INTAKE SYSTEM ON-VEHICLE INSPECTION

INSPECT INTAKE SYSTEM
1. Check that there is no air suction or leaks at the points shown in the illustration.
  - For engine room area:
    
    Text in Illustration
    
    *A for RHD - -
  - For engine area:

Text in Illustration
*A	for RHD	-	-

CHECK INTAKE AIR CONTROL SYSTEM

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

CHECK EXHAUST SYSTEM

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

CHECK BOOST PRESSURE

Connect the intelligent tester to the DLC3.
Start the engine and turn the tester on.
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).
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.
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.

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 inspection above is only for vehicles equipped with a manual transaxle.
If the driving inspection using the intelligent tester above cannot be performed (e.g. due to road conditions), or if the vehicle is equipped with an automatic transaxle, perform the following inspection.

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).

Text in Illustration
*1	Gas Filter
*2	Diesel Turbo Pressure Sensor
*3	3-Way Connector

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

SST: 09992-00242

for Manual Transaxle:

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

Standard pressure

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

57.2 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 electric EGR control valve does not close.
- The diesel throttle body does not open.
- The vacuum hose connected to the diesel turbo 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 vacuum regulating valve.

Standard pressure
49 to 71 kPa (0.5 to 0.7 kgf/cm², 7.1 to 10.3 psi)

Standard pressure
57.2 to 63.8 kPa (0.5 to 0.7 kgf/cm², 7.6 to 9.3 psi)

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 for vehicles equipped with a manual transaxle. For vehicles with an automatic transaxle, use these values as a reference only as they may differ from the actual values.
The values in the chart are valid in an area with an 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 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	-	117 g/sec	99.60%	0%	0%	OK	-	-3 to +3 mm³/st
Values which represent a malfunction *1	MAP is lower than Target Booster Pressure by 25 kPa or more	MAF is less than 90 g/sec	Accel Position is less than 90%	Actual Throttle Position is not within 5% of Target Throttle Position	Actual EGR Valve Position is not within 5% of Target EGR Valve Position	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) *2	○ (EGR valve does not close) *2	-	-
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	○	○	-	-	-	-	-	-
Diesel turbo pressure sensor	○	○	-	-	-	-	-	-
Diesel turbo 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)	○ *3

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: 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.
*3: If Injection Feedback Val # of a cylinder is not within -3 to +3 mm³/st, the corresponding cylinder has 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.

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 No. 1 engine cover.
2. Disconnect the vacuum hose from the actuator.
3. Connect a vacuum pump to the actuator.
4. 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.
5. Connect the vacuum hose from the actuator.
6. Install the No. 1 engine cover.