ENGINE ON-VEHICLE INSPECTION

INSPECT ENGINE COOLANT
1. Remove the radiator cap.
  
  CAUTION:
  
  Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
2. Check if there are any excessive deposits of rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil.
  
  If excessively dirty, clean the coolant passage and replace the coolant.
3. Install the radiator cap.
INSPECT ENGINE OIL
1. Warm up the engine, then stop the engine and wait 5 minutes. Check that the engine oil level is between the Low and Full level marks.
  
  If low, check for leakage and add oil up to the full level mark.
  Note
  
  Do not add engine oil above the Full mark.
  
  If the oil level is 25 mm (0.98 in.) above the Full mark, replace engine oil.
INSPECT BATTERY
1. Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.
2. Check the volume of electrolyte in each cell (for maintenance-free batteries).
  1. If the electrolyte volume is below the lower line, add distilled water to each cell or replace the battery.
3. Check the volume of electrolyte in each cell (for non-maintenance-free batteries).
  1. If the electrolyte volume is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity.
    
    Standard electrolyte specific gravity
    
    1.25 to 1.29 at 20°C (68°F)
    
    If the result is not as specified, recharge or replace the battery.
4. Measure the battery voltage.
  1. If it has been less than 20 minutes since you stopped driving the vehicle or since the engine was stopped, turn the ignition switch and electrical systems (headlight, blower motor, rear defogger etc.) to the ON position for 20 seconds. This will remove the surface charge on the battery.
  2. Turn the ignition switch off.
  3. Turn the electrical systems to OFF.
  4. Using a voltmeter, measure the battery voltage between the positive (+) and negative (-) terminals of the battery.
    
    Standard voltage
    
    24.0 to 25.0 V at 20°C (68°F)
    
    If the result is not as specified, recharge or replace the battery.
INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Standard electrolyte specific gravity
1.25 to 1.29 at 20°C (68°F)

Standard voltage
24.0 to 25.0 V at 20°C (68°F)

INSPECT DRIVE BELT

Check the V belt deflection.

Tech Tips

The specified deflection values per belt are shown in the following table.

Deflection

Item	Specified Condition
New belt	10.5 to 12.5 mm (0.41 to 0.49 in )
Used belt	12.5 to 16.0 mm (0.49 to 0.63 in )

Note

Check the V belt deflection at the specified point.
When inspecting a belt which has been used for over 5 minutes, apply the used belt specifications.

CHECK TAPPET FOR ABNORMAL NOISE
CHECK IDLE SPEED AND MAXIMUM SPEED
Note

Turn all the electrical systems and the A/C OFF.
1. Warm up and stop the engine.
2. When using the intelligent tester:
  1. (a) Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.
    
    Note
    
    Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.
  2. Connect the intelligent tester to the DLC3.
  3. Turn the ignition switch to the ON position.
3. Select the following menu items: Powertrain / Engine and ECT / Data List
  
  Tech Tips
  
  Refer to the intelligent tester operator's manual for further information regarding the selection of Data List.
  1. Inspect the engine idling speed.
    
    Idling speed
    
    550 to 650 rpm
4. Fully depress the accelerator pedal.
5. Check the maximum speed.
  
  Maximum speed
  
  3600 to 3700 rpm
6. Turn the ignition switch off.
7. Disconnect the intelligent tester from the DLC3.
8. When not using the intelligent tester:
  1. Install SST to terminal TAC of the DLC3, then connect a tachometer.
    
    SST
    
    09843-18040
    
    Note
    
    Examine the terminal number before connecting SST. Connecting to the wrong terminal can damage the engine.
  2. Turn the ignition switch to the ON position.
  3. Inspect the engine idling speed.
    
    Idling speed
    
    550 to 650 rpm
  4. Fully depress the accelerator pedal.
  5. Check the maximum speed.
    
    Maximum speed
    
    3600 to 3700 rpm
  6. Turn the ignition switch off.
  7. Disconnect the tachometer.
  8. Remove SST from terminal TAC.
INSPECT COMPRESSION
1. Warm up and stop the engine.
2. Remove the 4 bolts from the glow plug hole.
3. Remove the oil filler cap.
4. Remove the 2 bolts, then remove the No. 2 cylinder head cover sub-assembly.
5. Disconnect all connectors from the 4 injectors.
6. Crank the engine to remove foreign matter before measuring the compression.
7. Install the SST into the glow plug hole.
  
  SST
  
  09992-00025
8. Connect a compression gauge to SST.
  
  SST
  
  09992-00025
9. While cranking the engine, measure the compression pressure.
  
  Compression pressure
  
  3200 kPa (33 kgf/cm², 464 psi)
  
  Minimum pressure
  
  2700 kPa (27 kgf/cm², 392 psi)
  
  Difference between each cylinder
  
  290 kPa (3 kgf/cm², 42 psi)
  Note
  - Use a fully-charged battery so that the engine speed can be increased to 250 rpm or more.
  - Inspect the other cylinders in the same way.
  - Measure the compression pressure in as short a time as possible.
  If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the glow plug hole, then inspect it again.
  Tech Tips
  - If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
  - If the pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket.
10. Remove the compression gauge and SST.
11. Disconnect the cable from the negative battery terminal.
12. Connect all connectors to the 4 injectors.
13. Install the No. 2 cylinder head cover sub-assembly with the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
14. Install the 4 bolts to the glow plug hole.
  
  Torque:
  
  23 N*m { 229 kgf*cm, 17 ft.*lbf }
INSPECT DIESEL SMOKE

Standard (Black smoke)

10% or less