ECD SYSTEM Rough Idling or Excessive Engine Vibrations

DESCRIPTION

Malfunction Condition Main Trouble Areas Related Trouble Areas

  • Rough idling or shuddering due to abnormal combustion

  • Shuddering when vehicle starting due to clutch system malfunctions

  1. Injector malfunctions


    • Injector sliding malfunction

    • Injector stuck closed

    • Injector stuck open

    • Deposit in injector

    • Injector circuit malfunction

  2. Clutch system malfunctions


    • Clutch system (shuddering when starting)

  • Injector compensation code

  • Fuel leak

  • Engine mounting insulator

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Throttle valve system

  • Supply pump

  • Pressure limiter

  • Fuel pressure sensor

  • EDU (P0200/97 set simultaneously)

  • 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's 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.

INSPECTION PROCEDURE

Note


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

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

Tech Tips


  • Before troubleshooting, conduct the following:


    1. Check the fuel quality.

    2. Check the fuel 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 the maximum engine speed.

    8. Check the vacuum pump.

PROCEDURE


  1. CHECK HARNESS AND CONNECTOR IN ENGINE COMPARTMENT


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

      Tech Tips

      Check the following components and systems:


      • Sensors

      • Supply pump

      • Common rail

      • Injectors

      • EDU

      • Turbocharger system

      • Intake and exhaust system

      OK
      The wire harnesses and connectors are connected securely.

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  2. PERFORM CONFIRMATION DRIVING PATTERN

    Tech Tips

    Drive the vehicle according to the driving pattern below to allow the ECM to set DTCs relating to malfunctions of the fuel system, EGR system, and throttle valve. If DTCs are set, problem areas can be identified.


    1. Start the engine (Procedure "A").

    2. Stop the engine and wait for at least 10 seconds (Procedure "B").

    3. Perform steps "A" (See procedure "A") and "B" (See procedure "B") described above (to allow the ECM to set pressure discharge valve malfunction DTCs again).

    4. Enter CHECK MODE Click here.

    5. Fully warm up the engine.

    6. Allow the engine to idle for 5 minutes or more.

    7. Drive the vehicle at more than 40 km/h (25 mph) for 1 minute or more (Procedure "C").

    8. Decelerate and stop the vehicle (Procedure "D").

    9. Repeat steps "C" (See procedure "C") and "D" (See procedure "D") 4 times or more.

    10. Stop the engine and wait for at least 10 seconds (Procedure "E").

    11. Repeat steps "C" (See procedure "C") and "D" (See procedure "E") described above (to set DTCs relating to the EGR system and throttle valve).

    12. Drive the vehicle at more than 70 km/h (43 mph) for at least 1 minute (to set DTCs relating to the supply pump).


    NEXT

  3. CHECK OUTPUT DTC (RELATING TO ENGINE)


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

      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. Read pending DTCs.

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

    B

    GO TO DTC CHART

    A

  4. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL LEAK TEST)

    Tech Tips

    By performing this Active Test, the engine speed is maintained at 2,000 rpm and the common rail internal fuel pressure is raised to the maximum operating pressure. As a result, a fuel leak check can be conducted while retaining the high common rail pressure.


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine.

    3. Turn the tester on.

    4. Enter the following menu items: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.

    5. Visually check the supply pump, injector, and fuel line located between the supply pump and common rail for fuel leaks and fuel pressure leaks. Also, perform the same check on the fuel line between the common rail and the injector.

      Tech Tips

      There may be fuel leaks inside the components, such as the supply pump.

      OK
      No fuel leakage.

    NG

    REPAIR OR REPLACE FUEL LEAKAGE PARTS

    OK

  5. READ VALUE USING INTELLIGENT TESTER


    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 and warm it up.

    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.


      • MAP

      • MAF

      • Fuel Press

      Standard
      Item Engine Speed *1 Standard Range Description
      MAP Ignition switch in the ON position (engine stopped) Same as atmospheric pressure Intake manifold internal pressure detected by manifold absolute pressure sensor
      Idling 90 to 105 kPa (675 to 788 mmHg, 26.57 to 31.00 in.Hg)
      3,000 rpm (no engine load) 120 to 140 kPa (803 to 878 mmHg, 31.60 to 34.56 in.Hg)
      MAF Ignition switch in the ON position (engine stopped) 0 g/s Intake air volume detected by mass air flow meter
      Idling 5 to 20 g/s
      3,000 rpm (no engine load) 70 to 90 g/s
      Fuel Pressure Idling 25 to 35 MPa Common rail internal fuel pressure
      2,000 rpm (no engine load) 80 to 90 MPa
      3,000 rpm (no engine load) 80 to 90 MPa
      Result
      Item Result Proceed to
      MAP, MAF and Fuel press Standard range A
      MAP and MAF Outside standard range B
      Only MAP Outside standard range C
      Only MAF Outside standard range D
      Only Fuel Press Outside standard range E

      Tech Tips

      *1: The A/C switch and all accessory switches should be off with a fully-warmed engine.


    B

    CHECK EGR VALVE ASSEMBLY Click here

    C

    GO TO DTC P0105, P0107, AND P0108 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR)

    D

    GO TO DTC P0100, P0102, AND P0103 (RELATED TO MAF METER)

    E

    INSPECT SUPPLY PUMP ASSEMBLY Click here

    A

  6. READ VALUE USING INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)


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


      • Injection Feedback Val #1, #2, #3, and #4

      • Injection Volume

      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.

      Standard
      Item Engine Speed* Standard Range Description
      Injection Feedback Val #1 Idling

      -3.0 to 3.0 mm3

      Value of injector fuel injection volume compensates for differences in combustion condition of cylinders


      • Positive values indicate control which corrects combustion degradation

      • Negative values indicate control which corrects excessive combustion pressure

      • If problems exist, "Injection Feedback Val" may deviate from the -3.0 and 3.0 mm range
      Injection Feedback Val #2 Idling

      -3.0 to 3.0 mm3

      Injection Feedback Val #3 Idling

      -3.0 to 3.0 mm3

      Injection Feedback Val #4 Idling

      -3.0 to 3.0 mm3

      Injection Volume Idling

      5.0 to 15.0 mm3

      Fuel injection volume value controlled by ECU


      • Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure, and EGR volume.

      • If problems exist, "Injection Volume" may be outside the standard range
      Result
      Result Proceed to
      Standard range A
      Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range B

      Tech Tips

      *: The A/C switch and all accessory switches should be off with a fully-warmed engine.


    B

    INSPECT INJECTOR ASSEMBLY Click here

    A

  7. CHECK INJECTOR COMPENSATION CODE


    1. Read the injector compensation code Click here.

      Tech Tips

      If the injector compensation code is not correctly registered, it may cause malfunctions Click here.

    2. Check the injector compensation code.

      OK
      Compensation code of the installed injector is the same as the code registered in the ECM.

    NG

    PERFORM REGISTRATION INJECTOR COMPENSATION CODE

    OK

  8. RESET ECM


    1. Disconnect the cable from the negative (-) battery terminal for at least 2 minutes.

    2. Reconnect the cable to the negative (-) battery terminal.

    3. Check whether the malfunction has been successfully repaired by performing a driving test using the freeze frame data recorded at the time the malfunction occurred.

      OK
      Malfunction has been repaired successfully.

    OK

    CHECK FOR INTERMITTENT PROBLEMS

    NG

  9. 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

  10. CHECK INTAKE SYSTEM


    1. Check for air leaks and blockage between the air cleaner and turbocharger.

    2. Check for air leaks and blockage between the turbocharger and intake manifold.

      OK
      No air leaks or blockage.

    NG

    REPAIR OR REPLACE INTAKE SYSTEM

    OK

  11. INSPECT EXHAUST RETARDER ASSEMBLY


    1. Inspect the exhaust retarder assembly.


    NG

    REPLACE EXHAUST RETARDER ASSEMBLY

    OK

  12. CHECK EGR VALVE ASSEMBLY


    1. Check the EGR valve assembly Click here.


    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    OK

  13. INSPECT DIESEL THROTTLE BODY ASSEMBLY


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menu items: Powertrain / Engine and ECT / Diesel Throttle Angle.

    4. Read the value.

      Standard
      Ignition switch in the ON position
      0%
      Idling (Warmed up engine)
      70%
      Accelerator pedal fully depressed
      0%

    OK

    CHECK CYLINDER COMPRESSION PRESSURE Click here

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

  14. IDENTIFY MALFUNCTIONING CYLINDER INJECTOR


    1. Follow the instructions in the table below according to the check result of the intelligent tester.

      Tech Tips

      This operation is based on the premise that the common rail pressure is normal.

      Standard
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #4 Idling

      -3.0 to 3.0 mm3

      Injection Volume Idling

      5.0 to 15.0 mm3

      Tech Tips

      *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.

      Result
      Injection Feedback Val #1 to #4 Injection volume

      Less than 5.0 mm3

      Between 5.0 and 15.0 mm3(Normal)

      More than 15.0 mm3

      3.0 mm3or more, -3.0 mm3or less

      		 A B B

      Between -3.0 and 3.0 mm3

      		- Normal C*
      Proceed to Inspection Areas Descriptions
      A

      Inspect and repair cylinder injector with revised injection volume of less than -2.0 mm3:


      • Perform power balance inspection and identify malfunctioning cylinder

      • Replace malfunctioning cylinder injector

      		 Abnormal value cylinder injector injects excessively large quantity of fuel
      B

      Identify malfunctioning cylinders by conducting power balance inspection:


      • Perform power balance inspection to identify malfunctioning cylinders

      • Clean malfunctioning cylinder injector, then check and repair it

      Abnormal value cylinder injector injects excessively large quantity of fuel


      • Fuel injection volume too low due to injector nozzle being blocked by deposits

      • Abnormal value cylinder injector compression decreases

      • Abnormal value cylinder injector injects excessively large quantity of fuel
      C

      Inspect and repair all cylinder injectors:

      Clean all cylinder injectors, inspect, and repair them

      All cylinder injectors inject excessively small quantity of fuel:

      Fuel injection volume too low due to all cylinder injector nozzles being blocked by deposits

      Tech Tips

      *: When the Injection Volume displayed on the intelligent tester is large despite the Fuel Press and Injection Feedback Val #1 to #4 in the Data List being normal, the injector may be clogged. In this case, there may be deposits inside or outside the tip of the injector.


      • Despite the injector functioning normally, the indicated Injection Feedback Val #1 to #4 value may be outside the normal operating range due to compensation for other problems (such as low compression).

      • Injection Feedback Val #1 to #4 is the value used to correct the fuel injection volumes of each cylinder, in order to optimize (compensate for the unevenness between) all the cylinder combustion conditions. If any of the cylinders malfunction, the fuel injection volumes for the normal cylinders are corrected simultaneously. As a result, the Injection Feedback Val #1 to #4 may deviate from the standard range.


    B

    CHECK CYLINDER COMPRESSION PRESSURE Click here

    C

    CLEAN INJECTOR ASSEMBLY Click here

    A

  15. 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.


    NEXT

    REPLACE INJECTOR OF MALFUNCTIONING CYLINDER

  16. PERFORM ACTIVE TEST USING INJECTOR ASSEMBLY


    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 / Active Test / Control the Cylinder #1, #2, #3, and #4 Fuel Cut.

    6. Check the four cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.

      Tech Tips


      • If the engine idle does not change when an injector 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

  17. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure. Click here


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  18. CHECK MALFUNCTIONING CYLINDER'S INJECTOR FOR DEPOSITS

    Tech Tips

    If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This may cause malfunctions.


    1. Check the injector for any deposits.

      Result
      Injector Condition Proceed to
      Deposits A
      No deposits B

    B

    REPLACE INJECTOR OF MALFUNCTIONING CYLINDER

    A

  19. CLEAN INJECTOR ASSEMBLY


    1. Wipe away deposits from the tips of the injectors.

      Tech Tips


      • Solvent or carbon removal agents help remove deposits easily.

      • Exercise extreme care not to damage the injectors while wiping off the deposits.


    NEXT

  20. READ VALUE USING INJECTOR ASSEMBLY (INJECTION FEEDBACK VAL AND INJECTION VOLUME)


    1. Reinstall the injector to the cylinder head.

    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. Start the engine and warm it up.

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

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


      • Injection Feedback Val #1, #2, #3, and #4

      • Injection Volume

      Standard
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #4 Idling

      -2.0 to 2.0 mm3

      Injection Volume Idling

      5.0 to 15.0 mm3

      Tech Tips

      *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up. When the values are outside the standard range, deposits inside the injector may be causing the problem.

      OK
      Values are within the standard range.

    NG

    REPLACE INJECTOR OF MALFUNCTIONING CYLINDER

    OK

    END

  21. CHECK INJECTORS FOR DEPOSITS (EXCEPT FUEL ADDITION INJECTOR)

    Tech Tips

    If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This may cause malfunctions.


    1. Check the injector for any deposits.

      Result
      Injector Condition Proceed to
      Deposits A
      No deposits B

    B

    REPLACE INJECTOR ASSEMBLY

    A

  22. CLEAN INJECTOR ASSEMBLY


    1. Wipe away deposits from the tips of the injectors.

      Tech Tips


      • Solvent or carbon removal agents help remove deposits easily.

      • Exercise extreme care not to damage the injectors while wiping off the deposits.


    NEXT

  23. READ VALUE USING INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)


    1. Reinstall the injector to the cylinder head.

    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. Start the engine and warm it up.

    7. Turn the tester on.

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

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


      • Injection Feedback Val #1, #2, #3, and #4

      • Injection Volume

      Standard
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #4 Idling

      -2.0 to 2.0 mm3

      Injection Volume Idling

      5.0 to 15.0 mm3

      Tech Tips

      *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up. When the values are outside the standard range, deposits inside the injector may be causing the problem.

      OK
      Values are within the standard range.

    NG

    REPLACE INJECTOR ASSEMBLY

    OK

    END

  24. 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
      F8-5 (PFUEL) - F8-6 (A-VCC) 3 kΩ or less
      F8-2 (PFUEL) - F8-1 (A-VCC) 3 kΩ or less

    3. Reconnect the fuel pressure sensor connector.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

  25. INSPECT SUPPLY PUMP ASSEMBLY


    1. A01CGPEE01

      Disconnect the suction control valve connector.

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

      Standard resistance
      Tester Connection Condition Specified Condition
      1 - 2 20°C (68°F) 7.6 to 8.2 Ω

    NG

    REPLACE SUPPLY PUMP ASSEMBLY

    OK

    CHECK AND REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)