Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Kd-Ftv Intake Exhaust. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
Intake System (W/O Dpf) -- On-Vehicle Inspection |
| 1. CHECK INTAKE AIR SYSTEM |
Check that there is no air suction or leaks at the points shown in the illustration.
Text in Illustration (w/ EGR Cooler) *1 Air Cleaner *2 Mass Air Flow Meter *3 Turbocharger *4 Ventilation Pipe *5 EGR Cooler *6 No. 2 EGR Valve *7 Vacuum Switching Valve
(for EGR By-pass Valve)*8 Intercooler *9 Intake Air Temperature Sensor *10 Diesel Throttle Body *11 Manifold Absolute Pressure Sensor *12 EGR Valve *13 Electric Vacuum Regulating Valve
(for EGR Valve)*14 Vacuum Switching Valve
(for Swirl Control Valve)*15 Swirl Control Valve *16 Vacuum Pump 
Text in Illustration (w/ EGR System without EGR Cooler) *1 Air Cleaner *2 Mass Air Flow Meter *3 Turbocharger *4 Diesel Throttle Body *5 Manifold Absolute Pressure Sensor *6 EGR Valve *7 Electric Vacuum Regulating Valve
(for EGR)*8 Vacuum Pump 
Text in Illustration (w/o EGR System) *1 Air Cleaner *2 Mass Air Flow Meter *3 Turbocharger *4 Diesel Throttle Body *5 Manifold Absolute Pressure Sensor *6 Ventilation Pipe *7 Vacuum Pump - -
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 |
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 and replace
| 3. CHECK BOOST PRESSURE |
Warm up the engine.
- HINT:
- Be sure to perform the inspection when the engine coolant temperature is between 75 and 90°C (167 and 194°F).
Using a 3-way connector, connect SST (turbocharger pressure gauge) to the hose between the manifold absolute pressure sensor and the gas filter leading to the intake air connector.
- SST
- 09992-00242
Text in Illustration *A w/ Intercooler *B w/o Intercooler *1 Gas Filter *2 3-Way Connector
 |
Fully apply the parking brake and chock the 4 wheels.
w/ EGR System:
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):
- 53 to 83 kPa (0.5 to 0.8 kgf/cm2, 7.7 to 12 psi)
- 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.
w/o EGR System:
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):
- 53 to 83 kPa (0.5 to 0.8 kgf/cm2, 7.7 to 12 psi)
- The intake system or exhaust system has leakage or blockage.
- The turbocharger sub-assembly is malfunctioning.
- 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.
- A fuel injector is malfunctioning.
w/ EGR System:
Chart showing the suspected trouble areas when the pressure is below the standard.- HINT:
- ○: 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 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- 90 g/sec. 99% or more 0% Valve fully closed position calculated from EGR Close Lrn. Val. OK - -3 to +3 mm3/st Values which represent a malfunction
*1None MAF is less than 81 g/sec. Accel Position is not fully depressed position
*2Actual Throttle Position is not fully open position EGR Valve Lift Sensor Volt % is not valve fully closed position
*3NG (Determined after performing learning)
*3Fuel 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 discharge valve relief pressure or valve is stuck)○
*5- HINT:
- *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: Check that the EGR Lift Sensor Volt %*6 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 EGR Lift Sensor Volt % 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.
- *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 exists between the values, the EGR valve may have a malfunction.
EGR valve fully closed position (%) = EGR Close Lrn. Val. / Sensor power source voltage 5 V x 100
The EGR Close Lrn. Status must be OK when applying the values to the formula above.
w/o EGR System:
Chart showing the suspected trouble areas when the pressure is below the standard.- HINT:
- ○: 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)Accel Position Actual Throttle Position Fuel Pressure Injection Feedback Val #1 (to #4) Values taken from an actual normal vehicle
*1- 99% or more None - -3 to +3 mm3/st Values which represent a malfunction
*1None Accel Position is not fully depressed position
*2None Fuel Pressure is below Target Common Rail Pressure by 10 MPa or more (Check while condition steady) Outside of above range Turbocharger ○ - - - - 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- HINT:
- *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: 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.