ENGINE ON-VEHICLE INSPECTION


  1. INSPECT ENGINE COOLANT

    Tech Tips

    Click here.

  2. INSPECT ENGINE OIL

    Tech Tips

    Click here.

  3. INSPECT BATTERY

    Tech Tips

    Click here.

  4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly.

    2. Visually check that the air cleaner filter is not excessively damaged or oily. If necessary, replace the air cleaner filter.

      Tech Tips


      • If there is any dirt or a blockage in the air cleaner filter element sub-assembly, clean it with compressed air.

      • If any dirt or a blockage remains even after cleaning the air cleaner filter element sub-assembly with compressed air, replace it.

    3. Install the air cleaner filter element sub-assembly.

  5. INSPECT DRIVE BELT


    1. A01CHS3E02
      Text in Illustration
      *1 Fan Pulley
      *2 Generator
      *3 Crankshaft Pulley

      Check the fan and generator V belt deflection.

      Tech Tips


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

      • When inspecting the V belt deflection, apply 98 N (10 kgf, 22 lbf) tensile force to it.

      Deflection
      Item Specified Condition
      New belt 10.5 to 12.5 mm (0.413 to 0.492 in.)
      Used belt 12.5 to 16.0 mm (0.492 to 0.630 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.

    2. A01CGPIE02
      Text in Illustration
      *1 Idler Pulley
      *2 A/C Compressor
      *3 Crankshaft Pulley

      Check the No. 1 V (cooler compressor to crankshaft pulley) belt deflection (w/ Air Conditioning System).

      Tech Tips


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

      • When inspecting the V belt deflection, apply 98 N (10 kgf, 22 lbf) tensile force to it.

      Deflection
      Item Specified Condition
      New belt 8.5 to 10.0 mm (0.335 to 0.394 in.)
      Used belt 10.0 to 12.0 mm (0.394 to 0.472 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.

  6. 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. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to ON.

    4. Enter the following menus: 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.

    5. Inspect the engine idle speed.

      Standard idle speed
      600 to 700 rpm

    6. Fully depress the accelerator pedal.

    7. Check the maximum speed.

      Maximum speed
      3600 to 3700 rpm

    8. Turn the ignition switch off.

    9. Disconnect the intelligent tester from the DLC3.

  7. 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. A01CGX5E01

      Install SST into the glow plug hole.

      SST
      09992-00026

    7. Connect a compression gauge to SST.

    8. While cranking the engine, measure the compression pressure.

      Standard compression pressure
      3200 kPa (32.6 kgf/cm2, 464 psi)
      Minimum compression pressure
      2700 kPa (27.5 kgf/cm2, 392 psi)
      Maximum difference between each cylinder
      290 kPa (3.0 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 head gasket.

    9. Remove the compression gauge and SST.

    10. Disconnect the cable from the negative battery terminal.

    11. Connect all connectors to the 4 injectors.

    12. Install the No. 2 cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    13. Install the 4 bolts to the glow plug hole.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

  8. INSPECT DIESEL SMOKE

    Standard value (Black smoke)
    10% or less