Last Modified: 05-13-2024 |
6.11:8.1.0 |
Doc ID: RM100000001G44Z |
Model Year Start: 2020 |
Model: Corolla |
Prod Date Range: [01/2019 - 11/2022] |
Title: 2ZR-FAE (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION; 2020 - 2023 MY Corolla [01/2019 - 11/2022] |
ON-VEHICLE INSPECTION
CAUTION / NOTICE / HINT
CAUTION:
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When working near the engine room while the engine has started or the ignition switch is ON, do not touch the rotating components such as the V-ribbed belt or cooling fan.
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Touching the rotating components such as the V-ribbed belt or cooling fan. could result in your hand or clothing getting caught and pulled in.
PROCEDURE
1. INSPECT ENGINE COOLANT
Click here
2. INSPECT ENGINE OIL
Click here
3. INSPECT BATTERY
Click here
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
Click here
5. INSPECT SPARK PLUG
Click here
6. INSPECT V-RIBBED BELT
Click here
7. INSPECT VALVE AND ADJUSTER NOISE
(a) Rev up the engine several times. Check that the engine does not emit unusual noises.
(b) If unusual noises occur, warm up the engine and idle it for 30 minutes or more, then perform the inspection.
HINT:
If any defects or problems are found during the inspection, perform valve lash adjuster assembly inspection.
Click here
8. INSPECT IGNITION TIMING
NOTICE:
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Check the ignition timing with the cooling fan off.
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Turn off all electrical systems and the A/C.
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When checking the ignition timing, the transaxle should be in neutral or park.
(a) Warm up and stop the engine.
(b) Connect the Techstream to the DLC3.
(c) Start the engine and run it at idle.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance.
Powertrain > Engine and ECT > Data List
Tester Display
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IGN Advance
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Standard Ignition Timing:
0 to 14° BTDC at idle
(f) Check that the ignition timing advances immediately when the engine speed is increased.
(g) Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON.
Powertrain > Engine and ECT > Active Test
Active Test Display
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Connect the TC and TE1
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Data List Display
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IGN Advance
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(h) Monitor IGN Advance of the Data List.
Standard Ignition Timing:
8 to 12° BTDC at idle
NOTICE:
When checking the ignition timing, the transaxle should be in neutral or park.
9. INSPECT ENGINE IDLE SPEED
NOTICE:
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Turn off all electrical systems and the A/C.
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Inspect the engine idle speed with the cooling fan off.
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When checking the engine idle speed, the transaxle should be in neutral or park.
(a) Warm up and stop the engine.
(b) Connect the Techstream to the DLC3.
(c) Start the engine and run it at idle.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.
Powertrain > Engine and ECT > Data List
Tester Display
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Engine Speed
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(f) Read the value displayed on the Techstream.
Standard Idle Speed:
for CVT
700 to 800 rpm
for Manual Transaxle
600 to 700 rpm
10. INSPECT COMPRESSION
NOTICE:
Keep the spark plug holes free of foreign matter when measuring the compression pressure.
(a) Warm up and stop the engine.
(b) Check for DTCs.
Click here
(c) Remove the 4 spark plugs.
Click here
(d) Disconnect the 4 fuel injector connectors.
NOTICE:
Disable fuel injection in order to prevent catalyst damage due to unburned gasoline.
(e) Remove the air cleaner cap with air cleaner hose.
Click here
(f) w/ Stud Bolt:
(1) Remove the 2 bolts, 2 nuts and separate the throttle body assembly from the intake manifold.
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*A
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w/ Stud Bolt
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*B
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w/o Stud Bolt
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(g) w/o Stud Bolt:
(1) Remove the 4 bolts and separate the throttle body assembly from the intake manifold.
(h) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
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(2) While cranking the engine, measure the compression pressure.
Standard Compression Pressure:
1373 kPa (14.0 kgf/cm2, 199 psi)
Minimum Compression Pressure:
980 kPa (10.0 kgf/cm2, 142 psi)
Pressure Difference between Each Cylinder:
100 kPa (1.0 kgf/cm2, 15 psi)
NOTICE:
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Use a fully-charged battery so that the engine speed can be increased to 250 rpm or more.
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Inspect the other cylinders in the same way.
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Measure the compression pressure as quickly as possible.
(3) If the cylinder compression pressure is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect it again.
HINT:
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If adding engine oil increases the compression pressure, the piston rings and/or cylinder bore may be worn or damaged.
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If the compression pressure stays low, a valve may be stuck or seated improperly, or there may be leaks in the cylinder head gasket.
(i) w/ Stud Bolt:
(1) Install a new throttle body gasket and the throttle body assembly to the intake manifold with the 2 bolts and 2 nuts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
NOTICE:
If the throttle body assembly has been struck or dropped, replace it.
(j) w/o Stud Bolt:
(1) Install a new throttle body gasket and the throttle body assembly to the intake manifold with the 4 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
NOTICE:
If the throttle body assembly has been struck or dropped, replace it.
(k) Install the air cleaner cap with air cleaner hose.
Click here
(l) Connect the 4 fuel injector connectors.
(m) Install the 4 spark plugs.
Click here
(n) Clear the DTCs.
Click here
NOTICE:
After the inspection, clear the DTCs, check for DTCs again and make sure the normal system code is output.
11. INSPECT CO/HC
HINT:
This check determines whether or not the idle CO/HC complies with regulations.
(a) Start the engine.
(b) Keep the engine at 2500 rpm for approximately 180 seconds.
(c) Insert a CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idle.
(d) Immediately check the CO/HC concentration during idle and when the engine is running at 2500 rpm.
HINT:
When doing a 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.
If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below.
(1) Check for DTCs.
Click here
(2) See the following table for possible causes, then inspect the applicable parts and repair them if necessary.
CO
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HC
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Problem
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Possible Cause
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Normal
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High
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Rough idle
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Faulty ignition:
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Incorrect timing
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Fouled, shorted or improperly gapped plugs
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Incorrect valve clearance
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Leaks in intake or exhaust valves
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Leaks in cylinders
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Low
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High
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Rough idle (Fluctuating HC reading)
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Vacuum leaks:
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Ventilation hose
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Intake manifold
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Throttle body assembly
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Brake booster line
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Lean mixture causing misfire
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High
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High
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Rough idle (Black smoke from exhaust)
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Restricted air cleaner filter element sub-assembly
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Plugged PCV valve
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Faulty EFI systems:
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Pressure regulator
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Engine coolant temperature sensor
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Mass air flow meter sub-assembly
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ECM
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Injector assemblies
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Throttle body assembly
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