ENGINE ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:

To prevent injury due to contact with an operating fan and generator V belt or cooling fan, keep your hands and clothing away from the fan and generator V belt and cooling fans when working in the engine compartment with the engine running.

B003PKE

PROCEDURE


  1. INSPECT ENGINE COOLANT

    Click here

  2. INSPECT ENGINE OIL

    Click here

  3. INSPECT BATTERY

    Click here

  4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

    2. Check that the air cleaner filter element sub-assembly is not excessively dirty.

      If the air cleaner filter element sub-assembly is excessively dirty, replace the air cleaner filter element sub-assembly.

      If cleaning the air cleaner filter element sub-assembly, blow compressed air to clean it.

      Note


      • Do not start the engine with the air cleaner filter element sub-assembly removed, as this may damage the engine.

      • When using an air cleaner filter element sub-assembly that uses compressed air, wear safety glasses and a dust mask in order to protect your health.

      Tech Tips

      When an excessive amount of dirt is present, replace the air cleaner filter element sub-assembly.

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

  5. INSPECT INJECTION TIMING


    1. B003R0TC03
      *a Matchmark

      Using a mirror, check that the matchmarks of the injection pump flange and timing belt case sub-assembly are aligned.

  6. ADJUST INJECTION TIMING


    1. B003RCA

      Loosen the following nuts and bolts.


      1. The bolt holding the injection pump assembly to the No. 1 injection pump stay.

      2. The 2 nuts holding the injection pump assembly to the timing belt case sub-assembly.

    2. Align the matchmark by slightly tilting the injection pump assembly.

    3. Tighten the following nuts and bolts.


      1. The 2 nuts holding the injection pump assembly to the timing belt case sub-assembly.

        Torque:
        20.5 N*m  { 209 kgf*cm, 15 ft.*lbf }

      2. The bolt holding the injection pump assembly to the No. 1 injection pump stay.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  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.


        Powertrain > Engine > Data List
        Tester Display
        Engine Speed
    3. B003KN6C49
      *a Front view of DLC3

      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
      650 to 750 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 ENGINE SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Check the maximum engine speed.

      Maximum engine speed
      4850 to 4950 rpm

  9. INSPECT COMPRESSION

    Tech Tips

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


    1. Warm up and stop the engine.

    2. Remove the glow plugs.

    3. Disconnect the spill control valve connector.

    4. Inspect the cylinder compression pressure.


      1. B003OCFE04

        Install SST (attachment) to the glow plug hole.

        SST
        09992-19015   ( 09992-10070 )
        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      2. B003PUNE04

        Connect SST (gauge assembly) to SST (attachment D).

        SST
        09992-19015   ( 09992-10010 )

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

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

        Standard compression pressure
        3138 kPa (32.0 kgf/cm2, 455 psi) or higher
        Minimum pressure
        1961 kPa (20.0 kgf/cm2, 284 psi)
        Difference between each cylinder
        490 kPa (5.0 kgf/cm2, 71 psi) or less

        Note


        • Use a fully-charged battery so the engine speed can be increased to 250 rpm or more.

        • Inspect the other cylinders in the same way.

        • Measure the compression as quickly as possible.

      5. 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.

    5. Remove SST.

    6. Reinstall the glow plugs.

    7. Reconnect the spill control valve connector.