ECD SYSTEM(w/ Urea SCR System), Diagnostic DTC:P202D

DTC Code	DTC Name
P202D	Reductant Leakage

DESCRIPTION

P202D
DTC Detection Drive Pattern	DTC Detection Condition	Trouble Area
Idle the engine for 30 seconds or more	Condition1: When the rotation of the urea pump is equal to or greater than a fixed value, the pressure sensor value is below a fixed value. (1 trip detection logic) Condition2: When the level sensor value is equal to or greater than a fixed value and the injection accumulation amount is below a fixed value, the level sensor value decreases by a fixed value or greater compared to the last time the level sensor value was acquired. (1 trip detection logic)	Urea tube with heater assembly Urea injector set Urea pump

Related Data List
DTC No.	Data List
P202D	Reductant Level

CAUTION / NOTICE / HINT

Note

Handling urea solution

Wear protective equipment as necessary (protective glasses and gloves).
Do not dilute urea solution.
If urea solution contacts your eyes or skin, immediately wash the contacted area with a large amount of water and consult a doctor as necessary.
If urea solution dries, it deposits a white powder. Also, if urea solution contacts metals such as copper and aluminum for a long period of time, it may promote corrosion. Therefore, if urea solution is spilled, dampen a cloth or other item and wipe it up or rinse the area with cool or warm water.

Handling the urea injector set

The urea injector set is a precision instrument. Take necessary precautions for installation and shipping. Do not use the part if it has been struck or dropped.
If the urea solution remaining inside the urea injector set dries out, it may become unable to inject urea solution. Therefore, conduct urea tube with heater assembly installation and removal quickly.
If the urea solution dries out and deposition occurs, urea may cling to the O-ring of the pipe and cause seal problems. Therefore, clean the urea tube with heater assembly and intake port of the urea injector set with water before attaching them.
Perform this procedure in an environment where urea solution will not freeze.

Tech Tips

Read freeze frame data using the GTS. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, and other data from the time the malfunction occurred.

PROCEDURE

CHECK DTC OUTPUT

Connect the GTS to the DLC3.
Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

Result

Result	Proceed to
DTC P202D is output	A
DTC P202D and other DTCs are output*	B

Tech Tips

*: If any other DTCs (CAN communication malfunctions or open/short circuits) are output, perform troubleshooting for those DTCs first.

GO TO DTC CHART Click here

CHECK AROUND BOTTOM OF VEHICLE
1. Check around the bottom of the vehicle.
  
  Tech Tips
  
  If the urea solution dries on an object, deposition occurs and leaves behind a white powder.
  
  Area to check:
  - Areas connecting the urea pump and urea injector set.
  - Perforations in the urea tank sub-assembly.
  - Connectors not connected properly
  - Clogging of the cooling fins of the urea injector set
    
    Tech Tips
    
    If the cooling fins are clogged with foreign matter, remove the foreign matter and clean the cooling fins.
  Standard
  
  No urea solution leaks.
NG
REPAIR UREA SOLUTION LEAKS

OK
PERFORM ACTIVE TEST USING GTS (CHECK UREA INJECTOR OPERATION)
1. Connect the GTS to the DLC3.
2. Turn the engine switch on (IG) and turn the GTS on.
3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Pump Check (Backward).
4. Perform the Active Test.
5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Purge.
6. Perform the Active Test.
  
  Tech Tips
  
  Perform the Reductant Purge to draw the urea solution back into the urea tank sub-assembly from the urea injector set.
7. After performing the Active Test, remove the urea injector set from the front exhaust pipe assembly.
  Tech Tips
  - Do not disconnect the urea injector set from the urea tube with heater assembly.
  - Use a cover, etc., to prevent foreign matter from entering the exhaust pipe.
8. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Injection Valve.
9. Perform the Active Test and check for the sound of the urea injector set operating.
  
  Standard value
  
  Sound of urea injector set operation can be heard (a ticking sound).
NG
REPLACE UREA INJECTOR SET Click here

OK
PERFORM ACTIVE TEST USING GTS (CHECK INJECTION CONDITION OF UREA INJECTOR SET)
1. Prepare a bucket or other receptacle for collecting urea solution from the urea injector.
2. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Filling (Pressure Keep).
3. Execute "Reductant Filling (Pressure Keep)" and prepare to inject urea.
  Note
  - While "Reductant Filling (Pressure Keep)" is being executed, the pressure inside the pipe increases and the urea injector set intermittently opens, which may cause a certain amount of urea solution to leak out.
  - If the urea injector set is stuck open, urea solution will leak out continuously because intermittent operation cannot be performed once this operation starts.
4. After "Reductant Filling (Pressure Keep)" completes, enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Injection Valve.
5. Execute the Active Test and check the injection condition of the urea injector set.
  
  Standard value
  
  Urea solution is intermittently injected by the urea injector.
  
  Tech Tips
  
  If the urea injector set is stuck open, urea solution will leak out continuously because intermittent injection cannot be performed once this Active Test starts.
NG
CLEAN UREA INJECTOR SET Click here

OK
PERFORM ACTIVE TEST USING GTS (CHECK LEVEL SENSOR (UREA PUMP)
1. Turn the engine switch on (IG) and turn the GTS on.
2. Enter the following menus: Powertrain / Engine and ECT / Data List / Reductant Level.
3. Check the value of "Reductant Level". If the value of the level is 1, refill the urea solution.
  
  Tech Tips
  
  Refill approximately 3 to 5 L.
4. Disconnect the urea injector set from the urea tube with heater assembly.
  
  Note
  
  If the urea solution remaining inside the urea injector set dries out, it may become unable to inject urea solution. Therefore, seal the urea injector set with an item such as a cover or rubber cap so that the inside does not dry out.
5. Prepare a bucket or other receptacle for collecting urea solution from the urea tube with heater assembly.
6. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Discharge / Data List / Reductant Level.
7. Execute the Active Test and check the urea solution level.
  
  Note
  
  When the Active Test is executed, urea solution will come out of the urea tube with heater assembly. Collect the urea solution with a bucket or other receptacle.
  
  Standard
  
  Urea solution level decreases.
  
  Tech Tips
  
  When the level sensor value is stuck, the value does not decrease even when the urea solution is released.
8. Refill approximately 3 to 5 L of urea solution.
  
  Standard
  
  Urea solution level increases.
  
  Tech Tips
  
  When the level sensor value is stuck, the value does not increase even when the urea solution is refilled.
9. Install the urea injector set Click here.
OK
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

NG
REPLACE UREA PUMP Click here
REPLACE UREA INJECTOR SET
1. Replace the urea injector set Click here.
NEXT
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here
CLEAN UREA INJECTOR SET
1. Wash off any matter deposited by the urea solution.
  Note
  - Do not damage the urea injector set when washing it.
  - Make sure to leave the connector connected when washing to prevent water from entering via the connector.
  - Sufficiently wipe the area so that no urea solution remains on the flange sealing surface.
  - After washing, check that 3 streams of liquid are sprayed from the urea injector set.
NEXT
PERFORM ACTIVE TEST USING GTS (CHECK LEVEL SENSOR (UREA PUMP) Click here
REPLACE UREA PUMP
1. Replace the urea pump Click here.
NEXT
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
1. Connect the GTS to the DLC3.
2. Turn the engine switch on (IG) and turn the GTS on.
3. Clear the DTCs Click here.
4. Turn the engine switch off and wait for at least 30 seconds.
5. Turn the engine switch on (IG) and turn the GTS on.
6. Start the engine and wait for 30 minutes or more.
7. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
8. Confirm that the DTC is not output again.
NEXT
END