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)

(a) Injector malfunctions


  • Injector sliding malfunction

  • Injector stuck closed

  • Injector stuck open

  • Deposits in injector

  • Injector circuit malfunction

(b) Abnormal common rail pressure


  • Suction control valve

(c) Abnormal intake air volume


  • Turbocharger

  • Front exhaust pipe blockage

  • Exhaust manifold converter blockage

  • Pressure discharge valve (P1271 set simultaneously)

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Fuel filter element is clogged

  • Throttle valve

  • Mass air flow meter

  • Compression pressure

  • Injector compensation code

  • Fuel leak

  • Glow plug

  • Fuel pressure sensor

  • Manifold absolute pressure sensor

  • Vacuum hose connection for manifold absolute pressure sensor

  • Mass air flow meter

  • EDU (P0200 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 of 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


  • If the ECM is replaced, the new ECM needs initialization Click here.

  • If the supply pump is replaced, the ECM needs initialization Click here.

Tech Tips

Before troubleshooting, conduct the following:

  • (a)Check the fuel quality.


  • (b)Check the fuel for air.


  • (c)Check the fuel system for blockages.


  • (d)Check the air filter.


  • (e)Check the engine oil.


  • (f)Check the engine coolant.


  • (g)Check the engine idling speed and the maximum engine speed.


  • (h)Check the vacuum pump.

PROCEDURE


  1. CHECK HARNESS AND CONNECTOR IN ENGINE ROOM


    1. Check the wire harness and connector connections.

      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 are connected securely.

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  2. READ OUTPUT DTCS (RELATING TO PRESSURE DISCHARGE VALVE)

    Tech Tips

    Conduct the inspection below to detect malfunctions in the pressure discharge valve. If any of the DTCs relating to the pressure discharge valve are set, problems areas can be identified.


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Start the engine.

    4. Stop the engine and wait for at least 10 seconds.

    5. Repeat steps (a) and (b) described above (to allow the ECM to set pressure discharge valve malfunction DTCs).


    NEXT

  3. READ OUTPUT DTCS (RELATING TO ENGINE)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch ON and turn the tester ON.

    3. Select the following menu items: Powertrain / Engine and ECT / DTC.

    4. Read pending DTCs.

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

    B

    REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT

    A

  4. READ OUTPUT DTCS (RELATING TO FUEL SYSTEM AND INTAKE SYSTEM)

    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 and EGR system and throttle valve. If DTC are set, problem areas can be identified.


    1. Select the following menu items: Check Mode Click here.

    2. Fully warm up the engine.

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

    4. Drive the vehicle at more than 40 km/h (25 mph) for several tens of seconds.

    5. Decelerate and stop the vehicle.

    6. Repeat steps (d) and (e) 4 times or more.

    7. Stop the engine and wait for at least 10 seconds.

    8. Repeat steps (d) and (g) described above to set DTCs relating to the EGR system and throttle valve.

    9. 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

  5. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (TEST THE FUEL LEAK)

    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 an intelligent tester to the DLC3.

    2. Start the engine and turn the tester ON.

    3. Select the following menu items: Powertrain / Engine / Active Test / Test the Fuel Leak.

    4. 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 Click here.

      Tech Tips

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

      OK
      No fuel leakage.

    NG

    REPAIR OR REPLACE FUEL LEAKAGE POINT

    OK

  6. CHECK WHITE SMOKE


    1. Rev up the engine from idling to 3,000 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 TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM) Click here

    A

  7. READ VALUE USING INTELLIGENT TESTER (MAP, MAF, FUEL PRESS)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up, and turn the tester ON.

    3. Select 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* Standard Range Proceed to Description
      MAP Ignition switch ON (engine stopped) Same as atmospheric pressure

      • A (standard range)

      • B (both MAP and MAF outside standard range)

      • C (only MAP outside standard range)

      		 Intake manifold internal pressure detected by intake pressure sensor
      Idling 95 to 105 kPa (713 to 788 mmHg, 28.1 to 31 in.Hg)
      3,000 rpm (No engine load) 103 to 128 kPa (773 to 960 mm Hg, 30.4 to 37.8 in.Hg)
      3,000 rpm (full throttle acceleration) Min.: 185 kPa (1,388 mmHg, 54.6 in.Hg)
      MAF Ignition switch ON (engine stopped) 0 g/sec.

      • A (standard range)

      • B (both MAP and MAF outside standard range)

      • D (only MAF outside standard range)

      		 Intake air volume detected by mass air flow meter
      Idling 9 to 16 g/sec.
      3,000 rpm (No engine load) 60 to 80 g/sec.
      3,000 rpm (full throttle acceleration) Min.: 120 g/sec.
      Fuel Press Idling 30 to 40 MPa

      • A (standard range)

      • E ( fuel pressure outside standard range)

      		 Common rail internal fuel pressure
      2,000 rpm (No engine load) 50 to 60 MPa
      3,000 rpm (No engine load) 85 to 105 MPa
      3,000 rpm (full throttle acceleration) Min.: 170 MPa

      Tech Tips

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


    B

    INSPECT ELECTRIC EGR CONTROL 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 MASS AIR FLOW METER)

    E

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

    A

  8. READ VALUE USING INTELLIGENT TESTER (INJECTION FEED BACK VAL, 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 Proceed to Description
      Injection Feedback Val #1 Idling

      -3.0 to 3.0 mm3


      • A (standard range)

      • B (Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range)

      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 -3.0 and 3.0 mm3range
      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 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 standard range

      Tech Tips

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


    B

    CHECK INJECTOR ASSEMBLY (IDENTIFY MALFUNCTIONING CYLINDER INJECTOR) Click here

    A

  9. 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 Click here.

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

    NG

    REGISTER INJECTOR COMPENSATION CODE

    OK

  10. 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

  11. 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

  12. 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

  13. INSPECT GLOW PLUG ASSEMBLY


    1. A01KGI8E05
      Text in Illustration
      *1 Glow Plug Assembly

      Disconnect the glow plug wire.

    2. Measure the resistance of the glow plug.

    3. Check other glow plugs in the same way.

      Standard resistance
      Tester Connection Specified Condition
      Glow plug terminal - Body ground Approximately 0.95 Ω at 20°C (68°F)

      Tech Tips

      If any one of the glow plugs has an open malfunction, the engine power is insufficient only when the engine is cold.

      Note


      • Be careful not to damage the glow plug pipes. Damaging them could cause an open circuit, or shorten the life of the glow plugs.

      • Keep the glow plug free of oil and fuel while cleaning.

      • Wipe any oil off the terminal and Bakelite washer with a clean, dry cloth during inspection.

      • Do not apply more than 11 V to the glow plug as it could cause an open circuit.

    4. Reconnect the glow plug wire.


    NG

    REPAIR OR REPLACE GLOW PLUG ASSEMBLY

    OK

  14. BASIC INSPECTION


    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.

      OK
      Each inspection result is normal.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    OK

  15. CHECK INTAKE AND EXHAUST SYSTEM


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

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

      OK
      No leakage or blockage.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

    END

  16. CHECK INJECTOR ASSEMBLY (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 12.0mm3

      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 Feedback Val #1 to #4

      Less than 5.0 mm3

      Between 5.0 to 12.0 mm3(Normal)

      More than 12.0 mm3

      3.0 mm3or more, -3.0 mm3or less

      		 A B B

      Between -3.0 to 3.0 mm3

      		- Normal C*
      Proceed to Inspection Areas Descriptions
      A

      Inspect and repair cylinder injector with revised injection volume of less than -3.0 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 small 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, and then 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 injector.


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

      • Injection Feedback Val #1 to #4 are the values 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

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (INJECTOR CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER) Click here

    C

    CHECK INJECTORS FOR DEPOSITS (EXCEPT ADDITION INJECTOR) Click here

    A

  17. 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. Select the following menu items: 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.

      Tech Tips


      • While the engine is idling, if the idling stability variation is small despite cutting off the fuel injection, the cylinder is malfunctioning.

      • With normal cylinders, the engine idles roughly when the fuel injection is cut off.


    NEXT

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

  18. 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. Select the following menu items: 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.

      Tech Tips


      • While the engine is idling, if the idling stability variation is small despite cutting off the fuel injection, the cylinder is malfunctioning.

      • With normal cylinders, the engine idles roughly when the fuel injection is cut off.


    NEXT

  19. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.

      Standard pressure
      2,000 kPa (20.4 kgf/cm2, 290 psi) or more
      Minimum pressure
      1,630 kPa (16.6 kgf/cm2, 236 psi)
      Difference between each cylinder
      500 kPa (5.0 kgf/cm2, 71 psi) or less

    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  20. 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

  21. CLEAN INJECTOR


    1. Wipe away deposits from the tips injector.

      Tech Tips


      • Solvent or carbon removal agent help remove the deposits easily.

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


    NEXT

  22. READ VALUE USING INTELLIGENT TESTER (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 ON and turn the tester ON.

    4. Start the engine and warm it up.

    5. Select the following menu items: Powertrain / Engine and ECT / Data List.

    6. 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 warm engine.

      • When the values are outside the standard range, deposits inside the injector may be causing the problem.

      OK
      Values are within standard range.

    NG

    REPLACE ALL CYLINDER INJECTOR ASSEMBLY

    OK

    END

  23. CHECK INJECTORS FOR DEPOSITS (EXCEPT 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 ALL CYLINDER INJECTOR ASSEMBLY

    A

  24. CLEAN INJECTOR


    1. Wipe away deposits from the tips injector.

      Tech Tips


      • Solvent or carbon removal agent help remove the deposits easily.

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


    NEXT

  25. READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL, INJECTION VOLUME)


    1. Reinstall the injector to the cylinder head.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch ON and turn the tester ON.

    4. Start the engine and warm it up.

    5. Select the following menu items: Powertrain / Engine and ECT / Data List.

    6. 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 warm engine.

      • When the values are outside the standard range, deposits inside the injector may be causing the problem.

      OK
      Values are within standard range.

    NG

    REPLACE ALL CYLINDER INJECTOR ASSEMBLY

    OK

    END

  26. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Tech Tips

    In this inspection, measure the MAF rate while idling the engine with the EGR valve fully closed.


    1. Make sure the engine is stopped.

    2. Disconnect the EGR E-VRV connector.

    3. Connect the intelligent tester to the DLC3.

    4. Turn the ignition switch ON and turn the tester ON.

    5. Start the engine.

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

    7. Measure the MAF rate while idling the engine.

      Standard
      MAF rate is between 9 to 16 g/sec.

      Tech Tips


      • Standard MAF rate while idling the engine with the EGR valve operating: 5 to 12 g/sec

      • With the EGR E-VRV connector disconnected, a DTC is set when the ignition switch is turned ON. Therefore, clear the DTC upon completion of the inspection above Click here.

    8. Reconnect the EGR E-VRV connector.


    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    OK

  27. INSPECT DIESEL THROTTLE BODY ASSEMBLY


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch ON and turn the tester ON

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

    4. Read the value.

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

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

    OK

  28. CHECK INTAKE AND EXHAUST SYSTEM


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

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

      OK
      No leakage or blockage

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  29. CHECK INTAKE MANIFOLD (SWIRL CONTROL VALVE OPERATION)


    1. Inspect intake manifold (swirl control valve) Click here.

      OK
      The valve is not stuck and does not have heavy carbon deposits.

    NG

    REPAIR OR REPLACE INTAKE MANIFOLD (SWIRL CONTROL VALVE SYSTEM)

    OK

  30. INSPECT TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM)


    1. Disconnect the air cleaner hose.

    2. Use a mirror to visually check the turbocharger for any mechanical problems.

    3. When the engine is cold, check that the impeller of the turbocharger rotates smoothly, and perform a contact check to confirm if it is damaged.

      OK
      Impeller rotates smoothly and is not damaged.

    4. Reconnect the air cleaner hose.


    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  31. INSPECT TURBOCHARGER SUB-ASSEMBLY (DC MOTOR OPERATION)


    1. Turn the ignition switch ON.

    2. Turn the ignition switch OFF and check the DC motor operation.

      OK
      When ignition switch is turned OFF, operation link moves as shown in A to D in illustration below.
      A01KFR2E01

    3. After confirming that the operation link contacts stopper bolt, start the engine.

    4. Perform test drive.

    5. Turn the ignition switch to OFF.

    6. After ignition switch is turned to OFF, check that the operation link contacts stopper bolt again.

      OK
      Operation link contacts stopper bolt

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  32. INSPECT FRONT EXHAUST PIPE ASSEMBLY


    1. Visually confirm whether the front exhaust pipe is blocked. If blocked, replace the pipe.

      Tech Tips

      Blockage may not be found with a visual inspection alone.

      OK
      No leakage

    NG

    REPAIR OR REPLACE FRONT EXHAUST PIPE ASSEMBLY

    OK

  33. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up and turn the tester ON.

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

    4. Select the following menu item and read the value.


      • MAP

      • MAF

      Standard
      Item Engine Speed* Reference Value
      MAP 3,000 rpm (full throttle acceleration) Min.: 185 kPa (1,388 mmHg, 54.6 in.Hg)
      MAF 3,000 rpm (full throttle acceleration) Min.: 120 g/sec.

      Tech Tips

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

      OK
      Values are within standard value and malfunction has been successfully repaired.

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

    END

  34. CHECK AND REPLACE FUEL FILTER ASSEMBLY


    NEXT

  35. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up, and turn the tester ON.

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

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


      • Fuel Press

      Standard
      Item Engine Speed * Reference Value
      Fuel Press Idling 30 to 40 MPa
      Fuel Press 2,000 rpm (no engine load) 40 to 50 MPa
      Fuel Press 3,000 rpm (no engine load) 50 to 70MPa
      Fuel Press 3,500 rpm (full throttle acceleration) Min.: 150 MPa

      Tech Tips

      *: 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

  36. INSPECT SUPPLY PUMP ASSEMBLY


    1. A01KGU2E12
      Text in Illustration
      *1 Suction Control Valve

      Disconnect the S11 suction control valve connector.

    2. Measure the resistance of the suction control valve.

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

    3. Reconnect the suction control valve connector.


    NG

    REPLACE SUCTION CONTROL VALVE

    OK

  37. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. A01KHP6E11
      Text in Illustration
      *1 Fuel Pressure Sensor
      *a Component Side

      Disconnect the F16 fuel pressure sensor connector.

    2. Measure the resistance of the sensor.

      Standard resistance
      Tester Connection specified Condition
      F16-5 (PR) - F16-4 (E2) 16.4 kΩ or less
      F16-2 (PR2) - F16-3 (E2S) 16.4 kΩ or less
      F16-5 (PR) - F16-5 (VC) 3 kΩ or less
      F16-2 (PR2) - F16-1 (VCS) 3 kΩ or less

    3. Disconnect the fuel pressure sensor connector.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

    REPAIR OR REPLACE FUEL SYSTEM (FUEL LINE, AIR BLEED PROBLEM)