INTAKE SYSTEM ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT INTAKE SYSTEM


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

      A005K8X

  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
      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 air cleaner housing 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 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. A005K4BE18
      Text in Illustration
      *1 Snapshot Record Button

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

      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.

      Standard
      MAP is within 60 kPa 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 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. A005JMWE03
        Text in Illustration
        *1 Turbo Pressure Sensor
        *2 3-Way Connector

        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 the 4 wheels.

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

        Standard Pressure (Gauge Pressure)
        55 to 85 kPa (0.56 to 0.86 kgf/cm2, 7.9 to 12.3 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 turbocharger sub-assembly is malfunctioning.

        • The EGR 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 is malfunctioning.

        • A fuel injector is malfunctioning.

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

    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 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 or more MAF is less than 50 g/sec.

      Accel Position is not fully depressed position

      *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 or more (Check while 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 (injector, supply pump or common rail) ○ ○ - - - -

      ○

      (Fuel injector leakage, decrease in pressure control 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 around 100% when the accelerator pedal fully depressed. If the value does not indicate around 100% when the accelerator pedal 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 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 slowly, a feeling of hesitation may occur.

      • *5: If Injection Feedback Val # of a cylinder is not within -2 to +2 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 -2 to +2 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 TURBO PRESSURE SENSOR


    1. A005K41E02
      Text in Illustration
      *a

      Component without harness connected

      (Turbo Pressure Sensor)
      *b Voltmeter

      Inspect the power source voltage.


      1. Disconnect the turbo pressure sensor connector.

      2. Turn the ignition switch to ON.

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

        Standard Voltage
        Tester Connection Switch Condition Specified Condition
        1 (E2) - 3 (VC) Ignition switch ON 4.5 to 5.5 V

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

      4. Turn the ignition switch off.

      5. Reconnect the turbo pressure sensor connector.

    2. Check the power supply.


      1. Warm up the engine.

      2. Turn the ignition switch off.

      3. Connect an intelligent tester to the DLC3.

      4. Turn the ignition switch to ON and turn the tester on.

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

      6. Disconnect the vacuum hose from the turbo pressure sensor.

      7. A005HJOE02
        Text in Illustration
        *a Vacuum

        Apply negative pressure to the turbo pressure sensor and confirm that a vacuum occurs.

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

      8. A005I6IE02
        Text in Illustration
        *a Pressure

        Using SST, apply pressure to the turbo pressure sensor and make sure that the pressure increases.

        SST
        09992-00242

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