ENGINE ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT ENGINE COOLANT

    Click here

  2. INSPECT ENGINE OIL

    Click here

  3. INSPECT BATTERY

    Click here

  4. CHECK SPARK PLUG

    Click here

  5. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  6. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the fan and generator V belt.

      Click here

    2. Check that nothing is caught in the V-ribbed belt tensioner assembly by turning it clockwise and counterclockwise.

      If a malfunction exists, replace the V-ribbed belt tensioner assembly.

    3. Install the fan and generator V belt.

      Click here

  7. INSPECT VALVE CLEARANCE

    Click here

  8. INSPECT IGNITION TIMING


    1. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Start the engine and run it at idle.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine / Data List / IGN Advance.


        Powertrain > Engine > Data List
        Tester Display
        IGN Advance
        Standard Ignition Timing
        8 to 18° BTDC at idle

        Note


        • Check the ignition timing with the cooling fans off.

        • Turn off all electrical systems and the A/C.

        • When checking the ignition timing, the transmission should be in neutral or park.

      5. Check that the ignition timing advances immediately when the engine speed is increased.

      6. Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1 / ON.


        Powertrain > Engine > Active Test
        Active Test Display
        Connect the TC and TE1
        Data List Display
        IGN Advance

      7. Monitor IGN Advance.

      8. Perform the Active Test.

        Standard Ignition Timing
        8 to 12° BTDC at idle

        Note


        • Check the ignition timing with the cooling fan off.

        • Turn off all electrical systems and the A/C.

        • When checking the ignition timing, the transmission should be in neutral or park.

    3. When not using the GTS:


      1. Remove the V-bank cover sub-assembly.

        Click here

      2. B002ECN

        Connect the clip of a timing light to the ignition coil wire for the No. 1 cylinder.

        Note

        Use a timing light that detects primary signals.

      3. B002CDRC43
        *a DLC3

        Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST
        09843-18040

        Note


        • Confirm the terminal numbers before connecting them. Connecting the wrong terminals may damage to electrical components.

        • Check the ignition timing with the cooling fans off.

        • Turn off all the electrical systems and the A/C.

        • When checking the ignition timing, the transmission should be in neutral or park.

      4. Connect the clip of a timing light to the ignition coil wire for the No. 1 cylinder.

        Note

        Use a timing light that detects primary signals.

      5. Start the engine and run it at idle.

      6. Check the ignition timing at idle.

        Standard Ignition Timing
        8 to 12° BTDC at idle

        Note

        When checking the ignition timing, the transmission should be in neutral or park.

        Tech Tips

        Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm returns to engine idle speed.

      7. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

      8. Check the ignition timing at idle.

        Standard Ignition Timing
        8 to 18° BTDC at idle

      9. Check that the ignition timing advances immediately when the engine idle speed is increased.

      10. Disconnect the clip of the timing light from the ignition coil wire for the No. 1 cylinder.

      11. Install the V-bank cover sub-assembly.

        Click here

  9. INSPECT ENGINE IDLE SPEED


    1. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine idle speed should be stabilized.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Start the engine and run it at idle.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine / Data List / Engine Speed.


        Powertrain > Engine > Data List
        Tester Display
        Engine Speed

      5. Inspect the engine idle speed.

        Standard Idle Speed
        700 to 800 rpm

        Note


        • Check the idle speed with the cooling fans off.

        • Turn off all the electrical systems and the A/C.

        • When checking the engine idle speed, the transmission should be in neutral or park.

        Tech Tips

        Refer to the GTS operator's manual for further details.

        If the idle speed is not as specified, check the air intake system.

    3. When not using the GTS:


      1. B002CUYC01
        *a DLC3

        Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18030

        Note

        Confirm the terminal numbers before connecting them. Connecting the wrong terminals may damage the electrical components.

      2. Start the engine and run it at idle.

      3. Inspect the engine idle speed.

        Standard Idle Speed
        700 to 800 rpm

        Note


        • Check the engine idle speed with the cooling fans off.

        • Turn off all the electrical systems and the A/C.

        • When checking the engine idle speed, the transmission should be in neutral or park.

        Tech Tips

        If the idle speed is not as specified, check the air intake system.

      4. Turn the engine switch off.

      5. Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.

  10. INSPECT COMPRESSION


    1. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine idle speed should be stabilized.

    2. Disconnect the cable from the negative (-) battery terminal.

      Click here

    3. Remove the air cleaner cap with air cleaner hose.

      Click here

    4. Remove the battery.

      Click here

    5. Remove the 8 spark plugs.

      Click here

    6. Disconnect the throttle body with motor assembly connector.

    7. B002E5QC02
      *a Lock Lever
      *b Lock
      *c Connector (with Lock)

      Push the lock and move the lock lever of each connector (with lock) as shown in the illustration and disconnect the 6 connectors (with lock) from the 2 injector drivers.

    8. Disconnect the 2 injector driver connectors.

    9. Insert a compression gauge into the spark plug hole.

    10. Install the battery.

      Click here

    11. Connect the cable to the negative (-) battery terminal.

      Click here

    12. Fully open the throttle valve.

    13. Depress and hold the brake pedal, and turn the engine switch on (IG). Then check the compression pressure.

      Standard Compression Pressure
      1400 kPa (14.3 kgf/cm2, 203 psi)
      Minimum Compression Pressure
      1000 kPa (10.2 kgf/cm2, 145 psi)
      Pressure Difference between Each Cylinder
      100 kPa (1.0 kgf/cm2, 15 psi) or less

      Note


      • Always use a fully charged battery to obtain an engine speed of 250 rpm or more.

      • Inspect all cylinders in the same way.

      • Measure the compression pressure as quickly as possible.


      1. If the cylinder compression pressure is low, pour a small amount of engine oil into the cylinder through the spark plug hole, then inspect it again.

        Tech Tips


        • 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.

    14. Disconnect the cable to the negative (-) battery terminal.

      Click here

    15. Remove the battery.

      Click here

    16. Install the 8 spark plugs.

      Click here

    17. Install the battery.

      Click here

    18. Install the air cleaner cap with air cleaner hose.

      Click here

    19. B002COKC03
      *a Lock Lever
      *b Connector (with Lock)

      Connect the 2 injector driver connectors.

    20. Connect the 6 connectors (with lock) to the 2 injector drivers and move the lock lever to engage the lock of each connector (with lock) as shown in the illustration.

      Note

      Securely connect the connectors (with lock) to the injector driver and engage the lock.

    21. Connect the throttle body with motor assembly connector.

    22. Connect the cable to the negative (-) battery terminal.

      Click here

    23. Clear the DTCs.


      Note

      After the inspection, clear the DTCs, check for DTCs again and make sure the normal system code is output.

  11. INSPECT CO/HC

    Tech Tips

    This check determines whether the idle CO/HC complies with regulations.


    1. Start the engine.

    2. Keep the engine speed at 2500 rpm for approximately 180 seconds.

    3. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tail pipe during idle.

    4. Check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

      Tech Tips

      When performing the 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.

      If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the following order.


      1. Check the air fuel ratio sensor and heated oxygen sensor operation.

      2. Check for DTCs.


      3. 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

        1. Faulty ignition:


          • Incorrect valve timing

          • Fouled, shorted or improperly gapped spark plugs

        2. Leaks in intake or exhaust valves

        3. Leaks in cylinders
        Low High

        Rough idle

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • PCV hoses

          • Intake manifold

          • Throttle body with motor assembly

        2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air cleaner filter element sub-assembly

        2. Plugged PCV valve

        3. Faulty SFI system:


          • Incorrect pressure

          • ECT sensor

          • ECM

          • Fuel injector assemblies

          • Throttle position sensor (built into throttle body with motor assembly)

          • Mass air flow meter sub-assembly