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ENGINE MECHANICAL ENGINE ASSEMBLY (3ZZFE/4ZZFE)

ENGINE ASSEMBLY (3ZZFE/4ZZFE)

140M701

INSPECTION
1. INSPECT COOLANT (See page 1615)
2. INSPECT ENGINE OIL (See page 176)
3. INSPECT BATTERY
(See page 1917)
4. INSPECT AIR CLEANER FILTER ELEMENT SUBASSY

5. INSPECT SPARK PLUG

(See page 187)
6. INSPECT FAN AND GENERATOR V BELT

HINT:
You dont need to check the belt deflection because auto tensioner is adopted.
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using handheld tester.
(1) Connect the handheld tester to the DLC3.
Ignition timing : 8 12 _BTDC
HINT:
Please refer to the handheld tester operators manual for fur-
ther details.

(c) When not using handheld tester.

TC (1) Using SST, connect terminal 13 (TC) and 4 (CG) of
the DLC3.
SST 0984318030
NOTICE:
S Be sure not to connect incorrectly. It causes breakage
of the engine.
S Turn OFF all electrical systems.
CG
A62199 S Operate the inspection when the cooling fan motor is
turned OFF
(2) Remove the 2 nuts, 2 clips and cylinder head cover.
(3) Pull out the wire harness as shown in the illustration.
(4) Connect the clip of the timing light to the engine.
NOTICE:
S Use a timing light which can detect the first signal.
S After checking, be sure to tape the wire harness.

A62200

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ENGINE MECHANICAL ENGINE ASSEMBLY (3ZZFE/4ZZFE)

(5) Inspect ignition timing at idle.

Ignition timing : 8 12 _BTDC
NOTICE:
When checking the ignition timing, the transmission is at
neutral position.
HINT:
After engine r/min 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 :
3 13 _BTDC (3ZZFE)
6 9 _BTDC (4ZZFE)
(8) Confirm that ignition timing moves to advanced
angle side when the engine r/min is increased.
(9) Remove the timing light.
(10) Install cylinder head cover with the 2 nuts and 2
clips.
Torque: 7 Nm (71 kgfcm, 62 in.lbf)
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using handheld tester.
(1) Connect the handheld tester to the DLC3.
HINT:
Please refer to the hand held tester operators manual for fur-
ther details.

Tachometer (c) When not using handheld tester.

DLC3
(1) Using SST, connect tachometer test prove to termi-
nal 9 (TAC) of DLC3.
SST 0984318040
9 (TAC)
(d) Check the idle speed.
Idle speed:
600 700 rpm (M/T)
SST 650 750 rpm (A/T)
Battery A62201 NOTICE:
S Check idle speed with cooling fan OFF.
S Switch off all accessories and air conditioning.

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ENGINE MECHANICAL ENGINE ASSEMBLY (3ZZFE/4ZZFE)

9. INSPECT COMPRESSION
(a) Warm up and stop engine.
(b) Remove ignition coil.
(c) Remove spark plugs.
(d) Inspect cylinder compression pressure.
SST 0999200500
(1) Insert a compression gauge into the spark plug
hole.
A01037 (2) Fully open the throttle.
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1,300 kPa (13.3 kgfcm2, 189 psi)
Minimum pressure: 1,000 kPa (10.2 kgfcm2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgfcm2, 15 psi)
NOTICE:
S Always use a fully charged battery to obtain engine
speed of 250 rpm or more.
S Check other cylinders compression pressure in the
same way.
S This measurement must be done in as short a time as
possible.
(4) If the cylinder compression in one more cylinders is
low, pour a small amount of engine oil into the cylin-
der through the spark plug hole and repeat steps (1)
through (3) for cylinders with low compression.
HINT:
S If adding oil helps the compression, it is likely that the pis-
ton rings and/or cylinder bore are worn or damaged.
S If pressure stays low, a valve may be sticking or seating
is improper, or there may be leakage past the gasket.

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10. INSPECT CO/HC

(a) Start the engine.
(b) Race engine at 2,500 rpm for approx. 180 seconds.
(c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into tailpipe during idling.
(d) Immediately check CO/HC concentration at idle and/or 2,500 rpm.
HINT:
S Complete the measuring within 3 minutes.
S When doing the 2 mode (idle and 2,500 rpm) test, these measuring orders are prescribed by the appli-
cable local regulations.
(e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
(1) Check heated oxygen sensor operation. (See page 05219 or 05359)
(2) See the table below for possible causes, and then inspect and correct the applicable causes if
necessary.
CO HC Problems Causes
1. Faulty ignitions:
S Incorrect timing
S Fouled, shorted or improperly gapped plugs
Normal High Rough idle
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
1. Vacuum leaks:
S PCV hoses
S Intake manifold
Rough idle
Low High S Throttle body
(Fluctuating HC reading)
S ISC valve
S Brake booster line
2. Lean mixture causing misfire
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:
Rough idle S Faulty pressure regulator
High High S Defective water temperature sensor
(Black smoke form exhaust)
S DEFECTIVE Airflow meter
S Faulty ECU
S Faulty injectors
S Faulty throttle position sensor

COROLLA REPAIR MANUAL (RM925E)