egr sensor TOYOTA LAND CRUISER 1996 J80 User Guide

A00172
ON
THG E2 (+)(−)
BE6653
P24667
DI−76
−
DIAGNOSTICS ENGINE
1996 LAND CRUISER (RM451U)
3 Check for open in harness or ECM.
PREPARATION:
(a) Remove instrument panel speaker No.1 panel (See page
SF−65 ).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals of THG and E2 of ECM
connector.
HINT:
EGR gas temp. sensor connector is disconnected.
OK:
Voltage: 4.5 − 5.5 V
OK Open in harness between terminals E2 or THG. Repair or replace harness.
NG
Confirm connection at ECM.
If OK, replace ECM (See page IN−28).
4 Check connection of vacuum hose, EGR hose (See page EC−11).
NG Repair or replace.
OK
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P24665
−
DIAGNOSTICS ENGINE
DI−79
1996 LAND CRUISER (RM451U)
9 Check resistance of EGR gas temp. sensor (See page SF−63).
PREPARATION:
(a) Disconnect EGR gas temp. sensor connector.
(b) Start the engine and warm it up.
(c) Disconnect VSV connector for EGR.
(d) Race the engine at 4,000 rpm or 3 mins.
CHECK:
Measure the resistance of the EGR gas temp. sensor while rac-
ing the engine at 4,000 rpm.
OK:
Resistance of EGR gas temp. sensor after 3 mins.:
4.3 kΩ or less
HINT:
At 20° C (68° F): 188.6 − 439.0 kΩ for resistance.
NG Replace EGR gas temp. sensor.
OK
Check and replace ECM (See page IN−28 ).
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DI−80
−
DIAGNOSTICS ENGINE
1996 LAND CRUISER (RM451U)
DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected
CIRCUIT DESCRIPTION
Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on page DI−69.
DTC No.DTC Detecting ConditionTrouble Area
P0402
EGR gas temp. sensor value is high during EGR cut −off when
engine is cold (Race engine at about 4,000 rpm without load so
that vacuum is applied to port E)
(2 trip detection logic) EGR valve stuck open
 EGR VSV open malfunction
 Open in VSV circuit for EGR
 Short in EGR gas temp. sensor circuit
 ECM
EGR valve is always open (2 trip detection logic)
Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) for the System Check Driving
Pattern and Wiring Diagram.
INSPECTION PROCEDURE
TOYOTA hand −held tester
1 Connect the TOYOTA hand −held tester and read EGR gas temp. value.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand−held tester to the DLC3.
(c) Turn ignition switch ON and push the TOYOTA hand −held tester main switch ON.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 150° C (302°F) or less (Not immediately after driving)
HINT:
If there is a short circuit, the TOYOTA hand−held tester indicates Approx. 157.5°C (315.5°F).
OK Go to step 4.
NG
DI5PL−02
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A00174
ON
EGR Gas Temp.
Sensor 1
2 ECM
5V
E2
19
9
E4
E5 THG
BE6653
FI7054
A00175
ON
EGR Gas Temp.
Sensor ECM
5V
E2
E4 connector
THG
BE6653
FI7099
P22261
−
DIAGNOSTICS ENGINE
DI−81
1996 LAND CRUISER (RM451U)
2 Check for short in harness and ECM.
PREPARATION:
Disconnect the EGR gas temp. sensor connector.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 3.1° C (37.6°F)
OK Replace EGR gas temp. sensor.
NG
3 Check for short in harness or ECM.
PREPARATION:
(a) Remove the instrument panel speaker No.1 panel. (See page SF−65 ).
(b) Disconnect the E4 connector of ECM.
HINT:
EGR gas temp. sensor is disconnected.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 3.1° C (37.6°F)
OK Repair or replace harness or connector.
NG
Check and replace ECM (See page IN−28 ).
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P24665
DI−82
−
DIAGNOSTICS ENGINE
1996 LAND CRUISER (RM451U)
4 Check the VSV for EGR (See page DI−69 ).
OK Check EGR valve (See page EC−11).
NG
5 Check operation of the VSV for EGR (See page SF−60).
NG Replace VSV for EGR.
OK
Check for short in harness and connector
between VSV and ECM (See page IN−28).
OBD II scan tool (excluding TOYOTA hand −held tester)
1 Check resistance of EGR gas temp. sensor (See page DI−105).
PREPARATION:
Disconnect EGR gas temp. sensor connector.
CHECK:
Measure resistance between terminals of EGR gas temp. sen-
sor connector.
OK:
Resistance: 2.5 k Ω or more
(Not immediately after driving)
HINT:
If there is short circuit, ohmmeter indicates 200 Ω or less.
NG Replace EGR gas temp. sensor.
OK
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−
DIAGNOSTICS ENGINE
DI−83
1996 LAND CRUISER (RM451U)
2 Check for short in harness and connector between EGR gas temp. sensor and
ECM (See page IN−28 ).
NG Repair or replace harness or connector.
OK
3 Check the VSV for EGR (See page DI−69 , step 5).
OK Check EGR valve (See page EC−11).
NG
4 Check operation of the VSV for EGR (See page SF−60).
NG Replace VSV for EGR.
OK
5 Check for short in harness and connector between VSV and ECM (See page IN−28 ).
NG Repair or replace harness or connector.
OK
Check and replace ECM (See page IN−28 ).
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EM−2
−
ENGINE MECHANICAL CO/HC
505
Author: Date:
1996 LAND CRUISER (RM451U)
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
See the table below for possible causes, and then inspect and
correct the applicable causes if necessary.
COHCProblemsCauses
NormalHighRough idle
3. Faulty ignitions:
Incorrect timing
 Fouled, shorted or improperly gapped plugs
 Open or crossed high −tension cords
 Cracked distributor cap
4. Incorrect valve clearance
5. Leaky EGR valve
6. Leaky intake and exhaust valves
7. Leaky cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:
 PCV hose
 EGR valve
 Intake manifold
 Air intake chamber
 Throttle body
 IAC valve
 Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Faulty SFI systems:
 Faulty pressure regulator
 Clogged fuel return line
 Defective ECT sensor
 Faulty ECM
 Faulty injector
 Faulty throttle position sensor
 Faulty MAF meter
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EM−30
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(b) Disconnect the connectors.
(1) Disconnect the knock sensor connector.
(2) Disconnect the oil level sensor connector.
(3) Disconnect the 2 connectors from the transmission.
(4) Disconnect the starter connector.
(c) Disconnect the 2 heated oxygen sensor connectors.
(d) Disconnect the PNP switch connector.
(e) Remove the 2 bolts and disconnect the engine wire from the intake manifold and cylinder block.
(f) Disconnect the PCV hose from the PCV valve.
(g) Remove the bolt holding the engine wire to the intake manifold.
(h) Disconnect the connectors. (1) Disconnect the connector for the emission controlvalve set assembly.
(2) Disconnect the 3 injector connectors.
(i) Disconnect the engine wire clamp.
(j) Disconnect the engine wire clamp.
(k) Disconnect the connectors.
(1) Disconnect the 3 injector connectors.
(2) Disconnect the EGR gas temp. sensor connector.
(l) Disconnect the clamp of the No. 6 injector wire from the bracket.
(m) Disconnect the engine wire from the cylinder head and in-
take manifold.
25. DISCONNECT NO. 2 WATER BYPASS PIPE
Remove the 3 bolts, and disconnect the bypass pipe from the
cylinder head.
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−
ENGINE MECHANICAL CYLINDER HEAD
EM−61
1996 LAND CRUISER (RM451U)
14. INSTALL HEATER PIPE
Install a new gasket, the heater pipe and ground cable with the
2 bolts and 2 nuts.
Torque:
20 N·m (200 kgf·cm, 14 ft·lbf) for bolt:
21 N·m (210 kgf·cm, 15 ft·lbf) for nut
15. INSTALL NO. 1 AND NO. 2 EXHAUST MANIFOLDS
(a) Install 2 new gaskets, No. 1 exhaust manifold and No. 2
exhaust manifold with the 13 nuts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Install the No. 1 heat insulator and No. 2 heat insulator with the 6 bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
16. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe with the 4 nuts.
Torque: 63 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the No. 1 support bracket with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect the front exhaust pipe to the rear TWC with a new gasket, 2 bolts and 2 nuts.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
17. CONNECT NO. 2 WATER BYPASS PIPE
Connect the bypass pipe to the cylinder head with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
18. CONNECT ENGINE WIRE
(a) Place the engine wire on the intake manifold.
(b) Connect the connectors. (1) Connect the 3 injector connectors.
(2) Connect the EGR gas temp. sensor connector.
(c) Connect the clamp of the No.6 injector wire to the bracket.
(d) Connect the engine wire clamp.
(e) Connect the engine wire clamp.
(f) Connect the connectors. (1) Connect the connector for the emission control
valve set assembly.
(2) Connect the 3 injector connectors.
(g) Install the bolt holding the engine wire to the intake man- ifold.
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SF1EN−01
SF−26
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT CRUISE CONTROL ACTUATOR CABLE
3. DISCONNECT ACCELERATOR CABLE
4. DISCONNECT THROTTLE CABLE
5. DISCONNECT NO.2 PCV HOSE
6. DISCONNECT AIR CLEANER HOSE
7. REMOVE EGR VACUUM MODULATOR AND VALVE (See page EC−10 )
8. REMOVE BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER
9. DISCONNECT NO.1 PCV HOSE
10. DISCONNECT VACUUM SENSING HOSE
11. DISCONNECT NO.2 WATER BYPASS HOSE
12. DISCONNECT EVAP HOSE
13. DISCONNECT BRAKE BOOSTER HOSE
14. DISCONNECT THROTTLE POSITION SENSOR CON- NECTOR
15. DISCONNECT IDLE AIR CONTROL VALVE CONNEC-
TOR
16. DISCONNECT CONNECTOR FOR EMISSION CON- TROL VALVE SET ASSEMBLY
17. DISCONNECT EGR GAS TEMP. SENSOR CONNEC-
TOR
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