ENGINE ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT COOLANT (for Engine)

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  2. INSPECT ENGINE OIL

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  3. CHECK 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 the air cleaner filter element sub-assembly is not damaged or excessively oily. If necessary, replace the air cleaner filter element sub-assembly.

      Tech Tips


      • 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.

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

  6. INSPECT VALVE LASH ADJUSTER ASSEMBLY


    1. Put the engine in inspection 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.

      Click here

    2. Warm up and stop the engine.

    3. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Put the engine in inspection mode.

        Click here

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


        Powertrain > Engine and ECT > Data List
        Tester Display
        IGN Advance
        Standard Ignition Timing
        5 to 20° BTDC at idle

        Note


        • Check the ignition timing with the cooling fans off.

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

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

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


        Powertrain > Engine and ECT > Active Test
        Active Test Display
        Connect the TC and TE1
        Data List Display
        IGN Advance

      5. Monitor IGN Advance of the Data List.

        Standard Ignition Timing
        8 to 12° BTDC at idle

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

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

    4. When not using the GTS:


      1. A01ODWFC51
        *a 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 may damage electrical components.

        • Check the ignition timing with the cooling fans off.

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

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

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

        Click here

      3. Connect the clip of a timing light 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.

        Click here

      5. Check the ignition timing at idle.

        Standard Ignition Timing
        8 to 12° BTDC at idle

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

      7. Check the ignition timing at idle.

        Standard Ignition Timing
        5 to 20° BTDC at idle

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

      9. Disconnect the clip of the timing light from the ignition coil wire for the No. 1 cylinder.

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

        Click here

  8. INSPECT ENGINE IDLE SPEED


    1. Put the engine in inspection mode.

      Click here

    2. Warm up and stop the engine.

    3. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Put the engine in inspection mode.

        Click here

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


        Powertrain > Engine and ECT > Data List
        Tester Display
        Engine Speed

      4. Read the value displayed on the tester.

        Standard Idle Speed
        950 to 1050 rpm

        Note


        • Check the engine idle speed with the cooling fans off.

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

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

    4. When not using the GTS:


      1. A01OCZVC03
        *a DLC3

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

        SST
        09843-18030

        Note

        Be sure to connect the tachometer probe to the correct terminal. Connecting to the wrong terminal may cause damage to electrical components.

      2. Put the engine in inspection mode.

        Click here

      3. Inspect the engine idle speed.

        Standard Idle Speed
        950 to 1050 rpm

        Note


        • Check the engine idle speed with the cooling fans off.

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

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

      4. Turn the power switch off.

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

  9. INSPECT COMPRESSION

    Note

    Keep the spark plug holes free of foreign matter when measuring the compression pressure.


    1. Put the engine in inspection mode.

      Click here

    2. Warm up and stop the engine.

    3. Check for DTCs.

      Click here

    4. 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.

    5. 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.


        Powertrain > Hybrid Control > Active Test
        Tester Display
        Compression Test

      6. With the brake pedal depressed, turn the power switch on (READY). Then check the compression pressure.

        Standard Compression Pressure
        1100 kPa (11.2 kgf/cm2, 160 psi)
        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 all cylinders in the same way.

        • Measure the compression pressure as quickly as possible.

        • Noise may be emitted from the hybrid vehicle transaxle 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 and 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 compression pressure stays low, a valve may be stuck or seated improperly, or there may be leaks in the cylinder head gasket.

    6. Install the 4 spark plugs.

      Click here

    7. Clear the DTCs.

      Click here

      Note

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

  10. INSPECT CO/HC

    Tech Tips

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


    1. Put the engine in inspection mode.

      Click here

    2. Run the engine 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 idle.

    4. Immediately check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

      Tech Tips


      • When performing a 2 mode test (2500 rpm and idle) 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 order given below.


      1. Check for DTCs.

        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

        1. Faulty ignition:


          • Incorrect timing

          • Fouled, shorted or improperly gapped spark plugs

        2. Incorrect valve clearance (valve lash adjuster assembly)

        3. Leaks in intake or exhaust valves

        4. Leaks in cylinders

        5. Faulty EGR
        Low High Rough idle (Fluctuating HC reading)

        1. Vacuum leaks:


          • PCV hoses

          • Intake manifold

          • Throttle with motor body assembly

        2. Lean mixture causing misfire

        3. Faulty EGR
        High High Rough idle (Black smoke from exhaust)

        1. Restricted air cleaner filter element sub-assembly

        2. Plugged PCV valve

        3. Faulty EFI systems:


          • Fuel pressure regulator assembly

          • Engine coolant temperature sensor

          • Mass air flow meter sub-assembly

          • ECM

          • Fuel injector assemblies

          • Throttle position sensor (built into throttle with motor body assembly)

        4. Faulty EGR