INTAKE SYSTEM (w/ EGR Cooler) ON-VEHICLE INSPECTION


  1. CHECK INTAKE AIR 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
      Collapsed or deformed hoses Repair or replace
      Leakage from connections Check each connection and repair
      Cracks in components Check and replace

  2. 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 matter in passages Remove
      Leakage from components Repair or replace
      Cracks in components Check or replace

  3. 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 / Data List / All Data.

    5. A01DUXVE11
      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 30 kPa of Target Booster Pressure when accelerating with accelerator pedal fully depressed.

      Tech Tips


      • The specification above denotes the difference between the absolute pressure values.

      • The inspection above is only for vehicles equipped with a manual transmission.

      • 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 transmission, 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. A01E09NE01

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

        SST
        09992-00242

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

      4. for Manual Transmission:

        While depressing the clutch pedal, fully depress the accelerator pedal. Measure the boost pressure at maximum engine speed (approximately 4600 rpm).

        Standard Pressure (Gauge Pressure)
        15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.1 to 6.5 psi)

      5. for Automatic Transmission:

        Move the shift lever to P or N, and then fully depress the accelerator pedal. Measure the boost pressure at maximum engine speed (approximately 4600 rpm).

        Standard Pressure (Gauge Pressure)
        15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.1 to 6.5 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 or turbo motor driver 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 (turbo motor driver, 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 for vehicles equipped with a manual transmission. For vehicles with an automatic transmission, 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 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.

      or

      EGR Lift Sensor Volt %

      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

      		 - 131 g/sec. 99 % or more 0%

      Actual EGR Valve Pos.:

      0%

      		 OK -

      -3 to +3 mm3/st

      EGR Lift Sensor Volt %:

      Valve fully closed position calculated from EGR Close Lrn. Val.

      Values which represent a malfunction

      *1

      		 MAP is below Target Booster Pressure by 30 kPa or more MAF is less than 118 g/sec.

      Accel Position is not fully depressed position

      *2

      		 Actual Throttle Position is not fully open position

      Actual EGR Valve Pos. is not valve fully closed position

      *3

      NG

      (Determined after performing learning)

      		 Fuel Pressure is below Target Common Rail Pressure by 10 MPa or more (Check while condition steady) Outside of above range

      EGR Valve Lift Sensor Volt % is not valve fully closed position

      *3
      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 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 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. 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: The Data List items indicated on the tester differ according to vehicle model and engine type. If the Actual EGR Valve Pos. is not available but the EGR Lift Sensor Volt %*6is available, check that the EGR Lift Sensor Volt % is always following the Target EGR Position value (e.g. the EGR Lift Sensor Volt % is around fully closed position when the Target EGR Position value indicates 0%*7). 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. and/or EGR Lift Sensor Volt % values are 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.

      • *6: The Data List item EGR Lift Sensor Volt % is calculated from the EGR valve position sensor output voltage. Value is 0 to 5 V converted to 0 to 100%.

        Reference:

        Fully closed: around 15%

        Fully open: around 80%

      • *7: The EGR valve fully closed position value for comparing the EGR Lift Sensor Volt % value during EGR cut can be calculated from the EGR Close Lrn. Val.

        Compare the EGR Lift Sensor Volt % with the calculated EGR valve fully closed position value. If the great difference between the values, the EGR valve may have a malfunction.

        EGR valve fully closed position (%) = EGR Close Lrn. Val. / 5 V (sensor power source voltage) x 100

        The EGR Close Lrn. Status must be OK when applying the values to the formula above.

  4. CHECK MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A01E0K6E03

      Inspect the power source voltage.


      1. Disconnect the pressure sensor connector.

      2. Turn the ignition switch ON.

      3. Measure the voltage between terminals T9-3 (VC (+)) and T9-1 (E (-)) of the wire harness side connector.

        Standard voltage
        4.75 to 5.25 V

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

      4. Turn the ignition switch OFF.

      5. Connect the pressure sensor connector.

    2. A01E1HJE02

      Check the power supply.


      1. Turn the ignition switch ON.

      2. Disconnect the vacuum hose from the pressure sensor.

      3. Connect a voltmeter to terminals E7-28 (PIM (+)) and E8-28 (E2 (-)) of the ECM, and measure the output voltage at ambient atmospheric pressure.

      4. A01DZ7QE01

        Apply a vacuum to the pressure sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) increments until the pressure reaches 40.0 kPa (300 mmHg, 11.81 in.Hg). Measure the decrease in voltage for each increment.

        Standard voltage
        Applied Vacuum Voltage Decrease
        13.3 kPa (100 mmHg, 3.94 in.Hg) 0 to 0.3 V
        26.6 kPa (199 mmHg, 7.85 in.Hg) 0.1 to 0.4 V
        40 kPa (300 mmHg, 11.81 in.Hg) 0.2 to 0.6 V

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

      5. A01DV53E01

        Using SST (turbocharger pressure gauge), apply pressure to the pressure sensor in 19.6 kPa (0.20 kgf/cm2, 2.84 psi) increments until the pressure reaches 98.0 kPa (1.00 kgf/cm2, 14.2 psi). Measure the increase in voltage for each increment.

        SST
        09992-00242
        Standard voltage
        Applied Pressure Voltage Increase

        19.6 kPa (0.20 kgf/cm2, 2.84 psi)

        		 0.05 to 0.3 V

        39.2 kPa (0.40 kgf/cm2, 5.69 psi)

        		 0.25 to 0.55 V

        58.8 kPa (0.60 kgf/cm2, 8.53 psi)

        		 0.45 to 0.75 V

        78.5 kPa (0.80 kgf/cm2, 11.4 psi)

        		 0.65 to 0.95 V

        98.0 kPa (1.00 kgf/cm2, 14.2 psi)

        		 0.9 to 1.2 V

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

  5. CHECK TURBOCHARGER SUB-ASSEMBLY (ACTUATOR OPERATION)

    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 exhaust manifold heat insulator Click here and No. 1 turbo insulator Click here.

    2. Check the stroke.

      Note

      Make sure the DC motor's connectors are properly installed.


      1. Turn the ignition switch from ON to OFF.

      2. Check the DC motor's operation. Check that the motor rod stroke is as shown in A to D in the illustration below.

      3. After the DC motor operates, visually check that the vane activation link contacts the fully closed stopper.

        Note

        Never loosen or tighten the fully closed stopper's lock nut.

        A01DVU7E01

        If the result is not as specified, check the ECM Click here and turbo motor driver Click here.

  6. CHECK TURBO MOTOR DRIVER


    1. A01E0W3E01

      Check the voltage of the turbo motor driver.


      1. Turn the ignition switch ON.

      2. Measure the voltage of the motor driver.

        Standard voltage
        Tester Connection Specified Condition
        T8-3 (+B) - Body ground 9 to 14 V

        If the voltage is not as specified, refer to the following procedures Click here.

    2. A01E291E01

      Check the resistance of the wire harness side connector.


      1. Turn the ignition switch OFF.

      2. Disconnect the T8 wire harness side connector.

      3. Measure the resistance of the motor driver.

        Standard resistance
        Tester Connection Specified Condition
        T8-4 (GND) - Body ground Below 1 Ω

        If the voltage is not as specified, refer to the following procedures Click here.

    3. Connect the T8 turbo motor drive connector.

    4. Check the turbo motor signal.


      1. Connect an oscilloscope to the terminals of the ECM.

      2. While idling the engine, check the waveform of the ECM.

        Standard condition
        ECM Terminal

        (a) Between E8-10 (VNTO) and E7-7 (E1)

        (b) Between E8-17 (VNTI) and E7-7 (E1)
        Tester Range

        (a) 5 V/Division, 20 msec./Division

        (b) 5 V/Division, 50 msec./Division
        Specified Condition Idling with warm engine

        If the result is not as specified, replace the turbo motor driver.

        Tech Tips

        The waveform varies depending on the turbocharger operation.

        A01E0ZDE03