DESCRIPTION
Malfunction Condition | Main Trouble Area | Related Trouble Area |
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This troubleshooting procedure checks for the cause of rough idling and excessive engine vibrations.
Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result values may occur depending on the measuring conditions or the vehicle's 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.
Faults and Symptoms of Common Rail Diesel Components
Engine Control
Main fault | Decrease in performance (foreign matter is attached) |
Symptoms | Lack of power, black smoke |
Data List | MAF |
Tip:
The maximum fuel injection volume is controlled according to the output from the mass air flow meter assembly. |
Main fault | Glow system malfunction |
Symptoms | Difficult to start, rough idle, knocking, white smoke (when cold) |
Data List | Check the glow plug indicator light |
Diagnostic Point | Measure the resistance of the glow plug assembly |
Main fault | Loss of compression |
Symptoms | Rough idle (lack of power always) |
Data List |
Engine Speed of Cyl
Injection Feedback Val
|
Common Rail (ALL)
Main fault | - |
Symptoms | Difficult to start, engine stalling, rough idle, lack of power |
Data List |
Fuel Press, Target Common Rail Pressure, Target Pump SCV Current
Tip:
|
Diagnostic Trouble Code | Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored. |
Main fault | Blockage |
Symptoms | Difficult to start, engine stalling, rough idle, lack of power |
Data List |
Fuel Press, Target Common Rail Pressure
Tip:
The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up. |
Diagnostic Trouble Code | Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored. |
Main fault | Blockage |
Symptoms | Rough idle, lack of power, black smoke, white smoke, knocking |
Data List |
Injection Feedback Val
|
Main fault | Circuit fault: The injector assembly does not open. |
Symptoms | Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking |
Data List | Same as injector assembly |
Diagnostic Trouble Code | When the injector driver (EDU) has a fault, some DTCs may be stored. |
Main fault | Open circuit, decrease in performance (foreign matter is attached) |
Symptoms | Difficult to start, rough idle, engine stall, lack of power |
Data List |
Fuel Press, Target Common Rail Pressure
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Diagnostic Trouble Code | When the fuel pressure sensor has a fault, some DTCs may be stored. |
Main fault | - |
Symptoms | Difficult to start, rough idle (especially when cold) |
Diesel EGR
Main fault |
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Symptoms |
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Data List |
Actual EGR Valve Pos., Target EGR Position
EGR Close Lrn. Val., EGR Close Lrn. Status
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Diesel Throttle
Main fault | Stuck, does not move smoothly |
Symptoms |
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Data List |
Actual Throttle Position
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Data List Related to Rough Idling
Engine Speed
MAF
Intake Air
Coolant Temp
Engine Speed of Cyl #1 (to #4)
Target Common Rail Pressure
Fuel Press
Target Pump SCV Current
Injection Feedback Val #1 (to #4)
Injection Volume
Actual Throttle Position
Target EGR Position
Actual EGR Valve Pos.
EGR Close Lrn. Status
EGR Close Lrn. Val.
CAUTION / NOTICE / HINT
After replacing the suction control valve, the ECM needs initialization.
Click hereНажмите здесь
After replacing an injector assembly, the ECM needs registration.
Click hereНажмите здесь
PROCEDURE
CHECK MALFUNCTION CONDITION
Identify when shuddering occurs.
Result | ||||||
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B |
REPAIR OR REPLACE CLUTCH SYSTEM Click hereНажмите здесь |
A |
CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT
Check the wire harness and connector connections of common rail system components.
OK |
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The wire harnesses and connectors are connected securely. |
The engine may have problems when there is an intermittent disconnection in a circuit related to the fuel pressure sensor, crankshaft position sensor, engine coolant temperature sensor, etc.
Result | |||
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NG | Нажмите здесь |
OK |
READ OUTPUT DTC (RELATING TO ENGINE)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Read the pending DTCs.
Powertrain > Engine and ECT > Trouble CodesResult | ||||||
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If only DTC P1605 is output, proceed to procedure 4.
B |
GO TO DTC CHART Click here Нажмите здесь |
A |
TAKE SNAPSHOT DURING IDLING (PROCEDURE 4)
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.
Take a snapshot when idling with no load after the engine is warmed up and when the problem is occurring.
A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting.
The shift lever should be in neutral and the A/C switch and all accessory switches should be off.
If rough idling occurs when the A/C switch is on, take another snapshot with the A/C switch on.
Take a snapshot when the problem is occurring, such as when the engine is cold. However, if the problem does not reoccur, it is acceptable to only take a snapshot after the engine is warmed up.
Result | ||
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NEXT |
CHECK WHITE SMOKE
Start the engine.
Fully depress the accelerator pedal, and then release it.
Check whether white smoke is emitted when racing the engine.
Be sure not to check for white smoke indoors.
Depending on whether there is oil mixed with the fuel, or whether there is unburned fuel present, the smell of the exhaust gas differs. When oil is mixed in, the exhaust gas smells like burning oil.
Result | ||||||
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B | Нажмите здесь |
A |
CHECK DATA LIST (ENGINE SPEED)
Check engine speed in the snapshot taken in procedure 4 when the engine was idling.
Result | ||||||
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B | Нажмите здесь |
A |
CHECK DATA LIST (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)
Check Injection Feedback Val # in the snapshot taken in procedure 4 when the engine was idling.
Result | ||||||
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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, 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 |
A |
CHECK INJECTOR COMPENSATION CODE
Check the injector compensation codes.
Click hereНажмите здесь
OK |
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Compensation codes stored in the ECM match compensation codes of the installed injector assemblies. |
Result | |||
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NG | Нажмите здесь |
GO TO STEP 13 |
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 / #1 to #4.
Powertrain > Engine and ECT > Active TestTester Display |
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Control the Select Cylinder Fuel Cut |
Check the 4 cylinders in sequence to identify any faulty cylinders by performing the power-balance inspection.
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 |
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
Replace the injector assembly of the malfunctioning cylinder.
Click here Нажмите здесь
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
Result | ||
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NEXT |
REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY
Replace the fuel filter element sub-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 |
REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING
Register the injector compensation codes.
Click hereНажмите здесь
Perform the pilot quantity learning.
Click hereНажмите здесь
Result | ||
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NEXT | Нажмите здесь |
GO TO STEP 29 |
REPAIR OR REPLACE HARNESS AND CONNECTOR
Repair or replace the harness or connector.
Result | ||
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NEXT | Нажмите здесь |
GO TO STEP 29 |
CHECK DATA LIST (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)
Check engine speed in the snapshot taken in procedure 4 when the engine was idling after having been warmed up.
Result | ||||||
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B | Нажмите здесь |
A |
INSPECT CLOGGED FUEL PIPE
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail (ALL).
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.
Check the Target Common Rail Pressure and Fuel Press value.
Result | |||||||
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*1: The cause may be a squashed or blocked fuel pipe or hose.
*2: The cause may be a clogged fuel filter.
B | Нажмите здесь |
A |
REPAIR OR REPLACE CLOGGED FUEL LINE
Repair or replace the clogged (including frozen fuel) fuel pipe.
Replace the fuel filter element sub-assembly.
Click hereНажмите здесь
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 | ||
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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 | Нажмите здесь |
GO TO STEP 29 |
REPLACE SUCTION CONTROL VALVE
Replace the suction control valve.
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 |
PERFORM SUPPLY PUMP INITIALIZATION
Perform the supply pump initialization.
Click hereНажмите здесь
Result | ||
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NEXT | Нажмите здесь |
GO TO STEP 29 |
PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)
Connect the GTS to the DLC3.
Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
Turn the ignition switch off and wait for 30 seconds.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAF.
Powertrain > Engine and ECT > Data ListTester Display |
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MAF |
Read the MAF value displayed on the GTS while the engine is idling.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the EGR Valve Close / All Data / MAF.
Powertrain > Engine and ECT > Active TestActive Test Display |
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Activate the EGR Valve Close |
Data List Display |
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MAF |
Read the MAF value when the EGR valve is closed using the Active Test function.
If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.
Before performing diagnosis, confirm that the EGR valve target opening angle is not 0%.
When "Coolant Temp" is 75°C (167°F) or higher during idle, the exhaust gas flows through the EGR pipe with cooler sub-assembly. If MAF does not change when the EGR is cut even though the EGR valve is operating normally, the EGR pipe with cooler sub-assembly may be clogged.
When idling while warming up the engine, the actuator operates and the EGR pipe with cooler sub-assembly is bypassed. However, if the connector of the No. 1 vacuum switching valve assembly (for EGR cooler) is disconnected, the EGR pipe with cooler sub-assembly is not bypassed and it is possible to check if the EGR pipe with cooler sub-assembly is clogged.
Result | ||||||||
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As the measured values may differ from those shown below due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.
The problem may be a temporary, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the electric EGR control valve assembly or mass air flow meter assembly.
Reference | ||||||||
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B | Нажмите здесь |
A |
CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)
Remove the electric EGR control valve assembly.
Click hereНажмите здесь
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.
When cleaning the electric EGR control valve assembly, perform initialization procedure.
Click hereНажмите здесь
Do not forcibly open the valve, as it may be damaged or deformed.
When cleaning the electric EGR control valve 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 cleaning the EGR control valve, care should be taken to prevent the ingress of cleaning solvent into the bearings of valve shaft, and when wiping off deposits on the EGR control valve, care should be taken not to push the deposits into the bearings of valve shaft. These contaminants may adversely affect on the function of EGR control valve.
If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.
If the EGR valve does not close properly or is stuck open, the amount of recirculated exhaust gas becomes excessive and combustion becomes unstable. Also, there may be a lack of power. In this case, clean the electric EGR control valve assembly.
Result | ||
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NEXT | Нажмите здесь |
GO TO STEP 29 |
CHECK AIR CONDITIONING SYSTEM
Check the air conditioning system.
Be sure to check the air conditioning hoses and pipes.
Check the refrigerant pressure.
for HFC-134a (R134a): Click hereНажмите здесь
for HFO-1234yf (R1234yf): Click hereНажмите здесь
Result | ||
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NEXT | Нажмите здесь |
GO TO STEP 29 |
PERFORM PILOT QUANTITY LEARNING (DETAIL)
Perform the pilot quantity learning (detail).
Click hereНажмите здесь
Result | ||
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NEXT |
CHECK ROUGH IDLING OR EXCESSIVE ENGINE VIBRATIONS
Check rough idling or excessive engine vibrations.
Result | ||||||
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A |
END |
B | Нажмите здесь |
CHECK AND REPAIR ENGINE ASSEMBLY
Check the following items and repair the malfunctioning part if necessary.
Check cylinder compression pressure.
Click hereНажмите здесь
Result | ||
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NEXT | Нажмите здесь |
GO TO STEP 29 |
CHECK AND REPLACE ENGINE MOUNTING INSULATOR
Check the following items and repair or replace the malfunctioning part if necessary.
Check that the engine mounting insulators are installed correctly.
Check that the engine mounting insulators are not twisted.
Check that deformation of an engine mounting insulator is not causing the engine to contact the vehicle body.
Result | ||
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NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
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NEXT |
END |