7GR-FKS ENGINE MECHANICAL ENGINE ON-VEHICLE INSPECTION
PROCEDURE
1.INSPECT ENGINE COOLANT
2.INSPECT ENGINE OIL
3.INSPECT BATTERY
19100P
4.INSPECT SPARK PLUG
17801
5.INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
Remove the air cleaner filter element sub-assembly.
Visually check that there is no dirt, blockage, and/or damage to the air cleaner filter element.
- HINT:
- ·
If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air.
·If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it.
Install the air cleaner filter element sub-assembly.
16620
6.INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
Remove the fan and generator V belt.
Check that nothing is caught in the tensioner by turning it clockwise and counterclockwise.
If a malfunction exists, replace the V-ribbed belt tensioner.
Install the fan and generator V belt.
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7.INSPECT VALVE LASH ADJUSTER NOISE
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.
8.INSPECT IGNITION TIMING
Warm up the engine 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 speed should be stabilized.
Connect the GTS to the DLC3.
Start the engine and idle it.
Turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / Ignition Timing Cylinder #1.
- Powertrain > Engine > Data List
-
Tester Display Ignition Timing Cylinder #1 - 50003 372 213
- Standard Ignition Timing:
Transmission Ignition Timing Manual Transmission 5 to 22° BTDC at idle Automatic Transmission 5 to 22° BTDC at idle
- NOTICE:
-
When checking the ignition timing, the transmission should be in neutral or park.
- HINT:
-
Refer to the GTS operator's manual for further details.
Check that the ignition timing advances immediately when the engine speed is increased.
Enter the following menus: Powertrain / Engine / Active Test / Activate the TC Terminal / ON.
- Powertrain > Engine > Active Test
-
Active Test Display Activate the TC Terminal -
Data List Display Ignition Timing Cylinder #1 - 50004 372 22 213
Monitor Ignition Timing Cylinder #1 of the Data List.
Perform the Active Test.
- Standard Ignition Timing:
Transmission Ignition Timing Manual Transmission 8 to 12° BTDC at idle Automatic Transmission 8 to 12° BTDC at idle
- NOTICE:
-
When checking the ignition timing, the transmission should be in neutral or park.
- HINT:
-
Refer to the GTS operator's manual for further details.
9.INSPECT ENGINE IDLE SPEED
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 speed should be stabilized.
Connect the GTS to the DLC3.
- NOTICE:
-
Switch off all accessories and A/C before connecting the GTS.
Race the engine at 2500 rpm for approximately 90 seconds.
Turn the GTS on.
Enter the following menus: powertrain / Engine / Data list / Engine Speed.
- Powertrain > Engine > Data List
-
Tester Display Engine Speed - 50003 372 211
- Standard idle speed:
550 to 700 rpm
- NOTICE:
-
When checking the idle speed, the transmission should be in neutral or park.
- HINT:
-
Refer to the GTS operator's manual for further details.
If the idle speed is not as specified, check the air intake system.
Disconnect the GTS from the DLC3.
10.INSPECT COMPRESSION
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 speed should be stabilized.
Remove the intake air surge tank.
Remove the 6 spark plugs.
Remove the upper No. 1 relay block cover.
Discharge the fuel pressure.
- HINT:
-
DTCs may be stored during this inspection. Check for DTCs and clear them using the GTS.
Remove the EFI-MAIN NO. 2 fuse from the No. 1 engine room relay block and junction block assembly.
Start the engine.
After the engine has stopped on its own, turn the ignition switch off.
Crank the engine again and make sure that the engine does not start.
Insert a compression gauge into the spark plug hole.
Fully open the throttle.
While cranking the engine, measure the compression pressure.
- Standard compression pressure:
1400 kPa (14.3 kgf/cm2, 203 psi) or higher
- Minimum pressure:
1050 kPa (10.7 kgf/cm2, 152 psi)
- NOTICE:
-
The measurement must be done as quickly as possible.
- HINT:
-
Always use a fully charged battery to obtain an engine speed of 250 rpm or more.
Perform the inspection above for each cylinder.
- Difference between each cylinder:
100 kPa (1.0 kgf/cm2, 15 psi) or less
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 is worn or damaged.
·If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
Install the EFI-MAIN NO. 2 fuse to the No. 1 engine room relay block and junction block assembly.
Install the upper No. 1 relay block cover.
Install the 6 spark plugs.
11.INSPECT CO/HC
- HINT:
-
This is a check for determining whether or not the idle CO/HC complies with regulations.
Start the engine.
Keep the engine speed at 2500 rpm for approximately 180 seconds.
Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling.
Immediately check the CO/HC concentration at idle and/or 2500 rpm.
- HINT:
- ·
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.
See the table below for possible causes, then inspect and correct the applicable causes if necessary.
| CO | HC | Problem | Cause |
|---|---|---|---|
| Normal | High | Rough idle | 1.
Faulty ignitions: -
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 |
| Low | High | Rough idle (Fluctuating HC reading) | 1.
Vacuum leaks: -
PCV hose -
Intake manifold -
Throttle body with motor assembly 2.
Lean mixture causing misfire |
| High | High | Rough idle (Black smoke from exhaust) | 1.
Restricted air cleaner filter 2.
Faulty fuel SFI system: -
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) |