ECD SYSTEM Engine Difficult to Start or Stalling

INSPECTION PROCEDURE

Note


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

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

Tech Tips


  • 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's age. Do not assume the vehicle is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

  • If the vehicle runs out of fuel while the engine is operating, there is a chance that the engine may be difficult to restart after fuel is refilled.

PROCEDURE


  1. CHECK OUTPUT DTC (RELATED TO ENGINE)


    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. Turn the ignition switch to the ON position and turn the intelligent tester on.

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

    5. Read the DTCs.

      Result
      Display (DTC Output) Proceed to
      No output A
      DTCs related to engine B

    B

    GO TO DTC CHART

    A

  2. CHECK FUEL FILTER ASSEMBLY


    1. Check that the fuel filter is not clogged.

      OK
      Fuel filter is not clogged.

    NG

    REPLACE FUEL FILTER ASSEMBLY

    OK

  3. CHECK ENGINE CRANKING CONDITION


    1. Check the engine cranking condition.

    2. Compare the cranking condition with that of a normal engine of the same model, and carefully check if there is any difference between them.

      OK
      Engine cranking condition is normal.

    NG

    CHECK AND REPLACE BATTERY, CHARGING SYSTEM, STARTER ASSEMBLY AND STARTING SYSTEM

    OK

  4. READ VALUE USING FUEL PRESSURE SENSOR


    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. Turn the ignition switch to the ON position.

    4. Turn the tester on.

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

    6. Read the value.

      Standard
      Item Inspection Condition Reference Value
      Fuel Press Cranking, and engine coolant temperature 0°C (32°F) or more 20 to 55 MPa

    NG

    BLEED AIR FROM FUEL SYSTEM

    OK

  5. CHECK IF INITIAL COMBUSTION OCCURS


    1. Check if initial combustion occurs.

      Result
      Result Proceed to
      No initial combustion A
      Initial combustion occurs B

    B

    CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM Click here

    A

  6. READ VALUE USING FUEL PRESSURE SENSOR


    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

    CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP Click here

    OK

  7. CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM


    1. Inspect the engine condition Click here.


    NG

    REPAIR OR REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST

    OK

  8. INSPECT EXHAUST RETARDER ASSEMBLY


    1. Inspect exhaust retarder assembly.


    NG

    REPLACE EXHAUST RETARDER ASSEMBLY

    OK

  9. READ VALUE USING FUEL PRESSURE SENSOR AND INJECTOR


    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.

    6. Select the following menu items in order and read the values.


      • Fuel Press

      • Injection Volume

      Standard
      Item Engine Speed * Reference Value
      Fuel Press Idling 25 to 35 MPa
      Fuel Press 2,000 rpm (No engine load) 80 to 90 MPa
      Fuel Press 3,000 rpm (No engine load) 80 to 90 MPa
      Injection Volume Idling

      5 to 15 mm3

      Injection Volume 2,000 rpm (No engine load)

      10 to 20 mm3

      Injection Volume 3,000 rpm (No engine load)

      10 to 20 mm3

      Tech Tips

      *: If no idling conditions are specified, the shift lever should be in the neutral position, and the A/C switch and all accessory switches should be OFF.


    NG

    CHECK TERMINAL VOLTAGE (NE+ AND NE- TERMINALS) Click here

    OK

  10. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  11. CHECK HARNESS AND CONNECTOR (INJECTOR - EDU)


    1. A01CGNSE01

      Check the wire harness between the injector and injector driver (INJ terminal).


      1. Disconnect the injector connectors.

      2. Disconnect the EDU connector.

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

        Standard resistance
        Check for open
        Tester Connection Condition Specified Condition
        I2-2 - E26-4 (INJ#1) Always Below 1 Ω
        I3-2 - E26-2 (INJ#2) Always Below 1 Ω
        I4-2 - E26-1 (INJ#3) Always Below 1 Ω
        I5-2 - E26-3 (INJ#4) Always Below 1 Ω
        I2-1 - E26-5 (COM1) Always Below 1 Ω
        I3-1 - E26-6 (COM2) Always Below 1 Ω
        I4-1 - E26-6 (COM2) Always Below 1 Ω
        I5-1 - E26-5 (COM1) Always Below 1 Ω
        Check for short
        Tester Connection Condition Specified Condition
        I2-2 or E26-4 (INJ#1) - Body ground Always 10 kΩ or higher
        I3-2 or E26-2 (INJ#2) - Body ground Always 10 kΩ or higher
        I4-2 or E26-1 (INJ#3) - Body ground Always 10 kΩ or higher
        I5-2 or E26-3 (INJ#4) - Body ground Always 10 kΩ or higher
        I2-1 or E26-5 (COM1) - Body ground Always 10 kΩ or higher
        I3-1 or E26-6 (COM2) - Body ground Always 10 kΩ or higher
        I4-1 or E26-6 (COM2) - Body ground Always 10 kΩ or higher
        I5-1 or E26-5 (COM1) - Body ground Always 10 kΩ or higher

      4. Reconnect the injector connectors.

      5. Reconnect the EDU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (INJECTOR - EDU)

    OK

  12. INSPECT INJECTOR ASSEMBLY


    1. Start the engine.

    2. Disconnect the connectors for the No. 1 through No. 4 injectors in this order.

    3. Check the engine idling condition during the fuel injection of each cylinder.

      Result
      Engine Idling Condition Proceed to
      Becomes unstable A
      Does not change B

      Tech Tips

      Replace the injector mounted on the cylinder that causes no significant idle speed change.

    4. Clear the DTCs Click here.


    B

    REPLACE INJECTOR ASSEMBLY

    A

    REPLACE INJECTOR DRIVER ASSEMBLY

  13. CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP


    1. Disconnect the inlet hose from the supply pump.

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

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

    NG

    CHECK AND REPLACE FUEL PIPE CLOGGING (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP)

    OK

    REPLACE SUPPLY PUMP ASSEMBLY

  14. CHECK ECM TERMINAL VOLTAGE (THW TERMINAL)


    1. A01CGXCE05

      Start the engine.

    2. Measure the voltage of the ECM connector.

      Standard voltage
      Tester Connection Condition Specified Condition
      E22-19 (THW) - E22-28 (E2) Idling, engine coolant temperature between 60 and 120°C (140 and 248°F) 0.2 to 1.0 V

    NG

    INSPECT CRANKSHAFT POSITION SENSOR Click here

    OK

  15. CHECK TERMINAL VOLTAGE (NE+ AND NE- TERMINALS)


    1. A01CI68E01

      While idling the engine, check the waveform between the specified terminals of the ECM connector using an oscilloscope.

      Standard
      Tester Connection Specified Condition
      E22-27 (NE+) - E22-34 (NE-) Correct waveform appears as shown
      Tool Setting 5 V/DIV., 20 msec./DIV.
      Condition Idling with warm engine

      Tech Tips

      The waveform varies depending on the engine revolution.


    NG

    INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR) Click here

    OK

  16. CHECK HARNESS AND CONNECTOR (STARTER RELAY - ECM)


    1. A01CIXEE01

      Disconnect the ECM connector.

    2. Disconnect the starter relay connector.

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

      Standard resistance
      Tester Connection Condition Specified Condition
      S8-1 - E23-18 (STA) Always Below 1 Ω
      S8-1 or E23-18 (STA) - Body ground Always 10 kΩ or higher

    4. Reinstall the starter relay.

    5. Reconnect the ECM connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (STARTER RELAY - ECM)

    OK

  17. CHECK ECM TERMINAL VOLTAGE (PCR1 TERMINAL)


    1. A01CGXCE06

      Start the engine.

    2. Measure the voltage according to the value(s) in the table below.

      Standard voltage
      Tester Connection Condition Specified Condition
      E22-26 (PCR1) - E22-28 (E2) Idling 1.7 to 2.2 V

    NG

    CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM) Click here

    OK

    REPLACE ECM

  18. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. A01CHW0E02

      Remove the engine coolant temperature sensor.

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

      Standard resistance
      Tester Connection Condition Specified Condition
      W5-1 - W5-2 20°C (68°F) 2.32 to 2.59 kΩ
      W5-1 - W5-2 80°C (176°F) 0.31 to 0.326 kΩ
      W5-3 - Body ground 75°C (167°F) 79 to 93 Ω
      W5-3 - Body ground 100°C (212°F) 35.5 to 41.5 Ω

      Note

      When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry.

      Tech Tips

      Alternative procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values against the resistance/ temperature graph. Change the engine temperature (warm up or cool down) and repeat the test.

    3. Reinstall the engine coolant temperature sensor.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - ENGINE COOLANT TEMPERATURE SENSOR)

  19. INSPECT CRANKSHAFT POSITION SENSOR


    1. A01CGNOE30

      Disconnect the crankshaft position sensor connector.

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

      Standard resistance
      Tester Connection Condition Specified Condition
      C3-1 - C3-2 Cold 1,630 to 2,740 Ω
      C3-1 - C3-2 Hot 2,065 to 3,225 Ω

      Note

      In the table above, the terms "cold" and "hot" refer to the temperature of the coils in the sensors. "Cold" means approximately -10° to 50°C (14° to 122°F). "Hot" means approximately 50° to 100°C (122° to 212°F).

    3. Reconnect the crankshaft position sensor.


    NG

    REPLACE CRANKSHAFT POSITION SENSOR

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - CRANKSHAFT POSITION SENSOR)

  20. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. A01CJCNE01

      Disconnect the fuel pressure sensor connector.

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

      Standard resistance
      Tester Connection Specified Condition
      F8-5 (PFUEL) - F8-4 (A-GND) 16.4 kΩ or less
      F8-2 (PFUEL) - F8-3 (A-GND) 16.4 kΩ or less
      F8-6 (A-VCC) - F8-5 (PFUEL) 3 kΩ or less
      F8-1 (A-VCC) - F8-2 (PFUEL) 3 kΩ or less

    3. Reconnect the fuel pressure sensor connector.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

  21. CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)


    1. A01CGR7E01

      Disconnect the ECM connector.

    2. Disconnect the fuel pressure sensor connector.

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

      Standard resistance
      Check for open
      Tester Connection Condition Specified Condition
      E22-26 (PCR1) - F8-5 (PFUEL) Always Below 1 Ω
      E22-33 (PCR2) - F8-2 (PFUEL) Always Below 1 Ω
      E22-18 (VC) - F8-6 (A-VCC) Always Below 1 Ω
      E22-18 (VC) - F8-1 (A-VCC) Always Below 1 Ω
      E22-28 (E2) - F8-4 (A-GND) Always Below 1 Ω
      E22-28 (E2) - F8-3 (A-GND) Always Below 1 Ω
      Check for short
      Tester Connection Condition Specified Condition
      E22-26 (PCR1) or F8-5 (PFUEL) - Body ground Always 10 kΩ or higher
      E22-33 (PCR2) or F8-2 (PFUEL) - Body ground Always 10 kΩ or higher
      E22-18 (VC) or F8-6 (A-VCC) - Body ground Always 10 kΩ or higher
      E22-18 (VC) or F8-1 (A-VCC) - Body ground Always 10 kΩ or higher
      E22-28 (E2) or F8-4 (A-GND) - Body ground Always 10 kΩ or higher
      E22-28 (E2) or F8-3 (A-GND) - Body ground Always 10 kΩ or higher

    4. Reconnect the ECM connectors.

    5. Reconnect the fuel pressure sensor connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (FUEL PRESSURE SENSOR - ECM)

    OK

  22. REPLACE ECM


    1. Replace the ECM. Click here

      Note

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

    2. Check if the engine starts smoothly or if the engine stalls.

      OK
      The engine starts smoothly and does not stall.

    NG

    REPLACE SUPPLY PUMP ASSEMBLY

    OK

    END