Code No. P0546: No. 1 exhaust gas temperature sensor Circuit High Input <Vehicles with closed type DPF>

OPERATION

A power voltage of 5 V is applied to the No. 1 exhaust gas temperature sensor output terminal (terminal No. 1 <M/T>, No. 2 <A/T>) from the engine-ECU (terminal No. 58).
The power voltage is earthed to the engine-ECU (terminal No. 82) from the No. 1 exhaust gas temperature sensor (terminal No. 2 <M/T>, No. 1 <A/T>).

FUNCTION

The No. 1 exhaust gas temperature sensor converts the exhaust gas temperature into a voltage and inputs the voltage signal to the engine-ECU.
Engine-ECU uses this voltage for DPF regeneration control.
The No. 1 exhaust gas temperature sensor is a kind of resistor, which has characteristics to reduce its resistance as the exhaust gas temperature rises. Therefore, the sensor output voltage varies with the exhaust gas temperature, and becomes lower as the exhaust gas temperature rises.

TROUBLE JUDGMENT

Check Conditions

Battery positive voltage is 8 - 16 V.
2 seconds later after the ignition switch has been in "ON" position or the engine has started up.
Vehicle speed is 20 km/h or higher.

Judgment Criterion

The No. 1 exhaust gas temperature sensor output voltage is 4.95 V or more.

PROBABLE CAUSES

Failed No. 1 exhaust gas temperature sensor
Open circuit or harness damage in No. 1 exhaust gas temperature sensor circuit or loose connector contact
Failed engine-ECU

DIAGNOSTIC PROCEDURE

STEP 1. M.U.T.-III data list

Refer to Data List Reference Table

Item 117: No. 1 exhaust gas temperature sensor

Q. Is the check result normal?

	Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).

	Go to Step 2 .

STEP 2. Connector check: B-45 <M/T>, B-44 <A/T> No. 1 exhaust gas temperature sensor connector

Q. Is the check result normal?

	Go to Step 3 .

	Repair or replace the connector.

STEP 3. Check No. 1 exhaust gas temperature sensor itself.

Check No. 1 exhaust gas temperature sensor itself (Refer to GROUP 17 - Diesel Particulate Filter (DPF) System - No. 1 exhaust gas temperature sensor Check ).

Q. Is the check result normal?

	Go to Step 4 .

	Replace the No. 1 exhaust gas temperature sensor. After replacing the No. 1 exhaust gas temperature sensor, carry out the forcible DPF regeneration. (Refer to GROUP 17 - Diesel Particulate Filter (DPF) System - Forcible DPF Regeneration ).

STEP 4. Perform voltage measurement at B-45 <M/T>, B-44 <A/T> No. 1 exhaust gas temperature sensor connector.

Disconnect connector, and measure at harness side.
Ignition switch: ON
Voltage between terminal No. 1 <M/T>, No. 2 <A/T> and earth.

OK: 4.5 - 4.9 V

Q. Is the check result normal?

	Go to Step 8 .

	Go to Step 5 .

STEP 5. Connector check: D-213 engine-ECU connector.

Q. Is the check result normal?

	Go to Step 6 .

	Repair or replace the connector.

STEP 6. Check harness between B-45 (terminal No. 1) <M/T>, B-44 (terminal No. 2) <A/T> No. 1 exhaust gas temperature sensor connector and D-213 (terminal No. 58) engine-ECU connector.

Check output line for open circuit.

Q. Is the check result normal?

	Go to Step 7 .

	Repair the damaged harness wire.

STEP 7. M.U.T.-III data list

Refer to Data List Reference Table

Item 117: No. 1 exhaust gas temperature sensor

Q. Is the check result normal?

	Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).

Replace the engine-ECU. When the engine-ECU is replaced, write the chassis number (Refer to GROUP 00 - Precautions Before Service - How to Perform Chassis Number Writing

). After replacing the engine-ECU, register the injector identification code and learn fuel injection (Refer to GROUP 00 - Precautions Before Service - What The Common Rail Engine Learns

). After registering the injector identification code, carry out the forcible DPF regeneration. (Refer to GROUP 17 - Diesel Particulate Filter (DPF) System - Forcible DPF Regeneration

STEP 8. Perform resistance measurement at B-45 <M/T>, B-44 <A/T> No. 1 exhaust gas temperature sensor connector.

Disconnect connector, and measure at harness side.
Resistance between terminal No. 2 <M/T>, No. 1 <A/T> and earth.

OK: Continuity (2 Ω or less)

Q. Is the check result normal?

	Go to Step 11 .

	Go to Step 9 .

STEP 9. Connector check: D-213 engine-ECU connector

Q. Is the check result normal?

	Go to Step 10 .

	Repair or replace the connector.

STEP 10. Check harness between B-45 (terminal No. 2) <M/T>, B-44 (terminal No. 1) <A/T> No. 1 exhaust gas temperature sensor connector and D-213 (terminal No. 82) engine-ECU connector.

Check earthing line for open circuit and damage.

Q. Is the check result normal?

	Go to Step 7 .

	Repair the damaged harness wire.

STEP 11. Connector check: D-213 engine-ECU connector.

Q. Is the check result normal?

	Go to Step 12 .

	Repair or replace the connector.

STEP 12. Check harness between B-45 (terminal No. 1) <M/T>, B-44 (terminal No. 2) <A/T> No. 1 exhaust gas temperature sensor connector and D-213 (terminal No. 58) engine-ECU connector.

Check output line for damage.

Q. Is the check result normal?

	Go to Step 7 .

	Repair the damaged harness wire.