ENGINE ON-VEHICLE INSPECTION

INSPECT ENGINE COOLANT
1. Remove the water filler cap sub-assembly.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot.
  
  Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.
2. Check for excessive deposits of rust or scale around the water filler cap sub-assembly and radiator filler hole. The engine coolant should be free of oil.
  
  If excessively dirty, replace the engine coolant.
3. Reinstall the water filler cap sub-assembly.
INSPECT ENGINE OIL
1. Check engine oil level.
  1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low level mark and full level mark.
    
    If low, check for leakage and add oil up to the full level mark.
    
    Note
    
    Do not fill engine oil above the full level mark.
2. Check engine oil quality.
  1. Check the oil for deterioration, water contamination, discoloration and thinning.
    
    If the quality is visibly poor, replace the oil.
INSPECT BATTERY
1. Check the battery for damage and deformation. If severe damage, deformation or leak is found, replace the battery.
2. Check the volume of electrolyte quantity in each cell.
  1. For batteries that are maintenance-free:
    
    If the electrolyte volume is below the lower line, replace the battery.
    
    If the electrolyte volume 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 the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
  2. For batteries that are not maintenance-free:
    
    If the electrolyte volume is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity.
    
    Standard specific gravity
    
    1.25 to 1.29 at 20°C (68°F)
    
    If the electrolyte volume is above the lower line, check the battery voltage when cranking the engine. If the battery voltage is less than 9.6 V, recharge or replace the battery.
    
    Tech Tips
    
    Before checking the 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 and hose Click here.
2. Remove the air cleaner filter element sub-assembly.
3. Visually check that there is no dirt, clogging, or damage to the air cleaner filter element.
  Tech Tips
  - If there is any dirt or a clog on the air cleaner filter element, clean it with compressed air.
  - If any dirt or a clog remains even after cleaning the air cleaner filter element with compressed air, replace it.
4. Install the air cleaner filter element sub-assembly.
5. Install the air cleaner and hose Click here.

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

INSPECT SPARK PLUG

Check the electrode using a megohmmeter:
1. Using a megohmmeter, measure the insulation resistance.
  
  Standard Insulation Resistance
  
  10 MΩ or more
  
  If the result is below 10 MΩ, clan the plug and measure the resistance again.
Check the electrode without using a megohmmeter:
1. Quickly accelerate the engine to 4000 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.

Standard Insulation Resistance
10 MΩ or more

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

If there is any damage, replace the spark plug.

Recommended Spark Plug

Manufacturer	Spark Plug Type
DENSO	SK16HR11

Check the spark plug electrode gap.

Maximum Electrode Gap for Used Spark Plug

1.3 mm (0.05118 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 (0.03937 to 0.04331 in.)

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

Standard Air Pressure

588 kPa (6 kgf/cm², 85 psi)

Standard 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 IGNITION TIMING
Note
- Turn all the electrical systems and the air conditioning off.
- Inspect the ignition timing with the cooling fan off.
- When checking the ignition timing, shift the transmission to the neutral position.
1. When using the intelligent tester:
  1. Warm up and stop the engine.
  2. Connect the intelligent tester to the DLC3.
  3. Turn the ignition switch to ON.
  4. Enter the following menus: Powertrain / Engine and ECT / Active Test / TE1 (TC) / ON.
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further information regarding the selection of Active Test.
  5. Inspect the ignition timing during idling.
    
    Ignition timing
    
    8 to 12° BTDC
  6. Enter the following menus: Powertrain / Engine and ECT / Active Test / TE1 (TC) / OFF.
  7. Turn the ignition switch off.
  8. Disconnect the intelligent tester from the DLC3.
2. When not using the intelligent tester:
  1. Remove the No. 3 engine under cover (w/ No. 1 Engine Cover) Click here.
  2. Remove the No. 1 engine cover (w/ No. 1 Engine Cover) Click here.
  3. Warm up and stop the engine.
  4. Install the tester terminal of a timing light onto the position shown in the illustration.
    
    Note
    
    Use a timing light that detects the first signal.
    
    Wrap the wire harness with tape after checking.
  5. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
    
    SST
    
    09843-18040
    
    Note
    
    Check the terminal numbers before connecting them. Connecting the wrong terminals could damage the engine.
  6. Turn the ignition switch to ON.
  7. Inspect the ignition timing during idling.
    
    Ignition timing
    
    8 to 12° BTDC
    
    Tech Tips
    
    Run the engine speed at 1000 to 1300 rpm for 5 seconds and then check that the engine speed returns to the idling speed.
  8. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.
  9. Turn the ignition switch off.
  10. Remove the timing light.
  11. Install the No. 1 engine cover (w/ No. 1 Engine Cover) Click here.
  12. Install the No. 3 engine under cover (w/ No. 1 Engine Cover) Click here.
INSPECT ENGINE IDLING SPEED
Note
- Turn all the electrical systems and the air conditioning off.
- Inspect the engine idling speed with the cooling fan off.
- When checking the idling speed, shift the transmission to the neutral position.
1. Warm up and stop the engine.
2. When using the intelligent tester:
  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to ON.
  3. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine SPD.
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further information regarding the selection of Data List.
  4. Inspect the engine idling speed.
    
    Idling speed
    
    650 to 800 rpm
  5. Turn the ignition switch off.
  6. Disconnect the intelligent tester from the DLC3.
3. When not using an intelligent tester:
  1. Install SST to terminal 9 (TAC) of the DLC3, and then connect a tachometer.
    
    SST
    
    09843-18040
    
    Note
    
    Check the terminal numbers before connecting them. Connecting the wrong terminals could damage the engine.
  2. Turn the ignition switch to ON.
  3. Inspect the engine idling speed.
    
    Idling speed
    
    650 to 800 rpm
  4. Turn the ignition switch off.
  5. Disconnect the tachometer.
  6. Remove SST from terminal 9 (TAC).
INSPECT COMPRESSION
1. Warm up and stop the engine.
2. Remove the 3 spark plugs Click here.
3. Disconnect the 3 fuel injector connectors.
4. Inspect 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 (Normal condition)
    
    1422 kPa (14.5 kgf/cm², 206 psi)
    
    Minimum pressure
    
    1079 kPa (11.0 kgf/cm², 156 psi)
    
    Difference between each cylinder
    
    147 kPa (1.5 kgf/cm², 21 psi) or less
    
    Note
    
    Use a fully-charged battery so the engine speed can be increased to 400 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 spark plug hole, and then inspect it again.
    
    Tech Tips
    
    If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
    
    If the pressure remains low, the valve may be stuck or seated improperly, or there may be leakage from the gasket.
5. Connect the 3 fuel injector connectors.
6. Install the 3 spark plugs Click here.

Maximum Electrode Gap for Used Spark Plug
1.3 mm (0.05118 in.)

Electrode Gap for New Spark Plug
1.0 to 1.1 mm (0.03937 to 0.04331 in.)

Standard Air Pressure
588 kPa (6 kgf/cm², 85 psi)

Standard Duration
20 seconds or less

Ignition timing
8 to 12° BTDC

Ignition timing
8 to 12° BTDC

Idling speed
650 to 800 rpm

Idling speed
650 to 800 rpm

Compression pressure (Normal condition)
1422 kPa (14.5 kgf/cm², 206 psi)

Minimum pressure
1079 kPa (11.0 kgf/cm², 156 psi)

Difference between each cylinder
147 kPa (1.5 kgf/cm², 21 psi) or less

INSPECT CO/HC

Tech Tips

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

Start the engine.
Run the engine at 2500 rpm for approximately 180 seconds.
Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.

Check the CO/HC concentration during idling and when running at 2500 rpm.

Standard
CO concentration
0.2 % or less
HC concentration
70 ppm or less

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

CO	HC	Problem	Cause
Normal	High	Rough idling	Faulty ignition: Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leakage from intake and exhaust valves Leakage from cylinders
Low	High	Rough idling (Fluctuating HC reading)	Lean mixture causing misfire Faulty SFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Faulty throttle body
High	High	Rough idling (Black smoke from exhaust)	Faulty SFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Faulty throttle body

Problem

Cause

Normal

High

Rough idling

Faulty ignition:

Fouled, shorted or improperly gapped plugs

Incorrect valve clearance
Leakage from intake and exhaust valves
Leakage from cylinders

Low

High

Rough idling

(Fluctuating HC reading)

Lean mixture causing misfire
Faulty SFI systems:

Faulty pressure regulator
Faulty engine coolant temperature sensor
Faulty mass air flow meter
Faulty ECM
Faulty injectors
Faulty throttle body

High

Rough idling

(Black smoke from exhaust)

Faulty SFI systems:

Faulty pressure regulator
Faulty engine coolant temperature sensor
Faulty mass air flow meter
Faulty ECM
Faulty injectors
Faulty throttle body