RM3660EC _51 Engine / Hybrid System _080739 NR Series ENGINE MECHANICAL _0391929 ENGINE G

NR Series ENGINE MECHANICAL ENGINE ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:: ·

When working near the engine room while the engine has started or the ignition switch is ON, do not touch the V-ribbed belt or rotating components such as the fan, etc.

·

Touching the V-ribbed belt or rotating components such as the fan, etc. could result in your hand or clothing getting caught and pulled in.

PROCEDURE

Hide Display 1.INSPECT ENGINE COOLANT

Click hereEngine / Hybrid System>NR Series (COOLING)>COOLING SYSTEM>ON-VEHICLE INSPECTION201906,999999,_51,_080776,_0392635,RM100000001HRVO,

Hide Display 2.INSPECT ENGINE OIL

Click hereEngine / Hybrid System>NR Series (LUBRICATION)>LUBRICATION SYSTEM>ON-VEHICLE INSPECTION201906,999999,_51,_080758,_0392358,RM100000001HQ61,

Hide Display 3.INSPECT BATTERY CONDITION

Click herePower Source / Network>NR Series (BATTERY / CHARGING)>CHARGING SYSTEM>ON-VEHICLE INSPECTION201906,999999,_57,_080760,_0394911,RM100000001I8RV,

Hide Display 19100P 4.INSPECT SPARK PLUG

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>IGNITION SYSTEM>ON-VEHICLE INSPECTION201906,999999,_51,_080777,_0392332,RM100000001HQ1A,

Hide Display 17801 5.INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Click hereGeneral>MAINTENANCE>NR Series AIR CLEANER FILTER ELEMENT>REMOVAL201906,999999,_V1,_080956,_0392162,RM100000001HOG3_01_0003,

Hide Display 16361A 6.INSPECT V-RIBBED BELT

Click hereEngine / Hybrid System>NR Series (ENGINE MECHANICAL)>DRIVE BELT>ON-VEHICLE INSPECTION201906,999999,_51,_080739,_0391930,RM100000001HN1W_01_0001,

Hide Display 16620 7.INSPECT V-RIBBED BELT TENSIONER ASSEMBLY

Remove the V-ribbed belt.

Click hereGeneral>MAINTENANCE>NR Series DRIVE BELT>REMOVAL201906,999999,_V1,_080956,_0392300,RM100000001HPPO_03_0020,

Turn the V-ribbed belt tensioner assembly clockwise and counterclockwise and check that it turns smoothly and does not catch.

HINT:: If the V-ribbed belt tensioner assembly does not turn smoothly or catches, replace the V-ribbed belt tensioner assembly.

Install the V-ribbed belt.

Click hereGeneral>MAINTENANCE>NR Series DRIVE BELT>INSTALLATION201906,999999,_V1,_080956,_0392300,RM100000001HPPP_03_0012,

Hide Display 13750 8.INSPECT VALVE LASH ADJUSTER ASSEMBLY 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 30 minutes or more, then perform the inspection.

HINT:: If any defects or problems are found during the inspection, perform valve lash adjuster assembly inspection.; Click hereEngine / Hybrid System>NR Series (ENGINE MECHANICAL)>ENGINE UNIT>INSPECTION201906,999999,_51,_080739,_0391936,RM100000001HN2D_01_0014,

Hide Display 9.INSPECT IGNITION TIMING

Warm up and stop the engine.

Connect the GTS to the DLC3.

Start the engine and run it at idle.

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:: -5 to 25° BTDC at idle

NOTICE:: ·

Check the ignition timing with the cooling fans off.

·

Turn off all electrical systems and the A/C.

·

When checking the ignition timing, the transaxle should be in neutral or park.

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.

Standard Ignition Timing:: 8 to 12° BTDC at idle

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

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

Hide Display 10.INSPECT ENGINE IDLE SPEED

Warm up and stop the engine.

Connect the GTS to the DLC3.

Start the engine and run it at idle.

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

Read the value displayed on the tester.

Standard Idle Speed:: 680 to 780 rpm

NOTICE:: ·

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 transaxle should be in neutral or park.

Hide Display 11.INSPECT COMPRESSION

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

Warm up and stop the engine.

Check for DTCs.

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR201906,202304,_51,_080777,_0393969,RM100000001I1QP,202304,999999,_51,_080777,_0393969,RM100000002BZUH,

Remove the 4 spark plugs.

Click hereGeneral>MAINTENANCE>NR Series SPARK PLUG>REMOVAL201906,999999,_V1,_080956,_0392145,RM100000001HO9H,

Disconnect the engine wire connector as shown in the illustration.

NOTICE:: Disable fuel injection in order to prevent catalyst damage due to unburned gasoline.

Remove the 2 bolts and 2 nuts and disconnect the intercooler assembly from the throttle body with motor assembly.

Loosen the hose clamp and remove the intercooler assembly from the air tube assembly and throttle body with motor assembly.

Disconnect the throttle body with motor assembly.

Check the cylinder compression pressure.

Insert a compression gauge into the spark plug hole.

ii.

While cranking the engine, measure the compression pressure.

Standard Compression Pressure:: 1080 kPa (11.0 kgf/cm², 157 psi)

Minimum Compression Pressure:: 880 kPa (9.0 kgf/cm², 128 psi)

Pressure Difference between Each Cylinder:: 100 kPa (1.0 kgf/cm², 15 psi) or less

NOTICE:: ·

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

·

Inspect all cylinders in the same way.

·

Measure the compression pressure as quickly as possible.

iii.

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.

HINT:: ·

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.

Connect the throttle body with motor assembly.

Temporarily install the intercooler assembly to the air tube assembly and throttle body with motor assembly with the hose clamp.

Temporarily install the intercooler assembly to the throttle body with motor assembly with the 2 bolts and 2 nuts.

1.083,1.438 1.24,1.635 0.156,0.198 10 true 4 2.26,1.76 2.542,1.938 0.281,0.177 10 true 1, 5 1.646,0.156 1.792,0.323 0.146,0.167 10 true 2 2.583,0.531 2.729,0.698 0.146,0.167 10 true 3

Tighten the 2 bolts and 2 nuts in the order shown in the illustration.

Torque:: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Tighten the hose clamp.

Torque:: 6.3 N*m (64 kgf*cm, 56 in.*lbf)

Connect the engine wire connector.

Install the 4 spark plugs.

Click hereGeneral>MAINTENANCE>NR Series SPARK PLUG>INSTALLATION201906,999999,_V1,_080956,_0392145,RM100000001HO9I,

Clear the DTCs.

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR201906,202304,_51,_080777,_0393969,RM100000001I1QP,202304,999999,_51,_080777,_0393969,RM100000002BZUH,

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

Hide Display 12.INSPECT CO/HC

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

Start the engine.

Run the engine at 2500 rpm for approximately 180 seconds.

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

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

HINT:: When performing a 2 mode (with the engine idling/running at 2500 rpm) 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.

Check for DTCs.

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR201906,202304,_51,_080777,_0393969,RM100000001I1QP,202304,999999,_51,_080777,_0393969,RM100000002BZUH,

ii.

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

CO	HC	Problem	Cause
Normal	High	Rough idle	1. Faulty ignition: - Incorrect valve 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 hoses - Intake manifold - Throttle with motor body assembly 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 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)