ENGINE ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT ENGINE COOLANT

    Click here

  2. INSPECT ENGINE OIL

    Click here

  3. INSPECT AUXILIARY BATTERY

    Click here

  4. INSPECT SPARK PLUG

    Click here

  5. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

    2. Visually check that there is no dirt, blockage, and/or damage to the air cleaner filter element.

      Tech Tips


      • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air.

      • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it.

  6. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the fan and generator V belt Click here.

    2. Check that nothing is caught in the tensioner by turning it clockwise and counterclockwise.

      If a malfunction exists, replace the tensioner.

    3. Install the fan and generator V belt Click here.

  7. INSPECT VALVE LASH ADJUSTER ASSEMBLY


    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 inspection above again.

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

  8. INSPECT IGNITION TIMING


    1. Put the engine in inspection mode Click here.

    2. Warm up the engine and stop the engine.

      Note

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

    3. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Start the engine and idle it.

      3. Turn the GTS on.

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

        Standard ignition timing
        8 to 18° BTDC at idle

        Note

        When checking the ignition timing, the transmission should be in park.

        Tech Tips

        Refer to the GTS operator's manual for further details.

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

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

      7. Monitor IGN Advance.

      8. Perform the Active Test.

        Standard ignition timing
        8 to 12° BTDC at idle

        Note

        When checking the ignition timing, the transmission should be in park.

        Tech Tips

        Refer to the GTS operator's manual for further details.

    4. When not using the GTS:


      1. Remove the V-bank cover sub-assembly.

      2. Connect the tester probe of a timing light to the wire of the ignition connector for the No. 1 cylinder.

        Note

        Use a timing light which can detect the primary signal.

      3. A000S2YE21
        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.

        • When checking the ignition timing, the transmission should be in park.

      4. Using a timing light, check the ignition timing.

        Standard ignition timing
        8 to 12° BTDC at idle

      5. Remove SST from the DLC3.

      6. Check the ignition timing.

        Standard ignition timing
        8 to 18° BTDC at idle

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

      8. Disconnect the timing light from the engine.

      9. Install the V-bank cover sub-assembly.

  9. INSPECT ENGINE IDLE SPEED


    1. Put the engine in inspection mode Click here.

    2. Warm up and stop the engine.

      Note

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

    3. When using the GTS:


      1. Connect the GTS to the DLC3.

        Note

        Switch off all accessories and A/C before connecting the GTS.

      2. Race the engine at 2500 rpm for approx. 90 seconds.

      3. Turn the GTS on.

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

        Standard idle speed
        950 to 1050 rpm

        Note

        When checking the idle speed, the transmission should be in park.

        Tech Tips

        Refer to the GTS operator's manual for further details.

        If the idle speed is not as specified, check the air intake system.

      5. Disconnect the GTS from the DLC3.

    4. When not using the GTS:


      1. A000S2YE54
        Text in Illustration
        *a Front view of DLC3

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

        SST
        09843-18030

        Note

        Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      2. Race the engine at 2500 rpm for approx. 90 seconds.

      3. Check the idle speed.

        Standard idle speed
        950 to 1050 rpm

        Note

        When checking the idle speed, the transmission should be in park.

        If the speed is not as specified, check the air intake system.

      4. Disconnect the tachometer from the DLC3.

  10. INSPECT COMPRESSION


    1. Put the engine in inspection mode Click here.

    2. Warm up the engine and then stop it.

      Note

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

    3. Check for DTCs Click here.

    4. Detach the 4 clips and remove the engine room side cover.

    5. Detach the 7 clips and remove the cool air intake duct seal.

    6. Remove the bolt and No. 1 air cleaner inlet.

    7. A000OJ2

      for RHD:

      Detach the 2 wire harness clamps from the inverter bracket.

    8. A000SIH

      for RHD:

      Remove the 2 bolts and inverter bracket from the inverter.

    9. A000Q09

      Remove the 2 bolts and disconnect the inverter reservoir tank.

    10. A000NZA

      Disconnect the engine wire from the left side of the engine room.


      1. Remove the 3 nuts and disconnect the 2 clamps.

      2. Disconnect the manifold absolute pressure sensor connector, VVT sensor connector and 3 ignition coil connectors to disconnect the engine wire.

      3. Remove the 3 bolts and 3 ignition coils.

    11. A000QQ7

      Disconnect the engine wire from the right side of the engine room.


      1. Remove the 2 nuts and disconnect the clamp.

      2. Disconnect the VVT sensor connector and 3 ignition coil connectors to disconnect the engine wire.

      3. Remove the 3 bolts and 3 ignition coils.

    12. Remove the 6 spark plugs Click here.

    13. A000PJK

      Disconnect the 4 injector connectors.

    14. A000QFEE01
      Text in Illustration
      *1 Lock Lever
      *a Release

      Disconnect the 2 injector driver connectors by using the following procedures: 1) move the lock lever in the direction indicated by the arrow to release the connector lock, and then 2) disconnect the connectors together with the wire harness locks.

    15. Attach a compression gauge.

    16. Connect the GTS to the DLC3 and turn the power switch on (IG).

      Note

      Display the HV battery voltage (VB) in the ECU Data List and make sure the battery voltage is sufficient.

    17. Enter the following menus: Powertrain / Hybrid Control / Active Test / Compress Test / On.

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

      Standard compression pressure
      1000 kPa (10.2 kgf/cm2, 145 psi) or higher
      Minimum pressure
      700 kPa (7.1 kgf/cm2, 102 psi)

      Note

      The measurement must be done as quickly as possible.

      Tech Tips

      Always use a fully charged battery to obtain engine speed of 200 rpm or more.

    19. Perform the inspection above for each cylinder.

      Difference between each cylinder
      200 kPa (2.0 kgf/cm2, 29 psi) or less

    20. If the compression pressure is low, add a small amount of engine oil into the cylinder and measure 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 gasket.

    21. Connect the 2 injector driver connectors.

    22. Connect the 4 injector connectors.

    23. Install the 6 spark plugs Click here.

    24. Connect the engine wire to the right side of the engine room.


      1. Install the 3 ignition coils with the 3 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Connect the VVT sensor connector and 3 ignition coil connectors to connect the engine wire.

      3. Connect the clamp and install the 2 nuts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    25. Connect the engine wire to the left side of the engine room.


      1. Install the 3 ignition coils with the 3 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Connect the manifold absolute pressure sensor connector, VVT sensor connector and 3 ignition coil connectors to connect the engine wire.

      3. Connect the 2 clamps and install the 3 nuts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    26. Install the inverter reservoir tank with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    27. for RHD:

      Install the inverter bracket to the inverter with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    28. for RHD:

      Attach the 2 wire harness clamps to the inverter bracket.

    29. Install the No. 1 air cleaner inlet with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    30. Install the cool air intake duct seal with the 7 clips.

    31. Install the engine room side cover with the 4 clips.

    32. Clear the DTCs Click here.

      Note

      After finishing the procedure, clear all the DTCs and check that the normal DTCs are output.

  11. INSPECT CO/HC

    Tech Tips

    This is a check for determining whether or not the idle CO/HC complies with regulations.


    1. Put the engine in inspection mode Click here.

    2. Start the engine.

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

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

    5. Immediately check CO/HC concentration at idle and/or 2500 rpm.

      Tech Tips


      • When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.

      • If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.


      1. Check the DTCs Click here.

      2. See the table below for possible causes, and then inspect and correct the applicable causes if necessary.

        CO HC Symptom Causes
        Normal High Rough idle

        • 1. Faulty ignitions


        • Incorrect timing


        • Fouled, shorted or improperly gapped plugs


        • 2. Leaky intake and exhaust valves


        • 3. Leaky cylinder
        Low High

        Rough idle

        (Fluctuating HC reading)

        • 1. Vacuum leaks


        • PCV hose


        • Intake manifold


        • Throttle body


        • 2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        • 1. Restricted air filter


        • 2. Faulty fuel SFI system


        • Faulty pressure


        • Defective engine coolant temperature sensor


        • Faulty ECM


        • Faulty injector


        • Faulty throttle position sensor


        • Faulty mass air flow meter