INTAKE SYSTEM ON-VEHICLE INSPECTION


  1. INSPECT INTAKE SYSTEM


    1. Check that there is no air suction or leaks at the points shown in the illustration.


      • For engine room area:

        A00E97BE01
      • For engine area:

        A00E8XKE01
  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.

      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
  3. 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
  4. 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. A00E9JXE11

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

      Text in Illustration

      *1

      Snapshot Record Button

      Tech Tips


      • Graphs can be displayed by transferring the stored snapshot 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.

      Tech Tips

      The specification below denote the difference between the absolute pressure values.

      Standard (for Manual Transaxle)
      MAP is within 30 kPa of Target Booster Pressure when accelerating with accelerator pedal fully depressed.
      Standard (for Automatic Transaxle)
      MAP is within 25 kPa of Target Booster Pressure when accelerating with accelerator pedal fully depressed.

      Tech Tips

      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. A00E8HGE01

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

        SST
        09992-00242
        Text in Illustration

        *1

        Gas Filter

        *2

        Manifold Absolute Pressure Sensor

        *3

        3-Way Connector
      3. Measure the boost pressure.


        • for Manual Transaxle:

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

          Standard pressure (Gauge Pressure for Manual Transaxle)
          49 to 71 kPa (0.5 to 0.7 kgf/cm2, 7.1 to 10.3 psi)
        • for Automatic Transaxle:

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

          Standard pressure (Gauge Pressure for Automatic Transaxle)
          52.7 to 63.8 kPa (0.5 to 0.7 kgf/cm2, 7.6 to 9.3 psi)

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


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

        • The vacuum hose connected to the turbocharger actuator is cracked or disconnected.

        • The turbocharger sub-assembly or vacuum regulating valve 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 is cracked or disconnected.

        • The mass air flow meter is malfunctioning.

        • A fuel injector assembly is malfunctioning.

        If the pressure is higher than the standard, check the turbocharger and vacuum regulating valve.

    7. Chart showing 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 "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 absolute atmospheric pressure higher than 95 kPa. (Standard atmospheric pressure is 101 kPa. Atmospheric pressure decreases by 1 kPa 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 Pos.

      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

      -
      • for MT:

        120 g/sec


      • for AT:

        117 g/sec

      99.60% 0% 0% OK -

      -3 to +3 mm3/ st

      Values which represent a malfunction

      *1


      • for MT:

        MAP is lower than Target Booster Pressure by 30 kPa or more


      • for AT:

        MAP is lower than Target Booster Pressure by 25 kPa or more


      • for MT:

        MAF is less than 93 g/sec


      • for AT:

        MAF is less than 90 g/sec

      Accel Position is less than 90%

      *2

      Actual Throttle Position is not within 5% of Target Throttle Position

      Actual EGR Valve Pos. is more than 5%

      *3

      NG

      (Determined after performing learning)

      Fuel Pressure is lower than Target Common Rail Pressure by 10 MPa or more (Check while steady condition) Outside of above range
      Turbocharger - - - - - -
      Turbocharger actuator hose is disconnected - - - - - -
      E-VRV - - - - - -
      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 - - - - - - -

      Fuel system

      (injector, supply pump or common rail)

      - - - -

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

      *5

      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 99.60% when the accelerator pedal fully depressed. If the value indicates less than 90% when the accelerator pedal 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: Check that the Actual EGR Valve Pos. is around 0% when the Target EGR position value indicates 0%. The EGR valve may be malfunctioning if the value is stuck or does not fluctuate smoothly. However, 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 slowly, a feeling of hesitation may occur.

      • *5: 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.

  5. CHECK TURBOCHARGER SUB-ASSEMBLY

    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 front wiper motor and link assembly Click here.

    2. Remove the inner cowl top panel.

    3. Remove the No. 1 engine cover.

    4. Disconnect the vacuum hose from the actuator.

    5. A00EAS2

      Connect a vacuum pump to the actuator.

    6. Check that the rod moves toward the actuator when vacuum is applied to the actuator.

      If the rod does not move, replace the turbocharger sub-assembly.

    7. Reconnect the vacuum hose to the actuator.

    8. Install the No. 1 engine cover.

    9. Install the inner cowl top panel.

    10. Install the front wiper motor and link assembly Click here.