Page 1342 of 6020
EXHAUST SYSTEM 6F – 9
EGR SYSTEM DIAGRAM 4JA1T (L)
RTW 46AMF000301
EGR System Operation
Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
• Inspection point (Engine RPM)
RPM Idling 900 ∼ 960 2000 3250
Engine Front Side VSV-1
ON ON ON OFF
Engine Rear Side VSV-2 ON OFF ON OFF
ON means VSV should receive signal to move EGR valve.
OFF means VSV shouldn’t receive signal to move EGR valve.
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Page 1343 of 6020
6F – 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail.
RTW 46EMF000701
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Page 1344 of 6020
EXHAUST SYSTEM 6F – 11
INSPECTION
4JA1T(L)
Vacuum switch valve (VSV)
Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance Ω at 20°C
37 ~ 44
If the resistance is not within specification, replace it.
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure
4JA1TC/4JH1TC
RTW 46ESH000301
EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance Ω at 20°C
14
If the resistance is not within specification, replace it.
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure 4JH1TC
Less than 250 mmHg Not operation
More than 300 mmHg Operation
Negative Pressure 4JA1TC
Less than 100 mmHg Not operation
More than 170 mmHg Operation
Less then 180 mmHg Not operation
More than 240 mmHg
Operation
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Page 1345 of 6020
6F – 12 EXHAUST SYSTEM
EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)
REMOVAL AND INSTALLATION
RTW 46EMF000201
Removal Steps
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly
8. Gasket
9. Bolt
10. EGR Cooler Assembly
11. Gasket
12. EGR Cooler Adapter
Removal
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly
8. Gasket
9. Bolt
10. EGR Cooler Assembly
11.Gasket
12.EGR Cooler Adapter
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Page 1346 of 6020
EXHAUST SYSTEM 6F – 13
RTW 46EMF000901
Installation steps
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Gasket
5. Bolt
6. EGR Pipe Assembly
7. Bolt
8. Bolt
9. Gasket
10. EGR Valve Assembly
11. Bolt
12. EXH Manifold
13. Gasket
14. Bolt
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6F – 14 EXHAUST SYSTEM
Installation
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Bolt
Tighten the bolts to the specified torque.
EGR adapter bolt torque N⋅m(kg ⋅m/lb ft)
27(2.8/20)
5. Gasket
6. EGR Pipe Assembly
7. Bolt
Tighten bolts temporarily.
8. Bolt
Tighten bolts temporarily.
9. Gasket
10. Bolt
Tighten bolts temporarily.
11.Gasket
12.Bolt
Tighten bolts temporarily.
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing surface.
Bolt torque (Cooler-pipe) N ⋅m(kg ⋅m/lb ft)
27(2.8/20)
Bolt torque (Cooler-bracket) N ⋅m (kg ⋅m/lb ft)
24(2.4/17)
Bolt torque (Adapter-EGR valve) N ⋅m (kg ⋅m/lb ft)
27(2.8/20)
Bolt torque (Pipe-manifold) N ⋅m (kg ⋅m/lb ft)
27(2.8/20)
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Page 1364 of 6020
6A-4 ENGINE MECHANICAL (4JK1/4JJ1)
How to read the model (This illustration is 4JK1 engine)
RTW 56ALF004701
Legend
1. Engine Model (Stamped)
2. Engine Number (Stamped)
3. Front
Explanation of functions and operations
Electronic engine control
W ith the control unit, the range from injection to ai
r
intake/exhaust, including fuel injection quantity, injection
timing, intake air restriction, EGR, and idling rpm, is
controlled.
Piston
The piston is aluminum-alloy and a thermal flow piston
with a strut cast, while the combustion chamber is a
round reentrant type.
Cylinder head
The cylinder head is aluminum-alloy and there are 4
valves per cylinder. The angular tightening method o
f
the cylinder head bolt further increases reliability and
durability.
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Page 1365 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-5
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it. Each
is controlled via ECM based upon various signals, while
injection timing or fuel injection quantity is controlled
under every possible driving condition.
Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening o
r
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantit
y
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.
Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.
Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.
Functional inspection
Inspection/adjustment of valve clearance 1. Inspection of valve clearance
• Remove the fuel injector harness assembly.
• Remove the leak off hose.
• Remove the cylinder head cover.
• Rotate the crankshaft to make the No.1
cylinder meet the compression top dead cente
r
(TDC).
RTW 76ASH001301
Legend
1. TDC
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