ECD SYSTEM Black Smoke Emitted

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 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 to be normal when the Data List outputs standard values. There may be concealed factors causing the malfunction.

PROCEDURE


  1. CHECK OUTPUT DTC (RELATED TO ENGINE)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to the ON position.

    3. Turn the 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 the engine B

    B

    GO TO DTC CHART

    A

  2. READ VALUE USING INJECTOR ASSEMBLY (INJECTION VOLUME AND INJECTION FEED BACK VAL #1 TO #4)


    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 / Data List.

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


      • Injection Volume

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

      Standard
      Item Engine Speed* Reference Value
      Injection Volume Idling (No engine load)

      5 to 12 mm3

      Injection Feedback Val #1 Idling (No engine load)

      -3.0 to 3.0 mm3

      Injection Feedback Val #2 Idling (No engine load)

      -3.0 to 3.0 mm3

      Injection Feedback Val #3 Idling (No engine load)

      -3.0 to 3.0 mm3

      Injection Feedback Val #4 Idling (No engine load)

      -3.0 to 3.0 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 ECM TERMINAL VOLTAGE (THW TERMINAL) Click here

    OK

  3. PERFORM ENGINE RPM ACCELERATION

    Tech Tips

    If the exhaust gas contains excessive black smoke, perform the following operations:


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

    2. Check for black smoke in the exhaust gas.

      Result
      Result Proceed to
      Black smoke is not present OK
      Black smoke remains in the exhaust gas NG

      Tech Tips

      Soot deposits in the exhaust system may cause excessive black smoke.


    NG

    CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM Click here

    OK

    END

  4. CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM


    1. Inspect the engine condition Click here.


    NG

    CHECK AND REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST

    OK

  5. INSPECT EXHAUST RETARDER ASSEMBLY


    1. Inspect the exhaust retarder assembly.


    NG

    REPLACE EXHAUST RETARDER ASSEMBLY

    OK

  6. CHECK ECM TERMINAL VOLTAGE (EGLS TERMINAL)

    Tech Tips

    The lifting amount of the EGR valve can be checked using the output of the EGR position sensor.


    1. A01CGXCE07

      Start the engine.

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

      Standard voltage
      Tester Connection Condition Specified Condition
      E23-33 (EGLS) - E22-28 (E2) Engine: Idling 2.7 to 3.0 V
      E23-33 (EGLS) - E22-28 (E2) Engine: 3000 rpm 3.3 to 3.6 V

      Tech Tips

      In the chart above, "Idling" means that the engine should be idled under the following conditions:


      • The A/C switch is off and the shift lever is in the neutral position.

      • After the engine is warmed up, the engine should have no load.


    NG

    REPLACE EGR VALVE ASSEMBLY

    OK

  7. CHECK TURBOCHARGER SUB-ASSEMBLY (PRESSURE)


    1. Check the turbocharger pressure Click here.


    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  8. PERFORM ACTIVE TEST USING FUEL PRESSURE SENSOR AND INJECTOR ASSEMBLY


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the intelligent tester on.

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

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


      • Fuel Press

      • Injection Volume

      • Main Injection Period

      • Pilot 2 Injection Period

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

      Result
      Item Engine Speed* Reference Value
      Fuel Pressure Idling 25 to 35 MPa
      Fuel Pressure 2,000 rpm (no engine load) 80 to 90 MPa
      Fuel Pressure 3,000 rpm (no engine load) 100 to 110 MPa
      Injection Volume Idling

      5.0 to 12.0 mm3

      Injection Volume 2,000 rpm (no engine load)

      8.0 to 15.0 mm3

      Injection Volume 3,000 rpm (no engine load)

      13.0 to 20.0 mm3

      Main Injection Period Idling 500 to 700 μs
      Pilot 2 Injection Period Idling 500 to 600 μs
      Injection Feedback Val #1 Idling

      -3.0 to 3.0 mm3

      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

      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.

      Result
      Result Proceed to
      Within reference value A
      One of Injection Feedback Val #1 to #4 is not within reference value B
      Other result C

    B

    REPLACE INJECTOR ASSEMBLY

    C

    CHECK ECM TERMINAL VOLTAGE (THW TERMINAL) Click here

    A

  9. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  10. CHECK HARNESS AND CONNECTOR (INJECTOR ASSEMBLY - EDU)


    1. A01CGNSE01

      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 EDU connector.

    5. Reconnect the injector connectors.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (INJECTOR ASSEMBLY - EDU)

    OK

  11. 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 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 EDU

  12. CHECK ECM TERMINAL VOLTAGE (THW TERMINAL)


    1. A01CGXCE12

      Start the engine.

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

      Standard voltage
      Tester Connection Condition Specified Condition
      E22-19 (THW) - E22-28 (E2) Idling, engine coolant temperature between 80 and 120°C (176 and 248°F) 0.4 to 1.0 V

    NG

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  13. CHECK ECM TERMINAL VOLTAGE (PIM TERMINAL)


    1. A01CGXCE13

      Turn the ignition switch to the ON position.

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

      Standard voltage
      Tester Connection Condition Specified Condition
      E23-28 (PIM) - E22-28 (E2) Applied negative pressure of 93 kPa (700 mmHg, 27.5 in.Hg) 0.25 to 0.4 V
      E23-28 (PIM) - E22-28 (E2) Applied positive pressure of 150 kPa (1125 mmHg, 44 in.Hg) 1.0 to 1.4 V

    NG

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

    OK

  14. CHECK ECM TERMINAL VOLTAGE (NE+ AND NE- TERMINALS)


    1. A01CI68E01

      While idling the engine, check the waveform 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 engine revolution.


    NG

    INSPECT CRANKSHAFT POSITION SENSOR Click here

    OK

  15. CHECK ECM TERMINAL VOLTAGE (VPA AND VPA2 TERMINALS)


    1. A01CGXCE14

      Turn the ignition switch to the ON position.

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

      Standard voltage
      Tester Condition Accelerator Pedal Condition Specified Condition
      E25-22 (VPA) - E25-28 (EPA) Released 0.6 to 1.0 V
      E25-22 (VPA) - E25-28 (EPA) Depressed 2.8 to 3.6 V
      E25-23 (VPA2) - E25-29 (EPA2) Released 1.4 to 1.8 V
      E25-23 (VPA2) - E25-29 (EPA2) Depressed 3.6 to 4.4 V

    NG

    CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM) Click here

    OK

  16. CHECK ECM TERMINAL VOLTAGE (THA TERMINAL)


    1. A01CGXCE15

      Start the engine.

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

      Standard voltage
      Tester Connection Condition Specified Condition
      E22-31 (THA) - E22-28 (E2) Idling, intake air temperature at 20°C (68°F) 0.5 to 3.4 V

    NG

    INSPECT INTAKE AIR TEMPERATURE SENSOR Click here

    OK

  17. CHECK ECM TERMINAL VOLTAGE (PCR1 TERMINAL)


    1. A01CGXCE80

      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

    INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR) 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

      Note

      When checking the ECT 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 (INJECTOR ASSEMBLY - EDU)

  19. CHECK HARNESS AND CONNECTOR (TURBO PRESSURE SENSOR - ECM)


    1. A01CJ58E01

      Disconnect the turbo pressure sensor connector.

    2. Disconnect the ECM connectors.

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

      Standard resistance
      Check for open
      Tester Connection Condition Specified Condition
      E23-28 (PIM) - T2-2 (PB) Always Below 1 Ω
      E22-18 (VC) - T2-3 (VC) Always Below 1 Ω
      E22-28 (E2) - T2-1 (GND) Always Below 1 Ω
      Check for short
      Tester Connection Condition Specified Condition
      E23-28 (PIM) or T2-2 (PB) - Body ground Always 10 kΩ or higher
      E22-18 (VC) or T2-3 (VC) - Body ground Always 10 kΩ or higher
      E22-28 (E2) or T2-1 (GND) - Body ground Always 10 kΩ or higher

    4. Reconnect the turbo pressure sensor.

    5. Reconnect the ECM connectors.


    NG

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

    OK

    REPLACE TURBO PRESSURE SENSOR

  20. 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 1630 to 2740 Ω
      C3-1 - C3-2 Hot 2065 to 3225 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).


    NG

    REPLACE CRANKSHAFT POSITION SENSOR

    OK

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

  21. CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM)


    1. A01CH9FE02

      Disconnect the accelerator pedal position sensor connector.

    2. Disconnect the ECM connector.

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

      Standard resistance
      Check for open
      Tester Connection Condition Specified Condition
      A11-1 (VCP2) - E25-21 (VCP2) Always Below 1 Ω
      A11-2 (EP2) - E25-29 (EPA2) Always Below 1 Ω
      A11-3 (VPA2) - E25-23 (VPA2) Always Below 1 Ω
      A11-4 (VCP1) - E25-20 (VCPA) Always Below 1 Ω
      A11-5 (EP1) - E25-28 (EPA) Always Below 1 Ω
      A11-6 (VPA1) - E25-22 (VPA) Always Below 1 Ω
      Check for short
      Tester Connection Condition Specified Condition
      A11-1 (VCP2) or E25-21 (VCP2) - Body ground Always 10 kΩ or higher
      A11-2 (EP2) or E25-29 (EPA2) - Body ground Always 10 kΩ or higher
      A11-3 (VPA2) or E25-23 (VPA2) - Body ground Always 10 kΩ or higher
      A11-4 (VCP1) or E25-20 (VCPA) - Body ground Always 10 kΩ or higher
      A11-5 (EP1) or E25-28 (EPA) - Body ground Always 10 kΩ or higher
      A11-6 (VPA1) or E25-22 (VPA) - Body ground Always 10 kΩ or higher

    4. Reconnect the accelerator pedal position sensor connector.

    5. Reconnect the ECM connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM)

    OK

    REPLACE ACCELERATOR PEDAL (ACCELERATOR PEDAL POSITION SENSOR)

  22. INSPECT INTAKE AIR TEMPERATURE SENSOR


    1. A01CI4BE05

      Remove the intake air temperature sensor.

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

      Standard resistance
      Tester Connection Condition Specified Condition
      I9-1 - I9-2 20°C (68°F) 2.21 to 2.65 kΩ
      I9-1 - I9-2 60°C (140°F) 0.55 to 0.61 kΩ

      Note

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


    NG

    REPLACE INTAKE AIR TEMPERATURE SENSOR

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR (INTAKE AIR TEMPERATURE SENSOR - ECM)

  23. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. A01CIYSE04

      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
      F17-2 (VP) - F17-1 (GND) 16.4 kΩ or less
      F17-3 (VC) - F17-2 (VP) 3 kΩ or less

    3. Reconnect the fuel pressure sensor connector.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

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


    1. A01CGPSE03

      Disconnect the ECM connectors.

    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) - F17-2 (VP) Always Below 1 Ω
      E22-18 (VC) - F17-3 (VC) Always Below 1 Ω
      E22-28 (E2) - F17-1 (GND) Always Below 1 Ω
      Check for short
      Tester Connection Condition Specified Condition
      E22-26 (PCR1) or F17-2 (VP) - Body ground Always 10 kΩ or higher
      E22-18 (VC) or F17-3 (VC) - Body ground Always 10 kΩ or higher
      E22-28 (E2) or F17-1 (GND) - Body ground Always 10 kΩ or higher

    4. Reconnect the ECM connector.

    5. Reconnect the fuel pressure sensor connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (INJECTOR ASSEMBLY - EDU)

    OK

  25. REPLACE ECM


    1. Replace the ECM.

      Note

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

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

      OK
      Black smoke is not present.

    NG

    REPLACE SUPPLY PUMP ASSEMBLY

    OK

    END