ENGINE ON-VEHICLE INSPECTION


  1. INSPECT ENGINE COOLANT

    Click here

  2. INSPECT ENGINE OIL

    Click here

  3. INSPECT BATTERY SPECIFIC GRAVITY

    Click here

  4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Visually check that the filter is not excessively dirty or oily.

    2. Clean the filter element with compressed air. First blow from the inside thoroughly. Then blow off the out side of the filter element.

  5. INSPECT FAN AND GENERATOR V BELT

    A01KHB0E01

    Tech Tips

    Use of automatic tensioner has made the tension and flexibility measurement unnecessary.


    1. Check that the indicator mark on the automatic tensioner is within the A range as shown in the illustration.

    2. When the mark is out of the A range, replace the V belt with new one.

      Tech Tips

      When replacing the drive belt with a new one, the belts tension should be within the B range on the belt tensioner scale.

  6. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the V belt from the tensioner pulley. Then check that nothing gets cough the tensioner by turning it clockwise and counterclockwise.

    2. When a malfunction exists, replace the tensioner.

  7. WARM UP ENGINE

  8. CHECK ENGINE IDLE SPEED AND MAXIMUM SPEED

    Tech Tips

    Check should be done under the following condition.


    • Engine at normal operating temperature.

    • Air cleaner installed.

    • All pipes and hoses of air induction system connected.

    • All accessories switched OFF.

    • All vacuum lines properly connected.

    • ECD system wiring connectors fully plugged.

    • Valve clearance set correctly.


    1. A01KGNRE01
      Text in Illustration
      *1 intelligent tester
      *a DLC3

      Connect a intelligent tester to the DLC3.

    2. Please refer to the intelligent tester operator's manual for further details.

    3. A01KGT3E01
      Text in Illustration
      *1 TAC

      If you have no intelligent tester, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18040

    4. Inspect the idle speed.


      1. Start the engine and check the idle speed.

        Idle speed
        650 - 750 rpm

        If the idle speed is not as specified, check the troubleshooting in DI section.

    5. Inspect the maximum speed.


      1. Start the engine.

      2. Depress the accelerator pedal all the way.

      3. Check the maximum speed.

        Maximum speed
        4500 - 4700 rpm

        If the maximum speed is not as specified, check the troubleshooting in DI section.

    6. Disconnect the tester probe of a tachometer from terminal 9 (TAC) of the DLC3 with SST.

    7. Disconnect a intelligent tester from the DLC3.

  9. INSPECT CYLINDER COMPRESSION PRESSURE

    Tech Tips

    If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.


    1. Remove the glow plugs Click here.

    2. Disconnect the injection pipes Click here.

    3. A01KH76E01
      Text in Illustration
      *1 SST (Attachment)

      Check the cylinder compression pressure.

      Tech Tips

      Turn the starter before measuring the compression and discharge the foreign objects.


      1. Install SST (attachment) to the glow plug hole.

        SST
        09992-00026   ( 09992-00121 )
        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      2. A01KIKHE01
        Text in Illustration
        *1 SST (Attachment)

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

      3. Fully open the throttle valve, and start the engine.

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

        Tech Tips

        Always use a fully charged battery to obtain engine revolution of 250 rpm or more.

      5. Repeat steps (1) through (4) for each cylinder.

        Note

        This measurement must be done in as short a time as possible.

        Compression pressure
        2700 kPa (27.5 kgf*cm2, 391 psi) or more
        Minimum pressure
        2200 kPa (22.5 kgf*cm2, 320 psi) or more
        Difference between each cylinder
        500 kPa (5.0 kgf*cm2, 71 psi) or less

        If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder the glow plug hole and repeat steps (1) through (4) for the cylinder with low compression.


        • If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged.

        • If pressure stays low, a valve may be sticking or seating improperly, or there may be leakage past the gasket.

      6. Remove SST.

    4. Reconnect the injection pipes Click here.

    5. Reinstall the glow plugs Click here.

    6. Start engine and check for leaks.