ECD SYSTEM Lack of Power or Hesitation

DESCRIPTION

Malfunction Condition Main Trouble Areas Related Trouble Areas

  • Lack of power caused by abnormal fuel injection volume (supply pump malfunction or injector malfunction)

  • Lack of power caused by intake air volume shortage (turbocharger malfunction, front exhaust pipe or exhaust manifold converter blocked)

  1. Injector malfunctions


    • Injector sliding malfunction

    • Injector stuck closed

    • Injector stuck open

    • Deposits in injector

    • Injector circuit malfunction

  2. Abnormal common rail pressure


    • Supply pump

  3. Abnormal intake air volume


    • Turbocharger

    • Front exhaust pipe blockage

    • Catalytic converter blockage

  • Pressure limiter

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Fuel filter element is clogged

  • Throttle valve

  • Compression pressure

  • Injector compensation code

  • Fuel leak

  • Fuel pressure sensor

  • EDU (P0200/97 set simultaneously)

  • Vehicle modifications

  • Low quality fuel

  • Frozen fuel

  • ECM

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 judge the vehicle to be normal even when the Data List values indicate a standard level. There are possibly some concealed factors causing the malfunction.

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

  • This troubleshooting procedure checks for the cause of an obvious lack of engine power (the vehicle speed does not reach the target speed in the high speed range) while the vehicle is being driven.

INSPECTION PROCEDURE

Note


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

  • After replacing an 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 ROOM


    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 systems

      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") again described above (to allow the ECM to set pressure discharge valve malfunction DTCs).

    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 "E" (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. READ OUTPUT DTC (RELATING TO ENGINE)


    1. Read the 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 (TEST THE FUEL LEAK)

    Tech Tips

    By performing this Active Test, the engine speed is maintained at 2000 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 leakage.

    NG

    REPAIR OR REPLACE FUEL LEAKAGE POINT

    OK

  5. CHECK WHITE SMOKE


    1. Rev up the engine from idling to 3000 rpm several times to check whether white smoke is emitted from the exhaust pipe.

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

      If white smoke is emitted from the intake system, its pipes and hoses are excessively contaminated with oil. If the presence of white smoke in the exhaust gas is confirmed, there is a high possibility of mechanical problems in the turbocharger or engine.

      Result
      Result Proceed to
      No problems described above A
      White smoke emitted, or intake system pipes and hoses excessively contaminated with oil B

    B

    INSPECT EXHAUST RETARDER ASSEMBLY Click here

    A

  6. READ VALUE USING INTELLIGENT TESTER


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up. 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.


      • 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)
      3000 rpm (no engine load) 110 to 140 kPa (825 to 1050 mmHg, 32.48 to 41.35 in.Hg)
      MAF Ignition switch in the ON position (engine stopped) 0 g/s Intake air volume detected by mass air flow meter
      Idling 8 to 12 g/s
      3000 rpm (no engine load) 80 to 90 g/s
      Fuel Press Idling 25 to 35 MPa Common rail internal fuel pressure
      2000 rpm (no engine load) 80 to 90 MPa
      3000 rpm (no engine load) 100 to 110 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

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

    A

  7. READ VALUE USING INJECTOR (INJECTION FEED BACK 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

      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 -2.0 and 2.0 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 12.0 mm3

      Fuel injection volume 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, and the engine should be fully warmed up.


    B

    IDENTIFY MALFUNCTIONING CYLINDER INJECTOR Click here

    A

  8. 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 one registered in the ECM.

    NG

    REGISTER INJECTOR COMPENSATION CODE

    OK

  9. 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

  10. BLEED AIR FROM FUEL SYSTEM


    1. To bleed air from the priming pump, pump the priming pump until it becomes hard and cannot be pumped any more.


    NEXT

  11. CONFIRM WHETHER LACK OF POWER HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the lack of power has been successfully repaired by performing a driving test. Use the freeze frame data recorded at the time the malfunction occurred.

      OK
      Malfunction has been repaired successfully.

    OK

    END

    NG

  12. 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 leakage or blockage.

    NEXT

    END

  13. 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 12.0 mm3

      Tech Tips

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

      Result
      Injection Volume Injection Volume
      Injection Feedback Val #1 to #4

      Less than 5.0 mm3

      Between 5.0 and 15.0 mm3(Normal)

      More than 15.0 mm3

      2.0 mm3or more, -2.0 mm3or less

      		 A B B

      Between -2.0 and 2.0 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 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, check, and repair it

      Abnormal cylinder injector injects excessively small quantity of fuel:


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

      • Abnormal cylinder injector compression decreases

      • Abnormal 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 Pressure 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

    INSPECT INJECTOR ASSEMBLY Click here

    C

    READ VALUE USING INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME) Click here

    A

  14. 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 ASSEMBLY OF MALFUNCTIONING CYLINDER

  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

  16. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  17. 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 ASSEMBLY OF MALFUNCTIONING CYLINDER

    A

  18. 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

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


    1. Reinstall the injector to the cylinder head.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to the ON position.

    4. Turn the tester on.

    5. Start the engine and warm it up.

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

    7. 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

      -3.0 to 3.0 mm3

      Injection Volume Idling

      5.0 to 12.0 mm3

      Tech Tips


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

      • 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 OF MALFUNCTIONING CYLINDER

    OK

    END

  20. 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

  21. 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

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


    1. Reinstall the injector to the cylinder head.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to the ON position.

    4. Turn the tester on.

    5. Start the engine and warm it up.

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

    7. 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

      -3.0 to 3.0 mm3

      Injection Volume #1 to #4 Idling

      5.0 to 12.0 mm3

      Tech Tips


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

      • 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

  23. CHECK EGR VALVE ASSEMBLY


    1. Check the EGR valve assembly Click here.


    NG

    REPLACE EGR VALVE ASSEMBLY

    OK

  24. INSPECT DIESEL THROTTLE BODY ASSEMBLY


    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 / Actual Throttle Position.

    5. Read the value.

      Standard
      Ignition switch in the ON position
      0%
      Idling (Warmed up engine)
      95%
      Accelerator pedal fully depressed
      0%

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

    OK

  25. 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 leakage or blockage.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  26. INSPECT EXHAUST RETARDER ASSEMBLY


    1. Inspect the exhaust retarder assembly.


    NG

    REPLACE EXHAUST RETARDER ASSEMBLY

    OK

  27. INSPECT TURBOCHARGER SUB-ASSEMBLY


    1. Check the turbocharger Click here.


    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  28. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up.

    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.


      • 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)
      3000 rpm (no engine load) 110 to 140 kPa (825 to 1050 mmHg, 32.48 to 41.35 in.Hg)
      MAF Ignition switch in the ON position (engine stopped) 0 g/s Intake air volume detected by mass air flow meter
      Idling 8 to 12 g/s
      3000 rpm (no engine load) 80 to 90 g/s

      Tech Tips

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

      OK
      The values are within the standard range.

    OK

    END

    NG

  29. REPLACE CENTER EXHAUST PIPE ASSEMBLY


    NEXT

  30. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up.

    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.


      • MAP

      • MAF

      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)
      3000 rpm (no engine load) 110 to 140 kPa (825 to 1050 mmHg, 32.48 to 41.35 in.Hg)
      MAF Ignition switch in the ON position (engine stopped) 0 g/s Intake air volume detected by mass air flow meter
      Idling 8 to 12 g/s
      3000 rpm (no engine load) 80 to 90 g/s

      Tech Tips

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

      OK
      The values are within the standard range.

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

    END

  31. CHECK AND REPLACE FUEL FILTER ASSEMBLY


    NEXT

  32. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up.

    3. Turn the tester on.

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

    5. Select the following menu item and read the values.


      • Fuel Press

      Standard
      Item Engine Speed *1 Reference Value
      Fuel Press Idling 25 to 35 MPa
      Fuel Press 2000 rpm (no engine load) 80 to 90 MPa
      Fuel Press 3000 rpm (no engine load) 100 to 110 MPa

      Tech Tips

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

      OK
      The values are within the standard range.

    OK

    END

    NG

  33. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. A01CIYSE06

      Disconnect the fuel pressure sensor connector.

    2. Measure the resistance between each terminal of the fuel pressure sensor connector.

      Standard resistance
      Tester Connection Specified Condition
      F17-2 (VP) - F17-1 (GND) 16.4 kΩ or less
      F17-2 (VP) - F17-3 (VC) 3 kΩ or less

    3. Reconnect the fuel pressure sensor connector.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

  34. INSPECT SUPPLY PUMP ASSEMBLY


    1. A01CGPEE08

      Measure the resistance between the suction control valve terminals.

      Standard resistance
      Tester Connection Condition Specified Condition
      S9-1 - S9-2 20°C (68°F) 1.9 to 2.3 Ω

    NG

    REPLACE SUPPLY PUMP ASSEMBLY

    OK

  35. READ VALUE USING INTELLIGENT TESTER (PCV OPEN CURRENT FB VAL)


    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 / PCV Open Current FB Val.

    5. Read the value.

      Standard
      Engine Speed Result
      Idling 1050 to 1150 mA

    NG

    REPLACE SUPPLY PUMP ASSEMBLY

    OK

    CHECK AND REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)