ENGINE ON-VEHICLE INSPECTION

PROCEDURE

1. INSPECT COOLANT (for Engine)

   Click here

2. INSPECT ENGINE OIL

   Click here

3. INSPECT AUXILIARY BATTERY

   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 element sub-assembly is not excessively damaged or oily.

      Note

      
      

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

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

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

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

5. INSPECT SPARK PLUG

   Click here

6. INSPECT VALVE LASH ADJUSTER ASSEMBLY

   
   

   1. Put the engine in inspection mode (maintenance mode) Click here.

   2. Rev up the engine several times. Check that the engine does not emit unusual noises.

   3. If unusual noises occur, warm up the engine and idle it for 30 minutes or more, then perform the preceding inspection.

      Tech Tips

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

7. INSPECT IGNITION TIMING

   
   

   1. Put the engine in inspection mode (maintenance mode) Click here.

   2. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

   3. When using the GTS:

      Check the ignition timing.

      
      

      1. Connect the GTS to the DLC3.

      2. Put the engine in inspection mode (maintenance mode) Click here.

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

         Standard ignition timing
         5 to 20° BTDC @ idle

         Note

         
         

         • Check the ignition timing with the cooling fan off.

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

         • When checking the ignition timing, the shift lever should be in P.

      4. Check that the ignition timing advances immediately when the engine speed is increased.

      5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON.

      6. Monitor IGN Advance of the Data List.

         Standard ignition timing
         8 to 12° BTDC @ idle

         Note

         
         

         • Check the ignition timing with the cooling fan off.

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

         • When checking the ignition timing, the shift lever should be in P.

      7. Enter the following menus: Connect the TC and TE1 / OFF.

      8. Check that the ignition timing advances immediately when the engine speed is increased.

   4. When not using the GTS:

      
      
      1. 

         Text in Illustration

         *a	Front view of DLC3

         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.

         • Check the ignition timing with the cooling fan off.

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

         • When checking the ignition timing, the shift lever should be in P.

      2. Remove the No. 1 engine cover sub-assembly Click here.

      3. Connect the timing light probe to the ignition coil wire for the No. 1 cylinder.

         Note

         Use a timing light that detects primary signals.

      4. Put the engine in inspection mode (maintenance mode) Click here.

      5. Inspect the ignition timing at idle.

         Standard ignition timing
         8 to 12° BTDC @ idle

         Note

         
         

         • Check the ignition timing with the cooling fans off.

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

         • When checking the ignition timing, the shift lever should be in P.

         If the ignition timing is not as specified, check the valve timing.

      6. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

      7. Inspect the ignition timing at idle.

         Standard ignition timing
         5 to 20° BTDC @ idle

         Note

         
         

         • Check the ignition timing with the cooling fans off.

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

         • When checking the ignition timing, the shift lever should be in P.

      8. Check that the ignition timing advances immediately when the engine idle speed is increased.

      9. Remove the timing light probe from the engine.

      10. Install the No. 1 engine cover sub-assembly Click here.

8. INSPECT ENGINE IDLE SPEED

   
   

   1. Put the engine in inspection mode (maintenance mode) Click here.

   2. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine idle speed should be stabilized.

   3. When using the GTS:

      
      

      1. Connect the GTS to the DLC3.

      2. Put the engine in inspection mode (maintenance mode) Click here.

      3. Start the engine and run it at idle.

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

      5. Inspect the engine idle speed.

         Standard idle speed
         950 to 1050 rpm

         Note

         
         

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

         • Inspect the idle speed with the cooling fans off.

         • When checking the engine idle speed, the shift lever should be in P.

   4. When not using the GTS:

      
      
      1. 

         Text in Illustration

         *a	Front view of DLC3

         Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

         SST

         09843-18030

         Note

         Be sure to connect the tachometer to the correct terminal. Connecting the wrong terminals can cause damage to electrical components.

      2. Put the engine in inspection mode (maintenance mode) Click here.

      3. Inspect the engine idle speed.

         Standard idle speed
         950 to 1050 rpm

         Note

         
         

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

         • Inspect the idle speed with the cooling fans off.

         • When checking the engine idle speed, the shift lever should be in P.

      4. Turn the power switch off.

      5. Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.

9. INSPECT COMPRESSION

   Tech Tips

   Keep the intake manifold and spark plug holes free of foreign matter when measuring the compression pressure Click here.

   
   

   1. Put the engine in inspection mode (maintenance mode) Click here.

   2. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

   3. Remove the 4 spark plugs Click here.

      Note

      DTCs will be stored if the inspection is performed with the ignition coil assembly connectors disconnected. Make sure that the ignition coil assembly connectors are connected during the inspection.

   4. Check the cylinder compression pressure.

      
      

      1. Insert a compression gauge into the spark plug hole.

      2. Connect the GTS to the DLC3.

      3. Turn the power switch on (IG).

      4. Turn the GTS on.

         Note

         Check the HV battery voltage in the Data List to ensure that the battery is fully charged.

      5. Enter the following menus: Powertrain / Hybrid Control / Active Test / Compression Test / ON.

      6. Depress and hold the brake pedal, and turn the power switch on (READY).

         Standard compression pressure
         1100 kPa (11.2 kgf/cm2, 160 psi) or higher
         Minimum compression pressure
         900 kPa (9.2 kgf/cm2, 131 psi)
         Pressure difference between each cylinder
         100 kPa (1.0 kgf/cm2, 15 psi) or less

         Note

         
         

         • Inspect the other cylinders in the same way.

         • Measure the compression pressure as quickly as possible.

         • Noise may be emitted from the hybrid vehicle transmission assembly. However, this is not a malfunction.

      7. If the cylinder compression pressure is low, pour a small amount of engine oil into the cylinder through the spark plug hole, then inspect it again.

         Tech Tips

         
         

         • If adding oil increases the compression pressure, 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 leaks in the cylinder head gasket.

   5. Remove the compression gauge.

   6. Install the 4 spark plugs Click here.

   7. Clear the DTCs.

      
      

      • w/ EGR System: Click here

      • w/o EGR System: Click here

      Note

      After the inspection, clear the DTCs, check for DTCs again and make sure the normal system code is output.

10. INSPECT CO/HC

    Tech Tips

    This check determines whether the idle CO/HC complies with regulations.

    
    

    1. Put the engine in inspection mode (maintenance mode) Click here.

    2. Warm up the engine.

    3. Keep the engine speed at 2500 rpm for approximately 180 seconds.

    4. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe while idling.

    5. Immediately check the CO/HC concentration while idling and when the engine is running at 2500 rpm.

       Tech Tips

       
       

       • When performing the 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.

       • If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the following order.

       
       

       1. Check the DTCs.

          
          

          • w/ EGR System: Click here

          • w/o EGR System: Click here

       2. See the following table for possible causes, then inspect the applicable parts and repair them if necessary.

          CO	HC	Problem	Possible Cause
          Normal	High	Rough idle	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped spark plugs Incorrect valve clearance Leaks in intake or exhaust valves Leaks in cylinders Faulty EGR (w/ EGR System)
          Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle with motor body assembly Lean mixture causing misfire Faulty EGR (w/ EGR System)
          High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty EFI systems: Fuel pressure regulator assembly Engine coolant temperature sensor Mass air flow meter ECM Fuel injector assemblies Throttle body assembly Faulty EGR (w/ EGR System)