DESCRIPTION
Malfunction Condition | Main Trouble Area | Related Trouble Area |
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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.
Faults and Symptoms of Common Rail Diesel Components
Engine Control
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. |
Component | Intake system |
Symptom: Main fault |
|
Data List |
|
Component | Turbocharger system |
Main fault |
|
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
VN Turbo Command
|
Diagnostic Point |
|
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. |
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 |
Component | Engine |
Main fault | Damaged, seized up |
Symptoms | Cannot crank, crank speed is low, strange noise |
Component | Engine |
Main fault | Loss of compression |
Symptoms | Rough idle (lack of power always) |
Data List |
Engine Speed of Cyl
Injection Feedback Val
|
Diesel Injection
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
Tip:
|
Diagnostic Trouble Code | Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored. |
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
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. |
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
|
Component | Pressure control valve |
Main fault | Does not completely close |
Symptoms | Difficult to start, engine stall, rough idle, lack of power |
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
|
Diagnostic Trouble Code | When the fuel pressure sensor has a fault, some DTCs may be stored. |
Component | Irregular fuel |
Main fault | - |
Symptoms | Difficult to start, rough idle (especially when cold) |
Diesel EGR
Component | EGR system |
Main fault |
|
Symptoms |
|
Data List |
Actual EGR Valve Pos., Target EGR Pos.
|
Diesel Throttle
Component | Diesel throttle system |
Main fault | Stuck, does not move smoothly |
Symptoms |
|
Data List |
|
CAUTION / NOTICE / HINT
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. |
Trouble Area Chart According to Problem Cause
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.
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:
Check the fuel quality.
Check the fuel lines for air.
Check the fuel system for blockage.
Check the air filter.
Check the engine oil.
Check the engine coolant.
Check the engine idling speed and maximum engine speed.
PROCEDURE
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.
Powertrain > Engine and ECT > Trouble CodesRead pending DTCs.
Result | ||||||
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If DTC P1608 is output, proceed to step 2.
B |
GO TO DTC CHART Click hereНажмите здесь |
A |
TAKE SNAPSHOT DURING LACK OF POWER
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
The shift lever should be in neutral and the A/C switch and all accessory switches should be off.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.
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.
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.
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 | % |
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 | % |
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 | % |
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 | % |
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 |
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 | ||
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NEXT |
CHECK SNAPSHOT
Check the condition of the vehicle using the snapshot taken during the lack of power.
Result | ||||||||||||
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*: 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 |
CHECK SNAPSHOT
Check the condition of the vehicle using the snapshot taken during the lack of power.
Result | ||||||||||
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B | Нажмите здесь |
C | Нажмите здесь |
GO TO STEP 9 |
D | Нажмите здесь |
A |
INSPECT VACUUM HOSE
Check the vacuum hose connection (diesel turbo pressure sensor).
OK |
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Vacuum hose is connected securely. |
Result | |||
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NG |
REPLACE VACUUM HOSE |
OK |
READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)
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 / MAP and Atmosphere Pressure.
Powertrain > Engine and ECT > Data ListTester Display |
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Atmosphere Pressure |
MAP |
Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).
Standard |
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Difference between the MAP and the Atmosphere Pressure is less than 7 kPa. |
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 | ||||||||
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A |
REPLACE ECM Click hereНажмите здесь |
B |
REPLACE DIESEL TURBO PRESSURE SENSOR Click hereНажмите здесь |
C | Нажмите здесь |
GO TO STEP 9 |
INSPECT MASS AIR FLOW METER
Inspect the mass air flow meter.
Click hereНажмите здесь
Result | |||
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NG |
REPLACE MASS AIR FLOW METER Click hereНажмите здесь |
OK |
INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY
Remove the electric EGR control valve assembly.
Connect the electric EGR control valve assembly connector.
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 / Active Test / Control the EGR Step Position / Data List / Actual EGR Valve Pos.
Powertrain > Engine and ECT > Active TestActive Test Display |
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Control the EGR Step Position |
Data List Display |
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Actual EGR Valve Pos. |
When changing the Active Test value from 1 to 100%, check that Actual EGR Valve Pos. smoothly changes to the set opening angle.
OK |
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Value smoothly changes to the set opening angle. |
Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.
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.
Hold the electric EGR control valve up to a light and visually check that there is no clearance between the valve and body.
*1 | Electric EGR Control Valve Assembly | - | - |
*a | Part A | *b | Clearance |
*c | OK | *d | NG |
OK |
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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.
Light passes through part A shown in the illustration even if the valve is completely closed, this is not a malfunction.
Remove the diesel throttle body assembly, intake air connector and EGR pipe connector.
Remove the deposits from those parts and clean them.
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.
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 | |||
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NG |
REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY Click hereНажмите здесь |
OK |
READ VALUE USING GTS (ACCEL POSITION)
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 / Accel Position.
Powertrain > Engine and ECT > Data ListTester Display |
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Accel Position |
Read the value.
Standard | ||||||||
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*: Make sure that Accel Position changes smoothly.
Result | |||
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NG |
REPLACE ACCELERATOR PEDAL SENSOR ASSEMBLY Click hereНажмите здесь |
OK |
INSPECT DIESEL THROTTLE BODY ASSEMBLY
Inspect the diesel throttle body assembly.
Click hereНажмите здесь
Result | |||
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|
NG |
REPLACE DIESEL THROTTLE BODY ASSEMBLY Click hereНажмите здесь |
OK |
CHECK INTAKE SYSTEM
Check for air leakage and blockage between the air cleaner and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.
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 |
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No leakage or blockage. |
Result | |||
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|
NG |
REPAIR OR REPLACE MALFUNCTIONING PARTS |
OK |
INSPECT TURBOCHARGER SUB-ASSEMBLY
Inspect the turbocharger sub-assembly.
Click hereНажмите здесь
Result | |||
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|
NG |
REPLACE TURBOCHARGER SUB-ASSEMBLY Click hereНажмите здесь |
OK |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Check whether the lack of power has been successfully repaired.
OK |
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Malfunction has been repaired successfully. |
Symptoms may have appeared due to carbon deposits, etc.
Result | |||
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OK |
END |
NG |
CHECK INTAKE SYSTEM DEPOSIT
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 | ||
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NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
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NEXT |
END |
READ VALUE USING GTS (PM ACCUMULATION RATIO)
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.
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Start the engine and allow it to idle until the engine coolant temperature reaches 75°C (167°F) or higher.
Enter the following menus: Powertrain / Engine and ECT / Data List / PM Accumulation Ratio.
Powertrain > Engine and ECT > Data ListTester Display |
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PM Accumulation Ratio |
Check the PM Accumulation Ratio at an engine speed of 4000 rpm without load.
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 |
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PM Accumulation Ratio is less than 40%. |
Fully depress the accelerator pedal for 5 seconds and then release it when the vehicle is stopped (A).
Repeat procedure A 10 times (B).
Check for black smoke emission during the above procedures A and B.
OK |
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Black smoke is emitted less than 5 times. |
Even if the black smoke is very thin, count the black smoke emission if there is any visible smoke.
Result | ||||||||||||
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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 |
CHECK TEMPERATURE WHEN LACK OF POWER OCCURS
Check the temperature when the lack of power occurs.
Result | ||||||
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B | Нажмите здесь |
GO TO STEP 20 |
A |
INSPECT ENGINE COOLANT TEMPERATURE SENSOR
Inspect the engine coolant temperature sensor.
Click hereНажмите здесь
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 | |||
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|
NG |
REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click hereНажмите здесь |
OK |
CHECK PRE-HEATING CONTROL CIRCUIT
Check the pre-heating control circuit.
Click hereНажмите здесь
Result | |||
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NG |
REPAIR OR REPLACE MALFUNCTIONING PARTS |
OK |
CHECK INJECTOR COMPENSATION CODE
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 | |||
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|
NG | Нажмите здесь |
GO TO STEP 45 |
OK |
CHECK FUEL QUALITY
Check that fuel with a low cetane number is used.
Result | ||
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|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Check whether the lack of power has been successfully repaired.
Result | ||
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|
NEXT |
END |
PERFORM ACTIVE TEST USING GTS (FIRST TIME OF ACTIVATE THE DPF REJUVENATE (PM))
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
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 TestActive Test Display |
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Activate the DPF Rejuvenate (PM) |
Data List Display |
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Exhaust Temperature B1S1 |
Exhaust Temperature B1S2 |
DPNR/DPF Status Reju(PM) |
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.
While the Active Test is performed, the accelerator pedal opening angle should be kept as constant as possible.
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".
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 | ||
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|
NEXT |
PERFORM ACTIVE TEST USING GTS (SECOND TIME OF ACTIVATE THE DPF REJUVENATE (PM))
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
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 TestActive Test Display |
---|
Activate the DPF Rejuvenate (PM) |
Data List Display |
---|
Exhaust Temperature B1S1 |
Exhaust Temperature B1S2 |
DPNR/DPF Status Reju(PM) |
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.
While the Active Test is performed, the accelerator pedal opening angle should be kept as constant as possible.
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".
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 | ||
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|
NEXT |
END |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
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|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Check whether the lack of power has been successfully repaired.
Fuel Press is within +/-10000 kPa of Target Common Rail Pressure.
OK |
---|
Malfunction has been repaired successfully. |
Result | |||
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|
OK |
END |
NG |
CHECK AND REPLACE FUEL INLET LINE
Check the following items, and repair or replace the malfunctioning part if necessary.
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 | ||
---|---|---|
|
NEXT |
PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)
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/ Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure and Target Pump SCV Current.
Powertrain > Engine and ECT > Active TestActive Test Display |
---|
Test the Fuel Leak |
Data List Display |
---|
Target Common Rail Pressure |
Fuel Press |
Target Pump SCV Current |
Take a snapshot with the GTS during the Active Test.
Maintain an engine speed of 3500 rpm, and then press the "Start" button.
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.
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. |
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. |
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 | |||
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|
OK |
END |
NG |
CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)
Disconnect the suction control valve connector.
Disconnect the ECM connector.
Measure the resistance according to the value(s) in the table below.
Standard Resistance | |||||||||
---|---|---|---|---|---|---|---|---|---|
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Result | |||
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|
NG |
REPAIR OR REPLACE HARNESS OR CONNECTOR |
OK |
CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY
Disconnect the inlet hose from the supply pump assembly.
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. |
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 | |||
---|---|---|---|
|
NG | Нажмите здесь |
OK |
REPLACE SUPPLY PUMP ASSEMBLY
Replace the supply pump assembly.
Click hereНажмите здесь
Result | ||
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NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
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NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Check whether the lack of power has been successfully repaired.
Fuel Press will be within +/-10000 kPa of Target Common Rail Pressure.
Result | ||
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NEXT |
END |
CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY)
Check and replace the clogged fuel pipe.
Result | ||
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|
NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
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NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
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|
NEXT |
END |
CHECK INJECTOR COMPENSATION CODE
Read the injector compensation codes.
Click hereНажмите здесь
OK |
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Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies. |
Result | |||
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|
NG | Нажмите здесь |
OK |
PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)
Use this Active Test to determine the malfunctioning cylinder.
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Select Cylinder Fuel Cut.
Powertrain > Engine and ECT > Active TestTester Display |
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Control the Select Cylinder Fuel Cut |
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 | ||
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NEXT |
READ VALUE USING GTS (ENGINE SPEED OF CYL #1 TO #4)
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.
Warm up the engine.
Turn the ignition switch off.
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 / 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 TestActive Test Display |
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Check the Cylinder Compression |
Data List Display |
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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 |
Push the snapshot button to turn the snapshot function on.
Using the snapshot function, data can be recorded during the Active Test.
While the engine is not running, press the ON button to Change the Cylinder Compression to ON.
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.
Crank the engine for about 10 seconds.
Monitor the engine speed (Engine Speed of Cyl #1 to #4, Av Engine Speed of All Cyl) displayed on the GTS.
After approximately 10 seconds of engine cranking, the engine speed measurement of each cylinder will change to the actual engine speed.
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.
Stop cranking the engine, and then change "Check the Cylinder Compression" to OFF after the engine stops.
If the Active Test is changed to OFF while the engine is being cranked, the engine will start.
Push the snapshot button to turn the snapshot function off.
Select "Stored Data" on the GTS screen, select the recorded data and display the data as a graph.
If the data is not displayed as a graph, the change of the values cannot be observed.
Check the change in engine speed values.
Result | ||||||
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|
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 |
CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER
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
The injector assembly is determined to be malfunctioning if the corresponding cylinder is malfunctioning but has no compression loss.
Replace the injector assembly of the malfunctioning cylinder.
Click hereНажмите здесь
Result | ||
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|
NEXT |
PERFORM REGISTRATION AND INITIALIZATION
Register the injector compensation codes.
Click hereНажмите здесь
Perform Pilot Quantity Learning Values Reset.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
---|---|---|
|
NEXT |
END |
PERFORM REGISTRATION AND INITIALIZATION
Register the injector compensation codes.
Click hereНажмите здесь
Perform Pilot Quantity Learning Values Reset.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Check whether the lack of power has been successfully repaired.
Result | ||
---|---|---|
|
NEXT |
END |
REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS
Replace the injector assemblies.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
PERFORM REGISTRATION AND INITIALIZATION
Register the injector compensation codes.
Click hereНажмите здесь
Perform Pilot Quantity Learning Values Reset.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Click hereНажмите здесь
Result | ||
---|---|---|
|
NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
---|---|---|
|
NEXT |
END |