INTAKE SYSTEM (w/ DPF) ON-VEHICLE INSPECTION


  1. CHECK INTAKE AIR CONTROL SYSTEM


    1. Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between the turbocharger outlet and cylinder head.

      Condition Operation
      Clogged air cleaner Clean or replace element
      Hoses collapsed or deformed Repair or replace
      Leakage from connections Check each connection and repair
      Cracks in components Check and repair or replace

  2. CHECK EXHAUST SYSTEM


    1. Check for leakage or clogging between the cylinder head and turbocharger inlet and between the turbocharger outlet and exhaust pipe.

      Condition Operation
      Deformed components Repair or replace
      Foreign material in passages Remove
      Leakage from components Repair or replace
      Cracks in components Check and repair or replace

  3. CHECK BOOST PRESSURE


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Warm up the engine.

      Tech Tips

      Be sure to perform the inspection when the engine coolant temperature is between 75 and 90°C (167 and 194°F).

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.

    5. A01KG3HE11
      Text in Illustration
      *1 Snapshot Record Button

      Take a snapshot of the Data List items with the intelligent tester as shown in the illustration.

      Tech Tips


      • Graphs can be displayed by transferring the stored snapshot data from the tester to a PC. Intelligent Viewer must be installed on the PC.

      • The condition of the turbocharger can be determined by fully depressing the accelerator pedal while driving at 15 km/h (9 mph) in 2nd gear to accelerate the vehicle (obey all laws and regulations and pay attention to driving conditions while driving the vehicle), and then comparing MAP with Target Booster Pressure at an engine speed of 3000 rpm.

    6. Compare MAP with Target Booster Pressure.

      Standard
      MAP is within 20 kPa of Target Booster Pressure when accelerating with accelerator pedal fully depressed.

      Tech Tips


      • The specification above denotes the difference between the absolute pressure values.

      • If the driving inspection using the intelligent tester above cannot be performed (e.g. due to road conditions), perform the following inspection.


      1. Warm up the engine.

        Tech Tips

        Be sure to perform the inspection when the engine coolant temperature is between 75 and 90°C (167 and 194°F).

      2. A01KI9VE01
        Text in Illustration
        *1 Manifold Absolute Pressure Sensor
        *2 3-Way Connector
        *3 Gas Filter

        Using a 3-way connector, connect SST between the manifold absolute pressure sensor and gas filter.

        SST
        09992-00242

      3. Fully apply the parking brake and chock the 4 wheels.

      4. While depressing the clutch pedal, fully depress the accelerator pedal. Measure the boost pressure at maximum engine speed (approximately 4600 rpm).

        Standard pressure
        5 to 20 kPa (0.05 to 0.2 kgf*cm2, 0.7 to 2.9 psi)

        If the pressure is below the standard, the following problems may be present.


        • The intake system or exhaust system has leakage or blockage.

        • The turbocharger sub-assembly is malfunctioning.

        • The electric EGR control valve does not close.

        • The diesel throttle body does not open.

        • The vacuum hose connected to the diesel turbo pressure sensor (manifold absolute pressure sensor) is cracked or disconnected.

        • The mass air flow meter sub-assembly is malfunctioning.

        • A fuel injector assembly is malfunctioning.

        If the pressure is higher than the standard, check the turbocharger and/or boost control components (turbo motor driver, pressure sensor, vacuum hose, wire harness, etc.).

    7. Chart showing the suspected trouble areas when the pressure is below the standard.

      Tech Tips


      • ○: If a problem listed in the leftmost column of the chart exists, or if the part in the leftmost column of the chart has a malfunction, the value of the Data List item in the uppermost row of the chart will meet the conditions shown in the row labeled "Value which represents a malfunction".

      • The values in the chart are applicable when the engine coolant temperature is between 75 and 90°C (167 and 194°F).

      • The values in the chart are valid in an area with an atmospheric pressure higher than 95 kPa (1.0 kgf*cm2, 14 psi). Standard atmospheric pressure is 101 kPa (1.0 kgf*cm2, 15 psi). Atmospheric pressure decreases by 1 kPa (0.01 kgf*cm2, 0.1 psi) for every 100 m increase in altitude, and is also affected by the current weather conditions.

      • When the altitude increases, atmospheric pressure and MAP decrease.

      Item

      MAP

      (Absolute pressure inside intake manifold)

      MAF

      (Intake air flow rate)

      		 Accel Position Actual Throttle Position Actual EGR Valve Position

      EGR Close Lrn. Status

      (EGR valve fully closed position learning status)

      		 Fuel Pressure Injection Feedback Val #1 (to #4)

      Values taken from an actual normal vehicle

      *1

      		 - 115 to 150 g/ sec. 99% or more 0% 0% OK -

      -3 to +3 mm3/st

      Values which represent a malfunction

      *1

      		 None MAF is less than 115 g/sec.

      Accel Position is not fully depressed position

      *2

      		 Actual Throttle Position is not fully open position Actual EGR Valve Position is not 0%

      NG

      (Determined after performing learning)

      		 Fuel Pressure is below Target Common Rail Pressure by 10 MPa or more (Check while condition steady) Outside of above range
      Turbocharger ○ ○ - - - - - -
      EGR valve does not close or has problem with movement ○ ○ - -

      ○

      (Problem with EGR valve movement)

      *3

      ○

      (EGR valve does not close)

      *3

      		 - -
      Problem with diesel throttle movement

      ○

      (Intake airflow decreases)

      		 ○ - ○ - - - -
      Accelerator pedal cannot be fully depressed or problem with accelerator pedal position sensor exists - ○ ○ - - - - -
      Intake air system leakage or blockage ○ ○ - - - - - -
      Exhaust gas leakage before turbocharger or blockage ○ ○ - - - - - -
      Manifold absolute pressure sensor ○ ○ - - - - - -
      Manifold absolute pressure sensor hose is disconnected ○ ○ - - - - - -
      Mass air flow meter sub-assembly - ○ - - - - - -
      Fuel system (injector, supply pump or common rail) ○ ○ - - - -

      ○

      (Fuel injector leakage, decrease in pressure discharge valve relief pressure or valve is stuck)

      ○

      *4

      Tech Tips


      • *1: These values are measured when the transmission is in 2nd gear, the accelerator pedal is fully depressed, the vehicle is accelerating, and the engine speed is 3000 rpm.

      • *2: The Accel Position is the accelerator opening angle (%) for engine control use. The value indicates around 100% when the accelerator pedal is fully depressed. If the value does not indicate around 100% when the accelerator pedal is fully depressed, the accelerator pedal position sensor circuit or the pedal itself is malfunctioning. When the MIL is illuminated, even with the accelerator pedal fully depressed and an Accel Position of below 70%, it means the fail-safe is restricting the accelerator.

      • *3: DTC P0400 (P2BAB or P2BAC) may be stored at this time. If the actual EGR valve position follows the target EGR valve position slowly, a feeling of hesitation may occur.

      • *4: If Injection Feedback Val # of a cylinder is not within -3 to +3 mm3/st, the corresponding cylinder may have a malfunction (injector or compression). However, in some cases the cylinder may be malfunctioning even if the value is within -3 to +3 mm3/st because these values are injection volume correction values calculated by the ECM at the engine idling and not correction values for the high engine load condition related to the boost pressure control and engine output performance.

  4. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Inspect the power source voltage.


      1. Disconnect the manifold absolute pressure sensor connector.

      2. Turn the ignition switch to ON.

      3. A01KH7LE01
        Text in Illustration
        *a

        Front view of wire harness connector

        (to Manifold Absolute Pressure Sensor)

        Measure the voltage according to the value(s) in the table below.

        Standard Voltage
        Tester Connection Switch Condition Specified Condition
        3 VC (+) - 1 E (-) Ignition switch ON 4.75 to 5.25 V

        If the result is not as specified, inspect the wire harness or ECM Click here.

      4. Connect the manifold absolute pressure sensor connector.

    2. Check the power supply.


      1. Turn the ignition switch to ON.

      2. Disconnect the vacuum hose from the manifold absolute pressure sensor.

      3. Connect a voltmeter to terminals E12-5 (PIM (+)) and E12-16 (EPIM (-)) of the ECM and measure the output voltage at standard atmospheric pressure.

      4. A01KHGPE01
        Text in Illustration
        *1 Vacuum Pump
        *a

        Component with harness connected

        (ECM)
        A01KFFI Vacuum

        Using a vacuum pump, apply vacuum to the pressure sensor in 13.3 kPa (100 mmHg, 3.9 in.Hg) increments until the pressure reaches 40 kPa (300 mmHg, 11.8 in.Hg). Measure the decrease in voltage after each pressure decrease.

        Standard Voltage
        Tester Connection Condition Specified Condition
        E12-5 (PIM +) - E12-16 (EPIM -) 13.3 kPa (100 mmHg, 3.94 in.Hg) 0.8 to 1.1 V
        26.6 kPa (199 mmHg, 7.85 in.Hg) 0.6 to 1.0 V
        40 kPa (300 mmHg, 11.81 in.Hg) 0.4 to 0.8 V

        If the result is not as specified, replace the manifold absolute pressure sensor.

      5. A01KG6VE01
        Text in Illustration
        *a

        Component with harness connected

        (ECM)
        A01KFFI Pressure

        Using SST (turbocharger pressure gauge), apply pressure to the pressure sensor in 19.6 kPa (0.2 kgf*cm2, 2.8 psi) increments until the pressure reaches 98 kPa (1.00 kgf*cm2, 14.2 psi). Measure the increase in voltage after each pressure increase.

        SST
        09992-00242
        Standard Voltage
        Tester Connection Condition Specified Condition
        E12-5 (PIM +) - E12-16 (EPIM -)

        19.6 kPa (0.20 kgf*cm2, 2.84 psi)

        		 1.2 to 1.5 V

        39.2 kPa (0.40 kgf*cm2, 5.69 psi)

        		 1.4 to 1.7 V

        58.8 kPa (0.60 kgf*cm2, 8.53 psi)

        		 1.6 to 1.9 V

        78.5 kPa (0.80 kgf*cm2, 11.4 psi)

        		 1.8 to 2.1 V

        98.0 kPa (1.00 kgf*cm2, 14.2 psi)

        		 2.0 to 2.3 V

        If the result is not as specified, replace the manifold absolute pressure sensor.

  5. CHECK MOTOR FOR TURBOCHARGER CONTROL OPERATION

    CAUTION:


    • Wear protective gloves to prevent injuries and burns when checking the turbocharger.

    • The engine compartment becomes hot when the engine is running.


    1. Remove the No. 1 exhaust manifold heat insulator Click here and No. 1 turbo insulator Click here.

    2. Check the stroke.

      Note

      Make sure the DC motor connectors are properly connected.


      1. Turn the ignition switch from ON to off.

      2. Check the DC motor operation. Check that the motor rod stroke is as shown in A to C in the illustration below.

      3. After the DC motor operates, visually check that the vane actuation link contacts the fully closed stopper.

        Note

        Never loosen or tighten the lock nut of the fully closed stopper.

        A01KGHBE06
        Text in Illustration
        *1 Motor Rod Stroke *2 Ignition Switch
        *3 Ignition Switch Off Time *4 Motor Rod
        *5 Lock Nut *6 Fully Closed Stopper
        *a Fully Closed Stopper Contact *b ON
        *c OFF - -

        If the result is not as specified, check the ECM Click here.

  6. INSPECT SWIRL CONTROL VALVE ASSEMBLY

    A01KGH2

    Note

    Do not adjust the adjusting screw or 2 swirl control valve actuator installation bolts.


    1. Check the operation of the swirl control valve.


      1. Check that the valve is fully opened under normal conditions.

      2. Connect the vacuum pumps as shown in the illustration. First apply negative pressure to the diaphragm closer to the intake manifold. This cause the actuator rod to move, which causes the swirl control valve to move. Then, apply negative pressure to the diaphragm on the outer side. This cause the actuator rod to move further, which also causes the swirl control valve to move further. Check that the valve is fully closed when a negative pressure of 35 kPa (263 mmHg, 10.3 in.Hg) is applied.

      3. Wait for 1 minute and check that the vacuum pump needle does not move. If the result is not as specified, replace the intake manifold.

        Tech Tips

        When applying negative pressure to the diaphragm on the outer side, the diaphragm closer to the intake manifold must be in a vacuum state.

        A01KGAO