Isuzu Trooper (1998-2002 year). Manual — part 477
6E–278
6VE1 3.5 ENGINE DRIVEABILITY AND EMISSIONS
D
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
Diagnostic Aids
Check for the following conditions:
D
Poor connection or damaged harness – Inspect the
wiring harness for damage. If the harness appears to
be OK, observe the Actual EGR Position display on the
Tech 2 while moving connectors and wiring harnesses
related to the EGR valve. A change in the display will
indicate the location of the fault.
D
Ensure EGR valve is correctly mounted. See
On-Vehicle Service.
Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.
NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged catalytic converter) using the “Restricted
Exhaust System Check”.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart
3. A malfunctioning MAP sensor can set an EGR DTC.
The MAP sensor could send a constant signal which
is not low enough to set a low MAP DTC. The
constant signal from the MAP sensor also may not
be high enough to set a high MAP DTC. This step
verifies that the MAP sensor is responding.
6E–279
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
DTC P0401 – EGR Flow Insufficient
Step
Action
Value(s)
Yes
No
1
Was the “On-Board Diagnostic (OBD) System Check”
performed?
—
Go to
Step 2
Go to
OBD
System
Check
2
Is DTC P1404 also set?
—
Go to
DTC
1404
Go to
Step 3
3
1. Start the engine.
2. Monitor the MAP signal with a Tech 2 while idling.
3. While idling, jab the accelerator pedal about halfway
down and immediately let the engine return to idle.
Did the MAP value on the Tech 2 show an immediate
large change?
—
Go to
Step 5
Go to
Step 4
4
Replace the MAP sensor.
Is the action complete?
—
Verify repair
—
5
1. Inspect the exhaust system for modification of
original installed parts or leaks.
2. If a problem was found, repair exhaust system as
necessary.
Was a condition present that required repair?
—
Go to
Step 8
Go to
Step 6
6
1. Remove the EGR valve.
2. Visually and physically inspect the pintle, valve
passages and the adapter for excessive deposits or
any kind of a restriction.
3. If a problem is found, clean or replace EGR system
components as necessary.
Was a condition present that required repair?
—
Go to
Step 8
Go to
Step 7
7
1. Remove the EGR inlet and outlet pipes from the
exhaust manifold and the intake manifold.
2. Inspect the manifold EGR ports and the EGR inlet
and outlet pipes for a blockage caused by excessive
deposits or other damage.
3. If a problem is found, correct the condition as
necessary.
Was a condition present that required repair?
—
Go to
Step 8
Check the
Procedure
Refer to
Diagnostic
Aids
8
1. Review and record the Tech 2 Failure Records data.
2. Clear DTC and monitor the Tech 2 System Info
Screen while operating the vehicle as specified in
“Diagnostic Aids”.
3. Using a Tech 2, monitor “DTC” info for DTC P0401
until the DTC P0401 test runs.
4. Note the test result.
Does the Tech 2 indicate DTC P0401 failed this
ignition?
—
—
Repair
complete
6E–280
6VE1 3.5 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error
D06R200075
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to
detect a fault if pintle position is stuck open. If the PCM
detects a pintle position signal indicates more than 21.5%
and more than for 625 msec during cranking, the PCM will
set DTC P0402.
Conditions for Setting the DTC
D
Ignition voltage is between 11 and 16 volts.
D
At Engine revolution less than 600 RPM, EGR pintle
position indicates more than 21.0% and more than for
625 msecs.
Action Taken When the DTC Sets
D
The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
fault is detected.
D
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in Failure
Records data.
Conditions for Clearing the MIL/DTC
D
The PCM will turn the MIL “OFF” on the third
consecutive trip cycle during which the diagnostic has
been run and the fault condition is no longer present.
D
A history DTC P0402 will clear after 40 consecutive
warm-up cycles have occurred without a fault.
D
DTC P0402 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
D
Foreign material on EGR valve between pintle and
seat may cause EGR stuck open. Inspect foreign
material in EGR valve.
D
Excessive carbon deposit may cause unsmooth
operation of EGR valve shaft. Inspect for carbon
deposit and clean up inside of carbon deposit.
D
Poor connection or damaged harness–inspect the
wiring harness for damage If the harness appears to be
OK, observe the EGR actual position display on the
Tech 2 while moving connectors and wiring harnesses
related to EGR valve. A change in the display will
indicate the location of the fault.
NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged catalytic converter) using the “Restricted
Exhaust System Check”.
6E–281
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
DTC P0402 – EGR Pintle Crank Open Error
Step
Action
Value(s)
Yes
No
1
Was the “On-Board Diagnostic (OBD) System Check”
performed?
—
Go to
Step 2
Go to
OBD
System
Check
2
1. Ignition “ON”, engine “OFF”, review and record
Tech 2 Failure Records data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using a Tech 2, monitor “DTC” info for DTC P0402
until the DTC P0402 test runs. Note the result.
Does the Tech 2 indicates DTC P0402 failed this
ignition?
—
Go to
Step 3
Check the
Procedure
Refer to
Diagnostic
Aids
3
1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals?
—
Go to
Step 4
Go to
Step 5
4
Repair the damaged pin or terminal.
Is the action complete?
—
Verify repair
—
5
1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any foreign
material between seat and pintle.
Was any foreign material in EGR valve?
—
Go to
Step 6
Go to
Step 7
6
1. Remove EGR valve foreign material from EGR
valve and clean up inside.
2. Visually inspect for damage of pintle and seat,
which leakage may occur.
Was there any severe damage which affects function?
—
Go to
Step 7
Verify repair
Go to
Step 8
7
1. Reconnect.
2. Ignition “OFF”.
3. Install the Tech 2.
4. Run the engine at idle.
5. On Tech-II, select special function for EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly?
—
—
Go to
Step 8
8
Replace the EGR valve.
Does DTC P0402 still fail “DTC” test on the Tech 2?
—
Go to
Step 9
Verify repair
9
Replace the PCM.
Is the action complete?
—
Verify repair
—
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