СИСТЕМА ECD Fuel Injection System

CAUTION / NOTICE / HINT

Note:

PROCEDURE

  1. CHECK INJECTOR COMPENSATION CODE

    1. Check the injector compensation codes.

      Click hereНажмите здесь

      Result
      Result Proceed to
      Except below A
      Compensation codes of the installed injector assemblies are the same as the compensation codes registered in the ECM B
    B Нажмите здесь

    GO TO STEP 3


    A
  2. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

    1. Register the injector compensation codes.

      Click hereНажмите здесь

    2. Perform the pilot quantity learning.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  3. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 3)

    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 / Data List / All Data.

    4. Take a snapshot of the following Data List items.

      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.

      • Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.

      Result
      Proceed to
      NEXT
    NEXT
  4. READ VALUE USING GTS (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)

    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken in procedure 3 when the engine was idling and at 4000 rpm with no load.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3.0 mm3/st

      A

      Injection Volume is 5 mm3/st or less at 4000 rpm

      B
      Except above C
      Tip:
      • When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.

      • The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not malfunctioning.

    B Нажмите здесь

    GO TO STEP 23


    C Нажмите здесь

    A
  5. PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

    Tip:

    Use this Active Test to help determine whether a cylinder has compression loss or not.

    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 / Check the Cylinder Compression / Compression / Engine Speed of Cyl #1 to #4.

      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
    4. Check the engine speed during the Active Test.

      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 higher than the other cylinders, there is probably a complete loss of compression in that cylinder.

    B Нажмите здесь

    GO TO STEP 7


    A
  6. CHECK CYLINDER COMPRESSION PRESSURE

    1. Check the cylinder compression pressure.

      Click hereНажмите здесь

      Tip:

      When compression is low, there may be cracks in the piston or the injector assembly may be installed improperly.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  7. PERFORM PILOT QUANTITY LEARNING (DETAIL)

    1. Perform the pilot quantity learning (detail).

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  8. READ VALUE USING GTS (INJECTION FEEDBACK VAL #1 TO #4)

    1. Connect the GTS to the DLC3.

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

    3. Start the engine and warm it up.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Injection Feedback Val #1 to #4.

      Powertrain > Engine and ECT > Data List
      Tester Display
      Injection Feedback Val #1
      Injection Feedback Val #2
      Injection Feedback Val #3
      Injection Feedback Val #4
    5. Read the values.

      Standard
      GTS Display Engine Condition* Normal Value

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

      Idling

      -3.0 mm3/st to 3.0 mm3/st

      Tip:

      *: The A/C switch and all accessory switches should be off, the engine coolant temperature should be 75°C (167°F) or higher and the engine should be idled for 1 minute or more.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3.0 mm3/st

      A
      Except above B
      Tip:
      • When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.

      • The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not malfunctioning.

    B Нажмите здесь

    GO TO STEP 11


    A
  9. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here Нажмите здесь

      Note:
      • 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
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 24


  10. CHECK AND REPLACE ENGINE ASSEMBLY

    1. Check and replace the engine assembly.

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

    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 / Test the Fuel Leak / All Data / Fuel Press and Target Common Rail Pressure.

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

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

      Tip:

      In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

      A012GN8E06
      OK
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa (102.0 kgf/cm2, 1451 psi).
      Result
      Result Proceed to
      NG A
      OK* B
      Note:

      *: Even when the results of the Active Test are normal, take a snapshot of vehicle data when the vehicle is accelerating. If "Fuel Press" does not follow "Target Common Rail Pressure", proceed to step 12.

      If "Fuel Press" does not follow "Target Common Rail Pressure", the fuel filter element sub-assembly may be clogged.

      Tip:
      • "Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.

      • "Fuel Press" is the actual fuel pressure in common rail assembly.

      • If the pressure discharge valve mounted on the common rail assembly is malfunctioning, the actual fuel pressure may change as indicated by "Pressure Discharge Valve Abnormal Fuel Press" in the illustration.

      • The pressure discharge valve operates to discharge fuel pressure when the internal pressure of the common rail exceeds the target fuel pressure.

      • There are 2 fuel pressure sensor circuits and both of them display the same value. If the difference between Fuel Press and Common Rail Press Sens 2 exceeds 10000 kPa (102.0 kgf/cm2, 1451 psi) for 2 seconds or more, it is necessary to inspect or repair the wiring for the fuel pressure sensor.

    B Нажмите здесь

    GO TO STEP 17


    A
  12. CHECK COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)

    1. Connect the GTS to the DLC3.

    2. Start the engine.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Utility / Pressure Discharge Valve Check.

      Click hereНажмите здесь

      Powertrain > Engine and ECT > Utility
      Tester Display
      Pressure Discharge Valve Check
    5. Select "Always Closed Check".

    6. Press "Next".

    7. Read the value of fuel pressure values.

      OK
      Fuel pressure is properly maintained.
      Tip:
      • If the fuel pressure cannot be maintained, the pressure discharge valve may not have a tight seal.

      • If the fuel pressure is being properly maintained, there are no problems with the sealing properties of the high pressure fuel system. Therefore, an insufficient supply of fuel due to the fuel filter being clogged, or squashed or blocked low pressure fuel pipes or hoses may be causing the reduction in common rail pressure.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  13. INSPECT CLOGGED FUEL PIPE

    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 / Data List / Common Rail (ALL).

    4. With no load after the engine is warmed up, take a snapshot when idling and vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear.

    5. Check the Target Common Rail Pressure and Fuel Press value.

      A012IZTE07
      Result
      Result Proceed to
      While idling the vehicle, "Fuel Press" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1 A
      "Fuel Press" is normal while idling the vehicle, but "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear*2
      Except above B
      Note:
      • *1: The cause may be a squashed or blocked fuel pipe or hose.

      • *2: The cause may be a clogged fuel filter element sub-assembly.

    B Нажмите здесь

    GO TO STEP 18


    A
  14. REPAIR OR REPLACE CLOGGED FUEL LINE

    1. Repair or replace the clogged (including frozen fuel) fuel pipe.

    2. Replace the fuel filter element sub-assembly.

      Click hereНажмите здесь

      Tip:

      If "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element sub-assembly.

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 16


  15. REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)

    1. Replace the common rail assembly.

      Click hereНажмите здесь

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

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  17. READ VALUE USING GTS (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)

    1. Check Fuel Press and Target Common Rail Pressure in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to
      Except above A

      Difference between Fuel Press and Target Common Rail Pressure is 5000 kPa (51.0 kgf/cm2, 725 psi) or higher

      B
    A

    END


    B
  18. REPLACE SUCTION CONTROL VALVE

    1. Replace the suction control valve.

      Click hereНажмите здесь

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

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  20. PERFORM SUPPLY PUMP INITIALIZATION

    1. Perform the supply pump initialization.

      Click hereНажмите здесь

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

    Result
    Proceed to
    NEXT
    NEXT

    END


  22. READ VALUE USING GTS (INJECTION VOLUME)

    1. Check Injection Volume in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Injection Volume while idling after engine warm up is 15 mm3/st or more

      A
      Except above B
      Tip:

      Check that PM forced regeneration is not being performed.

    B Нажмите здесь

    GO TO STEP 11


    A
  23. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

    1. Replace the injector assemblies of all cylinders.

      Click here Нажмите здесь

      Note:
      • 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
      Proceed to
      NEXT
    NEXT
  24. REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY

    1. Replace the fuel filter element sub-assembly.

      Click hereНажмите здесь

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

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  26. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

    1. Register the injector compensation codes.

      Click hereНажмите здесь

    2. Perform the pilot quantity learning.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 11