ECD SYSTEM(w/o DPF) Rough Idling or Excessive Engine Vibrations

DESCRIPTION

Malfunction Condition Main Trouble Area Related Trouble Area

  • Rough idling or shuddering due to abnormal combustion

  • Shuddering when starting vehicle due to clutch system malfunctions

  1. Injector assembly malfunctions


    • Injector assembly sliding malfunction

    • Injector assembly stuck closed

    • Injector assembly stuck open

    • Deposit in injector assembly

    • Injector circuit malfunction

  2. Clutch system malfunctions


    • Clutch system (shuddering when starting)

  • Injector compensation code

  • Fuel leak

  • Engine mounting insulator

  • Intake system leakage

  • Intake system blockage

  • EGR system

  • Throttle valve system

  • Supply pump assembly

  • Low quality fuel

  • Vehicle modifications

  • Fuel filter air bleed problem

  • Accessory problem (A/C, generator, etc.)

  • ECM

Tech Tips


  • Rough idling and excessive engine vibrations are checked in this troubleshooting procedure.

  • Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result values may occur depending on the measuring conditions or the vehicle age. Do not judge the vehicle to be normal even when the Data List values indicate a standard level. There are possibly some concealed factors of the malfunction.

  • Check that the vehicle has not been modified in any way prior to the vehicle inspection.


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Mass Air Flow Meter
      Component Mass air flow meter
      Main fault Decrease in performance (foreign matter is stuck)
      Symptoms Lack of power, black smoke
      Data List MAF

      Tech Tips

      The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
      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
      Engine
      Component Engine
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      Data List

      Engine Speed of Cyl


      • The engine is cranked for approximately 10 seconds, then the speed of each cylinder is measured (compression test).

      • Indicates the speed of each cylinder when cranking. Example - Normal: Engine speed of all cylinders is approximately equal. When No. 1 cylinder compression is extremely low, "Engine speed of Cyl #1" is approximately 300 rpm, and "Engine speed of Cyl #2 to #4" is approximately 200 rpm.

      • Usually the tester displays the value of when the engine is started.

      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

      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.

      Tech Tips


      • 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.
      Fuel Filter
      Component Fuel filter
      Main fault Blockage
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure


      • 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.

      Tech Tips

      The fuel pressure changes at engine starting, but is approx. 25000 kPa at engine start after the engine is warmed up.
      Diagnostic Trouble Code Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored.
      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.
      Pressure Control Valve
      Component Pressure control valve (common rail assembly)
      Main fault Does not completely close
      Symptoms Difficult to start, engine stall, rough idle, lack of power
      Fuel Pressure Sensor
      Component Fuel pressure sensor (common rail assembly)
      Main fault Open circuit, decrease in performance (foreign matter is stuck)
      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.
      Irregular Fuel
      Component Irregular fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      EGR System
      Component EGR system
      Main fault

      • Does not move smoothly

      • Does not close completely
      Symptoms

      • Rough idle

      • EGR valve stuck closed: A 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 EGR and there is a 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

      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.

  2. Data List Related to Rough Idling or Excessive Engine Vibrations

    Tech Tips

    The Data List values in the table are the results of checking one vehicle under a specific condition (engine coolant temperature, intake air temperature, atmosphere pressure etc.). Therefore, use these values for reference only.


    1. Engine Control

      Engine Speed
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Engine Speed Idling: 720 to 820 rpm

      • Crankshaft position sensor

      • Crankshaft position sensor circuit

      		 When the crankshaft position sensor is malfunctioning, "Engine Speed" is approximately 0 or varies greatly from the actual engine speed.
      MAF
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      MAF -

      • Mass air flow meter

      • Mass air flow meter circuit

      • Intake system clogging, leaking

      • Exhaust system clogging

      • Turbocharger sub-assembly

      • Leaking or clogging of turbocharger passages

      • Electric EGR control valve assembly does not close

      • Based on the MAF, the ECM controls the fuel injection volume, injection timing, EGR, etc.

      • If the value is always approximately 0 gm/sec.:


        • Mass air flow meter power source circuit is open.

        • VG circuit is open or shorted.

      • If the value is always 130 gm/sec. or more:


        • E2G circuit is open.

      Results of real-vehicle check:


      • Ignition switch ON: 0 gm/sec.

      • Cranking (534 rpm): 3.27 gm/sec.

      • Idling (warm up the engine): 4.30 gm/sec. (2 minutes after starting the vehicle and "Actual EGR Valve Pos." = 65.4%)

      • Idling (warm up the engine): 8.30 gm/sec. (2 minutes after starting the vehicle and "Actual EGR Valve Pos." = 0.3%)

      • Running without load (2500 rpm): 19.97 gm/sec. (at "Actual EGR Valve Pos." = 61.9%)

      • Running without load (4000 rpm): 58.86 gm/sec.

      • Driving with the accelerator fully open at 2000 rpm: 37.22 gm/sec.

      • Driving with the accelerator fully open at 3000 rpm: 75.94 gm/sec.

      • Driving with the accelerator fully open at 4500 rpm: 92.24 gm/sec.

      Tech Tips


      • The maximum fuel injection volume is controlled according to the output from the mass air flow meter.

      • If the time of engine idling is long (approximately 20 minutes or more), EGR will be cut off. At this time, if the vehicle is driven in 4th gear between 90 and 100 km/h (56 and 62 mph) for 30 minutes, EGR resumes.
      Intake Air
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Intake Air - Intake air temperature sensor.

      • After a long soak, the engine coolant temperature, intake air temperature and ambient air temperature are approximately equal.

      • If the value is -40°C (-40°F) or 140°C (284°F), the sensor circuit is open or shorted.
      Coolant Temp
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Coolant Temp

      • Engine coolant temperature is approximately equal to intake air temperature after a long soak. After warm-up: Engine coolant temperature is 75°C (167°F) or more.

      • In cases when the engine coolant temperature output is obviously higher than the actual engine coolant temperature, when it is cold, there will be difficulty starting due to problems with glow plugs or insufficient fuel injection.

      • In cases when the engine coolant temperature sensor output is obviously lower than the actual engine coolant temperature, when it is warm, there will be difficulty starting (black smoke will also occur) due to an excess of injected fuel.

      		 Engine coolant temperature sensor

      • If the value is -30°C (-22°F) or 120°C (248°F), the sensor circuit is open or shorted.

      • After a long soak, the Coolant Temp, Intake Air and ambient air temperature are approximately equal.
      Engine Speed of Cyl #1 (to #4)
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Engine Speed of Cyl #1 (to #4)

      When cranking, the engine speed of each cylinder is the same under normal conditions. When a cylinder is approximately 100 rpm higher than the other cylinders, it is conceivable that the compression of that cylinder is being lost.

      Tech Tips

      Usually the tester displays the value of when the engine is started.

      		 -

      • The engine is cranked for approximately 10 seconds, then the speed of each cylinder is measured (compression test).

      • Indicates the speed of each cylinder when cranking. Example - Normal: Engine speed of all cylinders is approximately equal. When No. 1 cylinder compression is extremely low, "Engine speed of Cyl #1" is approximately 300 rpm, and "Engine speed of Cyl #2 to #4" is approximately 200 rpm.

    2. Diesel Injection

      Target Common Rail Pressure
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Target Common Rail Pressure - -

      • Inspect the (actual) fuel pressure, comparing it against the common rail target value.

      • Considered normal when the actual fuel pressure is within +/-10000 kPa of the target fuel pressure under stable conditions.

      Results of real-vehicle check:


      • Ignition switch ON: 25000 kPa

      • Cranking: 27150 kPa

      • Idling (warm up the engine): 25000 kPa (2 minutes after starting the vehicle)

      • Running without load (2500 rpm): 43990 kPa

      • Running without load (4000 rpm): 67100 kPa

      • Driving with the accelerator fully open at 2000 rpm: 107800 kPa

      • Driving with the accelerator fully open at 3000 rpm: 155480 kPa

      • Driving with the accelerator fully open at 4500 rpm: 159640 kPa
      Fuel Press
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Fuel Press

      • Idling: 19900 to 37000 kPa 4000 rpm: 50700 to 73000 kPa Fuel Press = Target Common Rail Pressure +/- 10000 kPa at stable condition

      • During cranking, if Fuel Press is lower than 25000 kPa, there may be difficulty starting (take care as there is a response lag when the pressure rises).

      • When Fuel Press is lower than 25000 kPa, rough idling will occur.

      • If there is a fault with the supply pump assembly (lack of discharge quantity) or pressure control valve (will not fully close), the fuel pressure will drop. Also, a blocked fuel filter, leakage from fuel pipes, and lack of fuel will also make the fuel pressure drop.

      • If air mixes with the fuel, the fuel pressure will shift away from the target fuel pressure.

      • When there is a fault with the supply pump assembly, there is a possibility of lack of power, engine stall, rough idle and difficulty starting.

      • Fuel pressure is the actual common rail fuel pressure.

      • Inspect by comparing the fuel pressure with the target fuel pressure.

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

      • The ECM uses fuel pressure for feedback control of the target fuel pressure via the supply pump. The injection amount is determined based on the injection timing and fuel pressure.

      Results of real-vehicle check:


      • Ignition switch ON: 360 kPa

      • Cranking: 33570 kPa

      • Idling (warm up the engine): 24330 kPa (2 minutes after starting the vehicle)

      • Running without load (2500 rpm): 43690 kPa

      • Running without load (4000 rpm): 66340 kPa

      • Driving with the accelerator fully open at 2000 rpm: 109670 kPa

      • Driving with the accelerator fully open at 3000 rpm: 156520 kPa

      • Driving with the accelerator fully open at 4500 rpm: 160260 kPa
      Target Pump SCV Current
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Target Pump SCV Current 1530 mA or less

      • Suction control valve malfunction

      • Clogged fuel filter

      • ECM-calculated value for the suction control valve actuation target current.


      • Value is large when a high fuel pressure is desired.

      • Value becomes stuck at 1800 mA or more or operation is poor (poor movement due to deposits, etc.).

      • When this deviates from the standard value, it indicates that for some reason, even though the pump is running hard, the actual fuel pressure is inconsistent with the target fuel pressure.

      Results of real-vehicle check:


      • Cranking: 1052 mA

      • Idling: 1156 mA

      • Running without load (2500 rpm): 1287 mA

      • Running without load (4000 rpm): 1217 mA

      • Driving with the accelerator fully open at 2000 rpm: 1140 mA

      • Driving with the accelerator fully open at 3000 rpm: 965 mA

      • Driving with the accelerator fully open at 4500 rpm: 954 mA
      Injection Feedback Val #1 (to #4)
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Injection Feedback Val #1 (to #4)

      • When idling after the engine is warmed up, the fuel quantity of each injector assembly is corrected to make each cylinder engine speed equal.

      • Cylinders more than 2 mm3/st may have a fault.

      Tech Tips

      Read the value after one minute of idling after warm up (engine coolant temperature above 75°C (167°F)). This value is only calculated when idling.

      • Injector assembly clogging

      • Injector assembly deterioration

      • Decrease in cylinder compression

      • Injector compensation code is incorrectly set (forgot to input code after replacement or made mistake during setting of code after replacing ECM with one from another vehicle)

      • With injector assembly faults, other than difficulty starting, there is a possibility of rough idling, lack of power, black smoke, white smoke and knocking.

      • When idling after warm up, the injection amount for each cylinder is corrected to optimize the difference between the engine speed of each cylinder. Example: For cylinders that are slowing the engine speed compared to other cylinders, the injection volume is increased.

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector assembly breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.
      Injection Volume
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Injection Volume - - If injector assemblies are clogged, fuel quality is poor, the fuel filter is clogged, or engine friction increases, then "Injection Volume" will increase.

      Results of real-vehicle check:


      • Cranking: 19.58 mm3/st

      • Idling (warm up the engine): 4.19 mm3/st (at "Actual EGR Valve Pos." = 0.3%)

      • Idling (warm up the engine): 4.78 mm3/st (at "Actual EGR Valve Pos." = 65.4%)

      • Running without load (2500 rpm): 4.58 mm3/st

      • Running without load (4000 rpm): 5.99 mm3/st

      • Driving with the accelerator fully open at 2000 rpm: 31.28 mm3/st

      • Driving with the accelerator fully open at 3000 rpm: 45.48 mm3/st

      • Driving with the accelerator fully open at 4500 rpm: 31.67 mm3/st

    3. Diesel Throttle

      Actual Throttle Position
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Actual Throttle Position

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

      • With the diesel throttle stuck almost fully closed, there is a possibility of rough idling, engine stall, black smoke, difficulty starting and lack of power.

      		 Diesel throttle body assembly

      Closing percentage of the throttle valve.


      • Fully closed: 100%

      • Fully open: 0%

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

      Results of real-vehicle check:


      • Ignition switch ON: -1%

      • Cranking: 0%

      • Idling (warm up the engine): 74%

      • Running without load (2500 rpm): 13%

      • Running without load (4000 rpm): -1%

      • Driving with the accelerator fully open at 2000 rpm: -1%

      • Driving with the accelerator fully open at 4500 rpm: 0%

      • Soon after engine running to ignition switch off: 0% → 99% → 0%
      Throttle Motor Duty
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Throttle Motor Duty - - When the value of the Throttle Motor Duty increases, the moving force to open and close the diesel throttle valve increases.

      Results of real-vehicle check:


      • Cranking: 14.9%

      • Idling (warm up the engine): 13.7%

      • Running without load (2500 rpm): 12.9%

      • Running without load (4000 rpm): 10.5%

      • Driving with the accelerator fully open at 2000 rpm: 13.7%

      • Driving with the accelerator fully open at 3000 rpm: 12.9%

    4. Diesel EGR

      Target EGR Position
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Target EGR Position - -

      • Fully open: 100%

      • Fully closed: 0%

      • Used for comparison to "Actual EGR Valve Pos".

      Tech Tips

      If the time of engine idling is long (approximately 20 minutes or more), EGR will be cut off. At this time, if the vehicle is driven in 4th gear between 90 and 100 km/h (56 and 62 mph) for 30 minutes, EGR resumes.

      Results of real-vehicle check:


      • Ignition switch ON: 0%

      • Cranking: 0%

      • Idling with EGR off (warm up the engine): 0.3%

      • Idling with EGR on (warm up the engine): 65.4%

      • Running without load (2500 rpm): 61.5%

      • Running without load (4000 rpm): 0%

      • Driving with the accelerator fully open at 2000 rpm: 0%

      • Driving with the accelerator fully open at 3000 rpm: 0%

      • Driving with the accelerator fully open at 4500 rpm: 0%
      Actual EGR Valve Pos.
      Data List Judgment of Data List Values Faulty Component Diagnosis Note
      Actual EGR Valve Pos.

      • Generally Actual EGR Valve Pos. = Target EGR Position (Fully closed = 0%, Fully open = 100%)

      • The EGR valve Active Test can be used to check whether the Actual EGR Valve Pos. = Target EGR Position

      		 Electric EGR control valve assembly

      • Fully open: 100%

      • Fully closed: 0%

      • Inspect while comparing to "Target EGR Position".

      • Check the valve movement via the Active Test.

      • Sometimes the malfunction only occurs around a certain temperature, so refer to the engine coolant temperature and outside temperature at the time the malfunction occurred.

      Tech Tips

      If the time of engine idling is long (approximately 20 minutes or more), EGR will be cut off. At this time, if the vehicle is driven in 4th gear between 90 and 100 km/h (56 and 62 mph) for 30 minutes, EGR resumes.

      Results of real-vehicle check:


      • Ignition switch ON: 0%

      • Cranking: 0%

      • Idling with EGR off (warm up the engine): 0%

      • Idling with EGR on (warm up the engine): 65.4%

      • Running without load (2500 rpm): 61.9%

      • Running without load (4000 rpm): 0%

      • Driving with the accelerator fully open at 2000 rpm: 0.3%

      • Driving with the accelerator fully open at 3000 rpm: 0.3%

      • Driving with the accelerator fully open at 4500 rpm: 0%

  3. Actual Examples of Malfunction

    Tech Tips


    • The purpose of the following examples is help to you understand the relationship between each Data List item when a certain malfunction occurs. Understanding this relationship helps you find the root cause easier.

    • The following are examples of actual malfunctions of a common rail diesel engine.

    • Use them for reference when diagnosing malfunctions.

    • These are not data of YARIS 1ND-TV.


    1. Supply pump malfunction (suction control valve momentarily sticking)

      A01VEMVE11

    2. Injector assemblies sticking

      A01VI7CE01

WIRING DIAGRAM

Refer to DTC P1228 Click here.

CAUTION / NOTICE / HINT

Note


  • 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.

  • When replacing the ECM and/or injector assembly, the ECM needs Registration and Initialization Click here.

Tech Tips

Before troubleshooting, conduct the following:


  • (a) Check the fuel quality.

  • (b) Check the fuel line for air.

  • (c) Check the fuel system for blockages.

  • (d) Check the air filter.

  • (e) Check the engine oil.

  • (f) Check the engine coolant.

  • (g) Check the engine idling speed and maximum engine speed.

  • (h) Check the vacuum pump.

PROCEDURE


  1. CHECK MALFUNCTION CONDITION


    1. Identify when shuddering occurs.

      Result
      Result Proceed to
      When idling A
      When engaging engine clutch at vehicle start

      B

      (Clutch system shudders)

    B

    REPAIR OR REPLACE CLUTCH SYSTEM

    A

  2. CHECK HARNESS AND CONNECTOR (IN ENGINE ROOM)


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

      OK
      The wire harnesses and connectors are connected securely.

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. READ OUTPUT DTC (RELATING TO ENGINE)


    1. Connect the intelligent tester to the DLC3.

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

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

    4. Read pending DTCs.

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

      Tech Tips

      If DTC P1605 is output, proceed to step 4.


    B

    GO TO DTC CHART Click here

    A

  4. TAKE SNAPSHOT DURING IDLING AND 3000 RPM


    1. A01VE2ME29
      Text in Illustration
      *1 Snapshot Button
      *a Reference

      Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up until the engine coolant temperature sensor reaches 75°C (167°F) or more.

      Tech Tips

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

    3. Turn the tester on.

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

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

      Tech Tips


      • 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.

      • Detailed graphs can be displayed by transferring the stored snapshot data from the tester to a PC (personal computer) with Intelligent Viewer installed.

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

      A01VFZ8E03
      A01VE8RE05
      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
      Target Pump SCV Current 1164 mA
      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
      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

    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.

      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 AND REPLACE FUEL INLET LINE Click 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.

    NG

    PERFORM REGISTRATION AND INITIALIZATION Click here

    OK

  8. CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 to #4)


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

      Tech Tips

      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

      Tech Tips


      • *1: When case "B" 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 all of the Injector 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 enters into the engine. Therefore, you should compare the Target EGR Position with the Actual EGR Valve Pos. by entering the following menus using the intelligent tester: 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 have a malfunction.


    B

    REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS Click here

    C

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER #1 TO #4 FUEL CUT) Click here

    A

  9. CHECK TEMPERATURE WHEN ROUGH IDLING TROUBLE OCCURS


    1. Check the temperature when rough idling trouble occurs.

      Result
      Result Proceed to
      Rough idling only for cold engine A
      Rough idling both for cold and warmed up engine B

    B

    INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY Click here

    A

  10. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.

      Tech Tips

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


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  11. CHECK PRE-HEATING CONTROL CIRCUIT


    1. Check the pre-heating control circuit Click here.


    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  12. 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 intelligent tester to the DLC3.

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

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

    6. When changing the Active Test value from 0 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 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 then from the side indicated by the arrow in the illustration, visually check that there is no clearance between the valve and body.

      A01VGZDE06
      Text in Illustration
      *1 Electric EGR Control Valve - -
      *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 a clearance between the valve and body), replace the electric EGR control valve assembly.

      Tech Tips

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

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

    10. Remove the deposits from those 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 the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.

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

      Tech Tips


      • 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.


    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY Click here

    OK

  13. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (DIESEL THROTTLE TARGET ANGLE)


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Diesel Throttle Target Angle.

    4. When continuously changing the Active Test value to 0, 30, 60, 90, 60, 30 and 0%, check that Actual Throttle Position smoothly changes to the set opening angle.

      OK
      Value smoothly changes to the set opening angle.

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY Click here

    OK

  14. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the malfunction has been successfully repaired.

      OK
      Malfunction has been repaired successfully.

    OK

    CHECK FOR INTERMITTENT PROBLEMS Click here

    NG

  15. 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.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  16. CHECK ENGINE MOUNTING INSULATOR


    1. Visually check that the engine mounting insulator is installed correctly and is not crooked or twisted.

      OK
      No abnormalities.

    NG

    REPAIR OR REPLACE ENGINE MOUNTING INSULATOR

    OK

  17. 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.


    NEXT

  18. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

  19. CHECK AND REPLACE FUEL INLET LINE


    1. Check the following items, and repair or replace the malfunctioning part if necessary.


      1. Check for fuel filter clogging.

      2. Check for fuel freezing in the fuel line.

      3. Check for clogging or leaks in the fuel pipe and hose between the fuel tank and fuel supply pump assembly.


    NEXT

  20. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  21. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel Press and Target Common Rail Pressure.

    5. Check that the fuel pressure of the common rail is within the specification below.

      Standard
      Fuel Press is within +/-10000 kPa of Target Common Rail Pressure when engine is idling and running at 3000 rpm without load.

    OK

    END

    NG

    REPLACE SUPPLY PUMP ASSEMBLY Click here

  22. 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
      B67-2 - B21-12 (PCV) Always Below 1 Ω
      B67-2 or B21-12 (PCV) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  23. 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.

      Tech Tips


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

      • Inspect for fuel filter clogging.

        (Check that the fuel filter is not clogged)


    NG

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

    OK

  24. REPLACE SUPPLY PUMP ASSEMBLY


    1. Replace the supply pump assembly Click here.


    NEXT

  25. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  26. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel Press and Target Common Rail Pressure.

    5. Check that the fuel pressure of the common rail is within the specification below.

      Standard
      Fuel Press is within +/-10000 kPa of Target Common Rail Pressure when engine is idling and running at 3000 rpm without load.

    NG

    REPLACE COMMON RAIL ASSEMBLY Click here

    OK

  27. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

  28. REPLACE COMMON RAIL ASSEMBLY


    1. Replace the common rail assembly Click here.


    NEXT

  29. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  30. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel Press and Target Common Rail Pressure.

    5. Check that the fuel pressure of the common rail is within the specification below.

      Standard
      Fuel Press is within +/-10000 kPa of Target Common Rail Pressure when engine is idling and running at 3000 rpm without load.

    NEXT

    END

  31. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER #1 TO #4 FUEL CUT)

    Tech Tips

    Use this Active Test to determine the malfunctioning cylinder.


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Cylinder #1 to #4 Fuel Cut.

      Tech Tips


      • 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.


    NEXT

  32. READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED OF CYL #1 TO #4)

    Tech Tips

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

    In the compression test, perform Active Test using intelligent tester (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 intelligent tester to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / 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.

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

      Tech Tips

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

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

      Tech Tips

      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 tester.

      Tech Tips

      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 the recorded data and display the data as a graph.

    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

      Tech Tips

      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 CYLINDER Click here

    A

  33. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER


    1. Check cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  34. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    1. Replace the injector assembly Click here.


    NEXT

  35. PERFORM REGISTRATION AND INITIALIZATION


    1. Register the injector compensation code Click here.

    2. Perform Pilot Quantity Learning Values Reset Click here.


    NEXT

  36. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  37. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

  38. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS


    1. Replace the injector assemblies Click here.


    NEXT

  39. PERFORM REGISTRATION AND INITIALIZATION


    1. Register the injector compensation code Click here.

    2. Perform Pilot Quantity Learning Values Reset Click here.


    NEXT

  40. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  41. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

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


    1. Check and replace the clogged fuel pipe.


    NEXT

  43. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  44. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

  45. PERFORM REGISTRATION AND INITIALIZATION


    1. Register the injector compensation code Click here.

    2. Perform Pilot Quantity Learning Values Reset Click here.


    NEXT

  46. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END