ECD SYSTEM Black Smoke Emitted

DTC Code DTC Name
Black Smoke Emitted

DESCRIPTION

  1. Faults and Symptoms of Common Rail Diesel Components

    1. Engine Control

      Table 1. Intake System

      Symptom and Corresponding Main Fault

      • Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct

      • Black smoke (no lack of power) due to leakage between the turbo and intake manifold

      Data List

      MAP
      Table 2. Glow System

      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
      Table 3. 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

      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.

    2. Common Rail (ALL)

      Table 4. 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

      • Fuel Press is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      • 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 start, but is approx. 25000 kPa at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.

      Diagnostic Trouble Code

      Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.
      Table 5. Injector Assembly

      Main fault

      Blockage, increase in fuel injection volume

      Symptoms

      Rough idle, lack of power, black smoke, white smoke, knocking

      Data List

      Injection Feedback Val

      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.
      Tip:

      • When the sliding resistance of the internal parts of the injector assemblies (i.e. armature shaft, command piston and plunger) has increased due to internal contamination, injection quantity will increase at high common rail pressure due to a delay in injector assembly closure.

      • When black smoke occurs due to contamination of the injector assemblies, there are usually other symptoms, such as engine knocking noise at cold idling, rough idling, difficulty starting, etc. which are also present when the common rail pressure is low.

      Table 6. Injector Driver (EDU)

      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.
      Table 7. 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 and Common Rail Pres Sens 2 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Fuel Press or Common Rail Pres Sens 2 decreases to a value less than Target Common Rail Pressure).

      Diagnostic Trouble Code

      When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 8. Irregular Fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 9. 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 Position

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

      • Using the EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Position (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 is warmed up.

      EGR Close Lrn. Val., EGR Close Lrn. Status

      • When leaving the vehicle idling, when EGR Close Lrn. Status is OK, the normal range of EGR Close Lrn. Val. is 0 to 1 V.

      • In cases when EGR Close Lrn. Status. is NG or EGR Close Lrn. Val. is out of the normal range (0 to 1 V), it is possible that the EGR valve cannot completely close.

    4. Diesel Throttle

      Table 10. 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

      • 0%: Fully open

      • 100%: Fully closed

      • When the ignition switch ON (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

  2. Data List Related to Starting Trouble

    • Engine Speed

    • MAP

    • 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.

WIRING DIAGRAM

Refer to DTC P0088.

Click here

CAUTION / NOTICE / HINT

Note:

  • After replacing the ECM, the new ECM needs registration (Click here) and initialization (Click here).

  • After replacing a suction control valve, the ECM needs initialization.

    Click here

  • After replacing an injector assembly, the ECM needs registration.

    Click here

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 assume the vehicle to be normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

  1. Explanation of Symptom

    Black Smoke

    The fuel used in diesel engines has a higher boiling point and evaporates much slower than that used in gasoline engines. Additionally, the fuel is injected directly, so the air fuel mixture in diesel engines is formed in a very short period of time and is less homogenous. This is why diesel engines must operate with a larger air fuel ratio across the entire operating range. An insufficient quantity of air results in imperfect combustion and increased particulate (soot) emissions.

    When the accelerator pedal is depressed, a large amount of fuel is injected. As a result, the air fuel ratio becomes rich. In this relatively rich environment, fuel droplets lacking in oxygen burn imperfectly producing soot, which is emitted as black smoke. In order to prevent black smoke production, the maximum injection quantity for a given intake air mass is limited (final injection quantity is limited by mass air flow).

    Black smoke is emitted when either 1) a lack of oxygen is present during combustion, or 2) Too much fuel is injected for a given intake air mass and the air fuel ratio becomes temporarily rich.

PROCEDURE

  1. READ OUTPUT DTC (RELATING TO ENGINE)

    1. Connect the GTS to the DLC3.

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

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

    4. Read the pending DTCs.

      Powertrain > Engine > Trouble Codes

      Result

      Result

      Proceed to

      DTCs are not output

      A

      Engine related DTCs are output

      B
      Tip:

      If only DTC P1609 is output, proceed to procedure 2.

    B

    GO TO DTC CHART

    Click hereClick here

    A

  2. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times or more [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK

      Black smoke is emitted less than 5 times.

      Tip:

      • Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

      • If the procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.

    Result

    Proceed to

    OK

    NG
    NG

    EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY TO BE REPLACEDClick here

    OK

  3. RECOVERY TO NORMAL

    Tip:

    If the racing procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.

    Result

    Proceed to

    NEXT
    NEXT

    END

  4. EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY TO BE REPLACED

    1. Even though it has been determined that the DPF catalytic converter (exhaust manifold converter sub-assembly) needs to be replaced, make sure to complete diagnosis for this problem before replacing it.

      Click here

      Tip:

      This problem is occurred because an excessive amount of PM has accumulated and resulted in abnormal combustion. It is necessary to diagnose the cause of abnormal PM accumulation and repair the problem. Therefore, do not perform replacement at this time.

    Result

    Proceed to

    NEXT
    NEXT

  5. CHECK INTAKE SYSTEM

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

      Tip:

      • Make sure that the air cleaner filter element sub-assembly is not clogged and the intake and exhaust system hoses are not disconnected.

      • When the vacuum hoses are disconnected.

      • 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

  6. CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT

    1. Check the wire harness and connector connections of common rail system components.

      OK

      The wire harnesses and connectors are connected securely.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTORClick here

    OK

  7. CHECK INJECTOR COMPENSATION CODE

    1. Check the injector compensation codes.

      Click here

      OK

      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.

    Result

    Proceed to

    OK

    NG
    NG

    REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNINGClick here

    OK

  8. PERFORM PILOT QUANTITY LEARNING (DETAIL)

    1. Perform the pilot quantity learning (detail).

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  9. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK

      Black smoke is emitted less than 5 times.

      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  10. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)

    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

  11. READ VALUE USING GTS (MAF AND MAP)

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAP and MAF.

      Powertrain > Engine > Data List

      Tester Display

      MAF

      MAP

    5. Take a snapshot when the engine speed is maintained at 4000 rpm with no load.

    6. Read the values of "MAP" and "MAF" in the Data List using the snapshot review function.

      Result

      Result

      Proceed to

      MAF 85 gm/sec or more and MAP 140 kPa or higher

      A

      Except above

      B
      Tip:

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

      • The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.

        Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.

    B

    PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)Click here

    A

  12. CHECK SNAPSHOT (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #4)

    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken after the engine is warmed up and idled for 1 minute.

      Result

      Result

      Proceed to

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

      A

      Injection Feedback Val for at least one cylinder is more than 3 mm3/st

      B

      Except above

      C
    B

    PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)Click here

    C

    READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)Click here

    A

  13. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

    1. Replace the injector assemblies.

      Click here

      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

    REPLACE FUEL FILTER ELEMENT ASSEMBLYClick here

  14. 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 > 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

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDERClick here

    A

  15. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    Tip:

    Measure the compression of the cylinder that had a high speed during the Active Test "Check the Cylinder Compression".

    1. Check the cylinder compression pressure.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  16. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here

      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

  17. REPLACE FUEL FILTER ELEMENT ASSEMBLY

    1. Replace the fuel filter element assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  18. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  19. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

    1. Register the injector compensation codes.

      Click here

    2. Perform the pilot quantity learning.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  20. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK

      Black smoke is emitted less than 5 times.

      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

    Result

    Proceed to

    NEXT
    NEXT

    END

  21. 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 / All Data / MAP and Atmosphere Pressure.

      Powertrain > Engine > Data List

      Tester Display

      Atmosphere Pressure

      MAP

    4. Compare MAP to Atmosphere Pressure when the ignition switch ON (engine stopped).

      Tip:

      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 10 kPa (0.1 kgf/cm2, 1.5 psi) or more, 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 (1.0 kgf/cm2, 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm2, 0.1 psi). This varies by weather (high atmospheric pressure, low atmospheric pressure).

      Result

      Result

      Proceed

      MAP and Atmosphere Pressure have same value

      A

      Atmosphere Pressure is different from actual atmospheric pressure

      B

      MAP is different from actual atmospheric pressure

      C
    B

    REPLACE ECMClick here

    C

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSORClick here

    A

  22. 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 > 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.

      A227749E06

      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).

      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.

      • When the pressure discharge valve on the common rail assembly has a malfunction, the actual fuel pressure changes as shown 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 kgf/cm2, 1451 psi) for 2 seconds or more, it is necessary to inspect or repair the wiring for the fuel pressure sensor.

    Result

    Proceed to

    OK

    NG
    NG

    CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)Click here

    OK

  23. READ VALUE USING GTS (COOLANT TEMP)

    1. Soak the engine for a long time.

    2. Connect the GTS to the DLC3.

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

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Coolant Temp.

      Powertrain > Engine > Data List

      Tester Display

      Coolant Temp

      OK

      Coolant Temp is the same as the ambient temperature.

      Tip:

      When the engine coolant temperature is low even though the engine has been fully warmed up, or when the engine coolant temperature is high even though the engine is cold, inspect the sensor.

    Result

    Proceed to

    OK

    NG
    NG

    CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSORClick here

    OK

  24. READ VALUE USING GTS (INTAKE AIR AND INTAKE AIR TEMP (TURBO))

    1. Soak the engine for a long time.

    2. Connect the GTS to the DLC3.

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

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Intake Air and Intake Air Temp (Turbo).

      Powertrain > Engine > Data List

      Tester Display

      Intake Air

      Intake Air Temp (Turbo)

      OK

      Intake Air is the same as Intake Air Temp (Turbo).

    Result

    Proceed to

    OK

    NG
    OK

    CHECK FOR BLACK SMOKEClick here

    NG

  25. CHECK AND REPLACE MALFUNCTIONING PARTS

    1. Inspect the mass air flow meter assembly.

      Click here

    2. Inspect the intake air temperature sensor (turbo).

      Click here

    3. Replace the mass air flow meter assembly.

      Click here

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

    4. Replace the intake air temperature sensor (turbo).

      Click here

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  26. CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    1. Inspect the engine coolant temperature sensor.

      Click here

    2. Replace the engine coolant temperature sensor.

      Click here

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  27. 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

      B48-1 - B76-41 (PCV+)

      Always

      Below 1 Ω

      B48-2 - B76-81 (PCV-)

      Always

      Below 1 Ω

      B48-1 or B76-41 (PCV+) - Body ground

      Always

      10 kΩ or higher

      B48-2 or B76-81 (PCV-) - Body ground

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTORClick here

    OK

  28. CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY

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

    2. Operate the hand pump and check that fuel is being supplied to the supply pump assembly.

      OK

      Fuel is properly supplied to the supply pump assembly when the hand pump is operated.

      Tip:

      • When there is a lack of fuel, the fuel pressure drops.

      • Check that the fuel filter element assembly is not clogged.

    Result

    Proceed to

    OK

    NG
    NG

    CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - SUPPLY PUMP ASSEMBLY)Click here

    OK

  29. REPLACE SUCTION CONTROL VALVE

    1. Replace the suction control valve.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  30. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  31. PERFORM SUPPLY PUMP INITIALIZATION

    1. Perform the supply pump initialization.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  32. CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - SUPPLY PUMP ASSEMBLY)

    1. Check and replace the clogged fuel pipe.

    Result

    Proceed to

    NEXT
    NEXT

  33. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  34. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK

      Black smoke is emitted less than 5 times.

      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

    Result

    Proceed to

    NEXT
    NEXT

    END

  35. REPAIR OR REPLACE HARNESS OR CONNECTOR

    1. Repair or replace the harness or connector.

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  36. REPLACE ECM

    1. Replace the ECM.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  37. REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

    1. Replace the manifold absolute pressure sensor.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  38. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)

    1. Connect the GTS to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off and wait for 30 seconds.

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine > Data List

      Tester Display

      MAF

    6. Read the MAF value displayed on the GTS while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the EGR Valve Close / All Data / MAF.

      Powertrain > Engine > Active Test

      Active Test Display

      Activate the EGR Valve Close

      Data List Display

      MAF

    8. Read the MAF value when the EGR valve is closed using the Active Test function.

      Tip:

      • 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

      GTS Display

      Result

      Proceed to

      Activate the EGR Valve Close:

      OFF (Open) to Close

      MAF value does not change

      A

      MAF value changes

      B
      Note:

      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.

      Tip:

      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

      EGR Valve Condition (Opening)

      Measuring Condition

      MAF (Reference)

      Open (67%)

      • Atmosphere pressure: 101 kPa

      • Intake air temperature: 30°C (86°F)

      • Engine coolant temperature: 88°C (190°F)

      3 to 12 gm/sec

      Closed (0%)

      7 gm/sec or more
    B

    CHECK SNAPSHOT (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #4)Click here

    A

  39. READ VALUE USING GTS (MAF)

    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 / All Data / MAF.

      Powertrain > Engine > Data List

      Tester Display

      MAF

    4. With the ignition switch ON and engine stopped, read the value when 30 seconds has elapsed.

      Standard

      GTS Display

      Condition

      Standard

      MAF

      Ignition switch ON (do not start engine)

      0.35 gm/sec or less

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE MASS AIR FLOW METER ASSEMBLYClick here

    OK

  40. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

    1. Connect the GTS to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off and wait for 30 seconds.

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine > Data List

      Tester Display

      MAF

    6. Read the MAF value displayed on the GTS while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EGR Cooler Bypass / All Data / EGR Cooler Bypass Position and MAF.

      Powertrain > Engine > Active Test

      Active Test Display

      Activate the VSV for EGR Cooler Bypass

      Data List Display

      MAF

      EGR Cooler Bypass Position
      Tip:

      Whether the EGR is passing through the bypass side or cooler side during the Active Test can be confirmed by checking EGR Cooler Bypass Position.

    8. Using the Active Test function, switch the No. 1 vacuum switching valve assembly (for EGR cooler) between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".

      Tip:

      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.

      Result

      GTS Display

      Result

      Proceed to

      Activate the VSV for EGR Cooler Bypass:

      Cooler to Bypass

      MAF value does not change

      A

      MAF value changes

      B
      Tip:

      If the EGR pipe with cooler sub-assembly is clogged, the MAF value changes.

    B

    REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLYClick here

    A

  41. CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    1. Remove the electric EGR control valve assembly.

      Click here

    2. 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.

      • When cleaning the electric EGR control valve assembly, perform initialization procedure.

        Click here

      • 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.

      Tip:

      • 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

    Proceed to

    NEXT
    NEXT

  42. REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLY

    1. Replace the EGR pipe with cooler sub-assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here

  43. REPLACE MASS AIR FLOW METER ASSEMBLY

    1. Replace the mass air flow meter assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CHECK FOR BLACK SMOKEClick here