ENGINE ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT ENGINE COOLANT

    Click here

  2. INSPECT ENGINE OIL

    Click here

  3. INSPECT BATTERY

    Click here

  4. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  5. CHECK VALVE LASH ADJUSTER NOISE


    1. Rev 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 more than 30 minutes. Then perform the inspection above again.

      If any defects or problems are found during the inspection above, perform a valve lash adjuster inspection Click here.

  6. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner cap.

    2. Remove the air cleaner filter element sub-assembly from the air cleaner case.

    3. Visually check that the air filter sub-assembly is not excessively damaged or oily.

      If necessary, replace the air cleaner filter element sub-assembly.

    4. Reinstall the air cleaner filter element sub-assembly to the air cleaner case.

    5. Reinstall the air cleaner cap.

  7. INSPECT ENGINE IDLE SPEED


    1. Warm up and stop the engine.

    2. When using the GTS:

      Tech Tips


      • For more information about the GTS, refer to its operator's manual.

      • If the GTS is not available, use a tachometer as a substitute.


      1. Connect the GTS to the DLC3.

      2. Start the engine and idle it.

      3. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

        Standard Idle Speed
        Item Specified Condition
        w/ Urea SCR System 650 to 750 rpm
        w/o Urea SCR system 630 to 730 rpm
    3. A01XJRVE06

      When not using the GTS:


      1. Connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

        SST
        09843-18040

      2. Start the engine and idle it.

    4. Inspect the engine idle speed.

      Standard Idle Speed
      Item Specified Condition
      w/ Urea SCR System 650 to 750 rpm
      w/o Urea SCR system 630 to 730 rpm

      Note


      • Turn all the electrical systems and A/C off.

      • When checking the idle speed, move the shift lever to neutral.

    5. Turn the ignition switch off.

    6. Disconnect the GTS or tachometer tester probe from the DLC3.

  8. INSPECT MAXIMUM SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Check the maximum engine speed.

      Maximum engine speed
      4450 to 4750 rpm

  9. INSPECT COMPRESSION


    1. Warm up and stop the engine.

    2. Remove the 4 injector assemblies Click here.

    3. Inspect the cylinder compression pressure.


      1. A01XH0AE02
        Text in Illustration
        *1 Bolt
        *2 Washer
        *3 Nozzle Holder Clamp
        *a SST (Attachment I)
        *b New O-Ring
        *c New Injection Nozzle Seat
        *d New Nozzle Holder Gasket

        Install a new nozzle holder gasket, new injection nozzle seat, new O-ring, SST (attachment I), nozzle holder clamp and washer to the cylinder head cover sub-assembly with the bolt.

        SST
        09992-19015   ( 09992-10120 )
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      2. A01XMCZE01
        Text in Illustration
        *a SST (Compression Gauge)
        *b SST (L-Joint)

        Connect SST (gauge assembly), SST (packing set) and SST (L-joint) to SST (attachment I).

        SST
        09992-19015   ( 09992-10010, 09992-10020, 09992-10030 )

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

        Standard compression pressure
        2700 kPa (27.5 kgf/cm2, 392 psi) or higher
        Minimum pressure
        2200 kPa (22.4 kgf/cm2, 319 psi)
        Difference between each cylinder
        500 kPa (5.1 kgf/cm2, 73 psi) or less

        Note


        • Use a fully-charged battery so the engine speed can be increased to 280 rpm or more.

        • Inspect the other cylinders in the same way.

        • Measure the compression as quickly as possible.

      4. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the injector holes, and then inspect it again.

        If adding oil increases the compression pressure, the piston rings and/or cylinder bore may be worn or damaged.

        If the pressure stays low, the valve may be stuck or seated improperly, or there may be leakage from the gasket.

    4. Remove SST.

    5. Install the 4 injector assemblies Click here.