СИСТЕМА ECD Lack of Power or Hesitation

DESCRIPTION

Table 1. Description
Malfunction Condition Main Trouble Area Related Trouble Area
  • Lack of power caused by abnormal injection volume (supply pump assembly malfunction or injector assembly malfunction etc.)

  • Lack of power caused by intake air volume shortage (turbocharger malfunction, front exhaust pipe or exhaust manifold converter blocked)

  1. Injector assembly

    • Injector assembly sliding malfunction

    • Injector assembly stuck closed

    • Injector assembly stuck open

    • Deposits in injector assembly

  2. Abnormal common rail pressure

    • Supply pump assembly

  3. Abnormal intake air volume

    • Turbocharger sub-assembly

    • Front exhaust pipe blockage

    • Exhaust manifold converter blockage

    • Diesel throttle does not open

    • Electric EGR control valve assembly does not close

  4. Shift position switch malfunction

  • Intake system leakage

  • Intake system blockage

  • Fuel filter element is clogged

  • Fuel is not supplied to supply pump

  • Diesel turbo pressure sensor

  • Mass air flow meter

  • Injector assembly

  • Injector compensation code

  • Vehicle modifications

  • Glow (Poor acceleration when engine is cold)

  • Low quality fuel

  • Shift position switch

  • ECM

Tip:
  • 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 judge the vehicle to be normal even when the Data List values indicate a standard level. Hidden factors of the malfunction are possible.

  • Check that the vehicle has not been modified in any way prior to the vehicle inspection.

  • This troubleshooting procedure checks for the cause of an obvious lack of engine power (e.g. the vehicle speed does not reach the target speed in the high speed range) while the vehicle is being driven.

  1. Faults and Symptoms of Common Rail Diesel Components

    1. Engine Control

      Table 2. Mass Air Flow Meter
      Component Mass air flow meter
      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.

      Table 3. Intake System
      Component Intake system
      Symptom: Main fault
      • Lack of power (No black smoke): air filter blockage, Air duct is crushed/leaking

      • Black smoke (No lack of power): Leakage between the turbo and intake manifold

      Data List
      • MAP (intake manifold absolute pressure)

      • Target Booster Pressure

        When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.

      Table 4. Turbocharger System
      Component Turbocharger system
      Main fault
      • Air leak in the turbocharger air passage

      • Turbo motor driver not operating well

      • Turbocharger (turbine, bearing)

      Symptoms

      Lack of power (when vehicle starting, when the engine while the vehicle is under heavy load)

      (Black smoke is not emitted when racing while vehicle stopped)

      Data List

      MAP (intake manifold absolute pressure), Target Booster Pressure

      • When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.

      • With the ignition switch ON or during idling, MAP = atmospheric pressure (standard atmospheric pressure = 101 kPa). When the engine speed is about 1500 rpm or more, the turbocharger starts to take effect and MAP becomes higher than atmospheric pressure.

      • Atmospheric pressure increases 1 kPa each time altitude increases by 100 m, and is also affected by the current weather conditions.

      VN Turbo Command

      • 0%: Vanes fully open (drive rod contracts)

      • Over 90%: Vanes fully closed (drive rod expands and turbo operates effectively)

      Diagnostic Point
      • Using the Active Test "Test the Turbo Charger Step Motor", check the drive rod movement.

      • Check the drive rod movement when the ignition switch is turned from ON to off.

      Table 5. Exhaust System
      Component Exhaust system
      Main fault Blockage
      Symptoms Lack of power (high engine speed, when vehicle under heavy load)
      Data List

      MAP (intake manifold absolute pressure)

      When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.

      Table 6. Glow System
      Component Glow system
      Main fault Open circuit, glow plug relay fault
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Data List Check the glow plug indicator light
      Diagnostic Point Try to measure the resistance of the glow plug
      Table 7. Engine - 1
      Component Engine
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      Table 8. Engine - 2
      Component Engine
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      Data List

      Engine Speed of Cyl

      • When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.

      Injection Feedback Val

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.

    2. Diesel Injection

      Table 9. Fuel Supply Pump
      Component Supply pump assembly
      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

      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel pressure.

      • If the fuel pressure is 20000 kPa below the target pressure then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa then idling will be rough.

      Tip:
      • The fuel pressure changes at engine starting, but is approx. 25000 kPa at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 1530 mA or more, the suction control valve has a tendency to become stuck.

      Diagnostic Trouble Code Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 10. Fuel Filter
      Component Fuel filter
      Main fault Blockage
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure

      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel pressure.

      • If the fuel pressure is 20000 kPa below the target pressure then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa then idling will be rough.

      Tip:

      The fuel pressure changes at engine starting, but is approx. 25000 kPa at engine start after the engine is warmed up.

      Diagnostic Trouble Code Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 11. Injector Assembly
      Component Injector Assembly
      Main fault

      Injection hole blockage

      Nozzle needle or valve piston does not move smoothly

      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.

      Table 12. Pressure Control Valve
      Component Pressure control valve
      Main fault Does not completely close
      Symptoms Difficult to start, engine stall, rough idle, lack of power
      Table 13. Fuel Pressure Sensor
      Component Fuel pressure sensor
      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

      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped, and check that Fuel Press follows Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure. (However, the value may not deviate even when a malfunction is present).

      Diagnostic Trouble Code When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 14. Irregular Fuel
      Component Irregular fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)
    3. Diesel EGR

      Table 15. EGR System
      Component EGR system
      Main fault
      • Does not move smoothly

      • Does not close completely

      Symptoms
      • Rough idle

      • EGR valve stuck closed: Loud turbocharger sound.

      • EGR valve stuck open: Difficult to start (does not stall), black smoke, lack of power (if there is an excess in the quantity of recirculated exhaust gas and the engine is under heavy load, when the vehicle starts moving, a lack of power will be felt).

      Data List

      Actual EGR Valve Pos., Target EGR Pos.

      • Generally, Actual EGR Valve Pos. = Target EGR Pos. +/-5% (fully closed 0%, fully open 100%).

      • Using EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Pos. (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).

      • EGR valve is fully closed when the ignition switch is turned to ON (engine stopped).

      • EGR valve opens to the halfway point at idling after the engine warmed up.

    4. Diesel Throttle

      Table 16. Diesel Throttle System
      Component Diesel throttle system
      Main fault Stuck, does not move smoothly
      Symptoms
      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

      • Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.

      Data List
      • Actual Throttle Position, Target Throttle Position

        0%: Fully open

        100%: Fully closed

      • If there is a malfunction of the throttle actuator, compare the target and actual throttle position values for the troubleshooting.

WIRING DIAGRAM

Refer to DTC P1228.

Click hereНажмите здесь

CAUTION / NOTICE / HINT

  1. Explanation of Symptom

    Lack of Power

    The power of the diesel engine is determined by the quantity of injected fuel and the quantity of intake air.

    The quantity of injected fuel is determined by the fuel pressure and the amount of time the injector is open for. Basically, the fuel pressure is controlled to reach the target fuel pressure. The throttle valve does not restrict air flow volume, so the manifold absolute pressure is almost the same as atmospheric pressure when idling. At more than approximately 1500 rpm, the turbo starts to operate, causing the manifold absolute pressure to become higher than atmospheric pressure.

    The manifold absolute pressure is controlled to reach the Target Booster Pressure. Also, when accelerating the vehicle at full throttle, the throttle is fully open and the EGR valve is fully closed, preserving the mass air flow.

  2. Trouble Area Chart According to Problem Cause

    A012I5HE08
    A012IFTE01
    Note:
    • When replacing the ECM, injector assembly and/or DPF catalyst, perform ECM Initialization and Registration.

      Click here Нажмите здесь

    • When cleaning the electric EGR control valve assembly or diesel throttle body assembly, use a piece of cloth soaked with cleaning solvent. Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

    Tip:
    • When the ECM must be replaced, before replacing the ECM, perform the "Learning Values Save" function using the GTS. Then after installing a new ECM, perform all of the initialization and registration procedures for the "Learning Values Write" function by following the instructions shown on the GTS display.

    • Before troubleshooting, conduct the following:

      1. Check the fuel quality.

      2. Check the fuel lines for air.

      3. Check the fuel system for blockage.

      4. Check the air filter.

      5. Check the engine oil.

      6. Check the engine coolant.

      7. Check the engine idling speed and maximum engine speed.

PROCEDURE

  1. READ OUTPUT DTC (RELATED TO ENGINE)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

      Powertrain > Engine and ECT > Trouble Codes
    4. Read pending DTCs.

      Result
      Result Proceed to
      No DTCs are output A
      Engine related DTCs are output B
      Tip:

      If DTC P1608 is output, proceed to step 2.

    B

    GO TO DTC CHART Click hereНажмите здесь


    A
  2. TAKE SNAPSHOT DURING LACK OF POWER

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

      Tip:

      The shift lever should be in neutral and the A/C switch and all accessory switches should be off.

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.

    4. Take a snapshot of the following Data List items with the GTS during lack of power.

      ОСТОРОЖНО

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

      Tip:
      • A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting. The data in the illustration below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

      • Accelerate the vehicle with the accelerator fully open in 2nd or 3rd gear. Then, check the Data List with the engine warmed up and idling.

      A012IGUE01
      A012MXME10
      A012ICBE03
      A012I29E02
      Table 17. Reference Values with Engine Speed at 2000 rpm
      Data List Value Unit
      Vehicle Speed 32 km/h
      Engine Speed 2000 rpm
      Accel Position 99.60 %
      Target Booster Pressure 201.46 kPa
      MAP 155 kPa
      MAF 37.22 gm/sec
      Calculate Load 81.9 %
      Target Common Rail Pressure 107800 kPa
      Fuel Press 109670 kPa
      Target Pump SCV Current 1140 mA
      Injection Volume 31.28

      mm3/st

      VN Turbo Command 95 %
      Actual EGR Valve Pos. 0.3 %
      Actual Throttle Position -1 %
      Table 18. Reference Values with Engine Speed at 3000 rpm
      Data List Value Unit
      Vehicle Speed 48 km/h
      Engine Speed 3000 rpm
      Accel Position 99.60 %
      Target Booster Pressure 234.25 kPa
      MAP 220 kPa
      MAF 75.49 gm/sec
      Calculate Load 98.8 %
      Target Common Rail Pressure 155480 kPa
      Fuel Press 156520 kPa
      Target Pump SCV Current 965 mA
      Injection Volume 45.48

      mm3/st

      VN Turbo Command 37 %
      Actual EGR Valve Pos. 0.3 %
      Actual Throttle Position 0 %
      Table 19. Reference Values with Engine Speed at 3500 rpm (Point A)
      Data List Value Unit
      Vehicle Speed 58 km/h
      Engine Speed 3500 rpm
      Accel Position 99.60 %
      Target Booster Pressure 231.75 kPa
      MAP 227 kPa
      MAF 86.97 gm/sec
      Calculate Load 100.0 %
      Target Common Rail Pressure 158520 kPa
      Fuel Press 159380 kPa
      Target Pump SCV Current 952 mA
      Injection Volume 42.28

      mm3/st

      VN Turbo Command 29 %
      Actual EGR Valve Pos. 0 %
      Actual Throttle Position 0 %
      Table 20. Reference Values with Engine Speed at 4000 rpm
      Data List Value Unit
      Vehicle Speed 66 km/h
      Engine Speed 4000 rpm
      Accel Position 99.60 %
      Target Booster Pressure 223.45 kPa
      MAP 219 kPa
      MAF 90.16 gm/sec
      Calculate Load 100.0 %
      Target Common Rail Pressure 158940 kPa
      Fuel Press 158720 kPa
      Target Pump SCV Current 947 mA
      Injection Volume 37.48

      mm3/st

      VN Turbo Command 19 %
      Actual EGR Valve Pos. 0 %
      Actual Throttle Position 0 %
      Table 21. Data Condition Idling (Engine warmed up, A/C Off, Shift Lever in neutral)
      Data List Value Unit
      Engine Speed 798 rpm
      Target Booster Pressure 100.97 kPa
      MAP 99 kPa
      MAF 4.3 gm/sec
      Target Common Rail Pressure 25000 kPa
      Fuel Press 24330 kPa
      Target Pump SCV Current 1164 mA
      Injection Volume 4.58

      mm3/st

      VN Turbo Command 90 %
      Actual EGR Valve Pos. 65.4 %
      Actual Throttle Position 74 %
      Accel Position 0.00 %
      Target EGR Position 65.4 %
      Atmosphere Pressure 99 kPa
      Coolant Temp 75 °C
      Tip:

      Actual Examples of Malfunction

      • Lack of power caused by overly low boost pressure

      • Lack of power caused by overly low MAF

      • EGR valve stuck in open position

      Result
      Proceed to
      NEXT
    NEXT
  3. CHECK SNAPSHOT

    1. Check the condition of the vehicle using the snapshot taken during the lack of power.

      Result
      Result Proceed to
      None of the conditions below apply A
      Fuel Press is less than "Target Common Rail Pressure - 15000 kPa" when accelerating with accelerator fully open B
      Target Pump SCV Current 1530 mA or more C

      One of the Injection Feedback Val #1 to 4 values is outside the range of +/-2 mm3/st when idling after warm up

      D

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is more than 8 mm3/st when idling after warm up

      E

      *

      Tip:
      • *: When this result occurs, usually symptoms may be noticeable, such as difficult starting, rough idling, knocking or black smoke at high common rail pressure.

      • If the value of Injection Volume is more than 8 mm3/st and the value Injection Feedback Val #1 to #4 is within the threshold, replace the injector assemblies for all cylinders.

      In this case, there is a possibility that too much recirculated exhaust gas is entering the engine. Therefore, compare the Target EGR Position with the Actual EGR Valve Pos. by entering the following menus using the GTS: Powertrain / Engine and ECT / Data List / Target EGR Position and Actual EGR Valve Pos.

      If the difference between Target EGR Position and Actual EGR Valve Pos. exceeds +/-10%, the EGR system may be malfunctioning.

    B Нажмите здесь

    C Нажмите здесь

    GO TO STEP 29


    D Нажмите здесь

    E Нажмите здесь

    A
  4. CHECK SNAPSHOT

    1. Check the condition of the vehicle using the snapshot taken during the lack of power.

      Result
      Result Proceed to
      MAP is less than "Target Booster Pressure - 15 kPa" (MAF is normal) when the engine speed is 3000 rpm or more with accelerator fully open A

      MAF is low when accelerating with accelerator fully open (MAP is normal)

      • 3000 rpm: 61 gm/sec or less

      • 3500 rpm: 67 gm/sec or less

      • 4000 rpm: 70 gm/sec or less

      Tip:

      If MAF (Mass Air Flow) decreases, Calculate Load will be 80% or less when accelerating with the accelerator fully open.

      B
      MAP and MAF are both low when accelerating with the accelerator fully open C
      None of the above conditions apply D
    B Нажмите здесь

    C Нажмите здесь

    GO TO STEP 9


    D Нажмите здесь

    A
  5. INSPECT VACUUM HOSE

    1. Check the vacuum hose connection (diesel turbo pressure sensor).

      OK
      Vacuum hose is connected securely.
      Result
      Proceed to
      OK
      NG
    NG

    REPLACE VACUUM HOSE


    OK
  6. READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / MAP and Atmosphere Pressure.

      Powertrain > Engine and ECT > Data List
      Tester Display
      Atmosphere Pressure
      MAP
    4. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).

      Standard
      Difference between the MAP and the Atmosphere Pressure is less than 7 kPa.
      Tip:
      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 7 kPa or higher, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.

      • Standard atmospheric pressure is 101 kPa. For every 100 m increase in altitude, pressure drops by 1 kPa. Atmosphere pressure varies with the weather (high atmospheric pressure, low atmospheric pressure).

      Result
      Result Proceed to
      Atmosphere Pressure is different from actual atmospheric pressure A
      MAP is different from actual atmospheric pressure B
      MAP and Atmosphere Pressure have the same value C
    A

    REPLACE ECM Click hereНажмите здесь


    B

    REPLACE DIESEL TURBO PRESSURE SENSOR Click hereНажмите здесь


    C Нажмите здесь

    GO TO STEP 9


  7. INSPECT MASS AIR FLOW METER

    1. Inspect the mass air flow meter.

      Click hereНажмите здесь

      Result
      Proceed to
      OK
      NG
    NG

    REPLACE MASS AIR FLOW METER Click hereНажмите здесь


    OK
  8. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY

    1. Remove the electric EGR control valve assembly.

    2. Connect the electric EGR control valve assembly connector.

    3. Connect the GTS to the DLC3.

    4. Turn the ignition switch to ON and turn the GTS on.

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position / Data List / Actual EGR Valve Pos.

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Control the EGR Step Position
      Data List Display
      Actual EGR Valve Pos.
    6. When changing the Active Test value from 1 to 100%, check that Actual EGR Valve Pos. smoothly changes to the set opening angle.

      OK
      Value smoothly changes to the set opening angle.
    7. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.

      Note:
      • When cleaning the electric EGR control valve assembly, make sure the valve is completely closed.

      • Do not forcibly open the valve, as it may be damaged or deformed.

      • When cleaning the electric EGR control valve assembly and the diesel throttle body assembly, use a piece of cloth with cleaning solvent. Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

    8. Hold the electric EGR control valve up to a light and visually check that there is no clearance between the valve and body.

      A012MOXC06
      *1 Electric EGR Control Valve Assembly - -
      *a Part A *b Clearance
      *c OK *d NG
      OK
      No light passes through (there is no clearance between the valve and body).

      If light passes through (there is clearance between the valve and body), replace the electric EGR control valve assembly.

      Tip:

      Light passes through part A shown in the illustration even if the valve is completely closed, this is not a malfunction.

    9. Remove the diesel throttle body assembly, intake air connector and EGR pipe connector.

    10. Remove the deposits from those parts and clean them.

      Note:
      • When cleaning the electric EGR control valve assembly and the diesel throttle body assembly, use a piece of cloth with cleaning solvent. Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

      • Extreme care must be taken to prevent the removed deposits from falling into the engine unit during cleaning.

      Tip:
      • Remove the intake manifold from the cylinder head when it has to be cleaned.

      • Do not leave any deposits in the electric EGR control valve assembly when cleaning the valve.

      Result
      Proceed to
      OK
      NG
    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY Click hereНажмите здесь


    OK
  9. READ VALUE USING GTS (ACCEL POSITION)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / Accel Position.

      Powertrain > Engine and ECT > Data List
      Tester Display
      Accel Position
    4. Read the value.

      Standard
      Condition Standard Value
      Accelerator pedal fully released 0%
      Accelerator pedal fully depressed 95% or more
      Accelerator pedal fully released → fully depressed* 0 to 95% or more*
      Tip:

      *: Make sure that Accel Position changes smoothly.

      Result
      Proceed to
      OK
      NG
    NG

    REPLACE ACCELERATOR PEDAL SENSOR ASSEMBLY Click hereНажмите здесь


    OK
  10. INSPECT DIESEL THROTTLE BODY ASSEMBLY

    1. Inspect the diesel throttle body assembly.

      Click hereНажмите здесь

      Result
      Proceed to
      OK
      NG
    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY Click hereНажмите здесь


    OK
  11. CHECK INTAKE SYSTEM

    1. Check for air leakage and blockage between the air cleaner and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.

      Tip:
      • Check that the intercooler is not clogged with foreign matter.

      • Check that there are no disconnected, pinched or leaking hoses or pipes.

      • Check that there are no modifications made by the user.

      OK
      No leakage or blockage.
      Result
      Proceed to
      OK
      NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS


    OK
  12. INSPECT TURBOCHARGER SUB-ASSEMBLY

    1. Inspect the turbocharger sub-assembly.

      Click hereНажмите здесь

      Result
      Proceed to
      OK
      NG
    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY Click hereНажмите здесь


    OK
  13. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      OK
      Malfunction has been repaired successfully.
      Tip:

      Symptoms may have appeared due to carbon deposits, etc.

      Result
      Proceed to
      OK
      NG
    OK

    END


    NG
  14. CHECK INTAKE SYSTEM DEPOSIT

    1. Check if 3 mm (0.12 in.) or more of carbon has accumulated on the intake manifold, cylinder head, etc. and if so, clean it off.

      Result
      Proceed to
      NEXT
    NEXT
  15. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT
    NEXT

    END


  16. READ VALUE USING GTS (PM ACCUMULATION RATIO)

    1. Drive the vehicle at a constant engine speed of 2000 rpm or more (3rd gear) at a vehicle speed between 65 to 100 km/h (40 to 62 mph) for 5 minutes or more.

      ОСТОРОЖНО

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to ON and turn the GTS on.

    4. Start the engine and allow it to idle until the engine coolant temperature reaches 75°C (167°F) or higher.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / PM Accumulation Ratio.

      Powertrain > Engine and ECT > Data List
      Tester Display
      PM Accumulation Ratio
    6. Check the PM Accumulation Ratio at an engine speed of 4000 rpm without load.

      Tip:

      When reading the values of the Data List, confirm that PM regeneration is not activated (value of "After Injection Period" is 0) by entering the following menus: Powertrain / Engine and ECT / Data List / After Injection Period.

      If PM regeneration is activated (value of "After Injection Period" is not 0), drive the vehicle until the PM regeneration is complete (value of "After Injection Period" becomes 0).

      Standard
      PM Accumulation Ratio is less than 40%.
    7. Fully depress the accelerator pedal for 5 seconds and then release it when the vehicle is stopped (A).

    8. Repeat procedure A 10 times (B).

    9. Check for black smoke emission during the above procedures A and B.

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      Even if the black smoke is very thin, count the black smoke emission if there is any visible smoke.

      Result
      Result Note Proceed to
      Except below - A
      Black smoke is emitted 5 times or more

      The DPF catalyst cannot trap PM because it is melted or cracked, and therefore must be replaced.

      If a piece of the catalyst breaks off, due to melting or another condition, and enters the exhaust pipe downstream, the exhaust pipe could be blocked, possibly causing a different malfunction.

      Therefore, when replacing the DPF catalyst, visually inspect the rear surface of the DPF filter substrate to determine if replacement of the exhaust pipe is necessary.

      B
      PM Accumulation Ratio 40% or more at 4000 rpm (No engine load)

      An extremely large amount of PM (Particulate Matter) has accumulated in the DPF catalyst.

      If DPF catalyst regeneration is performed in this condition, the heat generated will be excessive, possibly causing another malfunction. Therefore, replace the DPF catalyst.

      C
      Tip:
      • If the PM Accumulation Ratio is more than about 149% at an engine speed of 4000 rpm without load, DTC P2463 (Diesel Particulate Filter Restriction - Soot Accumulation) will be present.

      • If DPF Differential Pressure outputs a negative value when the engine is maintained at an engine speed of 3000 rpm with no load, the hose and pipe connections may be incorrect.

    B

    REPLACE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (DPF CATALYTIC CONVERTER) Click hereНажмите здесь


    C Нажмите здесь

    A
  17. CHECK TEMPERATURE WHEN LACK OF POWER OCCURS

    1. Check the temperature when the lack of power occurs.

      Result
      Result Proceed to
      Poor acceleration only when engine is cold A
      Poor acceleration when engine is cold and warm B
    B Нажмите здесь

    GO TO STEP 20


    A
  18. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

    1. Inspect the engine coolant temperature sensor.

      Click hereНажмите здесь

      Tip:

      Confirm that the engine coolant temperature is 60°C (140°F) or higher using the GTS, and then leave the vehicle overnight (7 hours or more). The actual engine coolant temperature and atmosphere temperature should be about the same.

      Result
      Proceed to
      OK
      NG
    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click hereНажмите здесь


    OK
  19. CHECK PRE-HEATING CONTROL CIRCUIT

    1. Check the pre-heating control circuit.

      Click hereНажмите здесь

      Result
      Proceed to
      OK
      NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS


    OK
  20. CHECK INJECTOR COMPENSATION CODE

    1. Read the injector compensation codes.

      Click hereНажмите здесь

      OK
      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.
      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    GO TO STEP 45


    OK
  21. CHECK FUEL QUALITY

    1. Check that fuel with a low cetane number is used.

      Result
      Proceed to
      NEXT
    NEXT
  22. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      Result
      Proceed to
      NEXT
    NEXT

    END


  23. PERFORM ACTIVE TEST USING GTS (FIRST TIME OF ACTIVATE THE DPF REJUVENATE (PM))

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the DPF Rejuvenate (PM) / Data List / Exhaust Temperature B1S1, Exhaust Temperature B1S2 and DPNR/DPF Status Reju(PM).

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Activate the DPF Rejuvenate (PM)
      Data List Display
      Exhaust Temperature B1S1
      Exhaust Temperature B1S2
      DPNR/DPF Status Reju(PM)
    4. Perform the Active Test and then drive the vehicle at a constant engine speed of 2000 rpm or more (3rd gear) at a vehicle speed between 65 to 100 km/h (40 to 62 mph).

      ОСТОРОЖНО

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

      Tip:

      While the Active Test is performed, the accelerator pedal opening angle should be kept as constant as possible.

    5. Confirm that both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher and the DPNR/DPF Status Reju(PM) turns from "Ready" to "Operate".

      Tip:
      • If the DPNR/DPF Status Reju(PM) does not turn from "Ready" to "Operate", drive the vehicle again with increased engine or vehicle speed until both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher.

      • Perform the Active Test until the DPNR/DPF Status Reju(PM) displays "Compl".

      Result
      Proceed to
      NEXT
    NEXT
  24. PERFORM ACTIVE TEST USING GTS (SECOND TIME OF ACTIVATE THE DPF REJUVENATE (PM))

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the DPF Rejuvenate (PM) / Data List / Exhaust Temperature B1S1, Exhaust Temperature B1S2 and DPNR/DPF Status Reju(PM).

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Activate the DPF Rejuvenate (PM)
      Data List Display
      Exhaust Temperature B1S1
      Exhaust Temperature B1S2
      DPNR/DPF Status Reju(PM)
    4. Perform the Active Test and then drive the vehicle at a constant engine speed of 2000 rpm or more (3rd gear) at a vehicle speed between 65 to 100 km/h (40 to 62 mph).

      ОСТОРОЖНО

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

      Tip:

      While the Active Test is performed, the accelerator pedal opening angle should be kept as constant as possible.

    5. Confirm that both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher and the DPNR/DPF Status Reju(PM) turns from "Ready" to "Operate".

      Tip:
      • If the DPNR/DPF Status Reju(PM) does not turn from "Ready" to "Operate", drive the vehicle again with increased engine or vehicle speed until both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher.

      • Perform the Active Test until the DPNR/DPF Status Reju(PM) displays "Compl".

      Result
      Proceed to
      NEXT
    NEXT

    END


  25. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  26. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      Tip:

      Fuel Press is within +/-10000 kPa of Target Common Rail Pressure.

      OK
      Malfunction has been repaired successfully.
      Result
      Proceed to
      OK
      NG
    OK

    END


    NG
  27. CHECK AND REPLACE FUEL INLET LINE

    1. Check the following items, and repair or replace the malfunctioning part if necessary.

      1. Check that the fuel filter is not clogged.

      2. Check for fuel freezing in the fuel line.

      3. Check for clogs or leaks in the fuel pipe and hose between the fuel tank and supply pump assembly.

      Result
      Proceed to
      NEXT
    NEXT
  28. PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT/ Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure and Target Pump SCV Current.

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Test the Fuel Leak
      Data List Display
      Target Common Rail Pressure
      Fuel Press
      Target Pump SCV Current
    4. Take a snapshot with the GTS during the Active Test.

    5. Maintain an engine speed of 3500 rpm, and then press the "Start" button.

    6. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Fuel Press) when the Active Test is performed.

      A012IBWE01
      Tip:
      • The EPS, ABS and SRS warning lights may blink when the engine speed exceeds 3500 rpm during this test.

      • To ensure accurate measurements, perform the Active Test with measurements 5 times or more.

      Standard
      The difference between the target fuel pressure and the actual fuel pressure is less than 15000 kPa when the target fuel pressure reaches the maximum value approximately 2 seconds after the Active Test starts.
    7. Read the value of Target Pump SCV Current in the Data List when the "Test the Fuel Leak" Active Test is performed.

      Standard current
      Target Pump SCV Current is less than 1530 mA.
      Tip:

      If the value of Target Pump SCV Current stored in the snapshot is higher than the standard, the intermittent suction control valve is probably stuck.

      Result
      Proceed to
      OK
      NG
    OK

    END


    NG
  29. CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

    1. Disconnect the suction control valve connector.

    2. Disconnect the ECM connector.

    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      B123-2 - B138-12 (PCV) Always Below 1 Ω
      B123-2 or B138-12 (PCV) - Body ground Always 10 kΩ or higher
      Result
      Proceed to
      OK
      NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR


    OK
  30. CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY

    1. Disconnect the inlet hose from the supply pump assembly.

    2. Operate the priming 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 priming pump is operated.
      Tip:
      • When there is a lack of fuel, fuel pressure drops.

      • Check that the fuel filter is not clogged.

      • Check for fuel freezing in the fuel line.

      • Check for clogs or leaks in the fuel pipe and hose between the fuel tank and supply pump assembly.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  31. REPLACE SUPPLY PUMP ASSEMBLY

    1. Replace the supply pump assembly.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  32. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  33. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      Tip:

      Fuel Press will be within +/-10000 kPa of Target Common Rail Pressure.

      Result
      Proceed to
      NEXT
    NEXT

    END


  34. CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY)

    1. Check and replace the clogged fuel pipe.

      Result
      Proceed to
      NEXT
    NEXT
  35. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT
    NEXT

    END


  37. CHECK INJECTOR COMPENSATION CODE

    1. Read the injector compensation codes.

      Click hereНажмите здесь

      OK
      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.
      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  38. PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)

    Tip:

    Use this Active Test to determine the malfunctioning cylinder.

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Select Cylinder Fuel Cut.

      Powertrain > Engine and ECT > Active Test
      Tester Display
      Control the Select Cylinder Fuel Cut
      Tip:
      • DTCs may be output after this Active Test. Make sure to check for DTCs after this Active Test. If any DTCs are output, make sure to clear them.

        Click hereНажмите здесь

      • If the engine idle speed does not change when an injector assembly is disabled, the cylinder being tested is malfunctioning.

      • If the cylinder being tested is normal, there will be a significant change in idle speed when the fuel injection is stopped for that cylinder.

      Result
      Proceed to
      NEXT
    NEXT
  39. READ VALUE USING GTS (ENGINE SPEED OF CYL #1 TO #4)

    Tip:

    The speed of each cylinder can be measured (compression test) by using the GTS.

    For the compression test, perform Active Test using GTS (Check the Cylinder Compression) and crank the engine for approximately 10 seconds. At this time, the speed of each cylinder is measured. If the speed of one cylinder is higher than the other cylinders, the compression pressure of that cylinder is determined to be lower than the other cylinders.

    1. Warm up the engine.

    2. Turn the ignition switch off.

    3. Connect the GTS to the DLC3.

    4. Turn the ignition switch to ON and turn the GTS on.

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Engine Speed of Cyl #1, Engine Speed of Cyl #2, Engine Speed of Cyl #3, Engine Speed of Cyl #4 and Av Engine Speed of All Cyl.

      Powertrain > Engine and ECT > Active Test
      Active 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
      Av Engine Speed of All Cyl
    6. Push the snapshot button to turn the snapshot function on.

      Tip:

      Using the snapshot function, data can be recorded during the Active Test.

    7. While the engine is not running, press the ON button to Change the Cylinder Compression to ON.

      Tip:

      After performing the above procedure, Check the Cylinder Compression will start. Fuel injection for all cylinders is prohibited and each cylinder engine speed measurement enters standby mode.

    8. Crank the engine for about 10 seconds.

    9. Monitor the engine speed (Engine Speed of Cyl #1 to #4, Av Engine Speed of All Cyl) displayed on the GTS.

      Tip:

      After approximately 10 seconds of engine cranking, the engine speed measurement of each cylinder will change to the actual engine speed.

      Note:
      • Do not crank the engine continuously for 20 seconds or more.

      • If Check the Cylinder Compression needs to be performed after it is turned ON and performed once, press Exit to return to the Active Test menu screen. Then perform Check the Cylinder Compression again.

      • Use a fully-charged battery.

    10. Stop cranking the engine, and then change "Check the Cylinder Compression" to OFF after the engine stops.

      Note:

      If the Active Test is changed to OFF while the engine is being cranked, the engine will start.

    11. Push the snapshot button to turn the snapshot function off.

    12. Select "Stored Data" on the GTS screen, select the recorded data and display the data as a graph.

      Tip:

      If the data is not displayed as a graph, the change of the values cannot be observed.

    13. Check the change in engine speed values.

      Result
      Result Proceed to
      Except below A
      The values of Engine Speed Cyl #1 to #4 are within +/-10 rpm of each other. B
      Tip:

      When cranking, if the speed of a cylinder is approximately 100 rpm more than the other cylinders, there is probably a complete loss of compression in that cylinder.

    B Нажмите здесь

    GO TO STEP 41


    A
  40. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    1. Check the cylinder compression pressure.

      Click hereНажмите здесь

      Result
      Proceed to
      OK
      NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION


    OK
  41. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tip:

    The injector assembly is determined to be malfunctioning if the corresponding cylinder is malfunctioning but has no compression loss.

    1. Replace the injector assembly of the malfunctioning cylinder.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  42. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click hereНажмите здесь

    2. Perform Pilot Quantity Learning Values Reset.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  43. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  44. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT
    NEXT

    END


  45. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click hereНажмите здесь

    2. Perform Pilot Quantity Learning Values Reset.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  46. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      Result
      Proceed to
      NEXT
    NEXT

    END


  47. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS

    1. Replace the injector assemblies.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  48. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click hereНажмите здесь

    2. Perform Pilot Quantity Learning Values Reset.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  49. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  50. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT
    NEXT

    END