Intake System -- On-Vehicle Inspection |
| 1. INSPECT INTAKE SYSTEM |
Check that there is no air suction or leaks at the points shown in the illustration.
Text in Illustration *1 Air Cleaner *2 Mass Air Flow Meter Sub-assembly *3 Turbocharger Sub-assembly *4 PCV Pipe *5 EGR Cooler *6 No. 2 EGR Valve *7 Intercooler *8 Diesel Throttle Body *9 Vacuum Switching Valve (for EGR By-pass Valve) *10 Intake Air Temperature Sensor *11 Electric EGR Control Valve *12 Vacuum Switching Valve (for Swirl Control Valve) *13 Swirl Control Valve *14 Vacuum Switching Valve (for Engine Mounting) *15 Front Engine Mounting Insulator RH *16 Front Engine Mounting Insulator LH *17 Intake Manifold *18 Vacuum Pump
| 2. 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
| 3. 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
| 4. CHECK BOOST PRESSURE |
Connect the GTS to the DLC3.
Start the engine and turn the tester on.
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).
Enter the following menus: Powertrain / Engine / Data List / All Data.
Take a snapshot of the Data List items with the GTS.
- HINT:
- The condition of the turbocharger sub-assembly 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 25 kPa of Target Booster Pressure when accelerating with accelerator pedal fully depressed.
- HINT:
- If the driving inspection using the GTS above cannot be performed (e.g. due to road conditions), perform the following inspection.
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) between the manifold absolute pressure sensor and No. 1 gas filter.
- SST
- 09992-00242
Text in Illustration *1 Manifold Absolute Pressure Sensor *2 No. 1 Gas Filter *a 3-Way Connector for Manual Transmission:
While depressing the clutch pedal, fully depress the accelerator pedal. Measure the boost pressure at maximum engine speed (4450 to 4750 rpm).- Standard pressure:
- 11.4 to 47.2 kPa (0.1 to 0.5 kgf/cm2, 1.7 to 6.8 psi)
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 (4450 to 4750 rpm).- Standard pressure:
- 11.4 to 47.2 kPa (0.1 to 0.5 kgf/cm2, 1.7 to 6.8 psi)
- The intake system or exhaust system has leakage or blockage.
- The turbocharger sub-assembly is malfunctioning.
- The electric EGR control valve does not close.
- The diesel throttle body assembly does not open.
- The vacuum hose connected to the manifold absolute pressure sensor is cracked or disconnected.
- The mass air flow meter sub-assembly is malfunctioning.
- A fuel injector assembly is malfunctioning.
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 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 atmospheric pressure higher than 95 kPa (1.0 kgf/cm2, 14 psi). Standard atmospheric pressure is 101 kPa (1.0 kgf/cm2, 15 psi). Atmospheric pressure decreases by 1 kPa (0.01 kgf/cm2, 0.1 psi) 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- 133 g/sec. 99.6% 0% 0% OK - -3 to +3 mm3/st Values which represent a malfunction
*1MAP is below Target Booster Pressure by 35 kPa or more MAF is less than 105 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 below Target Common Rail Pressure by 10 MPa or more (Check while condition steady) Outside of above range Turbocharger ○ ○ - - - - - - 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 ○ ○ - - - - - - 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)○
*3- 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: 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.