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 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 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 causing 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 ON and turn the tester on.

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

    5. Read the DTCs.

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

    B

    GO TO DTC CHART Click here

    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 Click here

    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 INTELLIGENT TESTER (FUEL PRESSURE)


    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 / 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 15000 kPa or more

    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 with cold engine (w/ glow plug assembly) A
      No initial combustion with hot engine (w/ glow plug assembly) B
      No initial combustion (w/o glow plug assembly) B
      Initial combustion occurs C

    B

    READ VALUE USING INTELLIGENT TESTER (FUEL PRESSURE) Click here

    C

    CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM Click here

    A

  6. CHECK GLOW INDICATOR LIGHTING TIME AND AFTER GLOW TIME


    1. Check the lighting duration of the glow indicator light Click here.

      OK
      Indicator lighting time is normal.

    NG

    REPAIR OR REPLACE PRE-HEATING SYSTEM

    OK

  7. READ VALUE USING INTELLIGENT TESTER (FUEL PRESSURE)


    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 / Fuel Press.

    6. Check that the internal fuel pressure of the common rail assembly is within the specification below.

      Standard
      Engine Speed Fuel Pressure
      Idling Approximately 25000 to 35000 kPa
      3000 rpm (No engine load) Approximately 120000 to 135000 kPa

    NG

    CHECK IF FUEL IS BEING SUPPLIED TO INJECTION OR SUPPLY PUMP ASSEMBLY Click here

    OK

  8. CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM


    1. Inspect the engine condition Click here.


    NG

    REPAIR OR REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST

    OK

  9. INSPECT EXHAUST RETARDER ASSEMBLY


    1. Inspect the exhaust retarder assembly.


    NG

    REPLACE EXHAUST RETARDER ASSEMBLY

    OK

  10. READ VALUE USING INTELLIGENT TESTER (FUEL PRESSURE AND INJECTION VOLUME)


    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.


      • Fuel Press

      • Injection Volume

      Standard
      Item Engine Speed * Reference Value
      Fuel Press Idling 25000 to 35000 kPa
      Injection Volume Idling

      5.0 to 16.0 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

  11. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  12. CHECK HARNESS AND CONNECTOR (INJECTOR ASSEMBLY - INJECTOR DRIVER ASSEMBLY)


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


      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
        I15-2 - I21-5 (INJ1) Always Below 1 Ω
        I16-2 - I20-4 (INJ2) Always Below 1 Ω
        I17-2 - I20-2 (INJ3) Always Below 1 Ω
        I18-2 - I21-4 (INJ4) Always Below 1 Ω
        I15-1 - I21-1 (COM1) Always Below 1 Ω
        I16-1 - I21-2 (COM2) Always Below 1 Ω
        I17-1 - I21-2 (COM2) Always Below 1 Ω
        I18-1 - I21-1 (COM1) Always Below 1 Ω
        Standard Resistance (Check for Short)
        Tester Connection Condition Specified Condition
        I15-2 or I21-5 (INJ1) - Body ground Always 10 kΩ or higher
        I16-2 or I20-4 (INJ2) - Body ground Always 10 kΩ or higher
        I17-2 or I20-2 (INJ3) - Body ground Always 10 kΩ or higher
        I18-2 or I21-4 (INJ4) - Body ground Always 10 kΩ or higher
        I15-1 or I21-1 (COM1) - Body ground Always 10 kΩ or higher
        I16-1 or I21-2 (COM2) - Body ground Always 10 kΩ or higher
        I17-1 or I21-2 (COM2) - Body ground Always 10 kΩ or higher
        I18-1 or I21-1 (COM1) - Body ground Always 10 kΩ or higher

      4. Reconnect the injector assembly connectors.

      5. Reconnect the injector driver assembly connector.


    NG

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

    OK

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


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

    5. 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

  14. CHECK IF FUEL IS BEING SUPPLIED TO INJECTION OR SUPPLY PUMP ASSEMBLY


    1. Disconnect the inlet pipe from the injection or supply pump assembly.

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

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

    NG

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

    OK

    CHECK FUEL INJECTION SYSTEM Click here

  15. CHECK ECM TERMINAL VOLTAGE (THW TERMINAL)


    1. A01CIKSE09
      Text in Illustration
      *a

      Component with harness connected

      (ECM)

      Start the engine.

    2. Measure the voltage of the ECM connector.

      Standard Voltage
      Tester Connection Condition Specified Condition
      E35-9 (THW) - E36-14 (E2) Idling, engine coolant temperature between 60 and 120°C (140 and 248°F) 0.2 to 0.6 V

    NG

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

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


    1. A01CH2QE04
      Text in Illustration
      *a

      Component with harness connected

      (ECM)
      *b G and NE Signal Waveform
      *c 5 V/DIV.
      *d 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
      E37-7 (NE+) - E37-8 (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

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


    1. Disconnect the ECM connector.

    2. Remove the starter relay.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S28-2 - E39-6 (STA) Always Below 1 Ω
      S28-2 or E39-6 (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

  18. CHECK ECM TERMINAL VOLTAGE (PCR1 AND PCR2 TERMINAL)


    1. A01CHEQE70
      Text in Illustration
      *a

      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
      E35-16 (PCR1) - E36-14 (E2) Idling 1.6 to 2.0 V
      E35-2 (PCR2) - E35-14 (E21) Idling 1.1 to 1.5 V

    NG

    INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR) Click here

    OK

    REPLACE ECM Click here

  19. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. A01CHW0E13
      Text in Illustration
      *1 Ohmmeter
      *2 Engine Coolant Temperature Sensor
      *a 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 (ECM - ENGINE COOLANT TEMPERATURE SENSOR)

  20. INSPECT CRANKSHAFT POSITION SENSOR


    1. A01CGNOE41
      Text in Illustration
      *a

      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 Cold 1630 to 2740 Ω
      1 - 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).

    3. Reconnect the crankshaft position sensor.


    NG

    REPLACE CRANKSHAFT POSITION SENSOR Click here

    OK

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

  21. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. Inspect the fuel pressure sensor Click here.


    NG

    REPLACE COMMON RAIL ASSEMBLY Click here

    OK

  22. 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
      E36-13 (VC) - C12-1 (VC1) Always Below 1 Ω
      E35-16 (PCR1) - C12-2 (PCR1) Always Below 1 Ω
      E36-14 (E2) - C12-3 (E1) Always Below 1 Ω
      E35-13 (VC2) - C12-6 (VC2) Always Below 1 Ω
      E35-2 (PCR2) - C12-5 (PCR2) Always Below 1 Ω
      E35-14 (E21) - C12-4 (E2) Always Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      E36-13 (VC) or C12-1 (VC1) - Body ground Always 10 kΩ or higher
      E35-16 (PCR1) or C12-2 (PCR1) - Body ground Always 10 kΩ or higher
      E35-13 (VC2) or C12-6 (VC2) - Body ground Always 10 kΩ or higher
      E35-2 (PCR2) or C12-5 (PCR2) - Body ground Always 10 kΩ or higher

    4. Reconnect the fuel pressure sensor connector.

    5. Reconnect the ECM connector.


    NG

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

    OK

  23. 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

    CHECK FUEL INJECTION SYSTEM Click here

    OK

    END