ENGINE ON-VEHICLE INSPECTION


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. INSPECT ENGINE COOLANT

    Click here

  3. INSPECT ENGINE OIL

    Click here

  4. INSPECT BATTERY

    Click here

  5. INSPECT DRIVE BELT

    Click here

  6. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

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

      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.

  7. CHECK IDLE SPEED AND MAXIMUM SPEED

    Note

    Turn all electrical systems and the A/C off.


    1. Warm up and stop the engine.

    2. 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.

    3. Connect the intelligent tester to the DLC3.

    4. Turn the ignition switch to ON.

    5. 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 the Data List.

    6. Inspect the engine idle speed.

      Standard idle speed
      600 to 700 rpm

    7. Fully depress the accelerator pedal.

    8. Check the maximum speed.

      Maximum speed
      3300 to 3400 rpm

    9. Turn the ignition switch off.

    10. Disconnect the intelligent tester from the DLC3.

  8. INSPECT COMPRESSION


    1. Warm up and stop the engine.

    2. Remove the oil filler cap sub-assembly.

    3. Remove the 2 bolts and cylinder head cover sub-assembly.

    4. for Cold Area Specification Vehicles:

      Remove the 4 glow plug assemblies Click here.

    5. Remove the 4 bolts from the 4 glow plug holes.

    6. A01CGKD

      Remove the bolt and disconnect the wire harness clamp bracket.

    7. Disconnect the 4 connectors from the 4 injector assemblies.

    8. A01CIO2E01
      Text in Illustration
      *1 SST (Compression Gauge)
      *2 SST (Attachment)

      Insert SST (attachment) into the glow plug hole.

      SST
      09992-00026

    9. Connect SST (compression gauge) to SST (attachment).

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

      Standard compression pressure
      3200 kPa (32.6 kgf/cm2, 464 psi) or higher
      Minimum compression pressure
      2700 kPa (27.5 kgf/cm2, 392 psi)
      Maximum difference between each cylinder
      290 kPa (3.0 kgf/cm2, 42 psi) or less

      Note


      • Use a fully-charged battery so that the engine speed can be increased to 280 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 and inspect the compression 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.

    11. Remove SST (compression gauge) and SST (attachment).

    12. Connect the 4 connectors to the 4 injector assemblies.

    13. Connect the wire harness clamp bracket with the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    14. Install the 4 bolts to the 4 glow plug holes.

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

    15. for Cold Area Specification Vehicles:

      Install the 4 glow plug assemblies Click here.

    16. Install the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    17. Install the oil filler cap sub-assembly.

  9. INSPECT DIESEL SMOKE

    Standard value (Black smoke)
    10% or less