Content .. 87 88 89 90 ..

Toyota Corolla (2004+). Manual - part 89

12-1

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

EMISSION CONTROL SYSTEM

1204D-01

ON-VEHICLE INSPECTION

INSPECT AIR-FUEL RATIO COMPENSATION SYS-

TEM

HINT:

You can also check the system by choosing ”DATA MONITOR”,

then ”O2 SENSOR OUTPUT VOLTAGE” on the monitor of the

hand-held tester.

(a) Connect the hand-held tester to the terminal 23 (OX1A)

 7 (E1) and 21 (OX1B)  7 (E1) of the ECM.

CAUTION:

Connect test l eads from the back side of the connector with

the ECU connected.

OX1B

(b) Warm up the oxygen sensor with the engine speed at

2,500 rpm for approx. 2 minutes.

(c)

Confirm that the voltage changes between 0V to 1V with

the engine speed at 2,500 rpm.

OK:

The voltage changes more than 8 times in 10 se-

conds.

CAUTION:

OX1A

A65749

Perform the check immediately after the end of the

warming up.

If not confirming the change of voltage, warming up

the oxygen sensor again.

INSPECT FUEL CUT OFF RPM

(a)

Increase the engine speed to at least 3,500 rpm.

(b)

Use a sound scope to check for injector operating noise.

(c)

Check that when the throttle lever is released, injector operation noise stops momentarily and then

resumes.

INSPECT EVAPORATIVE EMISSION CONTROL SYS-

TEM

(a) After starting the engine, disconnect the vacuum hose

shown in the illustration.

(b) Confirm vacuum occurs at the vsv port, when choosing

”ACTIVE TEST” and ”PURGE VSV” according to the dis-

play on hand-held tester.

(c)

Finish ”ACTIVE TEST”, then connect the vacuum hose

A65936

again.

(d) After going to ”ECM DATA MONITOR” on the hand-held

tester, choose ”PURGE VSV” to check the operation of

the purge VSV.

(e) After warm up the engine and drive the vehicle, confirm

the VSV turns on from off.

12-2

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

INSPECT EVAP SYSTEM LINE

Vacuum Gauge

(a) Warm up the engine and stop the engine. Allow the en-

gine to warm up to normal operating temperature.

(b) Install a vacuum gauge (EVAP control system test equip-

ment vacuum gauge) to the EVAP service port on the

purge line.

B06544

(c)

TOYOTA Hand-Held Tester:

Forced driving of the VSV for the EVAP.

(1)

Connect a TOYOTA hand-held tester to the DLC3

(2)

Start the engine.

(3)

Push the TOYOTA hand-held tester main switch

ON.

(4)

Use the ACTIVE TEST mode on the TOYOTA

hand-held tester to operate the VSV for the EVAP.

(d) If you have no TOYOTA Hand-Held Tester:

Forced driving of the VSV for the EVAP.

(1)

Disconnect the VSV connector for the EVAP.

(2)

Connect the positive (+) and negative (-) leads from

the battery to the VSV terminals for the EVAP.

(3)

Start the engine.

Battery

A65906

(e) Check the vacuum at idle

Vacuum Gauge

Vacuum:

Maintain at 0.368 - 19.713 in.Hg (5 -268 in.Aq) for over

5 seconds.

HINT:

If the vacuum does not change, you can conclude that the hose

connecting the VSV to the service port has come loose or is

blocked, or the VSV is malfunctioning.

B06545

(f)

TOYOTA Hand-Held Tester:

Conclude forced driving of the VSV for the EVAP.

(1)

Stop the engine.

(2)

Disconnect the TOYOTA hand-held tester from the

DLC3.

(g) If you have no TOYOTA Hand-Held tester:

Conclude forced driving of the VSV for the EVAP.

(1)

Stop the engine.

12-3

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

(2)

Disconnect the positive (+) and negative (-) leads

from the battery from the VSV terminals for the

EVAP.

(3)

Connect the VSV connector for the EVAP.

(h) Disconnect the vacuum gauge from the EVAP service

port on the purge line.

(i)

Connect a pressure gauge to the EVAP service port on

the purge line.

Air Drain Hose

(j)

Check the pressure.

(1)

Close off the air drain hose at the marked position

of the canister with a hose clipper or similar instru-

ment.

Hose Clipper

A63957

(2)

Add the pressure (13.5 - 15.5 in. Aq) from the EVAP

service port.

Pressure Gauge

Pressure:

2 minutes after the pressure is added, the gauge

should be over 7.7-8.8 in.Aq.

HINT:

If you can not add pressure, you can conclude that the hose

Pressure

connecting the VSV - canister - fuel tank has slipped off or the

B06546

VSV is open.

(3)

Check if the pressure decreases when the fuel tank

cap is removed while adding pressure.

HINT:

If the pressure dose not decrease when the filler cap is re-

moved, then you can conclude that the hose connecting the

service port to the fuel tank is blocked, etc.

(k)

Disconnect the pressure gauge from the EVAP service

port on the purge line.

A52634

12-4

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER

EVAP Line Hose

PIPE

(a) Disconnect the EVAP line hose from the charcoal canis-

ter.

(1)

Pinch portion A.

(2)

Pull out the connector.

(b) Pressurize and make the internal pressure in the fuel tank

4 kPa (41 gf/cm2, 0.58 psi).

(c)

Check that the internal pressure of the fuel tank can be

hold for 1 minute.

(d) Check the connected portions of each hose and pipe.

(e) Check the installed parts on the fuel tank.

If there is no abnormality, replace the fuel tank and filler pipe.

(f)

Reconnect the EVAP line hose to the charcoal canister.

A65905

INSPECT FUEL CUT OFF VALVE AND FILL CHECK

VALVE

(a) Disconnect the purge line hose and EVAP line hose from

the charcoal canister.

(b) Plug the cap to the air drain hose.

Air

(c)

Pressurize 4 kPa (41 gf/cm2, 0.58 psi) to the purge port

and check that there is ventilation through the EVAP line

hose.

Purge Line Hose

EVAP Line Hose

HINT:

A63960

In the condition that the fuel is full, as the float value of the fill

check valve is closed and has no ventilation, it is necessary to

check the fuel amount (volume).

(d) Check if there is anything struck in the vent line hose and

EVAP line hose.

If there is no stuck in hoses, replace the fuel cut off valve and

fill check valve.

(e) Reconnect the purge line hose and EVAP line hose to the

charcoal canister.

CHECK AIR INLET LINE

Air Inlet

(a) Disconnect the air inlet line hose from the charcoal canis-

Line Hose

ter.

(b) Check that there is ventilation in the air inlet line.

(c)

Reconnect the air inlet line hose to the charcoal canister.

Air

A63962

12-5

EMISSION CONTROL

- EMISSION CONTROL SYSTEM

VISUALLY INSPECT HOSES, CONNECTIONS AND

GASKETS

(a) Check for cracks, leaks or damage.

HINT:

Separation of the engine oil dipstick, oil filler cap, PCV hose,

etc. may cause the engine to run out of turn. Disconnection,

looseness or cracks in the parts of the air induction system be-

tween the throttle body and cylinder head will allow air suction

A65907

and cause the engine to run out of turn.

INSPECT HEATER RESISTANCE OF HEATED OXY-

GEN SENSOR

(a) Disconnect the oxygen sensor connector.

(b) Using an ohmmeter, measure the resistance between the

terminals HT and +B.

Resistance: 11 - 16

W at 20_C (68_F)

A60559

10. INSPECT FUEL TANK CAP

(a) Visually check if the cap and/or gasket are deformed or

damaged.

Gasket

B11870

14-93

ENGINE MECHANICAL

- CAMSHAFT

CAMSHAFT

140OI-01

COMPONENTS

Fan and Generator V Belt

7.0 (71, 62 in. lbf)

Clip

Cylinder Head Cover No. 2

52 (530, 38)

Engine Mounting Insulator RH

52 (530, 38)

Clip

Engine Under Cover RH

N·m (kgf·cm, ft·lbf)

: Specified torque

A64044

14-94

ENGINE MECHANICAL

- CAMSHAFT

9.0 (92, 80 in. lbf)

Engine Wire

9.0 (92, 80 in. lbf)

Ignition Coil Assy

Ventilation Hose No. 2

9.0 (92, 80 in. lbf)

11 (112, 8)

Seal Washer

11 (112, 8)

Clamp Bracket

11 (112, 8)

Ventilation Hose

Clamp Bracket

Cylinder Head Cover

Sub-assy

Gasket

N·m (kgf·cm, ft·lbf)

: Specified torque

A64043

14-95

ENGINE MECHANICAL

- CAMSHAFT

Camshaft Bearing Cap No. 3

13 (133, 10)

23 (235, 17)

Camshaft Bearing Cap No. 1

Camshaft No. 2

Camshaft Timing Gear

Camshaft

or Sprocket

54 (551, 40)

Camshaft Timing Gear Assy

54 (551, 40)

9.0 (92, 80 in. lbf)

Chain Tensioner

Assy No. 1

Timing Chain Sub-assy

29 (296, 21)

69 (704, 51)

V-ribbed Belt

Tensioner Assy

N·m (kgf·cm, ft·lbf)

: Specified torque

A64006

14-96

ENGINE MECHANICAL

- CAMSHAFT

140OJ-01

REPLACEMENT

REMOVE ENGINE UNDER COVER RH

REMOVE CYLINDER HEAD COVER NO.2

(a) Remove the 2 screw, 3 clips and engine under cover.

A65077

REMOVE FAN AND GENERATOR V BELT

(a) Turn the V-ribbed belt tensioner slowly clockwise and

loosen it. Then, remove the fan and generator V belt and

put back the V-ribbed belt tensioner little by little and fix

it quietly.

A60622

REMOVE ENGINE MOUNTING INSULATOR

SUB-ASSY RH

(a) Remove the PS oil pump reservoir and put it aside.

(b) Place a wooden block between the jack and engine, and

set the jack, then remove the 4 bolts, the 2 nuts and en-

gine mounting insulator RH.

A01045

A64005

14-97

ENGINE MECHANICAL

- CAMSHAFT

DISCONNECT ENGINE WIRE

(a) Remove the 5 clamps from the 5 clamp brackets.

(b) Disconnect the 4 ignition coil connectors.

A64021

(c)

Remove the bolt and nut installing the engine wire.

A64022

REMOVE IGNITION COIL ASSY

(a) Remove the 4 bolts and 4 ignition coils.

A64023

DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose from the cylinder head

cover.

A65078

DISCONNECT VENTILATION HOSE NO.2

(a) Disconnect the ventilation hose from the cylinder head

cover.

A64058

14-98

ENGINE MECHANICAL

- CAMSHAFT

REMOVE CYLINDER HEAD COVER SUB-ASSY

(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp

brackets and cylinder head cover.

A64856

10. SET NO. 1 CYLINDER TO TDC/COMPRESSION

Mark

(a) Turn the crankshaft pulley, and align its groove with timing

Mark

mark ”0” of the timing chain cover.

(b) Check that the point marks of the camshaft timing sprock-

et and VVT timing sprocket are in straight line on the tim-

ing chain cover surface as shown in the illustration.

HINT:

If not, turn the crankshaft 1 revolution (360_) and align the

Mark

marks as above.

Timing Chain

Cover Surface

Groove

A62185

11. REMOVE V-RIBBED BELT TENSIONER ASSY

(a) Remove the bolt, nut and V-ribbed belt tensioner.

HINT:

Handle a jack up and down to remove the bolt.

A11858

12. REMOVE CAMSHAFT

NOTICE:

Be sure not to revolve the crankshaft without the chain ten-

sioner.

(a) Set the No. 1 cylinder to the TDC/compression.

(b) Place match marks on the timing chain and camshaft tim-

Paint Mark

ing sprockets.

A62186

14-99

ENGINE MECHANICAL

- CAMSHAFT

(c)

Remove the 2 nuts and chain tensioner.

Push

A62178

(d) Fix the camshaft with a wrench and so on, then loosen

Fix

the camshaft timing gear set bolt.

Tighten

NOTICE:

Be careful not to damage the valve lifter.

A62187

(e) Loosen the camshaft bearing cap bolts on No. 2 camshaft

in the order as shown in the illustration in several

passes,and remove the caps.

A62188

(f)

Remove the camshaft timing gear as shown in the illustra-

tion.

A32124

(g) Loosen the camshaft bearing cap bolts on camshaft in the

order as shown in the illustration in several passes,and

remove the caps.

A62189

14-100

ENGINE MECHANICAL

- CAMSHAFT

(h) Remove the camshaft with holding the timing chain.

A32125

(i)

Tie the timing chain with a string as shown in the illustra-

tion.

NOTICE:

Be careful not to drop anything inside the timing chain cov-

er.

A32556

13. INSPECT CAMSHAFT TIMING GEAR ASSY

Retard Side

(a) Check the lock of camshaft timing gear.

Path

(1)

Grip the camshaft with a vice, and confirm the cam-

shaft timing gear is locked.

NOTICE:

Advance

Be careful not to damage the camshaft.

Side Path

(b) Release lock pin.

(1)

Cover 4 oil paths of cam journal with vinyl tape as

shown in the illustration.

HINT:

Two advance side paths are provided in the groove of the cam-

Open

shaft. Plug one of the path with a rubber piece.

(2)

Break through the tapes of the advance side path

and the retard side path on the opposite side of the

Open

groove.

Vinyl Tape

Rubber

A62190

(3)

Put air pressure into two broken paths (the advance

Retard

Advanced

side path and the retard side path) with about 150

Side Path

kPa {1.5 kgfcm}.

CAUTION:

Cover the pathes with shop rag to avoid oil splashing.

A62191

14-101

ENGINE MECHANICAL

- CAMSHAFT

(4)

Confirm if the camshaft timing gear assembly re-

Retard

Advanced

volves in the timing advance direction when weak-

Side Path

ening the air pressure of the timing retard path.

HINT:

The lock pin is released, and camshaft timing gear, revolves in

the advance direction.

Decompress

Hold Pressure

A62192

(5)

When the camshaft timing gear comes to the most

advanced position, take out the air pressure of the

timing retard side path, and then, take out that of

timing advance side path.

CAUTION:

Camshaft timing assembly gear occasionally shifts to the

retard side abruptly, if the air compression of the advanced

side path is released before retard side path. It often

causes the breakage of the lock pin.

(c)

Check smooth revolution

(1)

Revolve the camshaft timing gear assembly within

the movable range except for the most retarded

position several times, and check the smooth revo-

lution.

CAUTION:

Be sure to perform this check by hand, instead of air pres-

sure.

(d) Check the lock in the most retarded position.

(1)

Confirm that the camshaft timing gear assembly is

locked at the most retarded position.

14. REMOVE CAMSHAFT TIMING GEAR ASSY

Retard Side

(a) Grip the camshaft with a vice, and confirm that it the gear

Path

locked.

CAUTION:

Be careful not to damage the camshaft.

Advance

(b) Cover 4 oil paths of cam journal with vinyl tape as shown

Side Path

in the illustration.

HINT:

Two advance side paths are provided in the groove of the cam-

shaft. Plug one of the path with a rubber piece.

(c)

Break through the tapes of the advance side path and the

Open

retard side path on the opposite side of the groove.

Open

Vinyl Tape

Rubber

A62190

14-102

ENGINE MECHANICAL

- CAMSHAFT

(d) Put air pressure into two broken paths (the advance side

Retard

Advanced

path and the retard side path) with about 150 kPa {1.5

Side Path

kgfcm}.

CAUTION:

Cover the pathes with shop rag to avoid oil splashing.

A62191

(e) Confirm if the camshaft timing gear assembly revolves in

Retard

Advanced

the timing advance direction when weakening the air

Side Path

pressure of the timing retard path.

HINT:

The lock pin is released, and camshaft timing gear revolves in

the advance direction.

Decompress

(f)

When the camshaft timing gear comes to the most ad-

Hold Pressure

vanced position, take out the air pressure of the timing re-

A62192

tard side path, and then, takeout that of timing advance

side path.

CAUTION:

Camshaft timing gear assembly occasionally shifts to the

retard side abruptly, if the air compression of the advanced

side path is released before retard side paths. It often

causes the breakage of the lock pin.

(g) Remove the fringe bolt of camshaft timing gear assembly.

NOTICE:

Be sure not to remove the other 4 bolts.

Fringe Bolt

In case of reusing the camshaft timing gear, release

the strait pin locking first, and then install the gear.

Straight Pin

A62193

15. INSTALL CAMSHAFT TIMING GEAR ASSY

Straight Pin

(a) Put the camshaft timing gear assembly and the camshaft

together with the straight pin off the key groove.

(b) Turn the camshaft timing gear assembly to the left direc-

tion (as shown in the illustration) with pushing it lightly

against the camshaft. Push further at the position where

the pin gets into the groove.

CAUTION:

Key Groove

A62194

Be sure not to turn the camshaft timing gear to the retard

angle side (to the right angle).

(c)

Check that there is no clearance between the gear’s

fringe and the camshaft.

(d) Tighten the fringe bolt with the camshaft timing gear fixed.

Torque: 54 N m (551 kgf cm 40 ft lbf)

Content .. 87 88 89 90 ..