INTAKE SYSTEM ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT INTAKE SYSTEM


    1. Check that there are no vacuum leaks at the points shown in the illustration.

      B0044B8
      B0043XEC02
      *A for LHD *B for RHD
      B0043A1

  2. 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 sub-assembly.

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

  3. CHECK EXHAUST SYSTEM


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

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

  4. CHECK BOOST PRESSURE


    1. Connect the GTS to the DLC3.

    2. Start the engine.

    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. Turn the GTS on.

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

    6. Take a snapshot of the Data List items with the GTS.

      Tech Tips

      The condition of the turbocharger sub-assembly 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.

    7. Compare MAP with Target Booster Pressure.

      Standard
      MAP is within 60 kPa (0.6 kgf/cm2, 8.7 psi) of Target Booster Pressure when accelerating with accelerator pedal fully depressed.

      Tech Tips


      • The specifications above denote the difference between the absolute pressure values.

      • If the road test using the GTS 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. B00448EC03
        *1 Manifold Absolute Pressure Sensor (Diesel Turbo Pressure Sensor)
        *a 3-way Connector
        *b SST

        Using a 3-way connector, connect SST (turbocharger pressure gauge) to the hose leading to the intake air connector.

        SST
        09992-00242

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

      4. for Manual Transaxle:

        While depressing the clutch pedal, fully depress the accelerator pedal. Measure the boost pressure at maximum engine speed (approximately 5100 to 5250 rpm).

        Standard Boost Pressure (Gauge Pressure)
        55 to 85 kPa (0.6 to 0.9 kgf/cm2, 8.0 to 12.3 psi)

      5. for Multi-mode Manual Transaxle:

        Move the shift lever to N, and then fully depress the accelerator pedal. Measure the boost pressure at maximum engine speed (approximately 5100 to 5250 rpm).

        Standard Boost Pressure (Gauge Pressure)
        55 to 85 kPa (0.6 to 0.9 kgf/cm2, 8.0 to 12.3 psi)

        If the boost pressure is lower than 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 EGR valve does not close.

        • The diesel throttle body does not open.

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

        • The mass air flow meter is malfunctioning.

        • A fuel injector is malfunctioning.

        If the pressure is higher than the standard, check the turbocharger sub-assembly and/or boost control components (manifold absolute pressure sensor (diesel turbo pressure sensor), vacuum hose, wire harness, etc.).

    8. The following chart shows the suspected trouble areas when the pressure is lower than 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 "Values which represent 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 absolute atmospheric pressure higher than 95 kPa (1.0 kgf/cm2, 13.8 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 (328 ft.) 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 Pos.

      EGR Close Lrn. Status

      (EGR valve fully closed position learning status)

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

      Values taken from an actual normal vehicle

      *1

      		 - 77 g/sec. 99% or more 0% 0% None -

      -2 to +2 mm3/st

      Values which represent a malfunction

      *1

      MAP is lower than Target Booster Pressure by 60 kPa (0.6 kgf/cm2, 8.7 psi) or more

      		 MAF is less than 50 g/sec.

      Accel Position is not fully depressed

      *2

      		 Actual Throttle Position is not within 10% of Target Throttle Position

      Actual EGR Valve Pos. is more than 10%

      *3

      		 None

      Fuel Pressure is lower than Target Common Rail Pressure by 10 MPa (101.9 kgf/cm2, 1450 psi) or more (Check while in steady condition)

      		 Outside of above range
      Turbocharger ○ ○ - - - - - -
      EGR valve does not close or has problem with movement ○ ○ - -

      ○

      (Problem with EGR valve movement)

      *4

      ○

      (EGR valve does not close)

      *4

      		 - -
      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 (fuel filter, injector, supply pump or common rail) ○ ○ - - - -

      ○

      (Fuel filter is clogged, fuel injector leakage, decrease in pressure control valve relief pressure or valve is stuck)

      ○

      *5

      Tech Tips


      • *1: These values are measured when the transaxle 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 (%) used for engine control. 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.

      • *3: Check that the Actual EGR Valve Pos. value is around the fully closed position when the engine running conditions prohibit EGR operation.

        In some cases the EGR valve may be malfunctioning even if the Actual EGR Valve Pos. value is normal. Inspect the EGR valve for any defects (deposits, valve stuck, poor movement, etc.) if necessary.

      • *4: DTC P0400 may be stored at this time. If the actual EGR valve position follows the target EGR valve position too slowly, a hesitation may occur.

      • *5: If Injection Feedback Val # of a cylinder is not within -2 to +2 mm3/st, the corresponding cylinder may be malfunctioning (injector or compression). However, in some cases, the cylinder may be malfunctioning even if the value is within -2 to +2 mm3/st because these values are injection volume correction values calculated by the ECM when the engine is idling and not correction values for the high engine load condition related to the boost pressure control and engine output performance.

  5. CHECK TURBOCHARGER SUB-ASSEMBLY


    1. B0041UZC06
      *1 Actuator Sub-assembly
      *a Idling to Ignition Switch Off
      *b Ignition Switch ON to Idling

      Check the motor movement when turning the ignition switch to ON, when starting the engine, and then when turning the ignition switch off.

      OK
      Actuator sub-assembly moves smoothly as shown in the illustration.