ECD SYSTEM(w/o Glow Plug Controller) 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

      Component

      Intake system

      Symptom: Main fault

      • Lack of power (No black smoke): Air filter blockage, air duct is crushed/leaking

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

      Data List

      • MAP (inside manifold absolute pressure)

      • Target Booster Pressure

        When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.
      Table 2. Turbocharger System

      Component

      Turbocharger system

      Main fault

      • Air leak in the turbocharger air passage

      • Turbo motor driver not operating well

      • Turbocharger (turbine, bearing)

      Symptoms

      Lack of power (when vehicle starting, when heavy load)

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

      Data List

      MAP (inside manifold absolute pressure), Target Booster Pressure

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

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

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

      VN Turbo Command

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

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

      Diagnostic Point

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

      • Check the drive rod movement when the ignition switch is turned from ON to off.
      Table 3. Glow System

      Component

      Glow system

      Main fault

      Open circuit, glow plug relay fault

      Symptoms

      Difficult to start, rough idle, knocking, white smoke (when cold)

      Data List

      Check the glow plug indicator light

      Diagnostic Point

      Try to measure the resistance of the glow plug
      Table 4. Engine

      Component

      Engine

      Main fault

      Loss of compression

      Symptoms

      Rough idle (lack of power always)

      Data List

      Engine Speed of Cyl

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

      Injection Feedback Val

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

    2. Diesel Injection

      Table 5. Fuel Supply Pump

      Component

      Supply pump assembly

      Main fault

      -

      Symptoms

      Difficult to start, engine stalling, rough idle, lack of power

      Data List

      Fuel Press, Target Common Rail Pressure, Target Pump SCV Current

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

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

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

      Tip:

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

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

      Diagnostic Trouble Code

      Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 6. Injector Assembly

      Component

      Injector assembly

      Main fault

      Injection hole blockage

      Nozzle needle or valve piston does not move smoothly

      Symptoms

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

      Data List

      Injection Feedback Val

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector assembly breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.
      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 volume will increase at high common rail pressure due to a delay in injector assembly closing.

      • 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, difficult to start, etc. which are also present at low common rail pressure.

      Table 7. Fuel Pressure Sensor

      Component

      Fuel pressure sensor (common rail assembly)

      Main fault

      Open circuit, decrease in performance (foreign matter is attached)

      Symptoms

      Difficult to start, rough idle, engine stall, lack of power

      Data List

      Fuel Press, Target Common Rail Pressure

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

      Diagnostic Trouble Code

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

      Component

      Irregular fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 9. EGR System

      Component

      EGR system

      Main fault

      • Does not move smoothly

      • Does not close completely

      Symptoms

      • Rough idle

      • EGR valve stuck closed: Loud turbocharger sound.

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

      Data List

      Actual EGR Valve Pos., Target EGR Pos.

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

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

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

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

    4. Diesel Throttle

      Table 10. Diesel Throttle System

      Component

      Diesel throttle system

      Main fault

      Stuck, does not move smoothly

      Symptoms

      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

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

      Data List

      • Actual Throttle Position, Target Throttle Position

        0%: Fully open

        100%: Fully closed

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

WIRING DIAGRAM

Refer to DTC P1228.

Click here

CAUTION / NOTICE / HINT

Note:

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

    Click hereClick here

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

Tip:

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

  • 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 excess air fuel ratio across the entire operating range. An insufficient quantity of air results in imperfect combustion and increased particulate (soot) emission.

    When the accelerator pedal is depressed, a lot 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 volume for a given intake air mass is limited (final injection volume is limited by MAF).

    Black smoke is emitted either when:

    • A lack of oxygen is present during combustion

    • 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 on.

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

    4. Read the pending DTCs.

      Powertrain > Engine and ECT > Trouble Codes

      Result

      Result

      Proceed to

      DTC is not output

      A

      Engine related DTCs are output

      B
      Tip:

      If DTC P1609 is output, proceed to step 2.

  2. PERFORM ENGINE SPEED ACCELERATION (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 black smoke emission if there is any visible smoke.

    Result

    Proceed to

    OK

    NG
    OK

    END (TEMPORARY SOOT DEPOSITS DUE TO EXTREMELY LOW VEHICLE SPEED OR CONSECUTIVE SHORT TRIPS)

    NG

  3. CHECK HARNESS AND CONNECTOR (ENGINE ROOM)

    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 CONNECTOR

    OK

  4. TAKE SNAPSHOT DURING IDLING AND 3000 RPM

    1. Connect the GTS to the DLC3.

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

      Tip:

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

    3. Turn the GTS on.

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

    5. 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. The data in the list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

      • Check the Data List at idling and at 3000 rpm with no load after the engine is warmed up.

      • If black smoke emitted, take a snapshot while the smoke is being emitted.

      Table 11. Data Condition Idling (Engine Warmed Up, A/C Off, Shift Lever in neutral)

      Data List

      Value

      Unit

      Engine Speed

      798

      rpm

      MAP

      99

      kPa

      MAF

      4.3

      gm/sec

      Target Common Rail Pressure

      25000

      kPa

      Fuel Press

      24330

      kPa

      Injection Volume

      4.58

      mm3/st

      VN Turbo Command

      90

      %

      Target EGR Position

      65.4

      %

      Actual EGR Valve Pos.

      65.4

      %

      Target Throttle Position

      74

      %

      Actual Throttle Position

      74

      %

      Accel Position

      0.00

      %

      Atmosphere Pressure

      100

      kPa

      Coolant Temp

      75

      °C

      Calculate Load

      16.8

      %

      Pilot 1 Injection Period

      319

      μs

      Pilot 2 Injection Period

      234

      μs
      Table 12. Data Condition at 3000 rpm (Engine Warmed Up, A/C Off, Shift Lever in neutral)

      Data List

      Value

      Unit

      Engine Speed

      3000

      rpm

      Target Booster Pressure

      129.66

      kPa

      MAP

      129

      kPa

      MAF

      32.08

      gm/sec

      Target Common Rail Pressure

      52640

      kPa

      Fuel Press

      52480

      kPa

      Target Pump SCV Current

      1261.0

      mA

      Injection Volume

      5.29

      mm3/st

      VN Turbo Command

      89

      %

      Target EGR Position

      45.4

      %

      Actual EGR Valve Pos.

      45.4

      %

      Target Throttle Position

      0

      %

      Actual Throttle Position

      0

      %

      Accel Position

      10.15

      %

      Coolant Temp

      81

      °C

      Calculate Load

      21.1

      %

      Pilot 1 Injection Period

      176

      μs

      Pilot 2 Injection Period

      0

      μs

    Result

    Proceed to

    NEXT
    NEXT

  5. CHECK SNAPSHOT (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)

    1. Check Fuel Press and Target Common Rail Pressure in the snapshot taken when the engine was idling and at 3000 rpm with no load.

      Tip:

      If black smoke was emitted, check the snapshot from that moment.

      Result

      Result

      Proceed to

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

      A

      Fuel Press is outside range of +/-10000 kPa from Target Common Rail Pressure.

      B
    B

    CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLYClick here

    A

  6. CHECK SNAPSHOT (TARGET PUMP SCV CURRENT)

    1. Check Target Pump SCV Current in the snapshot taken when the engine was idling and at 3000 rpm with no load.

      Result

      Result

      Proceed to

      Target Pump SCV Current is less than 1530 mA

      A

      Target Pump SCV Current is 1530 mA or more

      B
    B

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

    A

  7. CHECK INJECTOR COMPENSATION CODE

    1. Read 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

    PERFORM REGISTRATION AND INITIALIZATIONClick here

    OK

  8. CHECK SNAPSHOT (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 has idled for 1 minute.

      Tip:

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

      Result

      Result

      Proceed to

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is 8 mm3/st or less

      A

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

      B

      *1

      Injection Feedback Val #1 to #4 is outside the range of +/-2 mm3/st*2

      C
      Tip:

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

      • *2: There may be a malfunction in the corresponding cylinder.

      • If the value of Injection Volume is more than 8 mm3/st and the value of 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, you should 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

    REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERSClick here

    C

    PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)Click here

    A

  9. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY

    1. Remove the electric EGR control valve assembly.

    2. Connect the electric EGR control valve assembly connector.

    3. Connect the GTS to the DLC3.

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

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

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Control the EGR Step Position

      Data List Display

      Actual EGR Valve Pos.

    6. When changing the Active Test value from 1 to 100%, check that Actual EGR Valve Pos. smoothly changes to the set opening angle.

      OK

      Value smoothly changes to the set opening angle.

    7. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.

      Note:

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

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

      • When cleaning the electric EGR control valve assembly and the diesel throttle body assembly, use a piece of cloth with cleaning solvent.

        Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

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

      A200348C06

      *1

      Electric EGR Control Valve Assembly

      -

      -

      *a

      Part A

      *b

      Clearance

      *c

      OK

      *d

      NG

      OK

      No light passes through (there is no clearance between the valve and body).

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

      Tip:

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

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

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

      Note:

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

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

      Tip:

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

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

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

    OK

  10. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

    1. Inspect the engine coolant temperature sensor.

      Click here

      Tip:

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

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    Click hereClick here

    OK

  11. READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

    1. Connect the GTS to the DLC3.

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

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

      Powertrain > Engine and ECT > Data List

      Tester Display

      Atmosphere Pressure

      MAP

    4. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).

      Standard

      The difference between MAP and Atmosphere Pressure is less than 7 kPa.

      Tip:

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

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

      Result

      Result

      Proceed to

      MAP and Atmosphere Pressure have the same value

      A

      MAP is different from actual atmospheric pressure

      B

      Atmosphere Pressure is different from actual atmospheric pressure

      C
    B

    REPLACE DIESEL TURBO PRESSURE SENSOR

    Click hereClick here

    C

    REPLACE ECM

    Click here

    A

  12. READ VALUE USING GTS (ACCEL POSITION)

    1. Connect the GTS to the DLC3.

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

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

      Powertrain > Engine and ECT > Data List

      Tester Display

      Accel Position

    4. Read the value.

      Standard

      Condition

      Standard Value

      Accelerator pedal released

      0%

      Accelerator pedal depressed

      95% or more

      Accelerator pedal released → depressed*1

      0 to 95% or more*1
      Tip:

      *1: Make sure the Accel Position opening angle changes smoothly.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ACCELERATOR PEDAL SENSOR ASSEMBLY

    Click here

    OK

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

    1. Leave the vehicle overnight (7 hours or more).

    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 / Intake Air and Intake Air Temp (Turbo).

      Powertrain > Engine and ECT > 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
    NG

    REPLACE MALFUNCTIONING PARTS

    OK

  14. TAKE SNAPSHOT WHILE ACCELERATING WITH ACCELERATOR FULLY OPEN

    1. Connect the GTS to the DLC3.

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

      Tip:

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

    3. Turn the GTS on.

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

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

      CAUTION:

      Obey all laws and regulations, and pay attention to driving conditions while driving the vehicle.

      Tip:

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

      • Accelerate the vehicle with the accelerator fully open in 2nd gear.

      A208571E01
      A208572E10
      A208573E03
      A208574E02
      Table 13. Reference Values with Engine Speed at 2000 rpm

      Data List

      Value

      Unit

      Vehicle Speed

      32

      km/h

      Engine Speed

      2000

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      201.46

      kPa

      MAP

      155

      kPa

      MAF

      37.22

      gm/sec

      Calculate Load

      81.9

      %

      Target Common Rail Pressure

      107800

      kPa

      Fuel Press

      109670

      kPa

      Target Pump SCV Current

      1140

      mA

      Injection Volume

      31.28

      mm3/st

      VN Turbo Command

      95

      %

      Actual EGR Valve Pos.

      0.3

      %

      Actual Throttle Position

      -1

      %
      Table 14. Reference Values with Engine Speed at 3000 rpm

      Data List

      Value

      Unit

      Vehicle Speed

      48

      km/h

      Engine Speed

      3000

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      234.25

      kPa

      MAP

      220

      kPa

      MAF

      75.94

      gm/sec

      Calculate Load

      98.8

      %

      Target Common Rail Pressure

      155480

      kPa

      Fuel Press

      156520

      kPa

      Target Pump SCV Current

      965

      mA

      Injection Volume

      45.48

      mm3/st

      VN Turbo Command

      37

      %

      Actual EGR Valve Pos.

      0.3

      %

      Actual Throttle Position

      0

      %
      Table 15. Reference Values with Engine Speed at 3500 rpm (Point A)

      Data List

      Value

      Unit

      Vehicle Speed

      52

      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.

      0.3

      %

      Actual Throttle Position

      0

      %
      Table 16. Reference Values with Engine Speed at 4000 rpm

      Data List

      Value

      Unit

      Vehicle Speed

      66

      km/h

      Engine Speed

      4000

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      223.45

      kPa

      MAP

      219

      kPa

      MAF

      90.16

      gm/sec

      Calculate Load

      100.0

      %

      Target Common Rail Pressure

      158940

      kPa

      Fuel Press

      158720

      kPa

      Target Pump SCV Current

      947

      mA

      Injection Volume

      37.48

      mm3/st

      VN Turbo Command

      19

      %

      Actual EGR Valve Pos.

      0.3

      %

      Actual Throttle Position

      0

      %

    Result

    Proceed to

    NEXT
    NEXT

  15. CHECK SNAPSHOT (MAP AND TARGET BOOSTER PRESSURE)

    1. Check the condition of the vehicle using the snapshot.

      Result

      Result

      Proceed to

      MAP is less than "Target Booster Pressure - 15 kPa" when accelerating with accelerator fully open

      A

      MAP and Target Booster Pressure values are almost the same

      B
    B

    PERFORM ENGINE SPEED ACCELERATION (CHECK FOR BLACK SMOKE)Click here

    A

  16. INSPECT VACUUM HOSE

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

      OK

      Vacuum hose is connected securely.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE VACUUM HOSE

    OK

  17. CHECK INTAKE SYSTEM

    1. Check for air leakage between the turbocharger and intake manifold.

    2. Check for air leakage at intake manifold.

      Tip:

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

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

      OK

      No leakage.

      A189402E18

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  18. INSPECT TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM)

    1. Inspect the turbocharger sub-assembly.

      Click hereClick here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    Click hereClick here

    OK

  19. PERFORM ENGINE SPEED ACCELERATION (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 above procedure A 10 times (B).

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

      OK

      Black smoke is emitted less than 5 times.

      Tip:

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

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  20. BASIC INSPECTION

    1. Check the fuel quality.

    2. Check the fuel line for air.

    3. Check the fuel system for blockages.

    4. Check the air filter.

    5. Check the engine oil.

    6. Check the engine coolant.

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

    8. Check the vacuum pump.

      OK

      Each inspection result is normal.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  21. REPLACE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (DPF CATALYTIC CONVERTER)

    1. Replace the No. 2 exhaust manifold converter sub-assembly (DPF catalytic converter).

      Click hereClick hereClick here

    2. Clear the DPF deterioration record using the GTS.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  22. CHECK INTAKE SYSTEM DEPOSIT

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

    Result

    Proceed to

    NEXT
    NEXT

  23. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  24. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS

    1. Replace the injector assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  25. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  26. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  27. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

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

    Tip:

    Use this Active Test to determine the malfunctioning cylinder.

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

      Powertrain > Engine and ECT > Active Test

      Tester Display

      Control the Select Cylinder Fuel Cut
      Tip:

      • DTCs may be output after this Active Test. Make sure to check for DTCs after this Active Test. If any DTCs are output, make sure to clear them.

        Click here

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

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

    Result

    Proceed to

    NEXT
    NEXT

  29. READ VALUE USING GTS (ENGINE SPEED OF CYL #1 TO #4)

    Tip:

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

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

    1. Warm up the engine.

    2. Turn the ignition switch off.

    3. Connect the GTS to the DLC3.

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

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

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Check the Cylinder Compression

      Data List Display

      Engine Speed of Cyl #1

      Engine Speed of Cyl #2

      Engine Speed of Cyl #3

      Engine Speed of Cyl #4

      Av Engine Speed of All Cyl

    6. Push the snapshot button to turn the snapshot function on.

      Tip:

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

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

      Tip:

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

    8. Crank the engine for about 10 seconds.

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

      Tip:

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

      Note:

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

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

      • Use a fully-charged battery.

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

      Note:

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

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

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

      Tip:

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

    13. Check the change in engine speed values.

      Result

      Result

      Proceed to

      Except below

      A

      The values of Engine Speed Cyl #1 to #4 are within +/-10 rpm of each other.

      B
      Tip:

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

    B

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDERClick here

    A

  30. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    1. Check the cylinder compression pressure.

      Click hereClick here

      OK

      The cylinder compression pressure is within the standard range.

    Result

    Proceed to

    OK

    NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  31. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  32. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  33. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  34. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  35. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

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

    1. Disconnect the suction control valve connector.

    2. Disconnect the ECM connector.

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

      Standard Resistance

      Tester Connection

      Condition

      Specified Condition

      B123-2 - B138-12 (PCV)

      Always

      Below 1 Ω

      B123-2 or B138-12 (PCV) - Body ground

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

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

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

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

      OK

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

      Tip:

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

      • Check that the fuel filter is not clogged.

    Result

    Proceed to

    OK

    NG
    NG

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

    OK

  39. REPLACE SUPPLY PUMP ASSEMBLY

    1. Replace the supply pump assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  40. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  41. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

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

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

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

      OK

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

      Tip:

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

      • Check that the fuel filter is not clogged.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE SUPPLY PUMP ASSEMBLYClick here

    OK

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

    1. Check and replace the clogged fuel pipe.

    Result

    Proceed to

    NEXT
    NEXT

  44. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  45. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  46. REPLACE SUPPLY PUMP ASSEMBLY

    1. Replace the supply pump assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  47. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  48. PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)

    1. Connect the GTS to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT/ Active Test / Test the Fuel Leak / Data List / Fuel Press 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. Maintain an engine speed of 3500 rpm, and then press the "Start" button.

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

      A293663E01
      Tip:

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

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

      Standard

      The difference between the target fuel pressure and the actual fuel pressure is less than 15000 kPa when the target fuel pressure reaches the maximum value approximately 2 seconds after the Active Test starts.

      Result

      Result

      Proceed to

      Difference between target fuel pressure and actual fuel pressure is 15000 kPa or higher

      A

      Difference between target fuel pressure and actual fuel pressure is less than 15000 kPa

      B
    B

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

    A

  49. REPLACE COMMON RAIL ASSEMBLY

    1. Replace the common rail assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  50. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  51. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END