ECD SYSTEM Clogging by DPF Catalytic Converter

DESCRIPTION

The differential pressure sensor is mounted on the exhaust pipe. It measures the pressure before and after the DPF catalytic converter (monolithic converter assembly), converts the difference in pressure into a voltage signal, and outputs it to the ECM. Based on this signal, the ECM determines whether the DPF catalytic converter is clogged. If the DPF catalytic converter is clogged, the ECM activates the forcible regeneration function of the DPF catalytic converter. In some cases, the forcible regeneration function may not be conducted depending on the driving conditions. In such cases, the indicator light in the combination meter and the DPF switch light blink to inform the driver that the converter is clogged. When the driver presses the DPF switch, the forcible regeneration function signal (RGSW) is transmitted to the ECM, and the forcible regeneration function starts. If the vehicle is driven continuously without performing the forcible regeneration function when the indicator lights are blinking, PM (Particulate Matter) accumulates and DTC P2002 is set. If the forcible regeneration function is activated when the amount of PM accumulation is too high, the temperature in the DPF catalytic converter rises beyond normal operating conditions, (it may reach 800°C (1,472°F) or higher), and the DPF catalytic converter may melt down. Therefore, if the forcible regeneration function is activated with DTC P2002 set, the differential pressure when the engine is running at near the maximum no-load speed (3550 r/m) must be checked. If the pressure exceeds the threshold, the DPF catalytic converter must be cleaned.

A01CI7GE01
Engine Speed Standard Differential Pressure MAF
3,500 to 3,600 rpm 15 kPa or less 100 to 110 g/s

INSPECTION PROCEDURE

Note


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

  • After replacing the supply pump, the ECM needs initialization Click here.

  • After replacing the injector, the ECM needs registration Click here.

PROCEDURE


  1. PERFORM ENGINE RPM ACCELERATION


    1. Warm up the engine.

    2. Disconnect the negative battery terminal and wait for at least 1 minute.

    3. Reconnect the negative battery terminal.

    4. Initialize the learning value of the supply pump Click here.

      Tech Tips

      Perform initialization with the engine warmed up (engine coolant temperature is 60°C (140°F) or more and fuel temperature is 20°C (68°F) or more).

    5. Initialize the learning value of the diesel throttle body Click here.

    6. Accelerate the engine speed to the maximum rpm with no load 20 times.

    7. Check the volume of black smoke in the exhaust gas.

      Tech Tips


      • If DTC P2002 is stored, the engine speed cannot be raised to the high-speed range because the engine output limiting control is performed.

      • If DTC P2002 is stored, be sure to clear the DTCs.

      Result
      Result Proceed to
      Black smoke remains in the exhaust gas A
      Black smoke is not present B

    B

    READ VALUE USING INTELLIGENT TESTER (DIFFERENTIAL PRESSURE) Click here

    A

  2. CHECK AIR FILTER ELEMENT


    1. Inspect the air filter element.


    NG

    REPAIR OR CLEAN AIR FILTER ELEMENT

    OK

  3. CHECK INTAKE SYSTEM


    1. Check for air leakage from the intake system and check that the intake system is installed properly.


    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    OK

  4. CHECK FUEL FILTER ASSEMBLY


    1. Inspect the fuel filter assembly Click here.


    NG

    REPLACE FUEL FILTER ASSEMBLY

    OK

  5. READ VALUE USING INTELLIGENT TESTER (FUEL PRESSURE)


    1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

      Note

      Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

    2. Connect the intelligent tester to the DLC3.

    3. Start the engine.

    4. Turn the tester on.

    5. Enter the following menu items: Powertrain / Engine and ECT / Data List / Fuel Press.

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

      Standard
      Engine Speed Fuel Pressure
      Idling Approximately 25 to 35 MPa
      3,000 rpm (No engine load) Approximately 80 to 90 MPa

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    OK

  6. INSPECT FOR ENGINE OIL LEAK


    1. Check that the intake system pipes and hoses are not excessively contaminated with oil.


    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    OK

  7. CHECK CONNECTION OF VACUUM HOSE (DIFFERENTIAL PRESSURE SENSOR - CATALYST CONVERTER)


    1. Check if the vacuum hose routing between the differential pressure sensor and the catalyst converter is correct.

    2. Check that there is no exhaust gas leakage between the differential pressure sensor and the catalyst converter.


    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    OK

  8. READ VALUE USING INTELLIGENT TESTER (DIFFERENTIAL PRESSURE)


    1. Warm up the engine.

    2. Disconnect the negative battery terminal and wait for at least 1 minute.

    3. Reconnect the negative battery terminal.

    4. Initialize the learning value of the supply pump Click here.

      Tech Tips

      Perform initialization with the engine warmed up (engine coolant temperature is 60°C (140°F) or more and fuel temperature is 20°C (68°F) or more).

    5. Initialize the learning value of the diesel throttle body Click here.

    6. Allow the engine to idle for at least 5 minutes.

    7. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

      Note

      Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

    8. Connect the intelligent tester to the DLC3.

    9. Turn the ignition switch to the ON position.

    10. Turn the tester on.

    11. Enter the following menu items: Powertrain / Engine and ECT / Data List / DPNR Differential Pressure.

      Tech Tips


      • If the exhaust gas temperature is high, the differential pressure cannot be measured correctly.

      • If the differential pressure is outside the normal range, the monolithic converter assembly may have deteriorated or the monolithic converter assembly may be clogged with PM.

      • Fully depress the accelerator pedal and when the engine speed becomes stable, promptly read the differential pressure.

      • If DTC P2002 is stored, the engine speed cannot be raised to the high-speed range because the engine output limiting control is performed.

      • If DTC P2002 is stored, be sure to clear the DTCs.

      Result
      Engine Speed (no engine load) Differential Pressure Proceed to
      3,500 to 3,600 rpm (Exhaust gas temperature (up stream) is 200°C or less) 30 kPa or more A
      3,500 to 3,600 rpm (Exhaust gas temperature (up stream) is 200°C or less) 30 kPa or less B

    B

    CLEAN EXHAUST SYSTEM Click here

    A

  9. READ VALUE USING INTELLIGENT TESTER (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION FUNCTION)


    1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

      Note

      Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

    2. Connect the intelligent tester to the DLC3.

    3. Start the engine.

    4. Turn the tester on.

    5. Perform the forcible regeneration function Click here.

    6. Enter the following menu items: Powertrain / Engine and ECT / Data List.

    7. Select the following menu items, and read the value every minute during the forcible regeneration function.


      • Initial Exhaust Temp (In)

      • Initial Exhaust Temp (Out)

      • Engine Speed

        Result
        Initial Exhaust Temp (OUT) Proceed to
        800°C (1,472°F) or less A
        800°C (1,472°F) or more B

      Note

      If Initial Exhaust Temp (Out) exceeds 800°C (1,472°F), cease the forcible regeneration function immediately.


    B

    CLEAN EXHAUST SYSTEM Click here

    A

  10. READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED DURING FORCIBLE REGENERATION FUNCTION)


    1. Read the engine speed during the forcible regeneration function.

      Standard
      Condition Engine Speed
      During forcible regeneration function 1,200 rpm or more

    NG

    READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME) Click here

    OK

  11. READ VALUE USING INTELLIGENT TESTER (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION FUNCTION)


    1. Read the exhaust gas temperature after at least 5 minutes have elapsed since the forcible regeneration function was started.

      Standard
      Condition Initial Exhaust Temp (IN)
      During forcible regeneration function 220°C (428°F) or more

    NG

    READ VALUE USING INTELLIGENT TESTER (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION FUNCTION) Click here

    OK

  12. READ VALUE USING INTELLIGENT TESTER (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION FUNCTION)


    1. Read the exhaust gas temperature just before the forcible regeneration function is completed.

      Standard
      Condition Initial Exhaust Temp (IN)
      During forcible regeneration function 480°C (896°F) or more

    NG

    READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME DURING FORCIBLE REGENERATION FUNCTION) Click here

    OK

  13. READ VALUE USING INTELLIGENT TESTER (DIFFERENTIAL PRESSURE)


    1. After the forcible regeneration is completed, allow the engine to idle for at least 5 minutes.

    2. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

      Note

      Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

    3. Connect the intelligent tester to the DLC3.

    4. Turn the ignition switch to the ON position.

    5. Turn the tester on.

    6. Enter the following menu items: Powertrain / Engine and ECT / Data List / DPNR Differential Pressure.

    7. Check the differential pressure when the exhaust gas temperature sensor indicates 200°C or less.

      Tech Tips


      • If the exhaust gas temperature is high, the differential pressure cannot be measured correctly.

      • If the differential pressure is outside the normal range, the monolithic converter assembly may have deteriorated or the monolithic converter assembly may be clogged with PM.

      • Fully depress the accelerator pedal and when the engine speed becomes stable, promptly read the differential pressure.

      Standard
      Engine Speed (no engine load) Differential Pressure
      3,500 to 3,600 rpm 15 kPa or less

    NG

    REPLACE MONOLITHIC CONVERTER ASSEMBLY

    OK

  14. INSPECT ENGINE OIL LEVEL


    1. Inspect the engine oil level.


    NG

    REPLACE ENGINE OIL

    OK

    END

  15. CLEAN EXHAUST SYSTEM


    1. Clean the catalytic converter and monolithic converter Click here.


    NEXT

  16. READ VALUE USING INTELLIGENT TESTER (DIFFERENTIAL PRESSURE)


    1. Allow the engine to idle for at least 5 minutes.

    2. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

      Note

      Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

    3. Connect the intelligent tester to the DLC3.

    4. Turn the ignition switch to the ON position.

    5. Turn the tester on.

    6. Enter the following menu items: Powertrain / Engine and ECT / Data List / DPNR Differential Pressure.

    7. Read the value.

      Tech Tips


      • If the exhaust gas temperature is high, the differential pressure cannot be measured correctly.

      • If the differential pressure is outside the normal range, the monolithic converter assembly may have deteriorated or the monolithic converter assembly may be clogged with PM.

      • Fully depress the accelerator pedal and when the engine speed becomes stable, promptly read the differential pressure.

      Result
      Engine Speed (no engine load) Differential Pressure Proceed to
      3,500 to 3,600 rpm (Exhaust gas temperature (up stream) is 200°C or less) 30 kPa or more A
      3,500 to 3,600 rpm (Exhaust gas temperature (up stream) is 200°C or less) 30 kPa or less B

    B

    READ VALUE USING INTELLIGENT TESTER (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION FUNCTION) Click here

    A

    REPLACE MONOLITHIC CONVERTER ASSEMBLY

  17. READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME)


    1. Cease the forcible regeneration function.

    2. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

      Note

      Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

    3. Connect the intelligent tester to the DLC3.

    4. Start the engine.

    5. Turn the tester on.

    6. Enter the following menu items: Powertrain / Engine and ECT / Data List / Injection Volume.

    7. Read the value.

      Standard
      Condition Injection Volume
      Idling

      5.0 to 15 mm3


    NG

    ADJUST EXHAUST RETARDER ASSEMBLY Click here

    OK

  18. REPLACE INJECTOR ASSEMBLY


    1. Replace the injector assembly Click here.


    NEXT

    PERFORM DPF FORCIBLE REGENERATION PROCEDURE

  19. ADJUST EXHAUST RETARDER ASSEMBLY


    1. A01CGN3E02

      Adjust the clearance of the exhaust retarder assembly (widen the clearance).


    NEXT

    PERFORM DPF FORCIBLE REGENERATION PROCEDURE

  20. READ VALUE USING INTELLIGENT TESTER (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION FUNCTION)


    1. Read the exhaust gas temperature during the forcible regeneration function.

      Standard
      Condition Initial Exhaust Temp (OUT)
      During forcible regeneration function 220°C (428°F) or more

    NG

    READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME DURING FORCIBLE REGENERATION FUNCTION) Click here

    OK

    REPLACE EXHAUST TEMPERATURE SENSOR (DOWN STREAM)

  21. READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME DURING FORCIBLE REGENERATION FUNCTION)


    1. Read the injection volume during the forcible regeneration function.

      Standard
      Condition Injection Volume
      During forcible regeneration function

      18 to 24 mm3


    NG

    ADJUST EXHAUST RETARDER ASSEMBLY Click here

    OK

  22. CHECK FOR EXHAUST GAS LEAK


    1. Check the exhaust gas leak.


    NEXT

    PERFORM DPF FORCIBLE REGENERATION PROCEDURE

  23. ADJUST EXHAUST RETARDER ASSEMBLY


    1. A01CGN3E02

      Adjust the clearance of the exhaust retarder assembly (widen the clearance).


    NEXT

    PERFORM DPF FORCIBLE REGENERATION PROCEDURE

  24. READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME DURING FORCIBLE REGENERATION FUNCTION)


    1. Read the injection volume during the forcible regeneration function.

      Standard
      Condition Injection Volume
      During forcible regeneration function

      18 to 24mm3


    NG

    ADJUST EXHAUST RETARDER ASSEMBLY Click here

    OK

  25. READ VALUE USING INTELLIGENT TESTER (FUEL PRESSURE)


    1. Cease the forcible regeneration function.

    2. Connect the intelligent tester to the DLC3.

    3. Start the engine.

    4. Turn the tester on.

    5. Enter the following menu items: Powertrain / Engine and ECT / Data List / Fuel Press.

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

      Standard
      Engine Speed Fuel Pressure
      Idling Approximately 25 to 35 MPa
      3,000 rpm (No engine load) Approximately 80 to 90 MPa

    NG

    REPAIR OR REPLACE FUEL SYSTEM

    OK

  26. INSPECT INJECTION OR SUPPLY PUMP ASSEMBLY


    1. Inspect the injection or supply pump assembly Click here.


    OK

    CLEAN EXHAUST SYSTEM Click here

    NG

    REPLACE INJECTION OR SUPPLY PUMP ASSEMBLY

  27. ADJUST EXHAUST RETARDER ASSEMBLY


    1. A01CGN3E02

      Adjust the clearance of the exhaust retarder assembly (widen the clearance).


    NEXT

    PERFORM DPF FORCIBLE REGENERATION PROCEDURE