Engine: Testing and Inspection
ENGINEON-VEHICLE INSPECTION
1. INSPECT VALVE LASH ADJUSTER NOISE
(a) 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.
2. INSPECT IGNITION TIMING
(a) Warm up and stop the engine.
NOTICE: 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 rpm should be stabilized.
(b) When using the intelligent tester:
(1) Connect the intelligent tester to the DLC3.
(2) Start the engine and idle it.
(3) Push the intelligent tester main switch ON.
(4) Enter the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / IGN ADVANCE.
Standard ignition timing: 8 to 18° BTDC @ idle
HINT: Refer to the intelligent tester operator's manual for further details.
(c) When not using the intelligent tester:
(1) Remove the V-bank cover.
(2) Connect the tester probe of a timing light to the wire of the ignition connector for No. 1 cylinder.
NOTICE: Use a timing light which can detect the primary current.
DLC3:
(3) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST 09843-18040
NOTICE:
^ Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
^ When checking the ignition timing, then transmission should be in neutral.
(4) Using a timing light, check the ignition timing.
Standard ignition timing: 8 to 12 BTDC @ idle
(5) Remove the SST from the DLC3.
(6) Check the ignition timing.
Standard ignition timing: 8 to 18° BTDC @ 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.
3. INSPECT ENGINE IDLE SPEED
(a) Warm up and stop the engine.
NOTICE: 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 rpm should be stabilized.
(b) When using the intelligent tester:
(1) Connect the intelligent tester to the DLC3.
NOTICE: Switch off all accessories and A/C before connecting the intelligent tester.
(2) Race the engine speed at 2,500 rpm for approximately 90 seconds.
(3) Push the intelligent tester main switch ON.
(4) Enter the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD.
Standard idle speed: 950 to 1,050 rpm
NOTICE: When checking the idle speed, the transmission should be in the neutral.
HINT:
Refer to the intelligent tester operator's manual for further details.
If the idle speed is not as specified, check the air intake system.
(5) Disconnect the intelligent tester from the DLC3.
DLC3:
(c) When not using the intelligent tester:
(1) Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3.
SST 09843-18040
NOTICE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
(2) Race the engine speed at 2,500 rpm for approximately 90 seconds.
(3) Check the idle speed.
Idle speed (Transmission neutral position): 950 to 1,050rpm
If the speed is not as specified, check the air intake system.
(4) Disconnect the tachometer from the DLC3.
4. INSPECT COMPRESSION
(a) Warm up and stop the engine.
NOTICE: 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 rpm should be stabilized.
(b) Remove the cool air intake duct seal.
(c) Remove the engine room side cover LH.
(d) Remove the engine room side cover RH.
(e) Remove the V-bank cover.
(f) Disconnect the No. 2 ventilation hose.
(g) Remove the air cleaner cap with the air cleaner hose.
(h) Remove the nut.
(i) Detach the protector from the bracket.
(j) Remove the 2 nuts and inverter motor cable bracket.
(k) Remove the bolt and water filler.
(l) Remove the clamp and plug.
(m) Disconnect the 3 clamps and connector.
(n) Disconnect the 4 connectors.
(o) Disconnect the throttle body connector.
(p) Disconnect the 6 injector connectors.
(q) Remove the 6 ignition coils.
(r) Remove the 6 spark plugs.
(s) Disconnect the 2 injector driver connectors as shown in the illustration.
(t) Inspect the compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Connect the intelligent tester to the DLC3.
(3) Turn the power switch ON (IG).
(4) Push the intelligent tester main switch ON.
(5) To check the HV battery voltage, enter the following items: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST /+B.
Standard voltage: 10 to 14 V
(6) Enter the following items: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST.
(7) Depress and hold the brake pedal, and turn the power switch ON (READY). Then check the compression pressure.
HINT:
^ Noise may emit from the transmission. However, this is not a malfunction.
^ Always use a fully charged battery to obtain engine speed of 200 rpm or more.
NOTICE: The measurement must be done as quickly as possible.
Standard compression pressure: 1.0 MPa (10 kgf/cm2, 143 psi) or more
Minimum pressure: 0.7 MPa (7.1 kgf/cm2, 101 psi)
(8) Turn the power switch OFF and the intelligent tester main switch off.
(u) Perform the following inspection procedures for the other cylinders.
HINT: Make sure to turn the power switch OFF and the intelligent tester main switch off between each pressure inspection. If not, the compression pressure cannot be inspected.
(1) Insert a compression gauge into the spark plug hole.
(2) Turn the power switch ON (IG).
(3) Push the intelligent tester main switch on.
(4) Enter the following items: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST.
(5) Depress and hold the brake pedal, and turn the power switch ON (READY). Then check the compression pressure.
HINT:
Noise may emit from the transmission. However, this is not a malfunction.
Always use a fully charged battery to obtain engine speed of 200 rpm or more.
NOTICE: The measurement must be done as quickly as possible.
Standard compression pressure: 1.0 MPa (10 kgf/cm2, 143 psi) or more
Minimum compression pressure: 0.7 MPa (7.1 kgf/cm2, 101 psi)
(6) Turn the power switch OFF and the intelligent tester main switch off.
(v) Check the pressure difference between each compression pressure.
Pressure difference: 0.1 MPa (1.0 kgf/cm2, 15 psi) or less
(w) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole. Then perform the first 3 steps under "inspect the cylinder compression pressure" for the cylinders with low compression.
HINT:
^ If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
^ If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
(x) Connect the 2 injector driver connectors as shown in the illustration.
(y) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(z) Install the 6 ignition coils.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(aa) Connect the 6 injector connectors.
(ab) Connect the throttle body connector.
(ac) Connect the 4 connectors.
(ad) Connect the 3 clamps and connector.
(ae) Install the clamp and plug.
(af) Install the water filler with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(ag) Install the inverter motor cable bracket with the 2 nuts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(ah) Attach the protector to the bracket.
(ai) Install the nut.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(aj) Install the air cleaner cap with the air cleaner hose.
(ak) Connect the No. 2 ventilation hose.
(al) Install the V-bank cover.
(am) Install the engine room side cover LH.
(an) Install the engine room side cover RH.
(ao) Install the cool air intake duct seal.
5. INSPECT CO/HC
HINT: This check for determines whether or not the idle CO/HC complies with regulations.
(a) Start the engine.
(b) Keep the engine speed at 2,500 rpm for approximately 180 seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Immediately check CO/HC concentration at idle and 2,500 rpm.
HINT:
^ When performing the 2 mode (2,500 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 A/F sensor and heated oxygen sensor operation.
(2) See the table below for possible causes, then inspect and correct the applicable causes if necessary.
Part 1:
Part 2:
