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 injection or supply pump assembly, the ECM needs initialization Click here.

  • After replacing an injector assembly, 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. 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 ON.

    4. Turn the tester on.

    5. Enter the following menus: Powertrain / Engine and ECT / DTC.

    6. Read the DTCs.

      Result
      Result Proceed to
      DTC is not output A
      DTCs related to the engine B

    B

    GO TO DTC CHART Click here

    A

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


    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 menus: Powertrain / Engine and ECT / Data List.

    6. Enter the following menus 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)

      5.0 to 16.0 mm3/st
      Injection Feedback Val #1 Idling (No engine load)

      -7.0 to 7.0 mm3/st
      Injection Feedback Val #2 Idling (No engine load)

      -7.0 to 7.0 mm3/st
      Injection Feedback Val #3 Idling (No engine load)

      -7.0 to 7.0 mm3/st
      Injection Feedback Val #4 Idling (No engine load)

      -7.0 to 7.0 mm3/st

      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 SPEED ACCELERATION

    Tech Tips

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


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

    2. Check for black smoke in the exhaust gas.

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

      Tech Tips

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


    B

    CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM Click here

    A

    PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE Click here

  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 VOLTAGE)

    Tech Tips

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


    1. A01CGYSE04
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      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 Click here

    OK

  7. CHECK TURBOCHARGER SUB-ASSEMBLY (PRESSURE)


    1. Check the turbocharger sub-assembly pressure Click here.


    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY Click here

    OK

  8. 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 turn the tester on.

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

    5. Enter the following menus 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 Press Idling 25000 to 35000 kPa
      Injection Volume Idling

      5.0 to 16.0 mm3/st
      Main Injection Period Idling 500 to 700 μs
      Pilot 2 Injection Period Idling 500 to 600 μs
      Injection Feedback Val #1 Idling

      -7.0 to 7.0 mm3/st
      Injection Feedback Val #2 Idling

      -7.0 to 7.0 mm3/st
      Injection Feedback Val #3 Idling

      -7.0 to 7.0 mm3/st
      Injection Feedback Val #4 Idling

      -7.0 to 7.0 mm3/st

      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 Click here

    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 - INJECTOR DRIVER ASSEMBLY)


    1. Disconnect the injector assembly connectors.

    2. Disconnect the injector driver assembly 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
      Standard Resistance (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 driver assembly connector.

    5. Reconnect the injector assembly connectors.


    NG

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

    OK

  11. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (INJECTOR CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Cylinder #1, #2, #3, and #4 Fuel Cut.

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

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

      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 of idle speed when the fuel injection is stopped for that cylinder.


    B

    REPLACE INJECTOR ASSEMBLY Click here

    A

    REPLACE INJECTOR DRIVER ASSEMBLY Click here

  12. CHECK ECM TERMINAL VOLTAGE (THW TERMINAL)


    1. A01CGYSE05
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      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. A01CGYSE06
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      Turn the ignition switch to ON.

    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 (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM) Click here

    OK

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


    1. A01CI68E14
      Text in Illustration
      *1

      Component without harness connected

      (ECM)
      *2 G and NE Signal Waveform
      *3 5 V/DIV.
      *4 20 ms./DIV.

      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 ms./DIV.
      Condition Idling with warm engine

      Tech Tips

      The waveform varies depending on the engine revolution.


    NG

    INSPECT CRANKSHAFT POSITION SENSOR Click here

    OK

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


    1. A01CGYSE07
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      Turn the ignition switch to ON.

    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. A01CGYSE08
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      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 0 to 80°C (32 to 176°F) 0.5 to 3.4 V

    NG

    INSPECT MASS AIR FLOW METER SUB-ASSEMBLY Click here

    OK

  17. CHECK ECM TERMINAL VOLTAGE (THIA TERMINAL)


    1. A01CGYSE11
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      Start the engine.

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      E22-20 (THIA) - E22-28 (E2) Idling, intake air temperature at 0 to 80°C (32 to 176°F) 1.0 to 4.4 V

    NG

    INSPECT INTAKE AIR TEMPERATURE SENSOR Click here

    OK

  18. CHECK ECM TERMINAL VOLTAGE (PCR1 TERMINAL)


    1. A01CGYSE09
      Text in Illustration
      *1

      Component with harness connected

      (ECM)

      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 1.3 to 1.7 V

    NG

    INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR) Click here

    OK

    REPLACE ECM Click here

  19. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. A01CHW0E10
      Text in Illustration
      *1 Ohmmeter
      *2 Engine Coolant Temperature Sensor
      *3 Acceptable

      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
      1 - 2 20°C (68°F) 2.32 to 2.59 kΩ
      1 - 2 80°C (176°F) 0.31 to 0.326 kΩ

      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 engine coolant temperature 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 Click here

    OK

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

  20. CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)


    1. Disconnect the manifold absolute 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
      Standard Resistance (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 manifold absolute pressure sensor.

    5. Reconnect the ECM connectors.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)

    OK

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

  21. INSPECT CRANKSHAFT POSITION SENSOR


    1. A01CGNOE39
      Text in Illustration
      *1

      Component without harness connected

      (Crankshaft Position Sensor)

      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
      1 - 2 20°C (68°F) 1850 to 2450 Ω

    NG

    REPLACE CRANKSHAFT POSITION SENSOR Click here

    OK

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

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


    1. 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
      Standard Resistance (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 LINK ASSEMBLY (ACCELERATOR PEDAL POSITION SENSOR) Click here

  23. INSPECT MASS AIR FLOW METER SUB-ASSEMBLY


    1. Inspect the mass air flow meter sub-assembly Click here.


    NG

    REPLACE MASS AIR FLOW METER SUB-ASSEMBLY Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR (MASS AIR FLOW METER SUB-ASSEMBLY - ECM)

  24. INSPECT INTAKE AIR TEMPERATURE SENSOR


    1. Inspect the intake air temperature sensor Click here.


    NG

    REPLACE INTAKE AIR TEMPERATURE SENSOR Click here

    OK

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

  25. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. A01CIYSE09
      Text in Illustration
      *1

      Component without harness connected

      (Fuel Pressure Sensor)

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

    3. Reconnect the fuel pressure sensor connector.


    NG

    REPLACE COMMON RAIL ASSEMBLY Click here

    OK

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


    1. 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) - 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
      Standard Resistance (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 (FUEL PRESSURE SENSOR - ECM)

    OK

  27. 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 the volume of black smoke in the exhaust gas.

      OK
      Black smoke is not present.

    NG

    REPLACE INJECTION OR SUPPLY PUMP ASSEMBLY Click here

    OK

    END