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Section 11 (Engine Assembly (Inspection) - 2ZZ-GE): Inspection

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT COOLANT (See  REPLACEMENT  ) 
  2. INSPECT ENGINE OIL (See  LUBRICATION SYSTEM - 2ZZ-GE  ) 
  3. INSPECT BATTERY (See  GENERATORS & REGULATORS  ) 
  4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY 
  5. INSPECT SPARK PLUG (See  COROLLA & MATRIX  ) 
  6. INSPECT IGNITION TIMING 
    1. Warm up engine.
    2. When using hand-held tester or OBDII scan tool.
      1. Connect the hand-held tester or OBDII scan tool to the DLC3.
        NOTE: Please refer to the hand-held tester or OBDII scan tool operator's manual for further details.
    3. When not using hand-held tester or OBDII scan tool.
      1. Using SST, connect terminals 13 (TC) and 4 (CG) of DLC3.
        Fig 1: Identifying DLC3 Connector Terminals
        G02864993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        SST 09843-18040

        NOTE:
        • Be sure not to connect incorrectly. It causes breakage of the engine.
        • Turn OFF all electrical systems.
        • Operate the inspection when the cooling fan motor is turned OFF.
      2. Remove the 3 bolts, the nut and the cylinder head cover No. 2.
      3. Pull out the wire harness as shown in the illustration.
        4. Fig 2: Removing Wire Harness
        G02864994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Connect timing light to engine.
        NOTE:
        • Use a timing light which can detect the first signal.
        • After checking, be sure to tape the wire harness.
      5. Inspect ignition timing at idle.

        Ignition timing: 8 - 12°BTDC 

        NOTE: When checking the ignition timing, the transmission is at neutral position.
        NOTE: After engine RPM is kept at 1,000 - 1,300 RPM for 5 seconds, check that it returns idle speed.
      6. Disconnect the terminal 13 (TC) and 4 (CG) of the DLC3.
      7. Inspect ignition timing at idle.

        Ignition timing: 

        M/T 4 - 12° BTDC 

        A/T 10 - 18° BTDC 

      8. Confirm that ignition timing moves to advanced angle side when the engine RPM is increased.
      9. Remove the timing light.
      10. Install cylinder head cover No. 2 with the 3 bolts and the nut.

        Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

  7. INSPECT ENGINE IDLE SPEED 
    1. Warm up engine.
    2. When using hand-held tester or OBDII scan tool.
      1. Connect the hand-held tester or OBDII scan tool to the DLC3.
        NOTE: Please refer to the hand - held tester or OBDII scan tool operator's manual for further details.
    3. Check the idle speed.

      Idle speed: 

      M/T 750 - 850 RPM 

      A/T 700 - 800 RPM 

      NOTE:
      • Check idle speed with cooling fan OFF.
      • Switch off all accessories and air conditioning.

        SST 09843-18040

  8. INSPECT COMPRESSION 
    1. Warm up and stop engine.
    2. Remove ignition coil.
    3. Remove spark plugs.
    4. Inspect cylinder compression pressure.
      Fig 3: Inspecting Cylinder Compression
      G02864995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09992-00500

    1. Insert a compression gauge into the spark plug hole.
    2. Fully open the throttle.
    3. While cranking the engine, measure the compression pressure.
      NOTE:
      • Always use a fully charged battery to obtain engine speed of 250 RPM or more.
      • Check other cylinder's compression pressure in the same way.
      • This measurement must be done in as short a time as possible.

        Compression pressure: 

        1,400 kpa (14.3 kgf/cm 2  , 203 psi) 

        Minimum pressure: 

        1,000 kpa (10.3 kgf/cm 2  , 145 psi) 

        Difference between each cylinder: 

        110 kpa (1.1 kgf/cm 2  ,16 psi) 

    4. If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (1) through (3) for cylinders with low compression.
      • If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
      • If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
  9. INSPECT CO/HC 
    1. Start engine.
    2. Race engine at 2,500 RPM for approx. 180 seconds.
    3. Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into tailpipe during idling.
    4. Immediately check CO/HC concentration at idle and/or 2,500 RPM.
      NOTE:
      • Complete the measuring within 3 minutes.
      • When doing the 2 mode (idle and 2,500 RPM) test, these measuring orders are prescribed by the applicable local regulations.
    5. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
      1. Check heated oxygen sensor operation. (See ON-VEHICLE INSPECTION )
        Fig 4: CO/HC Meter Testing Probe Diagnostic Chart
        G02864996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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