2ZR-FXE (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION; 2020 - 2025 MY Corolla Corolla HV [01/2019

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001GMHI
Model Year Start: 2020	Model: Corolla	Prod Date Range: [01/2019 - ]
Title: 2ZR-FXE (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION; 2020 - 2025 MY Corolla Corolla HV [01/2019 - ]

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:

To prevent injury due to contact with an operating cooling fan, keep your hands and clothing away from the cooling fans when working in the engine compartment with the engine running or the power switch on (IG).

PROCEDURE

1. INSPECT COOLANT (for Engine)

Click here

2. INSPECT ENGINE OIL

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3. CHECK AUXILIARY BATTERY

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4. INSPECT SPARK PLUG

Click here

5. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Click here

6. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOISE

(a) Put the engine in inspection mode.

Click here

(b) Rev up the engine several times. Check that the engine does not emit unusual noises.

HINT:

If any defects or problems are found during the inspection, perform valve lash adjuster assembly inspection.

Click here

7. INSPECT IGNITION TIMING

NOTICE:

Check the ignition timing with the cooling fans off.
Turn off all electrical systems and the A/C.
When checking the ignition timing, the transaxle should be in park.

(a) Put the engine in inspection mode.

Click here

(b) Warm up and stop the engine.

(d) Put the engine in inspection mode.

Click here

(e) Enter the following menus: Powertrain / Engine / Data List / Ignition Timing Cylinder #1.

Powertrain > Engine > Data List

Tester Display
Ignition Timing Cylinder #1

Standard Ignition Timing:

8 to 24° BTDC at idle

(f) Check that the ignition timing advances immediately when the engine speed is increased.

(g) Enter the following menus: Powertrain / Engine / Active Test / Activate the TC Terminal / ON.

Powertrain > Engine > Active Test

Active Test Display
Activate the TC Terminal

Data List Display
Ignition Timing Cylinder #1

(h) Monitor Ignition Timing Cylinder #1 of the Data List.

Standard Ignition Timing:

8 to 12° BTDC at idle

8. INSPECT ENGINE IDLE SPEED

NOTICE:

Check the engine idle speed with the cooling fans off.
Turn off all electrical systems and the A/C.
When checking the engine idle speed, the transaxle should be in park.

(a) Put the engine in inspection mode.

Click here

(b) Warm up and stop the engine.

(d) Put the engine in inspection mode.

Click here

(e) Enter the following menus: Powertrain / Engine / Data List / Engine Speed.

Powertrain > Engine > Data List

Tester Display
Engine Speed

(f) Read the value displayed on the Techstream.

Standard Idle Speed:

950 to 1050 rpm

9. INSPECT COMPRESSION

NOTICE:

Keep the spark plug holes free of foreign matter when measuring the compression pressure.

(a) Put the engine in inspection mode.

Click here

(b) Warm up and stop the engine.

Click here

(d) Remove the 4 spark plugs.

Click here

NOTICE:

DTCs will be stored if the inspection is performed with the ignition coil assembly connectors disconnected. Make sure that the ignition coil assembly connectors are connected during the inspection.

(e) Remove the air cleaner cap sub-assembly.

Click here

(f) Remove the air cleaner hose assembly.

Click here

(g) w/ Stud Bolt:

(1) Remove the 2 bolts, 2 nuts and separate the throttle body assembly from the intake manifold.

*A	w/ Stud Bolt
*B	w/o Stud Bolt

(h) w/o Stud Bolt:

(1) Remove the 4 bolts and separate the throttle body assembly from the intake manifold.

(i) Check the cylinder compression pressure.

(1) Insert a compression gauge into the spark plug hole.

(2) Connect the Techstream to the DLC3.

(3) Turn the power switch on (IG).

(4) Turn the Techstream on.

NOTICE:

Check the HV battery voltage in the Data List to ensure that the battery is fully charged.

(5) Enter the following menus: Powertrain / Hybrid Control / Active Test / Compression Test / ON.

Powertrain > Hybrid Control > Active Test

Tester Display
Compression Test

(6) Depress and hold the brake pedal, and turn the power switch on (READY). Then check the compression pressure.

Standard Compression Pressure:

813 kPa (8.3 kgf/cm², 118 psi)

Minimum Compression Pressure:

617 kPa (6.3 kgf/cm², 89.5 psi)

Pressure Difference between Each Cylinder:

100 kPa (1.0 kgf/cm², 15 psi) or less

NOTICE:

Inspect all cylinders in the same way.
Measure the compression pressure as quickly as possible.
Noise may be emitted from the hybrid vehicle transaxle assembly. However, this is not a malfunction.

(7) 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:

If adding oil increases the compression pressure, the piston rings and/or cylinder bore may be worn or damaged.
If the compression pressure stays low, a valve may be stuck or seated improperly, or there may be leaks in the cylinder head gasket.

(j) 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.

(k) 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.

(l) Install the air cleaner hose assembly.

Click here

(m) Install the air cleaner cap sub-assembly.

Click here

(n) Install the 4 spark plugs.

Click here

(o) Clear the DTCs.

Click here

NOTICE:

After performing the inspection, clear the DTCs and confirm that DTCs are not stored again or that the normal system code is output if using a check wire.

10. INSPECT CO/HC

HINT:

This check determines whether or not the idle CO/HC complies with regulations.

(a) Put the engine in inspection mode.

Click here

(b) Run the engine at 2500 rpm for approximately 180 seconds.

(d) Immediately check the CO/HC concentration at idle and then at an engine speed of 2500 rpm.

HINT:

When performing a 2 mode test (with the engine idling/running at 2500 rpm), 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	HC	Problem	Cause
Normal	High	Rough idle	Faulty ignition: Incorrect valve timing Fouled, shorted or improperly gapped spark plugs Incorrect valve clearance (valve lash adjuster assembly) Leaks in intake or exhaust valves Leaks in cylinders Faulty EGR
Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body assembly Lean mixture causing misfire Faulty EGR
High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty SFI systems: Fuel pressure regulator assembly Engine coolant temperature sensor Mass air flow meter ECM Fuel injector assemblies Throttle position sensor (built into throttle with motor body assembly) Faulty EGR