ENGINE ON-VEHICLE INSPECTION

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.

    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 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.

    2. 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

  8. INSPECT IGNITION TIMING


    1. Warm up and stop the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Turn the GTS on.

      3. Start the engine and idle it.

      4. Enter the following menus: Powertrain / Engine / Data List / Ignition Timing Cylinder #1.


        Powertrain > Engine > Data List
        Tester Display
        Ignition Timing Cylinder #1
        Standard ignition timing
        5 to 20° BTDC @ idle

        Note


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

        • Check the ignition timing with the cooling fan off.

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

        Tech Tips

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

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

      5. Enter the following menus: Powertrain / Engine / Active Test / Activate the TC Terminal / ON.


        Powertrain > Engine > Active Test
        Tester Display
        Activate the TC Terminal

      6. Monitor Ignition Timing Cylinder #1 of the Data List.

        Standard ignition timing
        8 to 12° BTDC @ idle

        Note


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

        • Check the ignition timing with the cooling fan off.

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

      7. Enter the following menus: Activate the TC Terminal / OFF.

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

      9. Turn the ignition switch off.

      10. Disconnect the GTS from the DLC3.

    3. When not using the GTS:


      1. Remove the No. 1 engine cover sub-assembly.

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

        Note

        Use a timing light that detects primary signals.

      3. B008GYCC83
        *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.

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

        • Check the ignition timing with the cooling fan off.

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

      4. Start the engine and idle it.

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

        Standard ignition timing
        8 to 12° BTDC @ idle

        Note


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

        • Check the ignition timing with the cooling fan off.

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

      6. Remove SST from the DLC3.

      7. Check the ignition timing.

        Standard ignition timing
        5 to 20° BTDC @ idle

        Note


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

        • Check the ignition timing with the cooling fan off.

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

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

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

      9. Turn the ignition switch off.

      10. Disconnect the timing light from the engine.

  9. INSPECT ENGINE IDLE SPEED


    1. Warm up and stop the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

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

      3. Turn the GTS on.

      4. Start the engine and run it at idle.

      5. Enter the following menus: Powertrain / Engine / Data List / Engine Speed.


        Powertrain > Engine > Data List
        Tester Display
        Engine Speed
        Standard idle speed
        w/ Canister Pump Module 700 to 850 rpm
        w/o Canister Pump Module 700 to 800 rpm

        Note


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

        • Check the ignition timing with the cooling fan off.

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

        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.

      6. Disconnect the GTS from the DLC3.

    3. B008GYCC82
      *a Front view of DLC3

      When not using the GTS:


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

        SST
        09843-18030

        Note

        Confirm the terminal number before connecting the probe. Connecting the wrong terminals can damage the engine.

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

      3. Check the idle speed.

        Standard idle speed
        w/ Canister Pump Module 700 to 850 rpm
        w/o Canister Pump Module 700 to 800 rpm

        Note


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

        • Check the ignition timing with the cooling fan off.

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

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

      4. Disconnect the tachometer probe from the DLC3.

  10. INSPECT COMPRESSION


    1. Warm up and stop the engine.

    2. Check for DTCs.


    3. Remove the air cleaner case sub-assembly.

      Tech Tips

      Be sure not to remove the battery.

      Click here

    4. Remove the 4 spark plugs.

      Click here

    5. B008H2S

      Disconnect the fuel injector connector (for Port Injection).

    6. B008HSD

      Disconnect the 2 fuel injector connectors (for Direct Injection).

    7. Check 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.

        Standard compression pressure
        1200 kPa (12.2 kgf/cm2, 174 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.

        Tech Tips

        Always use a fully charged battery to obtain an engine speed of 250 rpm or more.

      4. If the cylinder compression is low in one or more cylinders, pour a small amount of engine oil into the cylinder with low compression through its spark plug hole. Then inspect the cylinder compression pressure again.

        Tech Tips


        • If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore is worn or damaged.

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

    8. Connect the 2 fuel injector connectors (for Direct Injection).

    9. Connect the fuel injector connector (for Port Injection).

    10. Install the 4 spark plugs.

      Click here

    11. Install the air cleaner case sub-assembly.

      Click here

    12. Clear the DTCs.


      Note

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

  11. INSPECT CO/HC

    Tech Tips

    This check determines whether or not the idle CO/HC complies with regulations.


    1. Start the engine.

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

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

    4. Immediately check the CO/HC concentration at idle and at 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 air fuel ratio sensor operation.

        Click here

      2. Check the heated oxygen sensor operation.

        Click here

      3. 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 ignition:

          - Incorrect timing

          - Fouled, shorted or improperly gapped plugs

        2. Incorrect valve clearance

        3. Leaky intake and exhaust valves

        4. Leaky cylinder
        Low High

        Rough idle

        (Fluctuating HC reading)

        1. Vacuum leaks:

          - PCV hose

          - Intake manifold

          - Throttle with motor body assembly

          - Brake booster line

        2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air cleaner filter element sub-assembly

        2. Plugged PCV valve

        3. Faulty SFI system:

          - Fuel pressure regulator assembly

          - Engine coolant temperature sensor

          - ECM

          - Fuel injector assemblies

          - Throttle with motor body assembly

          - Mass air flow meter