Engine Mechanical: Diagnosis Toyota Corolla IX

INSPECTION

Note. This check is used only to determine whether or not the idle CO/HC complies with regulations.

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1. Install Conditions. Engine at normal operating temperature. Air cleaner installed. Air pipes and hoses of air induction system connected. All accessories switched OFF. All vacuum lines properly connected. SFI system wiring connectors fully plugged. Ignition timing check correctly. Transmission in neutral position. Tachometer and CO/HC meter calibrated by hand.
2. Start Engine.
3. Race Engine At 2,500 RPM For Approximately 180 Seconds.
4. Insert CO/HC Meter Testing Probe At Least 40 CM (1.3 ft) Into Tailpipe During Idling.
5. Immediately Check CO/HC Concentration At Idle And/Or 2,500 RPM. Complete the measuring with 3 minutes. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check the Heated Oxygen Sensor operation. See the table below for possible causes, and then inspect and correct the applicable causes if necessary.

Note. If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

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1. Warm Engine Up To Normal Operating Temperature And Stop Engine.
2. Remove Ignition Coils .
3. Remove Spark Plugs .
4. Inspect Cylinder Compression Pressure. : Insert a compression gauge into the spark plug hole. NOTE: Always use a fully charged battery to obtain engine speed of 250 rpm or more. Fully open the throttle. NOTE: This measurement must be done in as short a time as possible. While cranking the engine, measure the compression pressure. Repeat steps ( a ) through ( c ) for each cylinder. Compression pressure: 1,500 kPa (15.3 kgf/cm 2 , 218 psi) . Minimum pressure: 1,000 kPa (10.2 kgf/cm 2 , 145 psi) . Difference between each cylinder: 100 kPa (1.0 kgf/cm 2 , 15 psi) or less . 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 ( a ) through ( c ) 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.
5. Reinstall Spark Plugs .
6. Reinstall Ignition Coils .

1. Initial Conditions. Engine at normal operating temperature. Air cleaner installed. All pipes and hoses of air induction system connected. All vacuum lines properly connected. SFI system wiring connectors fully plugged. All operating accessories switched OFF. Ignition timing check correctly. Transmission in neutral position. A/C switched OFF.
2. Connect TOYOTA Hand-Held Tester Or OBD II Scan Tool. See step 2 in inspection under IGNITION TIMING.
3. Inspect Idle Speed. Race the engine at 2,500 rpm for approximately 90 seconds. Check the idle speed. Idle speed (with Cooling fan OFF): 700 +/- 50 rpm . If the idle speed is not as specified, check the IAC valve and air intake system.
4. Disconnect TOYOTA Hand-Held Tester Or OBD II Scan Tool.

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1. Drain Engine Coolant.
2. Remove Washer Tank.
3. Remove RH Front Wheel.
4. Remove RH Engine Under Cover.
5. Remove Drive Belt and Generator .
6. Disconnect PS Pump From Engine. Disconnect the PS oil pressure switch connector. Using SST, remove the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Remove the PS pump pulley. NOTE: Put aside the pump and suspend it to the cowl with a string. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.
7. Remove RH Engine Mounting Insulator. CAUTION: Place a wooden block or rubber block between a jack and the oil pan. Set the jack to the engine. With A/C: Remove the bolt holding the A/C piping clamp to the RH engine mounting insulator. Remove the 4 bolts, 2 nuts and RH engine mounting insulator.
8. Remove Cylinder Head Cover. Remove the 2 bolts, 2 clips and No. 2 cylinder head cover. Disconnect the ignition coil connectors. Remove the 2 bolts and engine wire. Remove the 4 bolts and 4 ignition coils. Disconnect the 2 PCV hoses from the cylinder head cover. Remove the 9 bolts, 2 seal washers, 2 nuts, cable bracket, cylinder head cover and gasket.
9. Set No. 1 Cylinder To TDC Compression. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
10. Remove Crankshaft Pulley. Using SST, remove the pulley bolt. SST 09213-70011, 09330-00021 NOTE: If necessary, remove the pulley with SST. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021). Remove the crankshaft pulley.
11. Disconnect Crankshaft Position Sensor From Timing Chain Cover. Remove the 2 bolts and crankshaft position sensor.
12. Remove The Bolt, Nut And Drive Belt Tensioner.
13. Remove The 3 Bolts And RH Engine Mounting Bracket.
14. Remove The 2 Nuts And Chain Tensioner.
15. Remove Water Pump .
16. Remove Timing Chain Cover. Remove the 11 bolts and nut. Using a torx wrench socket (E8), remove the stud bolt. CAUTION: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver.
17. Remove Crank Angle Sensor Plate.
18. Remove Bolt And Chain Tensioner Slipper.
19. Remove Timing Chain And Crankshaft Timing Sprocket. If necessary, pry between the timing chain and oil pump by 2 screwdrivers.
20. Remove 2 Bolts And Chain Vibration Damper.
21. Remove Camshaft Timing Sprocket And VVT Timing Sprocket. CAUTION: Be careful not to damage the cylinder head and valve lifter by a wrench. Hold the hexagonal head wrench portion of the camshaft with a wrench, and loosen the sprocket. Remove the bolt and camshaft timing sprocket. Remove the bolt and VVT timing sprocket.

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1. Inspect Timing Chain And Timing Sprockets. NOTE: Make the same measurements pulling at 3 or more places selected at random. Using vernier calipers, measure the length of the 16 links with the chain dully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) . If the elongation is greater than maximum, replace the chain. Wrap the chain around the timing sprocket. NOTE: Vernier calipers contact the chain rollers for measuring. Using vernier calipers, measure the timing sprocket diameter with the chain. If the diameter is less than minimum, replace the chain and sprockets.
2. Inspect Chain Tensioner Slipper And Vibration Damper. Measure the chain tensioner slipper and vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) . If the wear is greater than maximum, replace the slipper and/or damper.
3. Inspect Chain Tensioner. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
4. Inspect Oil Jet .
5. Inspect Drive Belt Tensioner. Check the oil leakage and crack. If necessary, replace the drive belt tensioner.