Frelander 2. Manual — part 284
module)
, regulates the amount of exhaust gases recirculated into the air intake system. The
ECM
uses signals from
various engine sensors and calculates a response based on the embedded software algorithm to control exhaust gas
recirculation. The
ECM
transmits this control signal to the valve's actuator, which is closed-loop controlled with the mass
air flow (MAF) sensor providing the feedback to the
ECM
.
COMPONENT DESCRIPTION
Exhaust Gas Recirculation (EGR) Valve and Cooler Assembly
Item
Part Number
Description
1
-
Actuator
2
-
Coolant outlet
3
-
Cooler
The EGR valve and cooler assembly is located on the RH side of the cylinder head above the exhaust manifold, and
secured with 4 fixings. An inlet pipe connects the EGR cooler to the exhaust manifold. A gas transfer tube is routed across
the engine and connects the EGR valve outlet to the intake manifold housing.
A pipe on the EGR cooler body connects to the climate control heater outlet hose, and provides the coolant supply to the
EGR cooler. The EGR cooler outlet connects to the coolant rail, located on the RH side of the engine. The coolant rail is
connected between the thermal control module and the coolant pump rear housing.
For additional information, refer to:
Engine Cooling
(303-03A Engine Cooling - I6 3.2L Petrol, Description and Operation).
The EGR is controlled by the ECM, and is enabled when the engine meets the correct operating temperatures and under
cruising conditions.
Oil Separator
The crankcase ventilation oil separator is also connected to the oil filler tube, located at the rear LH side of the engine. Oil
for replenishing the system passes through the oil separator and return hose, and into the oil pan. An oil baffle plate is
installed in the oil pan housing to reduce oil aeration and splash.
Engine Emission Control - TD4 2.2L Diesel - Engine Emission Control
Diagnosis and Testing
Principles of Operation
For a detailed description of the engine emission control systems, refer to the relevant Description and Operation section
in the workshop manual.
REFER to:
Engine Emission Control
(303-08B Engine Emission Control - TD4 2.2L Diesel, Description and Operation).
Inspection and Verification
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does
not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor
vehicle.
1. Verify the customer concern.
1.
2. Visually inspect for obvious signs of mechanical or electrical damage.
2.
Visual Inspection
Mechanical
Electrical
EGR valve
EGR pipes/hoses
Vacuum system
Engine breather system
Wiring harness
Electrical connector(s)
Fuses(s)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step
3.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
4.
Symptom Chart
Symptom
Possible Cause
Action
Rough idle, lack of power under acceleration,
excessive fuel consumption, excessive black
smoke
EGR valve stuck
Check EGR valve for correct operation.
Check for related DTCs and refer to the DTC
Index
Excessive engine blow-by/crankcase pressure
Engine breather system
blocked/restricted
Excessive engine wear
Check engine breather system for
blockage/restriction. Check for excessive
engine wear
REFER to:
Engine
(303-00 Engine System -
General Information, Diagnosis and
Testing).
DTC Index
• NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior
to the installation of a new module/component.
• NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. Match the five digits from the
scan tool to the first five digits of the seven digit code listed to identify the fault (the last two digits give additional
information read by the manufacturer approved diagnostic system).
• NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal
places, and with an up-to-date calibration certificate. W hen 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: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.
• NOTE: If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may
be the cause. Always check for loose connections and corroded terminals.
DTC
Description
Possible Cause
Action
P040500 Exhaust Gas Recirculation
Sensor A Circuit Low
EGR Valve position sensor
voltage below lower limit
Carry out the pinpoint tests associated with
this DTC using the manufacturer approved
diagnostic system
P040600 Exhaust Gas Recirculation
Sensor A Circuit High
EGR Valve position sensor
voltage above upper limit
Carry out the pinpoint tests associated with
this DTC using the manufacturer approved
diagnostic system
P042E00 Exhaust Gas Recirculation
Control Stuck Open
EGR Valve stuck during normal
engine running - attempt to
unstick valve unsuccessful
Check/clear EGR valve from
obstruction/sticking
DTC
Description
Possible Cause
Action
P042F00 Exhaust Gas Recirculation
Control Stuck Closed
EGR Valve stuck during normal
engine running - attempt to
unstick valve unsuccessful
EGR Valve stuck during after run
tests
Check/clear EGR valve from
obstruction/sticking
P048900 Exhaust Gas Recirculation
Control Circuit Low
EGR Valve position deviation -
valve stuck open
Check/clear EGR valve from
obstruction/sticking
P049000 Exhaust Gas Recirculation
Control Circuit High
EGR Valve position deviation -
valve stuck closed
Check/clear EGR valve from
obstruction/sticking
P140200 Exhaust Gas Recirculation
Metering Orifice
Restricted
EGR valve closed position offset
difference with first learning too
large
EGR valve closed position offset
difference with previous learning
too large
Check/clear EGR valve from
obstruction/sticking, clear DTC and re-test. If
DTC remains, install new EGR valve
P148700 Exhaust Gas Recirculation
Check Solenoid Circuit
EGR valve H-Bridge driver error
Clear the DTC and re-test. If the DTC
remains, install a new ECM
P154500 Exhaust Gas Recirculation
High Side Control Circuit /
Open
Exhaust gas recirculation control
circuit 1 (positive) - open circuit
Exhaust gas recirculation control
circuit 2 (negative) - open circuit
Refer to electrical circuit diagrams and check
exhaust gas recirculation control circuit for
open circuit
P154611 Exhaust Gas Recirculation
High Side Control Circuit
Low
Exhaust gas recirculation control
circuit 1 (positive) - short to
ground
Exhaust gas recirculation control
circuit 2 (negative) - short to
ground
Refer to electrical circuit diagrams and check
exhaust gas recirculation control circuit for
short to ground
P154712 Exhaust Gas Recirculation
High Side Control Circuit
High
Exhaust gas recirculation control
circuit 1 (positive) - short to
power
Exhaust gas recirculation control
circuit 2 (negative) - short to
power
Refer to electrical circuit diagrams and check
exhaust gas recirculation control circuit for
short to power
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