DESCRIPTION
Faults and Symptoms of Common Rail Diesel Components
Engine Control
Main fault | Decrease in performance (foreign matter is attached) |
Symptoms | Lack of power, black smoke |
Data List | MAF |
Tip:
The maximum fuel injection volume is controlled according to the output from the mass air flow meter assembly. |
Main fault |
|
Data List | MAP |
Symptom and Corresponding Main Fault |
|
Symptoms |
Lack of power (when vehicle is starting, under heavy load) (Black smoke is not emitted when racing the engine while the vehicle is stopped) |
Data List | MAP |
Main fault | Blockage |
Symptoms | Lack of power (high engine speed, under heavy load) |
Main fault | Glow system malfunction |
Symptoms | Difficult to start, rough idle, knocking, white smoke (when cold) |
Data List | Check the glow plug indicator light |
Diagnostic Point | Measure the resistance of the glow plug assembly |
Main fault | Battery is depleted |
Symptoms | Difficult to start (cannot crank, crank speed is low), horn is quiet |
Data List |
Battery Voltage When cranking, battery voltage is below 5 V. |
Main fault | Damaged, seized up |
Symptoms | Cannot crank, crank speed is low, strange noise |
Main fault | Loss of compression |
Symptoms | Rough idle (lack of power always) |
Data List |
Engine Speed of Cyl
Injection Feedback Val
|
Main fault | Starter system malfunction |
Symptoms | Difficult to start |
Data List |
Starter Signal
|
Common Rail (ALL)
Main fault | - |
Symptoms | Difficult to start, engine stalling, rough idle, lack of power |
Data List |
Fuel Press, Target Common Rail Pressure, Target Pump SCV Current
Tip:
|
Diagnostic Trouble Code | Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored. |
Main fault | Blockage |
Symptoms | Difficult to start, engine stalling, rough idle, lack of power |
Data List |
Fuel Press, Target Common Rail Pressure
Tip:
The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up. |
Diagnostic Trouble Code | Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored. |
Main fault | Blockage |
Symptoms | Rough idle, lack of power, black smoke, white smoke, knocking |
Data List |
Injection Feedback Val
|
Main fault | Does not completely close |
Symptoms | Difficult to start, engine stall, rough idle, lack of power |
Main fault | Circuit fault: The injector assembly does not open. |
Symptoms | Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking |
Data List | Same as injector assembly |
Diagnostic Trouble Code | When the injector driver (EDU) has a fault, some DTCs may be stored. |
Main fault | Open circuit, decrease in performance (foreign matter is attached) |
Symptoms | Difficult to start, rough idle, engine stall, lack of power |
Data List |
Fuel Press, Target Common Rail Pressure
|
Diagnostic Trouble Code | When the fuel pressure sensor has a fault, some DTCs may be stored. |
Main fault | - |
Symptoms | Difficult to start, rough idle (especially when cold) |
Diesel EGR
Main fault |
|
Symptoms |
|
Data List |
Actual EGR Valve Pos., Target EGR Position
EGR Close Lrn. Val., EGR Close Lrn. Status
|
Diesel Throttle
Main fault | Stuck, does not move smoothly |
Symptoms |
|
Data List |
Actual Throttle Position
|
Data List Related to Starting Trouble
MAP
MAF
Intake Air
Coolant Temp
Battery Voltage
Starter Signal
Engine Speed of Cyl #1 (to #4)
Target Common Rail Pressure
Fuel Press
Target Pump SCV Current
Injection Feedback Val #1 (to #4)
Injection Volume
Actual Throttle Position
Target EGR Position
Actual EGR Valve Pos.
EGR Close Lrn. Status
EGR Close Lrn. Val.
CAUTION / NOTICE / HINT
Explanation of Symptom
Starting Trouble |
For good starting it is essential to have:
The fuel is ignited by the heat which is generated by compression pressure. With problems such as a depleted battery, the crankshaft speed can become low, or if the engine compression is poor due to leakage, the compression pressure will not rise and there will be difficulty starting. When the engine is cold, even if there is compression heat, it will escape from the combustion chamber. For this reason, when the engine is started when it is cold, the glow plugs heat the compressed air. Also, after starting the engine, by charging the glow plugs for a fixed time set according to the engine coolant temperature, diesel knocking and white smoke are prevented. The quantity of fuel injected is determined by the fuel pressure and also the amount of time the injector assembly is open. |
Trouble Area Chart According to Problem Cause
After replacing the suction control valve, the ECM needs initialization.
Click hereНажмите здесь
After replacing an injector assembly, the ECM needs registration.
Click hereНажмите здесь
Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List values may occur depending on the measuring conditions or the vehicle age. Do not assume the vehicle is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.
PROCEDURE
CHECK ENGINE CRANKING CONDITION
Check the engine cranking condition.
Result | ||||||||
---|---|---|---|---|---|---|---|---|
|
B |
CHECK BATTERY CONDITION Click hereНажмите здесь |
C | Нажмите здесь |
A |
READ ALL OUTPUT DTCS
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: System Select / Health Check.
Check the DTCs.
Result | ||||||
---|---|---|---|---|---|---|
|
If only DTC P1604 is output, proceed to procedure 3.
B |
GO TO RELATED DTC Click here Нажмите здесь |
A |
TAKE SNAPSHOT DURING STARTING AND IDLING (PROCEDURE 3)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.
Take a snapshot when idling with no load after the engine is warmed up and when starting trouble is occurring.
A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting.
When there is trouble starting with a cold engine, take the snapshot when the engine is cold. Then warm up the engine (engine coolant temperature is 70°C (158°F) or higher) and after idling the vehicle for 1 minute (A/C off, electrical load off), take a snapshot of the data for 15 seconds while idling.
Take a snapshot when the problem is occurring, such as when the engine is cold. However, if the problem does not reoccur, it is acceptable to only take a snapshot after the engine is warmed up and when the engine is started.
Result | ||
---|---|---|
|
NEXT |
CHECK SNAPSHOT (FUEL PRESS)
Check Fuel Press in the snapshot taken in procedure 3 when the engine was started.
Result | ||||||||||
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|
Even if Fuel Press is temporarily higher than Target Common Rail Pressure, as shown at the point in the illustration labeled "b", the supply pump assembly is normal.
Fuel Press is about 25000 to 35000 kPa when the engine is cranking and the engine coolant temperature is 0°C (32°F) or higher.
Fuel Press increases rapidly during cranking.
B | Нажмите здесь |
C | Нажмите здесь |
D | Нажмите здесь |
A |
CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY
Disconnect the inlet hose from the supply pump assembly.
Operate the hand pump and check that fuel is being supplied to the supply pump assembly.
OK |
---|
Fuel is properly supplied to the supply pump assembly when the hand pump is operated. |
When there is a lack of fuel, fuel pressure drops.
check that the fuel filter element sub-assembly is not clogged.
Result | |||
---|---|---|---|
|
NG | Нажмите здесь |
OK |
CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)
Click hereНажмите здесь
Result | |||
---|---|---|---|
|
NG |
REPAIR OR REPLACE HARNESS OR CONNECTOR |
OK |
REPLACE SUCTION CONTROL VALVE
Replace the suction control valve.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
PERFORM SUPPLY PUMP INITIALIZATION
Perform the supply pump initialization.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
READ VALUE USING GTS (FUEL PRESS)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Fuel Press
Powertrain > Engine and ECT > Data ListTester Display |
---|
Fuel Press |
Start the engine.
Read the Fuel Press values while cranking and idling the engine.
Result | ||||||
---|---|---|---|---|---|---|
|
A |
END |
B |
INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)
Remove the glow plug assembly for all the cylinders.
Click hereНажмите здесь
Visually check if there is fuel on the glow plug assemblies.
If there is fuel on a glow plug assembly, fuel may be leaking from an injector assembly.
After replacing an injector assembly, make sure that the common rail pressure (fuel pressure) is within 5000 kPa of the target fuel pressure while cranking the engine.
If there is fuel on a glow plug assembly, fuel may have mixed with the engine oil. Check the engine oil amount and whether the engine oil smells of diesel fuel. If the oil level is above the full line or the engine oil smells of diesel fuel, replace the engine oil.
Result | ||
---|---|---|
|
NEXT | Нажмите здесь |
GO TO STEP 25 |
CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - SUPPLY PUMP ASSEMBLY)
Check and repair or replace the clogged fuel pipe.
Result | ||
---|---|---|
|
NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT | Нажмите здесь |
GO TO STEP 29 |
READ VALUE USING GTS (FUEL PRESS)
Check Fuel Press in the snapshot taken in procedure 3 when the engine was warmed up.
Result | ||||||
---|---|---|---|---|---|---|
|
B | Нажмите здесь |
GO TO STEP 17 |
A |
REPLACE SUCTION CONTROL VALVE
Replace the suction control valve.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
PERFORM SUPPLY PUMP INITIALIZATION
Perform the supply pump initialization.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS
Replace the injector assemblies.
Click here Нажмите здесь
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
Result | ||
---|---|---|
|
NEXT | Нажмите здесь |
GO TO STEP 26 |
INSPECT INJECTOR DRIVER (EDU)
Even in cases where DTC P062D is not stored even though the engine cannot be started, perform the DTC P062D (No. 1 Fuel Injector Driver Circuit Performance) troubleshooting procedure.
Click hereНажмите здесь
When troubleshooting the injector driver (EDU) system, the source of the malfunction is likely to be in one of the following areas, so be sure to inspect these areas carefully.
Injector driver (EDU) system power source circuit
Injector assembly circuit
Injector driver (EDU)
ECM
When the engine cannot be started due to a malfunction in the injector driver (EDU) system, once the DTCs are cleared, the system cannot store DTC P062D even if it is confirmed that the engine cannot be started when trying to reproduce the problem symptoms.
As DTC P062D cannot be stored when starting the engine, fuel injection signals are output by the ECM, but fuel is not actually injected. Therefore, an excessive amount of fuel is supplied to the common rail by the supply pump assembly, and as a result, the fuel pressure is higher than the target common rail pressure in the data recorded at the time the engine was having trouble starting.
If the problem cannot be determined even after performing the DTC P062D (No. 1 Fuel Injector Driver Circuit Performance) troubleshooting procedure and the fuel pressure is higher than the target common rail pressure when attempting to start the engine, proceed to the next step.
Perform the troubleshooting procedure for DTC P062D and proceed to the diagnostic flow situations where the engine does not start.
Result | ||||||
---|---|---|---|---|---|---|
|
B |
REPAIR OR REPLACE MALFUNCTIONING PARTS |
A |
INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)
When the engine does not start, perform the following procedure.
Stop the engine and leave the vehicle for 4 hours or more.
It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.
Confirm the engine starts.
When the engine starts, perform the following procedure.
Bleed the air from the fuel system.
Click hereНажмите здесь
Confirm the engine starts.
Result | ||
---|---|---|
|
NEXT | Нажмите здесь |
GO TO STEP 38 |
INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)
When the engine does not start, perform the following procedure.
Stop the engine and leave the vehicle for 4 hours or more.
It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.
Check that the engine starts.
OK |
---|
The engine starts. |
When the engine starts, perform the following procedure.
Bleed the air from the fuel system.
Click hereНажмите здесь
Check that the engine starts.
OK |
---|
The engine starts. |
Result | |||
---|---|---|---|
|
OK |
END |
NG |
CHECK DATA LIST
Check Injection Feedback Val # in the snapshot taken in procedure 3 when the engine was idling.
Result | ||||||||
---|---|---|---|---|---|---|---|---|
|
*: When this case occurs, usually symptoms may be noticeable, such as difficulty starting, lack of power.
The shift lever should be in neutral and the A/C switch and all accessory switches should be off.
B | Нажмите здесь |
C | Нажмите здесь |
A |
REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS
Replace the injector assemblies.
Click here Нажмите здесь
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
Result | ||
---|---|---|
|
NEXT | Нажмите здесь |
GO TO STEP 26 |
PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)
Use this Active Test to help determine whether a cylinder has compression loss or not.
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Compression / Engine Speed of Cyl #1 to #4.
Powertrain > Engine and ECT > Active TestActive Test Display |
---|
Check the Cylinder Compression |
Data List Display |
---|
Engine Speed of Cyl #1 |
Engine Speed of Cyl #2 |
Engine Speed of Cyl #3 |
Engine Speed of Cyl #4 |
Check the engine speed during the Active Test.
Result | ||||||
---|---|---|---|---|---|---|
|
When cranking, if the speed of a cylinder is approximately 100 rpm higher than the other cylinders, there is probably a complete loss of compression in that cylinder.
B | Нажмите здесь |
GO TO STEP 25 |
A |
CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER
Measure the compression of the cylinder that had a high speed during the "Check the Cylinder Compression" Active Test.
Check the cylinder compression pressure.
Click hereНажмите здесь
Result | |||
---|---|---|---|
|
NG |
CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION |
OK |
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
It can be determined that the injector assembly is faulty as the corresponding cylinder is malfunctioning, but has no compression loss.
Replace the injector assembly.
Click here Нажмите здесь
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
Result | ||
---|---|---|
|
NEXT |
REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY
Replace the fuel filter element sub-assembly.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING
Register the injector compensation codes.
Click hereНажмите здесь
Perform the injector quantity learning.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
---|---|---|
|
NEXT |
END |
CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS
Check the temperature when starting trouble occurs.
Result | ||||||
---|---|---|---|---|---|---|
|
B | Нажмите здесь |
GO TO STEP 33 |
A |
READ VALUE USING GTS (COOLANT TEMP)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Coolant Temp.
Powertrain > Engine and ECT > Data ListTester Display |
---|
Coolant Temp |
Read the value displayed on the GTS.
OK |
---|
Coolant Temp is not high when the engine is cold, and not low after the engine is warmed up. |
Result | |||
---|---|---|---|
|
NG |
INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click hereНажмите здесь |
OK |
INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)
Inspect the glow plug assembly.
Click hereНажмите здесь
Result | |||
---|---|---|---|
|
NG |
REPLACE GLOW PLUG ASSEMBLY Click hereНажмите здесь |
OK |
CHECK FUEL QUALITY
Check that only diesel fuel is being used.
Check that the fuel does not contain any impurities.
Result | ||
---|---|---|
|
NEXT | Нажмите здесь |
GO TO STEP 38 |
READ OUTPUT DTC (RELATED TO ENGINE)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Read the DTCs.
Powertrain > Engine and ECT > Trouble CodesResult | ||||||
---|---|---|---|---|---|---|
|
B |
GO TO RELATED DTC Click here Нажмите здесь |
A |
CHECK COMMUNICATION BETWEEN GTS AND ECM
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Check if the normal starting screen appears (check whether communication with the ECM is possible).
Use a GTS that is able to communicate with other vehicles.
OK |
---|
Communication is possible (vehicle can be recognized). |
Result | |||
---|---|---|---|
|
NG |
CHECK VC OUTPUT CIRCUIT Click hereНажмите здесь |
OK |
READ VALUE USING GTS (STARTER SIGNAL)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Starter Signal.
Powertrain > Engine and ECT > Data ListTester Display |
---|
Starter Signal |
Read the value displayed on the GTS.
OK | ||||||
---|---|---|---|---|---|---|
|
Result | |||
---|---|---|---|
|
NG |
INSPECT CLUTCH START SWITCH ASSEMBLY Click here Нажмите здесь |
OK |
CHECK STARTING SYSTEM
Inspect the starting system.
Be sure to inspect the following areas:
Starter (ST NO. 1) relay
Click hereНажмите здесь
Starter assembly
Click hereНажмите здесь
Immobiliser system (w/ entry and start system)
Click here Нажмите здесь
Immobiliser system (w/o entry and start system)
Click here Нажмите здесь
Result | ||
---|---|---|
|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
---|---|---|
|
NEXT |
END |