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SEF552W
COMPONENT DESCRIPTIONNLEC0504S02EGR Volume Control ValveNLEC0504S0201The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the
ECM. Two windings are turned ON and OFF in sequence. Each
time an ON pulse is issued, the valve opens or closes, changing
the flow rate. When no change in the flow rate is needed, the ECM
does not issue the pulse signal. A certain voltage signal is issued
so that the valve remains at that particular opening.
CONSULT-II Reference Value in Data Monitor
Mode
NLEC0506Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
EGR VOL CON/V+Engine: After warming up
+Shift lever: ªNº
+No-loadIdle 0 step
Revving engine up to 3,000 rpm
quickly1 - 10 step
ECM Terminals and Reference ValueNLEC0507Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
NAL NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
8
9
17
18SB
W/B
R/Y
BR/REGR volume control valve[Engine is running]
+Warm-up condition
+Idle speed0 - 14V
On Board Diagnosis LogicNLEC0508
DTC No. Malfunction is detected when ... Check Items (Possible Cause)
P0403
0403+An improper voltage signal is sent to ECM through the
valve.+Harness or connectors
(The EGR volume control valve circuit is open or
shorted.)
+EGR volume control valve
SEF058Y
DTC Confirmation ProcedureNLEC0509NOTE:
If ªDTC Confirmation Procedureº has been previously conducted,
always turn ignition switch ªOFFº and wait at least 9 seconds
before conducting the next test.
With CONSULT-II
1) Turn ignition switch ªONº.
2) Select ªDATA MONITORº mode with CONSULT-II.
3) Start engine and warm it up to normal operating temperature.
4) Rev engine from idle to 2,000 rpm 20 times.
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
Description (Cont'd)
EC-320
Page 746 of 3051
If 1st trip DTC is detected, go to ªDIAGNOSTIC
PROCEDUREº, EC-324.
With GST
Follow the procedure ªWith CONSULT-IIº above.
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
DTC Confirmation Procedure (Cont'd)
EC-321
Page 747 of 3051
Wiring DiagramNLEC0510MODELS WITH ECM IN ENGINE COMPARTMENTNLEC0510S01
YEC665
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
Wiring Diagram
EC-322
Page 748 of 3051
MODELS WITH ECM IN CABINNLEC0510S02
YEC885
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
Wiring Diagram (Cont'd)
EC-323
Page 749 of 3051

Diagnostic ProcedureNLEC0511
1 CHECK POWER SUPPLY
1. Disconnect EGR volume control valve harness connector.
2. Turn ignition switch ªONº.
3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.
SEF782Z
OK or NG
OK©GO TO 3.
NG©GO TO 2.
2 DETECT MALFUNCTIONING PART
Check the following.
+15A fuse
+Harness connectors E76, F36
+Harness connectors M72, F44 (where fitted)
+Harness connectors M11, E106 (LHD models) (where fitted)
+Harness connectors M78, E120 (RHD models) (where fitted)
+Harness for open or short between fuse and ECM relay
+Harness for open or short between EGR volume control valve and ECM relay
+ECM relay
©Repair harness or connectors, or replace fuse or ECM relay.
3 CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch ªOFFº.
2. Disconnect ECM harness connector.
3. Check harness continuity between
ECM terminal 8 and EGR volume control valve terminal 1,
ECM terminal 9 and EGR volume control valve terminal 2,
ECM terminal 17 and EGR volume control valve terminal 3,
ECM terminal 18 and EGR volume control valve terminal 4.
Refer to wiring diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK©GO TO 4.
NG©Repair open circuit, short to ground or short to power in harness connectors.
4 CHECK EGR VOLUME CONTROL VALVE
Refer to ªCOMPONENT INSPECTIONº, EC-326.
OK or NG
OK©GO TO 5.
NG©Replace EGR volume control valve.
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
Diagnostic Procedure
EC-324
Page 750 of 3051
5 CHECK INTERMITTENT INCIDENT
Perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-145.
©INSPECTION END
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
Diagnostic Procedure (Cont'd)
EC-325
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SEF069X
SEF783Z
SEF015Y
SEF560W
Component InspectionNLEC0512EGR VOLUME CONTROL VALVENLEC0512S01With CONSULT-II
1) Disconnect EGR volume control valve harness connector.
2) Check resistance between the following terminals.
terminal 2 and terminals 1, 3
terminal 5 and terminals 4, 6
Temperature ÉC (ÉF) ResistanceW
20 (68) 20 - 24
3) Reconnect EGR volume control valve harness connector.
4) Remove EGR volume control valve from cylinder head.
(The EGR volume control valve harness connector should
remain connected.)
5) Turn ignition switch ªONº.
6) Perform ªEGR VOL CONT/Vº in ªACTIVE TESTº mode with
CONSULT-II. Check that EGR volume control valve shaft
moves smoothly forward and backward according to the valve
opening.
If NG, replace the EGR volume control valve.
Without CONSULT-II
1) Disconnect EGR volume control valve harness connector.
2) Check resistance between the following terminals.
terminal 2 and terminals 1, 3
terminal 5 and terminals 4, 6
Temperature ÉC (ÉF) ResistanceW
20 (68) 20 - 24
3) Turn ignition switch ªONº and ªOFFº. Check that EGR volume
control valve shaft moves smoothly forward and backward
according to the ignition switch position.
If NG, replace the EGR volume control valve.
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)
(WHERE FITTED)
QG18DE
Diagnostic Procedure (Cont'd)
EC-326
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SEF184UD
On Board Diagnosis LogicNLEC0240The ECM monitors the switching frequency ratio of heated oxygen
sensors 1 (front) and 2 (rear).
A three way catalyst with high oxygen storage capacity will indicate
a low switching frequency of heated oxygen sensor 2 (rear). As
oxygen storage capacity decreases, the heated oxygen sensor 2
(rear) switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 (front) and
2 (rear) approaches a specified limit value, the three way catalyst
malfunction is diagnosed.
DTC No. Malfunction is detected when ... Check Items (Possible Cause)
P0420
0420+Three way catalyst does not operate properly.
+Three way catalyst does not have enough oxygen stor-
age capacity.+Three way catalyst
+Exhaust tube
+Intake air leaks
+Injectors
+Injector leaks
+Spark plug
+Improper ignition timing
SEF847Y
SEF848Y
SEF560X
DTC Confirmation ProcedureNLEC0241CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If ªDTC Confirmation Procedureº has been previously conducted,
always turn ignition switch ªOFFº and wait at least 9 seconds
before conducting the next test.
With CONSULT-II
TESTING CONDITION:
+Open engine hood before conducting following proce-
dure.
+Do not hold engine speed more than specified minutes
below.
1) Turn ignition switch ªONº.
2) Select ªDTC & SRT CONFIRMATIONº then ªSRT WORK SUP-
PORTº mode with CONSULT-II.
3) Start engine.
4) Rev engine up to 3,000±500 rpm and hold it for 3 consecutive
minutes then release the accelerator pedal completely.
If ªCOMPLETEDº appears on the CONSULT-II screen, go to
step 7.
5) Wait 5 seconds at idle.
6) Rev engine up to 2,500±500 rpm and maintain it until ªINCMPº
of CATALYST changes to ªCMPLTº (it will take approximately
5 minutes.)
If not ªCMPLTº, stop engine and cool it down to less than 70ÉC
(158ÉF) and then retest from step 1.
7) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
8) Confirm that the 1st trip DTC is not detected.
If the 1st trip DTC is detected, go to ªDiagnostic Procedureº,
EC-328.
DTC P0420 THREE WAY CATALYST FUNCTIONQG18DE
On Board Diagnosis Logic
EC-327