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Engine Emission Control (2.7L Diesel): Diagnosis Jaguar S-type I рестайлинг

Engine Control Systems 18 illustrations ~4409 words

Inspection and verification

  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage.
MechanicalElectrical
Engine breather hoses Cyclone separator EGR Pipes (check for cracks)Electrical connections to the stepper motor(s) Stepper motor(s) Harnesses

Visual inspection chart

Symptom chart

SymptomPossible sourceAction
Difficult to startEGR valve stuck openInspect the system (see visual inspection). Check for DTCs.
Poor idle qualityEGR valve stuck openInspect the system (see visual inspection). Check for DTCs.
Lack of power when acceleratingEGR valve stuck openInspect the system (see visual inspection). Check for DTCs.
Engine stops/stallsEGR valve stuck openInspect the system (see visual inspection). Check for DTCs.
Excessive fuel consumptionEGR valve stuck openInspect the system (see visual inspection). Check for DTCs.
Excessive black smokeEGR valve stuck openInspect the system (see visual inspection). Check for DTCs.
Excessive emissionsEGR system not operatingInspect the system (see visual inspection). Check for DTCs.
Loud 'ticking' noise with engine runningEGR pipes crackedClosely inspect the pipes for cracks (particularly at the corrugated sections).
Excessive blow-byCrankcase ventilation system restrictedInspect the hoses. Check each hose for restriction/blockage by gently blowing through. Check for blockage of the separator.
Engine oil leaksCrankcase ventilation system restrictedInspect the hoses. Check each hose for restriction/blockage by gently blowing through. Check for blockage of the separator.
CAUTIONWhen probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00. Failure to follow this instruction may result in damage to the vehicle.

Note. When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.

Note. Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

Note. If diagnostic trouble codes (DTCs) are recorded and the symptom is not present when performing the pinpoint tests, an intermittent concern may be the cause. Always check for loose connections and corroded terminals.

Note. For a full list of DTCs, Refer to Electronic Engine Controls article.

DTCConditionPossible sourceAction
P0401Insufficient EGR flow detectedEGR valve(s) stuck closed Stepper motor(s) fault Harness fault Restriction/blockage in EGR pipe workCheck pipe work for restriction.
P0402Excessive EGR flow detectedEGR valve(s) stuck open Stepper motor(s) fault Harness fault Pipe work damaged/leakingCheck the pipe work, check the mechanical function of the throttle valve. For throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P0403EGR control circuitEGR valve control circuit: high resistance EGR valve control circuit: short circuit to battery EGR valve control circuit: short circuit to groundFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P0404EGR control circuitEGR control circuit: range/performanceFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P0405EGR sensor circuitEGR sensor circuit A: low input Stepper motor faultFor EGR sensor and circuit tests, Refer to Pinpoint Test B .
P0406EGR sensor circuitEGR sensor circuit A: high input Stepper motor faultFor EGR sensor and circuit tests, Refer to Pinpoint Test B .
P0407EGR sensor circuitEGR sensor circuit B: low input Stepper motor faultFor EGR sensor and circuit tests, Refer to Pinpoint Test B .
P0408EGR sensor circuitEGR sensor circuit B: high input Stepper motor faultFor EGR sensor and circuit tests, Refer to Pinpoint Test B .
P0487EGR throttle position control circuitEGR throttle position control circuit: high resistance EGR throttle position control circuit: short circuit to battery EGR throttle position control circuit: short circuit to groundFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P0488EGR throttle position range/performanceStepper motor fault Stepper motor harness faultFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P1334EGR throttle position sensor minimum/maximum stop performanceStepper motor fault Stepper motor harness faultFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P1335EGR position sensor minimum/maximum stop performanceStepper motor fault Stepper motor harness faultFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P2141EGR throttle circuit lowStepper motor fault Stepper motor harness faultFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .
P2142EGR throttle circuit highStepper motor fault Stepper motor harness faultFor throttle actuator and circuit tests, Refer to Pinpoint Test A and Pinpoint Test C .

Diagnostic Trouble Code (DTC) index

This pinpoint test is intended to diagnose the following

  1. Short circuit to GROUND in the EGR throttle actuator (ETA) circuit
  2. Short circuit to POWER in the EGR throttle actuator (ETA) circuit
  3. Open circuit in the EGR throttle actuator (ETA) circuit
  4. EGR throttle actuator (ETA) circuit
  5. ECM

EGR throttle actuator (ETA) connector

Scheme 71

Scheme 71
Scheme 71
EGR throttle sensor - signal02
EGR throttle sensor - supply06
EGR throttle sensor - ground01

Engine control module (ECM) connector

Scheme 72

Scheme 72
Scheme 72
EGR throttle sensor - groundB-F2
EGR throttle sensor - supplyB-F1
EGR throttle sensor - signalB-E1

Pinpoint Test A: EGR THROTTLE ACTUATOR AND CIRCUIT (1)

Pinpoint Test A

A1 CHECK THE ETA SENSOR RETURN LINE
  1. Key off.
  2. ETA connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - ground - Pin 01 Negative post
Is the resistance less than 10 ohms?
YES Go to step 2 . → A2
NO Go to step 14 . → A14
A2 CHECK THE ETA VOLTAGE
  1. Measure the voltage between
  2. EGR throttle sensor - supply - Pin 06 Negative post
Is the voltage between 4.8 volts - 5.2 volts?
YES Go to step 3 . → A3
NO Go to step 11 . → A11
A3 CHECK THE ETA SIGNAL LINE FOR SHORT CIRCUIT TO GROUND
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 Negative post
Is the resistance greater than 100 Kohms?
YES Go to step 4 . → A4
NO Go to step 7 . → A7
A4 CHECK THE ETA SIGNAL LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 Positive post
Is the resistance greater than 100 Kohms?
YES Go to step 5 . → A5
NO Go to step 9 . → A9
A5 CHECK THE ETA SIGNAL LINE FOR SHORT CIRCUIT TO SENSOR POWER
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - supply - Pin 06
Is the resistance greater than 100 Kohms?
YES Go to step 6 . → A6
NO Go to step 10 . → A10
A6 CHECK THE ETA SIGNAL LINE FOR OPEN CIRCUIT
  1. Key off.
  2. ECM connector disconnected.
  3. Measure the resistance between
  4. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - signal - Pin B-E1
Is the resistance less than 10 ohms?
YES An intermittent fault may be present in the wiring harness. Visually check for chaffed wires or other physical damage to the harness. If no fault is found in the circuit, suspect the following component(s): - ETA connector - ECM connector - ETA - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A7 CHECK THE ETA CIRCUIT(S) FOR SIGNAL AND RETURN LINES SHORTED TOGETHER
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - ground - Pin 01
Is the resistance greater than 100 Kohms?
YES Go to step 8 . → A8
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A8 CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ETA HARNESS OR ECU
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 Negative post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A9 CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ETA HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - signal - Pin 02 Positive post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A10 CHECK WHETHER THE SHORT CIRCUIT IS IN THE ETA HARNESS OR CONTROL UNIT
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - supply - Pin 06
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A11 CHECK THE 5 VOLT SUPPLY LINE FOR SHORT CIRCUIT TO GROUND
  1. Measure the resistance between
  2. EGR throttle sensor - supply - Pin 06 Negative post
Is the resistance greater than 100 Kohms?
YES Go to step 12 . → A12
NO Go to step 17 . → A17
A12 CHECK THE 5 VOLT SUPPLY LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle sensor - supply - Pin 06 Positive post
Is the resistance greater than 100 Kohms?
YES Go to step 13 . → A13
NO Go to step 19 . → A19
A13 CHECK THE ETA 5 VOLT SUPPLY LINE FOR OPEN CIRCUIT
  1. Key off.
  2. ECM connector disconnected.
  3. Measure the resistance between
  4. EGR throttle sensor - supply - Pin 06 EGR throttle sensor - supply - Pin B-F1
Is the resistance less than 10 ohms?
YES Suspect : - ECM connector - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A14 CHECK THE ETA SENSOR RETURN LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle sensor - ground - Pin 01 Positive post
Is the resistance greater than 100 Kohms?
YES Go to step 15 . → A15
NO Go to step 20 . → A20
A15 CHECK WHETHER THE 5 VOLT SUPPLY AND SIGNAL RETURN LINES ARE SHORTED TOGETHER
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - supply - Pin 06 EGR throttle sensor - ground - Pin 01
Is the resistance greater than 100 Kohms?
YES Go to step 16 . → A16
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A16 CHECK THE ETA SENSOR RETURN LINE FOR OPEN CIRCUIT
  1. Measure the resistance between
  2. EGR throttle sensor - ground - Pin 01 EGR throttle sensor - ground - Pin B-F2
Is the resistance less than 10 ohms?
YES Suspect : - ECM connector - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A17 CHECK WHETHER THE 5 VOLT SUPPLY AND SIGNAL RETURN LINES ARE SHORTED TOGETHER
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - supply - Pin 06 EGR throttle sensor - ground - Pin 01
Is the resistance greater than 100 Kohms?
YES Go to step 18 . → A18
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A18 CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ETA HARNESS OR ECU
  1. Measure the resistance between
  2. EGR throttle sensor - supply - Pin 06 Negative post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A19 CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ETA HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - ground - Pin 01 Positive post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
A20 CHECK WHETHER THE SHORT TO POWER IS IN THE ETA HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - ground - Pin 01 Positive post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
  1. This pinpoint test is intended to diagnose the following
  2. Short circuit to GROUND in the EGR throttle valve (ETV) circuit
  3. Short circuit to POWER in the EGR throttle valve (ETV) circuit
  4. Open circuit in the EGR throttle valve (ETV) circuit
  5. EGR throttle valve (ETV)
  6. ECM

EGR throttle actuator (ETA) connector

EGR throttle valve - control 204
EGR throttle valve - control 103

Engine control module (ECM) connector

EGR throttle valve - control 2C-K4
EGR throttle valve - control 1C-J4

Pinpoint Test B: EGR THROTTLE SENSOR AND CIRCUIT

Pinpoint Test B

B1 CHECK THE ETV SIGNAL LINE FOR A SHORT CIRCUIT TO GROUND
  1. Key off.
  2. ETA connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle valve - control 1 - Pin 03 Negative post EGR throttle valve - control 2 - Pin 04 Negative post
Are the resistances greater than 100 Kohms?
YES Go to step 2 . → B2
NO Go to step 4 . → B4
B2 CHECK THE ETV SIGNAL LINE FOR A SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle valve - control 1 - Pin 03 Positive post EGR throttle valve - control 2 - Pin 04 Positive post
Are the resistances greater than 100 Kohms?
YES Go to step 3 . → B3
NO Go to step 5 . → B5
B3 CHECK THE ETV SIGNAL CIRCUIT FOR CONTINUITY
  1. Key off.
  2. ECM connector disconnected.
  3. Measure the resistance between
  4. EGR throttle valve - control 1 - Pin 03 EGR throttle valve - control 1 - Pin C-J4 EGR throttle valve - control 2 - Pin 04 EGR throttle valve - control 2 - Pin C-K4
Are the resistances less than 10 ohms?
YES An intermittent fault may be present in the wiring harness. Visually check for chaffed wires or other physical damage to the harness. If no fault is found in the circuit, suspect the following component(s): - ETV connector - ECM connector - ETV - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
B4 CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ETV HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle valve - control 1 - Pin 03 Negative post EGR throttle valve - control 2 - Pin 04 Negative post
Are the resistances greater than 100 Kohms?
YES Harness is OK. Suspect : - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
B5 CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ETV HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle valve - control 1 - Pin 03 Positive post EGR throttle valve - control 2 - Pin 04 Positive post
Are the resistances greater than 100 Kohms?
YES Harness is OK. Suspect : - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.

This pinpoint test is intended to diagnose the following

  1. Short circuit to GROUND in the EGR throttle actuator (ETA) circuit
  2. Short circuit to POWER in the EGR throttle actuator (ETA) circuit
  3. Open circuit in the EGR throttle actuator (ETA) circuit
  4. EGR throttle actuator
  5. ECM

EGR throttle actuator (ETA) connector

EGR throttle valve - control 204
EGR throttle valve - control 103
EGR throttle sensor - signal02
EGR throttle sensor - supply06
EGR throttle sensor - ground01

Engine control module (ECM) connector

EGR throttle valve - control 2C-K4
EGR throttle valve - control 1C-J4
EGR throttle sensor - groundB-F2
EGR throttle sensor - supplyB-F1
EGR throttle sensor - signalB-E1

Pinpoint Test C: EGR THROTTLE ACTUATOR AND CIRCUIT (2)

Pinpoint Test C

C1 CHECK THE ETA PID
  1. Key on, engine off.
  2. Access the ECM-throttle controller deviation PID using a scan tool.
  3. Slowly increase the engine speed to 1500 RPM while monitoring the PID.
Did percentage deviation remain within the range of -15% and 5%?
YES No fault found.
NO Go to step 2 . → C2
C2 CHECK THE ETA SENSOR RETURN LINE CONTINUITY
  1. Key off.
  2. ETA connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - ground - Pin 01 Negative post
Is the resistance less than 10 ohms?
YES Go to step 3 . → C3
NO Go to step 15 . → C15
C3 CHECK THE ETA VOLTAGE
  1. Measure the voltage between
  2. EGR throttle sensor - supply - Pin 06 Negative post
Is the voltage between 4.8 volts - 5.2 volts?
YES Go to step 4 . → C4
NO Go to step 12 . → C12
C4 CHECK THE ETA SIGNAL LINE FOR SHORT CIRCUIT TO GROUND
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 Negative post
Is the resistance greater than 100 Kohms?
YES Go to step 5 . → C5
NO Go to step 8 . → C8
C5 CHECK THE ETA SIGNAL LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 Positive post
Is the resistance greater than 100 Kohms?
YES Go to step 6 . → C6
NO Go to step 10 . → C10
C6 CHECK THE ETA SIGNAL LINE FOR SHORT CIRCUIT TO SENSOR POWER
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - supply - Pin 06 EGR throttle sensor - signal - Pin 02 EGR throttle sensor - ground - Pin 01
Are the resistances greater than 100 Kohms?
YES Go to step 7 . → C7
NO Go to step 11 . → C11
C7 CHECK THE ETA SIGNAL LINE FOR OPEN CIRCUIT
  1. Key off.
  2. ECM connector disconnected.
  3. Measure the resistance between
  4. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - signal - Pin B-E1
Is the resistance less than 10 ohms?
YES Go to step 22 . → C22
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C8 CHECK THE ETA CIRCUIT(S) FOR SIGNAL AND RETURN LINES SHORTED TOGETHER
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - ground - Pin 01
Is the resistance greater than 100 Kohms?
YES Go to step 9 . → C9
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C9 CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ETA HARNESS OR ECU
  1. Measure the resistance between
  2. EGR throttle sensor - signal - Pin 02 Negative post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C10 CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ETA HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - signal - Pin 02 Positive post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C11 CHECK WHETHER THE SHORT CIRCUIT IS IN THE ETA HARNESS OR CONTROL UNIT
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - signal - Pin 02 EGR throttle sensor - supply - Pin 06 EGR throttle sensor - signal - Pin 02 EGR throttle sensor - ground - Pin 01
Are the resistances greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C12 CHECK THE 5 VOLT SUPPLY LINE FOR SHORT CIRCUIT TO GROUND
  1. Measure the resistance between
  2. EGR throttle sensor - supply - Pin 06 Negative post
Is the resistance greater than 100 Kohms?
YES Go to step 13 . → C13
NO Go to step 18 . → C18
C13 CHECK THE 5 VOLT SUPPLY LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle sensor - supply - Pin 06 Positive post
Is the resistance greater than 100 Kohms?
YES Go to step 14 . → C14
NO Go to step 20 . → C20
C14 CHECK THE ETA 5 VOLT SUPPLY LINE FOR OPEN CIRCUIT
  1. Key off.
  2. ECM connector disconnected.
  3. Measure the resistance between
  4. EGR throttle sensor - supply - Pin 06 EGR throttle sensor - supply - Pin B-F1
Is the resistance less than 10 ohms?
YES Suspect : - ECM connector - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C15 CHECK THE ETA SENSOR RETURN LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle sensor - ground - Pin 01 Positive post
Is the resistance greater than 100 Kohms?
YES Go to step 16 . → C16
NO Go to step 21 . → C21
C16 CHECK WHETHER THE 5 VOLT SUPPLY AND SIGNAL RETURN LINES ARE SHORTED TOGETHER
  1. Key off.
  2. ECM connector disconnected.
  3. Measure the resistance between
  4. EGR throttle sensor - supply - Pin 06 EGR throttle sensor - ground - Pin 01
Is the resistance greater than 100 Kohms?
YES Go to step 17 . → C17
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C17 CHECK THE ETA SENSOR RETURN LINE FOR OPEN CIRCUIT
  1. Measure the resistance between
  2. EGR throttle sensor - ground - Pin 01 EGR throttle sensor - ground - Pin B-F2
Is the resistance less than 10 ohms?
YES Suspect : - ECM connector - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C18 CHECK WHETHER THE 5 VOLT SUPPLY AND SIGNAL RETURN LINES ARE SHORTED TOGETHER
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - supply - Pin 06 EGR throttle sensor - ground - Pin 01
Is the resistance greater than 100 Kohms?
YES Go to step 19 . → C19
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C19 CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ETA HARNESS OR ECU
  1. Measure the resistance between
  2. EGR throttle sensor - supply - Pin 06 Negative post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C20 CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ETA HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - ground - Pin 01 Positive post
Is the resistance greater than 100 Kohm?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C21 CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ETA HARNESS OR ECU
  1. Key off.
  2. ECM connector disconnected.
  3. Key on, engine off.
  4. Measure the resistance between
  5. EGR throttle sensor - ground - Pin 01 Positive post
Is the resistance greater than 100 Kohms?
YES Suspect: - ECM
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C22 CHECK THE ETV SIGNAL LINE FOR SHORT CIRCUIT TO GROUND
  1. Measure the resistance between
  2. EGR throttle valve - control 1 - Pin 03 Negative post EGR throttle valve - control 2 - Pin 04 Negative post
Are the resistances greater than 100 Kohms?
YES Go to step 23 . → C23
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C23 CHECK THE ETV SIGNAL LINE FOR SHORT CIRCUIT TO POWER
  1. Measure the resistance between
  2. EGR throttle valve - control 1 - Pin 03 Positive post EGR throttle valve - control 2 - Pin 04 Positive post
Are the resistances greater than 100 Kohms?
YES Go to step 24 . → C24
NO REPAIR the short circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.
C24 CHECK THE ETV SIGNAL CIRCUIT FOR CONTINUITY
  1. Measure the resistance between
  2. EGR throttle valve - control 1 - Pin 03 EGR throttle valve - control 1 - Pin C-J4 EGR throttle valve - control 2 - Pin 04 EGR throttle valve - control 2 - Pin C-K4
Are the resistances less than 10 ohms?
YES An intermittent fault may be present in the wiring harness. Visually check for chaffed wires or other physical damage to the harness. If no fault is found in the circuit, suspect the following component(s): - ETA connector - ECM connector - ETA - ECM
NO REPAIR the open circuit. For additional information, See appropriate SYSTEM WIRING DIAGRAMS article.

Scheme 73

Scheme 73: Removal
Scheme 73: Removal

Scheme 74

Scheme 74
Scheme 74

Scheme 75

Scheme 75
Scheme 75

Scheme 76

Scheme 76
Scheme 76

Scheme 77

Scheme 77
Scheme 77

Scheme 78

Scheme 78
Scheme 78

Scheme 79

Scheme 79
Scheme 79

Scheme 80

Scheme 80
Scheme 80

Scheme 81

Scheme 81
Scheme 81

Scheme 82

Scheme 82
Scheme 82

Scheme 83

Scheme 83
Scheme 83
  1. Remove the exhaust gas recirculation (EGR) valve outlet tube. See «Exhaust Gas Recirculation (EGR) Valve Outlet Tube»(ref-311317-S22555038592009032500000) .
  2. Remove the fuel injector soundproofing.
  3. Drain the cooling system. Refer to «Cooling System Draining, Filling and Bleeding»(ref-311316-S03270466452009032500000) article.
  4. Remove the air cleaner. Refer to «Air Cleaner»(ref-311308-S42493331702009032500000) article.
  5. Remove the power steering reservoir. Refer to «Power Steering Fluid Reservoir»(ref-311260) article.
  6. Remove the left-hand engine compartment cover.
  7. Detach the fuel filter from the mounting bracket. Press the retaining tang. Detach the fuel filter from the mounting bracket.
  8. Remove the fuel filter retaining bracket.
  9. Disconnect the EGR valve electrical connector.
  10. Disconnect the EGR valve coolant outlet hose.
  11. Detach the EGR valve cooler outlet tube. Disconnect the outlet hose. Detach the EGR valve cooler outlet tube retaining clip.
  12. Detach the EGR valve cooler outlet tube from the EGR mounting bracket.
  13. Remove the left-hand catalytic converter. Refer to «Catalytic Converter - 2.7L Diesel»(ref-311281-S34306205972009032500000) article.
  14. Detach the EGR valve coolant outlet tube. Reposition the tube.
  15. Lower the vehicle.
  16. Disconnect the EGR valve coolant inlet hose.
  17. Detach the EGR valve inlet tube. Discard the gasket.
  18. Remove the EGR valve inlet tube. Detach and discard the retaining clip.
  19. Remove the EGR valve.

Scheme 84

Scheme 84
Scheme 84

Scheme 85

Scheme 85
Scheme 85
  1. Loosely install the EGR valve.
  2. Install the EGR valve inlet tube. Install a new retaining clip. Do not fully close the retaining clip at this stage.
  3. Raise the vehicle.
  4. Install the EGR valve inlet tube retaining bolts. Install a new gasket Do not fully tighten the retaining bolts at this stage.
  5. Lower the vehicle.
  6. Fully close the EGR valve inlet tube retaining clip.
  7. Tighten to 10 Nm.
  8. Tighten to 10 Nm.
  9. Connect the EGR valve coolant inlet hose.
  10. Raise the vehicle.
  11. Attach the EGR valve coolant outlet tube.
  12. Install the left-hand catalytic converter. Refer to «Catalytic Converter - 2.7L Diesel»(ref-311281-S34306205972009032500000) article.
  13. Lower the vehicle.
  14. Attach the EGR valve cooler outlet tube to the EGR mounting bracket.
  15. Attach the EGR valve cooler outlet tube. Connect the outlet hose. Attach the EGR valve cooler outlet tube retaining clip.
  16. Connect the EGR valve coolant outlet hose.
  17. Connect the EGR valve electrical connector.
  18. Install the fuel injector soundproofing.
  19. Tighten to 27 Nm.
  20. Attach the fuel filter.
  21. Install the left-hand engine compartment cover.
  22. Install the power steering reservoir. Refer to «Power Steering Fluid Reservoir»(ref-311260) article.
  23. Fill and bleed the cooling system. Refer to «Cooling System Draining, Filling and Bleeding»(ref-311316-S03270466452009032500000) article.
  24. Install the air cleaner. Refer to «Air Cleaner»(ref-311308-S42493331702009032500000) article.
  25. Install the fuel injector soundproofing.
  26. Install the exhaust gas recirculation (EGR) valve outlet tube. See «Exhaust Gas Recirculation (EGR) Valve Outlet Tube»(ref-311317-S22555038592009032500000) .

Scheme 86

Scheme 86: Removal
Scheme 86: Removal

Scheme 87

Scheme 87
Scheme 87

Scheme 88

Scheme 88
Scheme 88
  1. Remove the oil filler cap.
  2. Remove the engine cover.
  3. Detach the exhaust gas recirculation (EGR) valve outlet tube.
  4. Detach the EGR valve outlet tube.
  5. Remove the EGR valve outlet tube. Discard the gasket.

More articles — Engine Emission Control (2.7L Diesel)