ECD SYSTEM(w/ DPF) Turbocharger Oil Leak and White Smoke

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   CHECK TYPE OF OIL LEAK

   
   

   1. Check whether the oil leak is an internal or external oil leak.

      Tip:

      White smoke is not related to an external oil leak.

      Oil Leak Type	Description
      Internal oil leak (White smoke)	Oil leak from center housing to compressor housing (intake side) or turbine housing (exhaust side) through piston rings (seal rings). Internal oil leak is not visible from outside of turbocharger sub-assembly. If oil leak occurs from turbine side seal, large amount of white smoke will be emitted from exhaust pipe.
      External oil leak	Oil leak from inside of turbocharger sub-assembly to outside of turbocharger sub-assembly (e.g. from compressor housing O-ring, oil pipe flange or oil pipe union). Includes oil leaks visible from outside of turbocharger sub-assembly.

      Table 16. Result

      Result	Proceed to
      External oil leak	A
      Internal oil leak	B

   
   
   • AClick here
   • BClick here
2. Click here

   REPLACE THE PART WHICH IS LEAKING OIL

   
   

   1. Replace the part which is leaking oil.

   
   
   • NEXT

     END

3. Click here

   CHECK WHETHER WHITE SMOKE IS EMITTED

   
   

   1. Fully depress the accelerator pedal, and then release it.

   2. 

      Check whether white smoke is emitted or not when racing the engine.

      CAUTION:

      Be sure not to check for white smoke indoors.

      Table 17. Result

      Result	Proceed to
      White smoke is emitted	A
      White smoke is not emitted	B

   
   
   • AClick here
   • BClick here
4. Click here

   READ OUTPUT DTC (RELATED TO ENGINE)

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch to ON.

   3. Turn the tester on.

   4. Enter the following menus: Powertrain / Engine and ECT / DTC.

   5. Read DTCs.

      Table 18. Result

      Result	Proceed to
      No DTCs are output	A
      DTCs related to engine are output	B

   
   
   • AClick here
   • B

     GO TO DTC CHART (Click here)

5. Click here

   CHECK WHITE SMOKE (ACCORDING TO ENGINE CONDITION)

   
   
   1. 

      Check whether the white smoke is emitted only just after engine start and disappears later, or not.

      Tip:
      

      • If white smoke appears for only a short period of time immediately after the engine is started, the white smoke is not from the turbocharger sub-assembly.

      • If the turbocharger sub-assembly is the cause of the problem, regardless of whether the engine is cold or warmed up, there will be a large amount of white smoke to the extent that visibility is obstructed for a few meters in the area of the smoke (as shown in the illustration).

      • 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.

      Table 19. Result

      Result	Proceed to
      Yes (white smoke is emitted only just after engine start)	A
      No (white smoke is always and continuously emitted)	B

   
   
   • AClick here
   • BClick here
6. Click here

   CHECK TEMPERATURE WHEN WHITE SMOKE IS EMITTED

   
   

   1. Check whether the white smoke is emitted only in cold weather when the temperature is less than 0°C (32°F).

      Tip:
      

      • If the white smoke is emitted only in cold conditions, the smoke is not from the turbocharger sub-assembly and may be the smoke of unburned fuel.

      • If misfiring occurs, unburned fuel is emitted.

      Table 20. Result

      Result	Proceed to
      Yes (white smoke is emitted in only cold conditions)	A
      No (white smoke is emitted in both cold and warm conditions)	B

   
   
   • AClick here
   • BClick here
7. Click here

   INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)

   
   

   1. Inspect the glow plug assembly (Click here).

   
   
   • OKClick here
   • NG

     REPLACE GLOW PLUG ASSEMBLY (Click here)

8. Click here

   CHECK INJECTOR COMPENSATION CODE

   
   

   1. Read the injector compensation codes (Click here).

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

      Tip:
      

      • If those do not match, register correct compensation code.

      • If necessary, perform "Learning Values Reset" (Click here).

   
   
   • OKClick here
   • NG

     REGISTER INJECTOR COMPENSATION CODE (AND PERFORM LEARNING VALUES RESET) (Click here)

9. Click here

   CHECK FUEL SYSTEM (DIESEL INJECTION SYSTEM)

   
   

   1. Check the fuel system (Click here).

   
   
   • OKClick here
   • NG

     REPAIR OR REPLACE FUEL SYSTEM

10. Click here

    CHECK ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Tip:
    

    • If the amount of EGR is excessive due to a failure of the electric EGR control valve assembly, combustion when the coolant temperature is cold becomes unstable and leads to misfire.

    • When the electric EGR control valve assembly cannot completely close, a lack of power is felt and the mass air flow meter value deviates from the standard value.

    
    

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position.

    5. When changing the Active Test value, check that Actual EGR Valve Pos. smoothly changes to the set opening angle.

       OK
       Value smoothly changes to set opening angle.

    6. Remove the electric EGR control valve assembly (Click here).

    7. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the EGR valve and EGR passage (intake/exhaust manifold, EGR cooler, EGR pipes, etc.).

       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, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.

    8. 

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

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

       Tip:
       

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

       • Even if the electric EGR control valve assembly is closed completely, light leaks from the closed gap of valve seat (*a) as shown the illustration, but this is normal.

       Table 21. Text in Illustration

       *1	Electric EGR Control Valve Assembly (DC Motor Type EGR Valve)	-	-
       *a	Gap	*b	OK
       *c	NG	*d	Clearance

       Tip:

       If any inspection result above is NG, check the EGR system, referring to the inspection procedure for DTC P042E.

    
    
    • OKClick here
    • NG

      GO TO EGR SYSTEM INSPECTION PROCEDURE (DTC P042E) (Click here)

11. Click here

    CHECK CYLINDER COMPRESSION PRESSURE

    
    

    1. Check the cylinder compression pressure (Click here).

       Tip:
       

       • If any of following malfunctions occurs, white smoke is emitted.

       • 
         

         1. Nozzle seat sealing failure

         2. Piston cracking

         3. Piston rings breakage

       • To check whether the pistons and piston rings have a malfunction, remove the oil level dipstick. If oil sprays out, the pressure inside the crankcase has risen which indicates that there is a malfunction in a piston or piston ring.

    
    
    • OKClick here
    • NG

      CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

12. Click here

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    
    

    1. Replace the turbocharger sub-assembly (Click here).

    2. Turn the ignition switch to ON.

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

    
    
    • NEXTClick here
13. Click here

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    
    

    1. Check whether the white smoke problem has been successfully repaired by starting the engine.

    
    
    • NEXT

      END

14. Click here

    INSPECT COMPRESSOR INLET

    
    

    1. Remove the air cleaner hose from the compressor inlet.

    2. Check whether an excessive amount of oil is present or not, and whether excessive oil deposits are attached to the compressor wheel or not.

       Tip:
       

       • A certain amount of oil may be present as shown in fig. 2 in "Description", because a certain amount of oil mist is contained in the PCV gas and this oil accumulates just before the compressor inlet.

       • If an excessive amount of oil is present at the compressor inlet, there may be a problem in the PCV system.

    
    
    • NEXTClick here
15. Click here

    INSPECT COMPRESSOR OUTLET

    
    

    1. Remove the air hose from the compressor outlet.

    2. Check whether or not an excessive amount of oil or excessive oil deposits are present at the compressor outlet.

       Tip:

       A certain amount of oil may be present as shown in fig. 3 in "Description", because a certain amount of oil mist is contained in the PCV gas.

       Table 22. Result

       Result	Proceed to
       Excessive amount of oil not present at compressor inlet and outlet	A
       Excessive amount of oil present only at compressor outlet	B
       Excessive amount of oil present at both compressor inlet and outlet	C

    
    
    • AClick here
    • BClick here
    • C

      CHECK PCV SYSTEM

16. Click here

    INSPECT TURBINE INLET

    
    

    1. Remove the turbocharger sub-assembly from the engine (Click here).

    2. Check whether an excessive amount of wet oil or excessive oil deposits are present at the turbine inlet.

       Tip:

       Be sure not to mistake carbon soot for oil.

    
    
    • NEXTClick here
17. Click here

    INSPECT TURBINE OUTLET

    
    

    1. Check whether an excessive amount of wet oil or excessive oil deposits are present at the turbine outlet.

       Tip:
       

       • Be sure not to mistake carbon soot for oil.

       • If the turbocharger shaft is tilted, some amount of oil will flow out from the center housing. Therefore, be sure not to mistake oil that flowed out from the center housing during or after the removal of the turbocharger sub-assembly for oil that was present before the removal of the turbocharger sub-assembly.

       • If an excessive amount of oil or excessive oil deposits are present at the turbine inlet, this oil is coming from the exhaust port of the cylinders, and may indicate a problem in 1 or more cylinders.

       Table 23. Result

       Result	Proceed to
       Excessive amount of oil present only at turbine outlet	A
       Excessive amount of oil present at both turbine inlet and outlet	B

    
    
    • AClick here
    • B

      CHECK ENGINE TO DETERMINE CAUSE OF OIL IN TURBOCHARGER SUB-ASSEMBLY

18. Click here

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    
    

    1. Replace the turbocharger sub-assembly (Click here).

    2. Turn the ignition switch to ON.

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

    
    
    • NEXTClick here
19. Click here

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    
    

    1. Check whether the oil leakage problem has been successfully repaired.

    
    
    • NEXT

      END