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 is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. The coolant should be free from oil.
  
  Tech Tips
  
  If excessively dirty, clean the coolant passage and replace the coolant.
3. Install the radiator cap.
INSPECT ENGINE OIL
1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low and full level marks.
  
  If the oil level is low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill with engine oil above the full level mark.
INSPECT BATTERY

Note

If the battery is weak or if the engine is difficult to start, perform the following procedures.
1. Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.
2. Check the electrolyte level of each cell.
  1. For maintenance-free batteries:
    - If the electrolyte level is below the lower line, replace the battery.
    - If the electrolyte level is above the lower line, check the battery voltage when cranking the engine.
    - If the voltage is less than 9.6 V, recharge or replace the battery.
    Tech Tips
    
    Before checking battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
  2. For non-maintenance-free batteries:
    - If the electrolyte level is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte gravity.
    Standard gravity
    
    1.25 to 1.29 at 20°C (68°F)
    
    If the electrolyte level is above the lower line, check battery voltage when cranking the engine. If the voltage is less than 9.6 V, recharge or replace the battery.
    
    Tech Tips
    
    Before checking battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
1. Remove the air cleaner filter element from the air cleaner case.
2. Visually check that there is no dirt, clog, and damage to the air cleaner filter element.
  Tech Tips
  - If there is any dirt or clog on the air cleaner filter element, clean it with compressed air.
  - If any dirt or clog remains even after cleaning the air cleaner filter element with compressed air, replace it.

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

INSPECT SPARK PLUG (for Leaded Gasoline Specification Vehicle)

Check the electrode.
1. Using a megohmmeter, measure the insulation resistance.
  
  Insulation resistance
  
  10 MΩ or more
  
  Tech Tips
  
  If a megohmmeter is not available, perform the following simple inspection instead.
Alternative inspection method:
1. Quickly accelerate the engine to 4,000 rpm 5 times.
2. Remove the spark plug.
3. Visually check the spark plug.
  
  If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step.

Insulation resistance
10 MΩ or more

Check the spark plug for any damage to its threads and insulator.

If there is damage, replace the spark plug. If not, reinstall the spark plug.

Recommended spark plug

Manufacture	Product
DENSO made	K20HR-U11
NGK made	LFR6C-11

Check the spark plug electrode gap.

Maximum electrode gap for used spark plug

1.3 mm (0.051 in.)

If the gap is greater than the maximum, replace the spark plug.

Electrode gap for new spark plug

1.1 mm (0.043 in.)

Note

When adjusting the gap of a new spark plug, bend only the base of the ground electrode. Never attempt to adjust the gap of a used plug.
Clean the spark plugs.

If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it.

Air pressure

588 kPa (6 kgf*cm², 85 psi)

Duration

20 seconds or less

Tech Tips

Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner.

Maximum electrode gap for used spark plug
1.3 mm (0.051 in.)

Electrode gap for new spark plug
1.1 mm (0.043 in.)

Air pressure
588 kPa (6 kgf*cm², 85 psi)

Duration
20 seconds or less

INSPECT SPARK PLUG (for Unleaded Gasoline Specification Vehicle)

Note

Do not use a wire brush for cleaning.
Do not attempt to adjust the electrode gap of a used spark plug.

Check the electrode.
1. Using a megohmmeter, measure the insulation resistance.
  
  Insulation resistance
  
  10 MΩ or more
  
  Tech Tips
  
  If a megohmmeter is not available, perform the following simple inspection instead.
Alternative inspection method.
1. Quickly accelerate the engine to 4,000 rpm 5 times.
2. Remove the spark plug.
3. Visually check the spark plug.
  
  If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step.

Insulation resistance
10 MΩ or more

Check the spark plug for any damage to its threads and insulator.

If there is damage, replace the spark plug. If not, reinstall the spark plug.

Recommended spark plug

Manufacture	Product
DENSO made	SK20HR11
NGK made	ILFR6C11

Check the spark plug electrode gap.

Maximum electrode gap for used spark plug

1.3 mm (0.051 in.)

If the gap is greater than the maximum, replace the spark plug.

Electrode gap for new spark plug

1.0 to 1.1 mm (0.039 to 0.043 in.)

Note

When adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap of a used plug.
Clean the spark plugs.

If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it.

Air pressure

588 kPa (6 kgf*cm², 85 psi)

Duration

20 seconds or less

Tech Tips

Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner.

INSPECT VALVE LASH ADJUSTER NOISE
1. Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the above inspection again.
  
  Tech Tips
  
  If any defects or problems are found during the above inspection, perform a lash adjuster inspection Click here.
INSPECT IGNITION TIMING
1. Warm up and stop the engine.
  
  Note
  
  A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
2. When using the intelligent tester:
  1. Connect the intelligent tester to the DLC3.
  2. Start the engine and idle it.
  3. Turn the intelligent tester main switch on.
  4. Enter the following items:
    
    Powertrain / Engine and ECT / Data list / IGN Advance
    
    Ignition timing
    
    5 to 15° BTDC at idle
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further detail.
3. When not using the intelligent tester:
  1. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No.4 cylinder.
    
    Note
    
    Use a timing light that detects the first signal.
    
    After checking, be sure to wrap the wire harness with tape.
  2. Turn the ignition switch to the ON position.
  3. 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 can damage the engine.
    
    When checking the ignition timing, the transmission should be in the neutral.
    
    Tech Tips
    
    After connecting terminals (TC and CG), engine rpm changes to approximately 1,000 to 1,500 rpm for 5 seconds, then returns to idle speed. This is because the ECM checks that the ISC (idle speed control system) operates properly.
    
    Perform the inspection of the ignition timing after engine rpm is returned to idle speed.
  4. Inspect the ignition timing
    
    Ignition timing
    
    3 to 7° BTDC at idle
  5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.
  6. Inspect the ignition timing
    
    Ignition timing
    
    5 to 15° BTDC at idle
  7. Check that the ignition timing advances immediately when the engine speed is increased.
  8. Turn the ignition switch off.
  9. Remove the timing light.
INSPECT ENGINE IDLE SPEED
1. Warm up and stop the engine.
  
  Note
  
  A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
2. When using the intelligent tester:
  1. Connect the intelligent tester to the DLC3.
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further details.
  2. Start the engine and idle it.
  3. Turn the intelligent tester main switch on.
  4. Enter the following items:
    
    Powertrain / Engine and ECT / Data list / Engine SPD
    
    Idle speed
    
    600 to 700 rpm
    Note
    
    When checking the idle speed, the transmission should be in the neutral position.
    
    Switch off all accessories and air conditioning before connecting the intelligent tester.
  5. Turn the ignition switch off.
  6. Disconnect the intelligent tester from the DLC3.
3. When not using the intelligent tester:
  1. Install SST to terminal 9 (TAC) of DLC3, then connect a tachometer.
    
    SST
    
    09843-18030
    
    Note
    
    Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
  2. Turn the ignition switch to the ON position.
  3. Inspect the engine idling speed.
    
    Idle speed
    
    600 to 700 rpm
  4. Turn the ignition switch off.
  5. Disconnect the tachometer.
  6. Remove the SST from terminal 9 (TAC).
    
    SST
    
    09843-18030
INSPECT ENGINE IDLE SPEED CONTROL SYSTEM
1. Check the idle speed control system.
  1. Using SST, connect terminals TC and CG of the DLC3.
    
    SST
    
    09843-18040
  2. Start the engine and idle it.
    
    Note
    
    Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
    
    Turn off all electrical systems before connecting the terminals.
    
    When checking ISC function, the transmission should be in the neutral position.
  3. After connecting terminals (TC and CG), check that the engine speed changes to approximately 1,000 to 1,500 rpm for 5 seconds, and then returns to idle speed.
    
    Tech Tips
    
    If the result is not as specified, check the throttle body, DTC and wire harness.
INSPECT COMPRESSION
1. Warm up and stop the engine.
  
  Note
  
  A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.
2. Remove the intake air connector.
3. Disconnect the injector connectors.
4. Remove the ignition coils.
5. Remove the spark plugs.
6. Check the cylinder compression pressure.
  1. Insert a compression gauge into the spark plug hole.
  2. Fully open the throttle.
  3. While cranking the engine, measure the compression pressure.
    
    Compression pressure
    
    1,230 kPa (12.5 kgf/cm², 178 psi)
    
    Minimum pressure
    
    883 kPa (9.0 kgf/cm², 128 psi)
    
    Difference between each cylinder
    
    98 kPa (1.0 kgf/cm², 14 psi)
    
    Note
    
    Always use a fully charged battery to obtain an engine speed of 250 rpm or more.
    
    Check the other cylinder's compression pressure in the same way.
    
    This measurement must be done as quickly as possible.
    
    Tech Tips
    
    If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and perform inspection again.
    
    If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
    
    If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
7. Install the spark plugs.
8. Install the ignition coils.
9. Connect the injector connectors.
10. Install the intake air connector.

Maximum electrode gap for used spark plug
1.3 mm (0.051 in.)

Electrode gap for new spark plug
1.0 to 1.1 mm (0.039 to 0.043 in.)

Air pressure
588 kPa (6 kgf*cm², 85 psi)

Duration
20 seconds or less

Ignition timing
5 to 15° BTDC at idle

Ignition timing
3 to 7° BTDC at idle

Ignition timing
5 to 15° BTDC at idle

Idle speed
600 to 700 rpm

Idle speed
600 to 700 rpm

Compression pressure
1,230 kPa (12.5 kgf/cm², 178 psi)

Minimum pressure
883 kPa (9.0 kgf/cm², 128 psi)

Difference between each cylinder
98 kPa (1.0 kgf/cm², 14 psi)

INSPECT CO (for Leaded Gasoline Specification Vehicle)

Tech Tips

This check is used only to determine whether or not the idle CO complies with regulations.

Initial condition:
1. Engine at normal operating temperature
2. Air cleaner installed
3. All pipes and hoses of the air induction system connected
4. All accessories switched off
5. All vacuum lines properly connected
6. EFI system wiring connectors fully seated
7. Ignition timing set correctly
8. Transmission in the neutral position
9. Tachometer and CO meter calibration at idle
  
  Note
  
  If a CO meter is not available, do not attempt to adjust the idle mixture. Always use a CO meter when adjusting the idle mixture. It is unnecessary to use the idle mixture screw for adjustments if the vehicle is in good condition.
Warm up the engine by driving at constant speed (approximately 50 km/h (31 mph)). Close the throttle valve for 5 minutes after the engine coolant temperature becomes stable (80 to 90°C (176 to 194°F)) and idle the engine for 5 minutes.
Insert a tester probe at least 40 cm (1.3 ft) into the tail pipe.
Wait at least 1 minute before measurement to allow the concentration to stabilize. Complete the measurement within 3 minutes.

Idle CO concentration

1.0 to 2.0%
If the CO concentration does not conform to regulations, adjust it by turning the idle mixture adjusting screw in the variable resistor with SST.

SST

09243-00020
The idle mixture adjusting screw can be adjusted within an 180° angle range.
Tech Tips
- If the CO concentration is within the specification, this adjustment is complete.
- If the CO concentration cannot be corrected by idle mixture adjustment, see the table below for other possible causes.

Idle CO concentration
1.0 to 2.0%

Remove the SST.

CO	Problems	Causes
High	Rough idle (black smoke from exhaust)	Clogged air filter Plugged ventilation valve Faulty SFI system: Faulty fuel pressure regulator Clogged fuel return line Defective engine coolant temperature (ECT) sensor Faulty ECM Faulty injectors Faulty throttle position sensor Faulty MAF meter

INSPECT CO/HC (for Unleaded Gasoline Specification Vehicle)

Tech Tips

The ECM properly controls the CO/HC concentration in the emission gas.

Start the engine.
Run the engine at 2,500 rpm for approximately 180 seconds.
Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tail pipe while idling.

Check the CO/HC concentration with the engine idling and/or running at 2,500 rpm.

Tech Tips

If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
Check the heated oxygen sensor operation Click here.
Check the heated air fuel ratio sensor operation Click here.
See the table below for possible causes, then inspect the applicable causes and repair them if necessary.

CO	HC	Problems	Causes
Normal	High	Rough idle	Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaks in intake and exhaust valves Leaks in cylinders
Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
High	High	Rough idle (Black smoke from exhaust)	Restricted air filter Plugged PCV valve Faulty SFI systems: Faulty pressure regulator Defective engine coolant temperature sensor Defective mass air flow meter Faulty ECM Faulty injectors Faulty throttle body