I think this was my first real win I guess with using a scope. Backstory on car had random “misfire” codes during cold start, 2018 Sienna with the 2GR-FKS motor, very low mileage (I think it was 5k can’t remember). Then like within 5-10 runs perfect. Van was a buyback (non lemon law), just the dealer bought it back. Another tech threw a starter at it before I got it and swapped some coils. Below is word for word what I submitted to TAS (Toyota Technical Assistance) when I was at the dealer. Documentation was key here and although I had to fight for it. I got over 10 hours of combined diagnostic time.
Codes:
P030000 (Random/Multiple Cylinder Misfire Detected) and
P030027 (Random/Multiple Cylinder Misfire Detected [Emission] Signal Rate of Change Above Threshold)
P030200 (Cylinder 2 Misfire Detected)
P030300 (Cylinder 3 Misfire Detected)
When van gets warm runs great, after finally being able to get a snapshot through tech-stream (first two attempts did not save / techstream quit on me and did not save car does not act up while hot every time it failed had to start over. I noticed that van only misfires while in direct injection mode, confirmed that with a snapshot, but wasn't sure if that was a coincidence.
Diagnostic Steps
-Relative Compression check with picoscope (techstream active test not working)
-Current ramped direct injectors (while cold)
-Current ramped port injectors (while cold)
-Current ramped ignition coils (while cold) w/ sync on cylinder 2
-Swapped Spark Plugs 2 and 6 and ignition coils 2 and 6
(Found no change or faults while scoping direct injectors and port injector current and voltage.)
^^Note each time I had to wait a full night to re do each specific test.^^
-Compression test (running and cranking w/ WPS pressure transducer) - all cylinders appeared to have good sealing and consistent pressure across the board (did not test cylinder 5 as I felt I did not need to continue on)
-Pressure pulse sensor in the radiator synced to IGT cylinder 2, no un even pulses leading to combustion pulses entering into radiator
(2 hours).
At this time given my snapshot watching it mis while in direct, I still had a hunch it was injector based, but most of my fuel pressures testing (with what info I had) looked good. Decided to go ahead and scope cam and crank while cold. Saw a bad tooth signal on 8 and 26/27, took another capture while hot and although you could still see an anomaly the same teeth still looked odd. Re-verified cam and crank signal with a known good sienna w/ same settings - known good sienna signal was perfect.
(note had to take apart ECM connector cover on each sienna to back probe ECM)
On teeth I believe 8 and 26th 27th, very odd reading. At this point decided to hit up TAS and show them what I saw before removing anything crazy. Confirmed that what I was seeing was weird and cleared up some fuel questions I had (of course had to go back and fill out the pre call worksheet lol). After talking to them we both agreed probably ditch the fuel idea and go look at the reluctor wheel for the crank. Stuck a borescope down there and bam chipped and bent teeth. Photos included along with some screen shots.
Replaced crank reluctor wheel re installed engine and trans.
