 8 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 8 [11/2023 - ]

    5. Remove the No. 1 engine under cover.

      Refer to PROCEDURE - Step 9 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 9 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 9 [11/2023 - ]

    6. Disengage the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.
      GTY749632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lock Lever
      NOTE:

      Perform this step in order to stop fuel injection and prevent damage to the catalyst due to unburned fuel.

    7. Disconnect the No. 5 engine wire connector.
      GTY761415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Perform this step in order to stop fuel injection and prevent damage to the catalyst due to unburned fuel.

    8. Install the spark plug to the ignition coil assembly, and then connect the ignition coil assembly connector.
    9. Put the engine in Inspection Mode (Maintenance Mode).

      Powertrain > Hybrid Control > Utility 

      Tester Display
      Inspection Mode
    10. Ground the spark plug.
    11. Check that spark occurs at each spark plug while the engine is being cranked.
      NOTE:
      • Be sure to ground the spark plugs when checking them.
      • Do not crank the engine for more than 2 seconds.
      • If an ignition coil assembly or spark plug has been struck or dropped, replace it.

      HINT: 

    12. Connect the No. 5 engine wire connector.
    13. Connect the No. 6 engine wire connector and push down the lock lever to engage the claw as shown in the illustration.
      GTY747627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lock Lever
    14. Install the No. 1 engine under cover.

      Refer to PROCEDURE - Step 63 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 63 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 61 [11/2023 - ]

    15. Install the front wheel opening extension pad LH.

      Refer to PROCEDURE - Step 64 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 64 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 62 [11/2023 - ]

    16. Install the front wheel opening extension pad RH.

      Refer to PROCEDURE - Step 65 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 65 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 63 [11/2023 - ]

    17. Install the 4 ignition coil assemblies and 4 spark plugs.

      Refer to INSTALLATION [12/2019 - ]

    18. Check for DTCs.

      Powertrain > Engine > Trouble Codes 

    19. Clear the DTCs.

      Powertrain > Engine > Clear DTCs 

  2. INSPECT IGNITION COIL ASSEMBLY AND SPARK TEST 

    HINT: 

    Perform "Inspection After Repair" after replacing an ignition coil assembly or spark plug.

    Refer to INITIALIZATION [12/2019 - 10/2021] , or refer to INITIALIZATION [10/2021 - ]

    1. Check that the ignition coil assembly connector is securely connected.

      Result

      Result Action
      NG Connect securely
      OK Go to next step
    2. Perform a spark test on each ignition coil assembly.
      1. Replace the ignition coil assembly with a known good one.
      2. Perform the spark test again.

        Result

        Result Action
        NG Go to next step
        OK Replace ignition coil assembly
        NOTE:

        If an ignition coil assembly or spark plug has been struck or dropped, replace it.

    3. Perform a spark test on each spark plug.
      1. Replace the spark plug with a known good one.
      2. Perform the spark test again.

        Result

        Result Action
        NG Inspect ignition system
        Refer to Ignition Circuit [12/2019 - 11/2023] , or refer to Ignition Circuit [11/2023 - ]
        OK Replace spark plug
        NOTE:

        If an ignition coil assembly or spark plug has been struck or dropped, replace it.

    4. Connect the No. 5 engine wire connector.
    5. Connect the No. 6 engine wire connector and push down the lock lever to engage the claw as shown in the illustration.
      GTY747627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lock Lever
    6. Install the No. 1 engine under cover.

      Refer to PROCEDURE - Step 63 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 63 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 61 [11/2023 - ]

    7. Install the front wheel opening extension pad LH.

      Refer to PROCEDURE - Step 64 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 64 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 62 [11/2023 - ]

    8. Install the front wheel opening extension pad RH.

      Refer to PROCEDURE - Step 65 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 65 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 63 [11/2023 - ]

    9. Install the 4 ignition coil assemblies and 4 spark plugs.

      Refer to INSTALLATION [12/2019 - ]

    10. Check for DTCs.

      Powertrain > Engine > Trouble Codes 

    11. Clear the DTCs.

      Powertrain > Engine > Clear DTCs 

  3. CHECK SPARK PLUG 
    NOTE:
    • Do not damage the iridium tip and platinum tip.
    • Check the iridium tip visually since the iridium tip may be damaged.
    • Never attempt to adjust the electrode gap of a used spark plug.
    • Replace with new spark plugs if extremely dirty due to sludge, etc.
    • Replace with new spark plugs if damaged at all.
    • Replace with a new spark plug if it has been struck or dropped.
    • When replacing with a new spark plug, do not remove the cap for protecting the spark plug tip until it is installed to the engine.

    HINT: 

    Perform "Inspection After Repair" after replacing a spark plug.

    Refer to INITIALIZATION [12/2019 - 10/2021] , or refer to INITIALIZATION [10/2021 - ]

    1. Check the electrode.
      GTY425641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Body Ground
      1. Using a megohmmeter, measure the insulation resistance.

        Standard Insulation Resistance

        Tester Connection Condition Specified Condition
        Spark plug (terminal part) - Body ground Always 10 MΩ or higher

        HINT: 

        • If the result is not as specified, clean the spark plug with a spark plug cleaner and measure the resistance again.
        • If a megohmmeter is not available, perform the following simple inspection instead.
    2. Alternative inspection method.
      1. Put the engine in Inspection Mode (Maintenance Mode).

        Powertrain > Hybrid Control > Utility 

        Tester Display
        Inspection Mode
      2. Start the engine.
        NOTE:

        Do not perform this step when any of the following DTCs are output: P0300-00, P0300-27, P0300-85, P0301-00, P0302-00, P0303-00, P0304-00 (Cylinder Misfire Detected).

      3. Quickly accelerate the engine to 2500 rpm 5 times.
        NOTE:

        Do not perform this step when any of the following DTCs are output: P0300-00, P0300-27, P0300-85, P0301-00, P0302-00, P0303-00, P0304-00 (Cylinder Misfire Detected).

      4. Remove the spark plug.

        Refer to REMOVAL [12/2019 - ]

      5. Visually check the spark plug.

        HINT: 

        If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step.

    3. Check the spark plug for any damage to its threads and insulator.

      If there is any damage, replace the spark plug.

      Recommended Spark Plug

      Manufacturer Spark Plug Type
      DENSO FC16HR-Q8
    4. Check the spark plug electrode gap.
      GTY425816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Spark Plug Electrode Gap

      Maximum Electrode Gap for Used Spark Plug

      1.2 mm (0.0472 in.)

      NOTE:

      Never attempt to adjust the electrode gap of a used spark plug.

      If the spark plug electrode gap is more than the maximum, replace the spark plug.

      Standard Electrode Gap for New Spark Plug

      0.7 to 0.8 mm (0.0276 to 0.0315 in.)

    5. Install the spark plug.

      Refer to INSTALLATION [12/2019 - ]

  4. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing an ignition coil assembly or spark plug.

      Refer to INITIALIZATION [12/2019 - 10/2021] , or refer to INITIALIZATION [10/2021 - ]

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