Group 17 Emission Control

GROUP 17 EMISSION CONTROL
STRUCTURE AND OPERATION

1. Exhaust Gas Recirculation System ............................................... 17-2
2. Blowby Gas Return System .......................................................... 17-7
EXHAUST GAS RECIRCULATION SYSTEM

1. Diagnosis Procedure .................................................................... 17-8
2. Diagnostic Precautions ................................................................ 17-8
3. Inspections Based on Diagnosis Codes ....................................... 17-9
4. Multi-Use Tester Service Data ..................................................... 17-17
5. Actuator Tests Performed Using Multi-Use Tester....................... 17-17
6. Inspections Performed at Electronic Control Unit Connectors.... 17-18
7. Inspection of Electrical Equipment ............................................. 17-19
8. Installed Locations of Parts ........................................................ 17-22
9. Electric Circuit Diagram .............................................................. 17-26
EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER .. 17-30
CRANKCASE EMISSION CONTROL SYSTEM............................... 17-32
17-1
1. Exhaust Gas Recirculation System
1.1 Overview
• In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con-
trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various
aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.).
• Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into
the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx),
which are harmful, in the exhaust emissions.
Further, an exhaust gas recirculation cooler cools the recirculated exhaust emissions, thereby reducing the peak
combustion temperature.
• The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas
recirculation is maximized.
17-2
17
1.2 Electronic control system
(1) System block diagram
Input signals Engine electronic control unit Output signals
Engine speed sensor EGR valve control Engine warning lamp

function
Water temperature sensor
Accelerator pedal position Exhaust brake 3-way

sensor Intake throttle magnetic valve
control function
Fault diagnosis
Diagnosis switch function EDU relay
Intake air temperature sensor
Boost air temperature sensor
Air flow sensor
CAN communication
Motor Motor drive signals Motor drive signals Motor
Position sensor Valve position data Valve position data Position sensor
EGR valve Fault data Fault data Intake throttle
EGR EDU Throttle EDU
CAN: Controller area network

EGR: Exhaust gas recirculation
EDU: Electronic drive unit
17-3
(2) Exhaust gas recirculation valve control function
• In accordance with data from sensors, the engine electronic control unit determines the exhaust gas recirculation
valve opening that suits the operating condition and sends a control signal (this indicates the target exhaust gas
recirculation valve opening) to the exhaust gas recirculation electronic drive unit.
When necessary to prevent black smoke emissions and engine speed instability (for example, when the engine is
heavily loaded, when the engine is lightly loaded, and when the exhaust brake is operating), the engine electronic
control unit stops exhaust gas recirculation valve control.
• The exhaust gas recirculation electronic drive unit activates the exhaust gas recirculation valve motor. At the
same time, it monitors the extent of valve lift using a position sensor and sends this information (this indicates the
actual exhaust gas recirculation valve opening) to the engine electronic control unit.
This operation makes it possible for the target exhaust gas recirculation valve opening indicated by the engine
electronic control unit to be precisely maintained.
(2.1) Exhaust gas recirculation valve
• DC motor in the exhaust gas recirculation valve is driven by con-
trol signals from the exhaust gas recirculation electronic drive
unit. Via a rod, the motor’s operation opens and closes the
valve.
(3) Intake throttle control function

• When the engine electronic control unit determines from sensor data on the engine speed and engine loading that
the vacuum pressure in the intake manifold is low, it increases the amount of exhaust emissions introduced into
the intake manifold by determining an appropriate butterfly valve opening and by sending corresponding control
signals (these indicate the target throttle opening) to the throttle electronic drive unit.
• The throttle electronic drive unit activates the valve motor. At the same time, it monitors the valve opening using a
position sensor and sends this information (this indicates the actual throttle opening) to the engine electronic con-
trol unit.
This operation makes it possible for the target throttle opening indicated by the engine electronic control unit to be
precisely maintained.
17-4
17
(3.1) Intake throttle
• In accordance with signals from the throttle electronic drive unit,
the motor opens and closes the butterfly valve, thereby adjusting
the intake air amount such that the effectiveness of exhaust gas
recirculation is maximized.
(4) Fault diagnosis function

• The engine electronic control unit continuously monitors the electronic drive units and sensors for faults. In the
event that the engine electronic control unit finds a component faulty, it causes an indication to be made in the
meter cluster to alert the driver. At the same time, it memorizes the fault location in the form of a diagnosis code
and starts a control during fault.
• While the engine is running, the exhaust gas recirculation electronic drive unit and throttle electronic drive unit
continuously monitor communication with the position sensor and motor of the exhaust gas recirculation valve,
communication with the position sensor and motor of the intake throttle, and communication with the engine elec-
tronic control unit. In the event that they identify a fault, they send fault data to the engine electronic control unit.
• While control necessitated by a fault is taking place, the system’s functionality is limited to ensure vehicle and
driver safety. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the
warning lamp.
• The control during fault recovers by servicing the faults. However, for some diagnosis codes, the warning lamp
stays illuminated until the normal signals are input for several times.
• Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different.
• The Multi-Use Tester is capable of showing more detailed diagnosis codes.
17-5
1.3 Electronic control unit connection diagram
17-6
17
2. Blowby Gas Return System
• The crankcase emission control system returns blowby gases to an air hose to prevent them from being released
to the outside air.
• The positive crankcase ventilation valve keeps constant the pressure inside the crankcase.
17-7
1. Diagnosis Procedure
• The system can be efficiently inspected for faults using a Multi-Use Tester.
System inspection can be accomplished basically in two ways according to trouble symptom and diagnosis code
as shown below.
• Check against each diagnosis code stored in memory by the electronic control unit
• Response to transient fault
Warning lamp lit
Vehicle in service shop
Read diagnosis code. (See Gr00.)
Fault code output Normal code output No communication with

Normal code output
after cleared Multi-Use Tester
Check against each diagnosis Response to transient fault (See Gr00.)

code
If communication cannot be established with all systems, the diag-

nosis circuit can most probably be the cause. If this system alone is
impossible to communicate, the system’s diagnosis output or power
circuit (including ground circuit) may be open.
Clear stored diagnosis code. (See Gr00.)
Test drive
After test driving, check for diagnosis code and warning lamp lighting. If diagnosis code is issued and warn-
ing lamp is lit, check fault again.
Clear stored diagnosis code. (See Gr00.)
2. Diagnostic Precautions
• Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is per-
formed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved.
• To avoid having electrical parts damaged, set the starter switch and lighting switch to LOCK or OFF before dis-
connecting and reconnecting battery cables.
• Before disconnecting connectors, set the starter switch to LOCK or OFF, then allow at least 20 seconds. Voltage
may remain in electric parts or connected circuit.
• When performing measurement with the tester, handle the test bar carefully so that it does not damage internal
circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in
connector or between connector and car body.
• Resistance is affected by temperature. Determine the necessity of resistance measurement following given tem-
perature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.
17-8
17
3. Inspections Based on Diagnosis Codes
3.1 Diagnosis code list
• Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different.
• The Multi-Use Tester is capable of showing more detailed diagnosis codes.
• The control during fault recovers by servicing the faults. However, for some diagnosis codes, the warning lamp
stays illuminated until the normal signals are input for several times.
Code Message Flashes Non-erasable
P0101 Airflow Sensor (Plausibility) 17 O

P0102 Airflow Sensor (Low) 17
P0103 Airflow Sensor (High) 17
P0120 TVA SNSR 28
P0401 EGR Flow (Insufficient) 2 O
P0402 EGR Flow (Excessive) 2 O
P0403 EGR1 (Actuator Circuit) 67
P0409 EGR1 (Position Sensor) 67
P040C EGR Gas Temp Sensor (Low) 9
P040D EGR Gas Temp Sensor (High) 9
P0600 CAN Communication 64,73
P0685 EDU Relay (Open) 84
P0686 EDU Relay (Low) 84
P0687 EDU Relay (High) 84
P1C01 Inter Cooler Performance 27
P2002 DPF MFF 55
P2100 TVA (Open) 28
P2101 TVA (System) 28
P2102 TVA (Short) 28
P2135 TVA SNSR (Voltage) 28
P2199 EGR Temp Sensor (Correlation) 9
P2413 EGR System 67
P242F DPF MFF (Accumulation) 55
P2453 DPF Diff SNSR (Plausi) & MFF 97
P2454 DPF Diff SNSR (Low) & MFF 97
P2455 DPF Diff SNSR (High) & MFF 97
P2457 EGR Cooler Performance 2
3.2 Diagnosis code generation conditions and inspection items
P0101: Airflow Sensor (Plausibility) (warning lamp flashes: 17)

Engine electronic control unit has judged air flow sensor abnormal as a result of
Generation condition
comparison with conditions of other sensors.
O sistema
System é reposta
recovers emvalid
if any estado normal
signal se when
is input um sinal válido
starter for enviado
switch is turnedquando
o interruptor
from OFF to do motor de arranque passar de OFF para ON (o indicador
Recoverability
luminoso
ON não se lamp
(the warning apaga a não
does not ser queunless
go out sejam 3enviados 3 sinais
consecutive valid válidos
signals are
consecutivos).
input).
• Realiza
Carriesoout controlcom
controlo using
umavalor
backupde value
apoio (airflow
(a taxa rate equivalent
do fluxo de ar étoigual
rate àfortaxa
low
idle
do speed operation).
funcionamento de velocidade de ralenti reduzida).
Control effected by electronic
• AInjection
quantidadequantity is limited.
da injecção é limitada.
control unit
• OExhaust
contrologas
de recirculation
recirculação control
do gás isdestopped.
escape é interrompido.
• OThrottle
controlocontrol is stopped.
do regulador é interrompido.
Service data 60: Air mass flow
Inspection Electrical equipment #306: Air flow sensor
Electric circuit diagram Air flow sensor system
17-9
P0102: Airflow Sensor (Low) (warning lamp flashes: 17)
Generation condition Airflow sensor voltage is lower than specified value.
System recovers if any valid signal is input when starter switch is turned from
Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals
are input).
• Carries out control using a backup value (airflow rate equivalent to rate for low
idle speed operation).
Control effected by electronic control unit • Injection quantity is limited.
• Exhaust gas recirculation control is stopped.
• Throttle control is stopped.
P0103: Airflow Sensor (High) (warning lamp flashes: 17)

Generation condition Airflow sensor voltage is higher than specified value.
are input).
• Carries out control using a backup value (airflow rate equivalent to rate for low
idle speed operation).
Control effected by electronic control unit • Injection quantity is limited.
P0120: TVA SNSR (warning lamp flashes: 28)

Generation condition Throttle electronic drive unit judges throttle position sensor faulty.
are input).
• Injection quantity is limited.
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Service data 52: Target Intake Throttle Position, 53: Actual Intake Throttle Position
Actuator test A3: Intake Throttle 1
Inspection
Electrical equipment #529: Intake throttle
Electric circuit diagram Intake throttle systems
P0401: EGR Flow (Insufficient) (warning lamp flashes: 2)

Generation condition Exhaust gas recirculation flow rate is excessively low.
are input).
Service data 50: Target EGR Valve Position, 51: Actual EGR Valve Position
Actuator test A0: EGR 1
Inspection
Electrical equipment #530: Exhaust gas recirculation valve
Electric circuit diagram Exhaust gas recirculation system
17-10
17
P0402: EGR Flow (Excessive) (warning lamp flashes: 2)
Generation condition Exhaust gas recirculation flow rate is excessively high.
are input).
Inspection
P0403: EGR 1 (Actuator Circuit) (warning lamp flashes: 67)

Exhaust gas recirculation electronic drive unit has judged that exhaust gas recir-
culation valve motor was faulty.
are input).
Control effected by electronic control unit
• VG turbocharger control is stopped.
Inspection
P0409: EGR 1 (Position Sensor) (warning lamp flashes: 67)

Exhaust gas recirculation electronic drive unit judges exhaust gas recirculation
position sensor faulty.
are input).
Inspection
P040C: EGR Gas Temp Sensor (Low) (warning lamp flashes: 9)

Generation condition Boost air temperature sensor voltage is at or below the specified value (0.15 V).
are input).
Service data 31: Intake Air Temp. (downstream)
Electronic control unit connector 05 : Boost air temperature sensor
Inspection
Electrical equipment #304: Boost air temperature sensor
Electric circuit diagram Boost air temperature sensor system
17-11
P040D: EGR Gas Temp Sensor (High) (warning lamp flashes: 9)
Generation condition Boost air temperature sensor voltage is at or above the specified value (4.8 V).
are input).
Service data 31: Intake Air Temp. (downstream)
Electronic control unit connector 05 : Boost air temperature sensor
Inspection
Electrical equipment #304: Boost air temperature sensor
Electric circuit diagram Boost air temperature sensor system
P0600: CAN Communication (warning lamp flashes: 64, 73)

Abnormal CAN bus communications between engine electronic control unit and
malfunction vehicle control unit or between engine electronic control unit and any
of electronic drive units (exhaust gas recirculation, intake throttle and VG turbo-
charger units).
are input).
Electronic control unit connector 01 : CAN resistor
Engine electronic control unit
Electrical equipment Exhaust gas recirculation electronic drive unit
Inspection
Intake throttle electronic drive unit
CAN communication system between engine electronic control unit and each
Electric circuit diagram
electronic drive unit (exhaust gas recirculation and intake throttle units)
P0685: EDU Relay (Open) (warning lamp flashes: 84)

Generation condition Electronic drive unit relay open-circuited.
are input).
• VG turbocharger target opening value is replaced by a backup value.
Service data D4: EDU Power Relay
Actuator test AF: EDU Relay
Inspection Electronic control unit connector 02 : Electronic drive unit relay
Electrical equipment #201: Electronic drive unit relay
Electric circuit diagram Electronic drive unit relay system
17-12
17
P0686: EDU Relay (Low) (warning lamp flashes: 84)
Generation condition Electronic drive unit relay circuit shorted to ground.
are input).
P0687: EDU Relay (High) (warning lamp flashes: 84)

Generation condition Electronic drive unit relay circuit shorted to power source.
are input).
P1C01: Inter Cooler Performance (warning lamp flashes: 27)

The electronic control unit has judged that the intercooler was not operating
properly, based on the diagnostic results of the intake system.
are input).
Inspection Others Inspection of intercooler proper (See Gr15.)
P2002: DPF MFF (warning lamp flashes: 55)

Diesel particulate filter differential pressure is determined to exceed the pro-
grammed value.
are input).
Control effected by electronic control unit Injection quantity is limited.
Service data 22: Difference pressure across DPF
Electronic control unit connector 04 : Diesel particulate filter differential pressure sensor
Inspection
Electrical equipment #334: Diesel particulate filter differential pressure sensor
Electric circuit diagram Diesel particulate filter differential pressure sensor system
17-13
P2100: TVA (Open) (warning lamp flashes: 28)
Generation condition Throttle electronic drive unit judges throttle position sensor open-circuited.
are input).
Inspection
Electric circuit diagram Intake throttle system
P2101: TVA (System) (warning lamp flashes: 28)

The throttle electronic drive unit has judged that the power supply to electronic
drive unit was faulty or the throttle position sensor was faulty.
are input).
Inspection
P2102: TVA (Short) (warning lamp flashes: 28)

Generation condition Throttle electronic drive unit judges throttle position sensor shorted.
are input).
Inspection
P2135: TVA SNSR (Voltage) (warning lamp flashes: 28)

Generation condition Throttle electronic drive unit judges throttle position sensor power abnormal.
are input).
Inspection
17-14
17
P2199: EGR Temp Sensor (Correlation) (warning lamp flashes: 9)
The exhaust gas recirculation temperature sensor was judged faulty based on
Generation condition the diagnostic results obtained by comparing boost temperature sensor and in-
take air temperature sensor outputs.
are input).
Service data 30: Intake Air Temp. (upper stream), 31: Intake Air Temp. (downstream)
03 Intake air temperature sensor,

Electronic controle unit connector
Inspection 05 Boost air temperature sensor
Electrical equipment #304: Boost air temperature sensor, #305: Intake air temperature sensor
Electric circuit diagram Boost air temperature sensor and Intake air temperature sensor systems
P2413: EGR System (warning lamp flashes: 67)

Generation condition Exhaust gas recirculation system abnormal
System recovers if any valid signal is input when starter switch is turned
Recoverability from OFF to ON (the warning lamp does not go out unless 3 consecutive
valid signals are input).
•Injection quantity is limited.
Control effected by electronic control unit •VG turbocharger target opening value is replaced by a backup value.
•Exhaust gas recirculation control is stopped.
•Throttle control is stopped.
Inspection
P242F: DPF MFF (Accumulation) (warning lamp flashes: 55)
Generation condition The voltage of diesel particulate filter differential pressure sensor is too high.
Electronic controle unit connector 04 Diesel particulate filter differential pressure sensor
Inspection Electrical equipment #334: Diesel particulate filter differential pressure sensor
Other Inspection of DPF (See Gr15.)
P2453: DPF Diff SNSR (Plausi) & MFF (warning lamp flashes: 97)
Output of diesel particulate filter differential pressure after start of engine is
too low (vacuum) or too high.
Inspection Electronic controle unit connector 04 : Diesel particulate filter differential pressure sensor
17-15
P2454: DPF Diff SNSR (Low) & MFF (warning lamp flashes: 97)
Generation condition Diesel particulate filter differential pressure sensor circuit shorted to ground.
are input).
Inspection
P2455: DPF Diff SNSR (High) & MFF (warning lamp flashes: 97)
Diesel particulate filter differential pressure sensor circuit shorted to power
source.
are input).
Inspection
P2457: EGR Cooler Performance (warning lamp flashes: 2)

Engine electronic control unit has judged operation of exhaust gas recirculation
cooler abnormal as a result of diagnosis of exhaust gas recirculation system.
are input).
Inspection other Exhaust gas recirculation cooler proper
17-16
17
4. Multi-Use Tester Service Data
• It is possible to see service data and actuator tests simultaneously.
No. Item Data Inspection condition Requirement
Agrees with atmospheric
Starter switch ON (engine stopped)
pressure.
21 Boost Pressure . kPa
Accelerator pedal depressed after start
Gradually increases.
of engine
22 Difference pressure across DPF . kPa Idling 0 kPa
Equal to ambient tempera-
30 Intake Air Temp. (upper stream) . °C On a cold engine
ture
Equal to ambient tempera-
31 Intake Air Temp. (downstream) . °C On a cold engine
ture
50 Target EGR Valve Position . % Idling 0%
. % Idling 0%
51 Actual EGR Valve Position
[Actuator test] A0: EGR 1
52 Target Intake Throttle Position . % Idling 90%
. % Idling 90%
53 Actual Intake Throttle Position
[Actuator test] A3: Intake Throttle 1
. g/s Accelerator pedal is depressed gradu- Flow rate to be increased
60 Air mass flow
ally. accordingly
Starter switch ON ON
ON/OFF
D4 EDU Power Relay Starter switch OFF OFF
[Actuator test] AF: EDU relay
5. Actuator Tests Performed Using Multi-Use Tester

• It is possible to see service data and actuator tests simultaneously.
No. Item Explanation Confirmation method
Maintain exhaust gas recirculation valve opening indicated Check that the EGR valve
by Multi-Use Tester during engine operation. opening is changed.
[Can be executed when the following conditions are satisfied] [Service data]
A0 EGR 1 • Vehicle: stationary (vehicle speed 0 km/h) 51: Actual EGR Valve Po-
• Starter switch: ON (engine started) sition
• Transmission: neutral
• Diagnosis switch: OFF (with fuse removed)
Maintain intake throttle opening indicated by Multi-Use Tester Check that the throttle
during engine operation. opening is changed.
A3 Intake Throttle 1 • Vehicle: stationary (vehicle speed 0 km/h) 53: Actual Intake Throttle
• Starter switch: ON (engine started) Position
• Transmission: neutral
• Diagnosis switch: OFF (with fuse removed)
Maintain EGR, intake throttle and variable geometry turbo- Check that the valve open-
charger throttle opening indicated by Multi-Use Tester during ing of each device is
engine operation or stop. changed.
• Vehicle: stationary (vehicle speed 0 km/h) 51: Actual EGR Valve Posi-
• Starter switch: ON (engine started) tion
A5 EGR, ETV, VGT • Transmission: neutral 53: Actual Intake Throttle
• Diagnosis switch: OFF (with fuse removed) Position
NOTE
• If the actuator test is to be conducted with the engine
stationary, turn the starter switch OFF after starting
the engine, and then turn the starter switch ON again
within 15 seconds.
Electronic drive unit relay drive signal Operating sound of relay
AF EDU Relay (Errors related to exhaust gas recirculation and to the intake [Service data]
throttle can be detected when this actuator test is executed.) D4: EDU Power Relay
17-17
6. Inspections Performed at Electronic Control Unit Connectors
• These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference number in
section “3. Inspections based on diagnosis codes”.
6.1 Electronic control unit connector terminal layout
6.2 Inspection instructions

CAUTION
• Some inspections are performed with the connectors removed. Others are performed with the connectors
fitted. Observe the following caution:
• Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.
Check item Measurement method

01 [Conditions]
• Starter switch OFF
Resistance of CAN resistor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: B5-B6
• 120 ± 6 Ω
02 [Conditions]
• Starter switch ON
Voltage of electronic drive unit relay
• Vehicle-side harness connected (Perform inspection on back of connector.)
[Requirements]
Terminals (+)-(–): B39-B14
• With relay operating: Corresponding to battery voltage
• With relay not operating: 0 V
17-18
17
03 [Conditions]
Resistance of intake air temperature sensor
• Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A63-A32
• 50°C: 2.20 +0.405
–0.334 kΩ
• 100°C: 0.51 +0.071
–0.061 kΩ
• 150°C: 0.16 +0.018
–0.016 kΩ
04 [Conditions]
• Starter switch ON
Output voltage diesel particulate filter differential
pressure sensor • Vehicle-side harness connected (Perform inspection on back of connector.)
[Requirements]
<Power supply voltage>
Terminals (+)-(–): A61-A85
• 5V
<Output voltage>
Terminals (+)-(–): A84-A85
• 1 to 4.5 V
05 [Conditions]
Resistance of boost air temperature sensor
• Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: B29-B30
• 0°C: 162.3 +48.8
–36.5 kΩ
• 20°C: 61.47 +15.99
–12.35 kΩ
• 80°C: 6.120 +1.095
–0.907 kΩ
7. Inspection of Electrical Equipment

#201 Inspection of relay (normally open, 5 pins)
• Perform a continuity check and an operation check. If there is
any abnormality, replace the relay.
#304 Boost air temperature sensor

• Place the sensor in a container filled with engine oil.
• Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
• Measure the resistance between terminals 1 and 2.
0°C 162.3 +48.8
–36.5 kΩ
Standard value 20°C 61.47 +15.99
–12.35 kΩ
80°C 6.120 +1.095
–0.907 kΩ
• If either measurement is out of specification, replace the sensor.
17-19
#305 Inspection of intake air temperature sensor
• Place the sensor in a container filled with engine oil.
• Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
50°C 2.20 +0.405
–0.334 kΩ
Standard value 100°C 0.51 +0.071
–0.061 kΩ
150°C 0.16 +0.018
–0.016 kΩ
#306 Inspection of airflow sensor

• It is hard to inspect the airflow sensor independently. Therefore,
measure the intake airflow of the sensor currently installed on
the vehicle and that of a newly installed sensor, based on Multi-
Use Tester service data. Then compare the intake airflows to
check the sensor currently installed on the vehicle for character-
istic deterioration.
(1) Preparation for inspection

• Clean or replace the air cleaner element.
• Make a new airflow sensor handy.
• Fully warm up the engine.
• Connect the Multi-Use Tester. (See Gr00.)
(2) Measuring the intake airflow of the current sensor

• From the idling state, keep stepping on the accelerator pedal un-
til it hits the stopper bolt. (maximum revolution without load)
• Measure the following items from “service data” of Multi-Use
Tester.
01: Engine Revolution (rpm)
60: Air mass flow (g/s)
(3) Measuring the intake airflow of a newly installed sensor

• Replace the sensor currently installed with a new one.
• From the idling state, keep stepping on the accelerator pedal un-
til it hits the stopper bolt. (maximum revolution without load)
• From “service data” of Multi-Use Tester, measure “60: Air mass
flow (g/s)” at the same engine speed as “01: Engine Revolution”
in (2) above.
(4) Comparing the measured intake airflows to check for char-

acteristic deterioration
• Determine the characteristic deterioration ratio (%) according to
the following expression:
intake airflow of new sensor –

Characteristic
intake airflow of current sensor
deterioration = × 100 (%)
ratio intake airflow of new sensor
• If the characteristic deterioration ratio thus determined is 10% or

more, the characteristics of the sensor currently installed on the
vehicle have been deteriorated. Replace the sensor with a new
one.
17-20
17
#334 Inspection of diesel particulate filter differential pressure
sensor
• Apply a 5V DC voltage between terminals 1 and 3 of the diesel
particulate filter differential pressure sensor.
• Apply air pressures to the sensor and measure the sensor out-
put voltage between terminals 1 and 2 (see illustration).
0 ± 3.5 kPa
1V
{0 ± 0.04 kgf/cm2}
Standard value
100 ± 3.5 kPa
4.5 V
{1.020 ± 0.04 kgf/cm2}
#529 Inspection of intake throttle

• Perform the following checks. If there is any abnormality, replace
the intake throttle.
(1) Coil resistance of motor
Standard value 1.45 ± 0.21 Ω
NOTE
• If the measurement deviates from the standard value, mea-
sure the resistance again after manually opening and clos-
ing the butterfly valve 5 times.
(2) Position sensor
• The sensor cannot easily be inspected in isolation, so you must
evaluate it indirectly by inspection of system harness and related
parts.
• If there is no abnormality in any related part but the system is ab-
normal, replace the intake throttle.
#530 Inspection of exhaust gas recirculation valve

• Perform the following checks. If there is any abnormality, replace
the exhaust gas recirculation valve.
(1) Coil resistance of motor
• Measure the resistance between terminals 8 and 7, the resis-
tance between terminals 8 and 6, and the resistance between
terminals 7 and 6.
Standard value 11.3 ± 1.5 Ω
(2) Position sensor
• The sensor cannot easily be inspected in isolation, so you must
evaluate it indirectly by inspection of system harness and related
parts.
• If there is no abnormality in any related part but the system is ab-
normal, replace the exhaust gas recirculation valve.
17-21
8. Installed Locations of Parts
17-22
17
17-23
17-24
17
17-25
9. Electric Circuit Diagram
17-26
17
17-27
17-28
17
17-29
EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER
Removal sequence
1 Air pipe 8 EGR gasket 15 O-ring
2 Connector 9 EGR valve
3 EGR pipe C 10 EGR gasket B *a:
Air inlet pipe
4 EGR gasket 11 EGR pipe B
5 EGR gasket A 12 EGR gasket
*b::
Exhaust manifold
Non-reusable parts
6 EGR pipe A 13 EGR cooler EGR: Exhaust gas recirculation
7 EGR pipe gasket 14 EGR cooler bracket
NOTE
• Even when all coolant in the crankcase has been drained out, approximately 1 dm3 {1 L} of coolant re-
mains in the EGR cooler. Before removing the EGR cooler, make ready a container to catch the coolant.
Installation sequence
Follow the removal sequence in reverse.
Service standards
Location Maintenance item Standard value Limit Remedy
Leakage into coolant (air
pressure: 196 kPa {2.0 kgf/ 0 cm3 {0 mL}
Air leakage from EGR cm2})
13 – Repair
cooler Leakage into exhaust gas
(air pressure: 294 kPa {3.0 0 cm3 {0 mL}
kgf/cm2})
17-30
17
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (mounting of connector) 47.5 {4.8} –
Nut (mounting of EGR pipe A) 20.6 {2.1} –
Bolt (mounting of EGR pipe A) 23.8 {2.4} –
Inspection procedures
Inspection: Exhaust gas recirculation cooler
• Perform the following inspection. If any abnormality is found, re-
place the exhaust gas recirculation cooler.
(1) Exhaust gas passage side
• Fit a cover over the exhaust gas outlet of the exhaust gas recir-
culation cooler, and connect a hose to the exhaust gas inlet.
Then, submerge the exhaust gas recirculation cooler in a con-
tainer of water. Make sure the coolant passage is full of water.
• Apply air pressure of 294 kPa {3 kgf/cm2} through the hose.
Check that air does not leak from any part of the exhaust gas re-
circulation cooler.
(2) Coolant passage side

• Fit covers over the exhaust gas recirculation cooler’s exhaust
gas inlet, exhaust gas outlet, and coolant outlet, and connect a
hose to the coolant inlet. Then, submerge the exhaust gas recir-
culation cooler in a container of water.
• Apply air pressure of 196 kPa {2 kgf/cm2} through the hose.
Check that air does not leak from any part of the exhaust gas re-
circulation cooler.
17-31
CRANKCASE EMISSION CONTROL SYSTEM
Removal sequence
1 Washer 7 Gasket *a: PCV pipe

2 Rubber bushing 8 Breather gasket
3 Spacer 9 PCV hose
*b::Front case
Non-reusable parts
4 Breather cover A 10 PCV valve PCV: Positive crankcase ventilation
5 Separator plate 11 O-ring
6 Breather cover B
Installation sequence
Perform installation by following the removal sequence in reverse.
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (mounting of breather cover)
23.2 {2.4} –
Bolt (mounting of PCV valve)
Bolt (mounting of breather cover) 9.8 {1.0} –
Screw (mounting of breather cover A) 7.8 to 11.8 {0.8 to 1.2} –
17-32
17
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
O-ring Engine oil As required
Mating surface of breather cover A or B ThreeBond 1216 As required
Installation procedures
Installation: Gasket
• Clean the sealant application surfaces of each part.
• Apply a bead of sealant to the breather cover B evenly and with-
out any breaks as shown in the illustration.
• Install the lower crankcase within three minutes of applying the
sealant to the upper crankcase, being careful not to dislodge the
sealant.
Installation: Breather cover A

• Clean the sealant application surfaces of each part.
• Apply a bead of sealant to the breather cover A evenly and with-
out any breaks as shown in the illustration.
• Install the lower crankcase within three minutes of applying the
sealant to the upper crankcase, being careful not to dislodge the
sealant.
17-33

Group 17 Emission Control

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GROUP 17 EMISSION CONTROL

STRUCTURE AND OPERATION

EXHAUST GAS RECIRCULATION SYSTEM

EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER .. 17-30

CRANKCASE EMISSION CONTROL SYSTEM............................... 17-32

Input signals Engine electronic control unit Output signals

Engine speed sensor EGR valve control Engine warning lamp

Accelerator pedal position Exhaust brake 3-way

Boost air temperature sensor

Air flow sensor

Motor Motor drive signals Motor drive signals Motor

EGR valve Fault data Fault data Intake throttle

EGR EDU Throttle EDU

CAN: Controller area network

(3) Intake throttle control function

(4) Fault diagnosis function

Warning lamp lit

Vehicle in service shop

Read diagnosis code. (See Gr00.)

Fault code output Normal code output No communication with

Check against each diagnosis Response to transient fault (See Gr00.)

If communication cannot be established with all systems, the diag-

Clear stored diagnosis code. (See Gr00.)

Clear stored diagnosis code. (See Gr00.)

Code Message Flashes Non-erasable

P0101 Airflow Sensor (Plausibility) 17 O

3.2 Diagnosis code generation conditions and inspection items

P0101: Airflow Sensor (Plausibility) (warning lamp flashes: 17)

P0103: Airflow Sensor (High) (warning lamp flashes: 17)

P0120: TVA SNSR (warning lamp flashes: 28)

P0401: EGR Flow (Insufficient) (warning lamp flashes: 2)

P0403: EGR 1 (Actuator Circuit) (warning lamp flashes: 67)

P0409: EGR 1 (Position Sensor) (warning lamp flashes: 67)

P040C: EGR Gas Temp Sensor (Low) (warning lamp flashes: 9)

P0600: CAN Communication (warning lamp flashes: 64, 73)

P0685: EDU Relay (Open) (warning lamp flashes: 84)

P0687: EDU Relay (High) (warning lamp flashes: 84)

P1C01: Inter Cooler Performance (warning lamp flashes: 27)

P2002: DPF MFF (warning lamp flashes: 55)

P2101: TVA (System) (warning lamp flashes: 28)

P2102: TVA (Short) (warning lamp flashes: 28)

P2135: TVA SNSR (Voltage) (warning lamp flashes: 28)

03 Intake air temperature sensor,

P2413: EGR System (warning lamp flashes: 67)

P2457: EGR Cooler Performance (warning lamp flashes: 2)

5. Actuator Tests Performed Using Multi-Use Tester

6.1 Electronic control unit connector terminal layout

6.2 Inspection instructions

Check item Measurement method

7. Inspection of Electrical Equipment

#304 Boost air temperature sensor

#306 Inspection of airflow sensor

(1) Preparation for inspection

(2) Measuring the intake airflow of the current sensor

(3) Measuring the intake airflow of a newly installed sensor

(4) Comparing the measured intake airflows to check for char-

intake airflow of new sensor –

• If the characteristic deterioration ratio thus determined is 10% or

#529 Inspection of intake throttle