ECD SYSTEM (w/ DPF) Engine Difficult to Start or Stalling

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Mass Air Flow Meter
      Main fault Decrease in performance (foreign matter is stuck)
      Symptoms Lack of power, black smoke
      Data List MAF

      Tech Tips

      The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
      Intake System
      Symptom and Corresponding Main Fault

      • Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct

      • Black smoke (no lack of power) due to leakage between the turbo and intake manifold
      Data List MAP
      Turbocharger System
      Main fault

      • Air leak in the turbocharged air passage

      • ECM not operating well

      • Turbocharger (turbine, bearing)
      Symptoms

      Lack of power (when vehicle is starting, under heavy load)

      (Black smoke is not emitted when racing while vehicle is stopped)
      Data List

      MAP


      • With the ignition switch ON or during idling, MAP = atmospheric pressure (standard atmospheric pressure = 101 kPa [758 mmHg, 29.8 in.Hg]). When the engine speed is about 1500 rpm or more, the turbocharger starts to take effect and MAP becomes higher than atmospheric pressure.

      • Atmospheric pressure decreases by 1 kPa (7.5 mmHg, 0.29 in.Hg) each time elevation increases by 100 m (328 ft.), and is also affected by the current weather conditions.
      Exhaust System
      Main fault Blockage
      Symptoms Lack of power (high engine speed, under heavy load)
      Glow System
      Main fault Glow system malfunction
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Data List Check the glow plug indicator light
      Diagnostic Point Measure the resistance of the glow plug
      Battery
      Main fault Battery is depleted
      Symptoms Difficult to start (cannot crank, crank speed is low), horn is quiet
      Data List

      Battery Voltage

      When cranking, battery voltage is below 5 V.
      Engine - 1
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      Engine - 2
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      Data List

      Engine Speed of Cyl


      • When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.

      Injection Feedback Val


      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.
      Start System
      Main fault Starter system malfunction
      Symptoms Difficult to start
      Data List

      Starter Signal


      • Ignition switch (STA) output:

        ON: Starter is operating

        OFF: Starter is not operating

    2. Diesel Injection

      Fuel Supply Pump
      Main fault -
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure, Target Pump SCV Current


      • Fuel Press is within 5000 kPa (50.9 kgf/cm2, 725 psi) of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C [158°F]).

      • If the fuel pressure is 20000 kPa (203.9 kgf/cm2, 2900 psi) below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa (254.9 kgf/cm2, 3625 psi), then idling will be rough.

      Tech Tips


      • The fuel pressure changes at engine start, but is approx. 25000 kPa (254.9 kgf/cm2, 3625 psi) at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.
      Diagnostic Trouble Code Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.
      Fuel Filter
      Main fault Blockage
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure


      • Fuel Press is within 5000 kPa (50.9 kgf/cm2, 725 psi) of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      • If the fuel pressure is 20000 kPa (203.9 kgf/cm2, 2900 psi) below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa (254.9 kgf/cm2, 3625 psi), then idling will be rough.

      Tech Tips

      The fuel pressure changes at engine start, but is approx. 25000 kPa (254.9 kgf/cm2, 3625 psi) at engine start after the engine is warmed up.
      Diagnostic Trouble Code Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.
      Injector Assembly
      Main fault Blockage
      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val


      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.
      Pressure Discharge Valve
      Main fault Does not completely close
      Symptoms Difficult to start, engine stall, rough idle, lack of power
      Injector Driver
      Main fault Circuit fault: The injector assembly does not open.
      Symptoms Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
      Data List Same as injector assembly
      Diagnostic Trouble Code When the injector driver (EDU) has a fault, some DTCs may be stored.
      Fuel Pressure Sensor
      Main fault Open circuit, decrease in performance (foreign matter is stuck)
      Symptoms Difficult to start, rough idle, engine stall, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure


      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped and check that Fuel Press and Common Rail Pres Sens 2 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Fuel Press or Common Rail Pres Sens 2 decreases to a value less than Target Common Rail Pressure).
      Diagnostic Trouble Code When the fuel pressure sensor has a fault, some DTCs may be stored.
      Irregular Fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      EGR System
      Main fault

      • Does not move smoothly

      • Does not close completely
      Symptoms

      • Rough idle

      • EGR valve stuck closed: A loud turbocharger sound.

      • EGR valve stuck open: Difficult to start (does not stall), black smoke, lack of power (if there is an excess in the quantity of EGR and there is a heavy load, when the vehicle starts moving, a lack of power will be felt).
      Data List

      Actual EGR Valve Pos., Target EGR Position


      • Generally, Actual EGR Valve Pos. = Target EGR Position +/-5% (fully closed: 0%, fully open: 100%).

      • Using the EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Position (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).

      • EGR valve is fully closed when the ignition switch is turned to ON (engine stopped).

      • EGR valve opens to the halfway point at idling after the engine is warmed up.

      EGR Close Lrn. Val., EGR Close Lrn. Status


      • When leaving the vehicle idling, when EGR Close Lrn. Status is OK, the normal range of EGR Close Lrn. Val. is 0 to 1 V.

      • In cases when EGR Close Lrn. Status. is NG or EGR Close Lrn. Val. is out of the normal range (0 to 1 V), it is possible that the EGR valve cannot completely close.

    4. Diesel Throttle

      Diesel Throttle System
      Main fault Stuck, does not move smoothly
      Symptoms

      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

      • Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.
      Data List

      • Actual Throttle Position

        0%: Fully open

        100%: Fully closed

      • When the ignition switch is ON (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

  2. Data List Related to Starting Trouble


    • MAP

    • MAF

    • Intake Air

    • Coolant Temp

    • Battery Voltage

    • Starter Signal

    • Engine Speed of Cyl #1 (to #4)

    • Target Common Rail Pressure

    • Fuel Press

    • Target Pump SCV Current

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

    • Actual Throttle Position

    • Target EGR Position

    • Actual EGR Valve Pos.

    • EGR Close Lrn. Status

    • EGR Close Lrn. Val.

WIRING DIAGRAM

Refer to DTC P0627 Click here.

INSPECTION PROCEDURE


  1. Explanation of Symptom

    Starting Trouble

    For good starting it is essential to have:


    • Sufficient cranking speed.

    • Properly operating engine preheating system.

    • Good quality fuel.

    The fuel is ignited by the heat which is generated by compression pressure.

    With problems such as a depleted battery, the crankshaft speed can become low, or if the engine compression is poor due to leakage, the compression pressure will not rise and there will be difficulty starting.

    When the engine is cold, even if there is compression heat, it will escape from the combustion chamber. For this reason, when the engine is started when it is cold, the glow plugs heat the compressed air.

    Also, after starting the engine, by charging the glow plugs for a fixed time set according to the engine coolant temperature, diesel knocking and white smoke are prevented. The quantity of fuel injected is determined by the fuel pressure and also the amount of time the injector assembly is open.

  2. Trouble Area Chart According to Problem Cause

    A01KFOVE01
    A01KHT8E01

    Note


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

    • After replacing the fuel supply pump assembly or suction control valve, 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 age. Do not assume the vehicle is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

PROCEDURE


  1. CHECK ENGINE CRANKING CONDITION


    1. Check the engine cranking condition.

      Result
      Result Proceed to
      Cranking is OK. A
      Low cranking speed. B
      Does not crank at all. C

      Tech Tips

      *1: When cranking speed is low, especially when the temperature is low, check if the engine oil grade matches the recommendation.


    B

    CHECK BATTERY CONDITION Click here

    C

    READ OUTPUT DTC (RELATED TO ENGINE) Click here

    A

  2. READ ALL OUTPUT DTCS


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Utility / All Codes.

      Result
      Result Proceed to
      No DTC is output A
      Engine related DTCs are output B

      Tech Tips

      If only DTC P1604 is output, proceed to step 3.


    B

    GO TO RELATED DTC Click here

    A

  3. TAKE SNAPSHOT DURING STARTING AND IDLING (PROCEDURE 3)


    1. Connect the intelligent tester to the DLC3.

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

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

    4. A01KG3HE35
      Text in Illustration
      *1 Snapshot Button
      *a Reference

      Take a snapshot when idling with no load after the engine is warmed up and when starting trouble is occurring.

      Tech Tips


      • A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting. The data in the illustration below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

      • When there is trouble starting with a cold engine, take the snapshot when the engine is cold. Then warm up the engine (engine coolant temperature is 70°C (158°F) or higher) and after idling the vehicle for 1 minute (A/C off, electrical load off), take a snapshot of the data for 15 seconds while idling.

      • Graphs like the ones shown below can be displayed by transferring the stored snapshot from the tester to a PC. Intelligent Viewer must be installed on the PC.

      • Take a snapshot when the problem is occurring, such as when the engine is cold. However, if the problem does not reoccur, it is acceptable to only take a snapshot after the engine is warmed up and when the engine is started.


    NEXT

  4. CHECK SNAPSHOT (FUEL PRESS)


    1. Check Fuel Press in the snapshot taken in procedure 3 when the engine was started.

      A01KEU1E01
      Result
      Result Proceed to

      At the point in the illustration labeled "a", Fuel Press is less than 10000 kPa (102 kgf/cm2, 14500 psi) from the value of Fuel Press when cranking started

      		 A

      At the point in the illustration labeled "c", Fuel Press is below Target Common Rail Pressure by 15000 kPa (153 kgf/cm2, 2175 psi) or more

      		 B
      Fuel Press increases to a value that is higher than Target Common Rail Pressure immediately after cranking, and, at the point in the illustration labeled "d", Fuel Press is higher than Target Common Rail Pressure and no initial combustion C
      Except above D

      Tech Tips


      • Even if Fuel Press is temporarily higher than Target Common Rail Pressure, as shown at the point in the illustration labeled "b", the fuel supply pump assembly is normal.

      • Fuel pressure is about 25000 to 35000 kPa (254.9 to 356.9 kgf/cm2, 3625 psi to 5075 psi) when the engine is cranking and the engine coolant temperature is 0°C (32°F) or higher.

      • Fuel pressure increases rapidly during cranking.


    B

    READ VALUE USING INTELLIGENT TESTER (FUEL PRESS) Click here

    C

    INSPECT INJECTOR DRIVER (EDU) Click here

    D

    INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR) Click here

    A

  5. CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY


    1. Disconnect the inlet hose from the fuel supply pump assembly.

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

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

      Tech Tips


      • When there is a lack of fuel, fuel pressure drops.

      • Inspect for fuel filter element sub-assembly clogging (check that the fuel filter element sub-assembly is not clogged).


    NG

    CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP ASSEMBLY) Click here

    OK

  6. CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)


    1. Disconnect the suction control valve connector.

    2. Disconnect the ECM connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S11-1 - E11-23 (PCV+) Always Below 1 Ω
      S11-2 - E11-12 (PCV-) Always Below 1 Ω
      S11-1 or E11-23 (PCV+) - Body ground Always 10 kΩ or higher
      S11-2 or E11-12 (PCV-) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. REPLACE SUCTION CONTROL VALVE


    1. Replace the fuel suction control valve Click here.


    NEXT

  8. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  9. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  10. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS)


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel Press.

    4. Start the engine.

    5. Read the Fuel Press values while cranking and idling the engine.

      Result
      Result Proceed to

      The engine cannot be started or the engine can be started but Fuel Press is below 20000 kPa (203.9 kgf/cm2, 2900 psi) 2 seconds after the starter signal changes from OFF to ON

      		 A
      Except above B

    B

    END

    A

  11. INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)


    1. Remove the glow plug for all the cylinders Click here.

    2. Visually check if there is fuel on the glow plugs.

      Tech Tips


      • If there is fuel on a glow plug, fuel may be leaking from an injector assembly.

      • After replacing an injector assembly, make sure that the common rail pressure (fuel pressure) is within 5000 kPa (50.9 kgf/cm2, 725 psi) of the target fuel pressure while cranking the engine.

      • If there is fuel on a glow plug, fuel may have mixed with the engine oil. Check the engine oil amount and whether the engine oil smells of diesel fuel. If the oil level is above the full line or the engine oil smells of diesel fuel, replace the engine oil.


    NEXT

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

  12. CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP ASSEMBLY)


    1. Check and repair or replace the clogged fuel pipe.


    NEXT

  13. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  14. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS)


    1. Check Fuel Press in the snapshot taken in procedure 3 when the engine was warmed up.

      Result
      Result Proceed to

      Difference between Fuel Press and Target Common Rail Pressure is 5000 kPa (50.9 kgf/cm2, 725 psi) or more

      		 A
      Except above B

    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS Click here

    A

  15. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT

  16. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  17. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. Replace the injector assemblies Click here.

      Note


      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.


    NEXT

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY Click here

  18. INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)


    1. When the engine does not start, perform the following procedure.


      1. Stop the engine and leave the vehicle for 4 hours or more.

        Tech Tips

        It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

      2. Check that the engine starts.

        OK
        The engine starts.

    2. When the engine starts, perform the following procedure.


      1. Bleed the air from the fuel system Click here.

      2. Check that the engine starts.

        OK
        The engine starts.

    NG

    CHECK DATA LIST Click here

    OK

    END

  19. CHECK DATA LIST


    1. A01KG3HE35
      Text in Illustration
      *1 Snapshot Button
      *a Reference

      Check Injection Feedback Val # in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Injection Feedback Val #1 to #4 are 3 mm3/st or less.

      Injection Volume is more than 16 mm3/st.

      		 A*2

      Injection Feedback Val for at least one cylinder is more than +3 mm3/st*1

      		 B
      Except above C

      Tech Tips


      • *1: There may be a malfunction in the corresponding cylinder.

      • *2: When this case occurs, usually symptoms may be noticeable, such as difficulty starting, lack of power.

      • The shift lever should be in neutral and the A/C switch and all accessory switches should be off.


    B

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CHECK THE CYLINDER COMPRESSION) Click here

    C

    CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS Click here

    A

  20. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. Replace the injector assemblies Click here.

      Note


      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.


    NEXT

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY Click here

  21. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CHECK THE CYLINDER COMPRESSION)

    Tech Tips

    Use this Active Test to help determine whether a cylinder has compression loss or not.


    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 / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #4.

    4. Check the engine speed during the Active Test.

      Result
      Result Proceed to
      Except below A
      The values of Engine Speed Cyl #1 to #4 are within +/-10 rpm of each other. B

      Tech Tips

      When cranking, if the speed of a cylinder is approximately 100 rpm more than the other cylinders, there is probably a complete loss of compression in that cylinder.


    B

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

    A

  22. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    Tech Tips

    Measure the compression of the cylinder that had a high speed during the "Check the Cylinder Compression" Active Test.


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  23. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tech Tips

    It can be determined that the injector assembly is faulty as the corresponding cylinder is malfunctioning, but has no compression loss.


    1. Replace the injector assembly Click here.

      Note


      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.


    NEXT

  24. CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. Clean the fuel filter case and replace the fuel filter element sub-assembly.

      Tech Tips

      Be sure to clean the inside of the fuel filter case as the injector assemblies may not operate properly if the fuel filter element sub-assembly is installed with foreign matter remaining inside the fuel filter case.


    NEXT

  25. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  26. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation codes Click here.

    2. Perform the injector pilot quantity learning Click here.


    NEXT

  27. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

  28. INSPECT INJECTOR DRIVER (EDU)


    1. Even in cases where DTC P062D is not stored even though the engine cannot be started, perform the DTC P062D (No. 1 Fuel Injector Driver Circuit Performance) troubleshooting procedure Click here.

      When troubleshooting the injector driver (EDU) circuit, the source of the malfunction is likely to be in one of the following areas, so be sure to inspect these areas carefully.


      • Injector driver (EDU) system power source circuit

      • Injector assembly circuit

      • Injector driver (EDU)

      • ECM

      Tech Tips


      • When the engine cannot be started due to a malfunction in the injector driver (EDU) circuit, once the DTCs are cleared, the system cannot store DTC P062D even if it is confirmed that the engine cannot be started when trying to reproduce the problem symptoms.

        As DTC P062D cannot be stored when starting the engine, fuel injection signals are output by the ECM, but fuel is not actually injected. Therefore, an excessive amount of fuel is supplied to the common rail by the fuel supply pump assembly, and as a result, the fuel pressure is higher than the target common rail pressure in the data recorded at the time the engine was having trouble starting.

      • If the problem cannot be determined even after performing the DTC P062D (No. 1 Fuel Injector Driver Circuit Performance) troubleshooting procedure and the fuel pressure is higher than the target common rail pressure when attempting to start the engine, proceed to the next step.

      • Perform the troubleshooting procedure for DTC P062D and proceed to the diagnostic flow situations where the engine does not start.

      Result
      Result Proceed to
      Injector driver (EDU) circuit is normal A
      Injector driver (EDU) circuit is abnormal B

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    A

  29. INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)


    1. When the engine does not start, perform the following procedure.


      1. Stop the engine and leave the vehicle for 4 hours or more.

        Tech Tips

        It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

      2. Confirm the engine starts.

    2. When the engine starts, perform the following procedure.


      1. Bleed the air from the fuel system Click here.

      2. Confirm the engine starts.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  30. CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS


    1. Check the temperature when starting trouble occurs.

      Result
      Result Proceed to
      Difficult to start only for cold engine. A
      Difficult to start both for cold and warmed up engine. B

    B

    CHECK FUEL QUALITY Click here

    A

  31. READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP)


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / Coolant Temp.

    4. Read the value displayed on the tester.

      OK
      Coolant Temp is not high when the engine is cold, and not low after the engine is warmed up

    NG

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  32. INSPECT GLOW PLUG (RESISTANCE)


    1. Inspect the glow plug Click here.


    NG

    REPLACE GLOW PLUG Click here

    OK

  33. CHECK FUEL QUALITY


    1. Check that only diesel fuel is being used.

    2. Check that the fuel does not contain any impurities.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  34. READ OUTPUT DTC (RELATED TO ENGINE)


    1. Connect the intelligent tester to the DLC3.

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

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

    4. Read DTCs.

      Result
      Result Proceed to
      No DTC is output A
      Engine related DTCs are output B

    B

    GO TO RELATED DTC Click here

    A

  35. CHECK COMMUNICATION BETWEEN INTELLIGENT TESTER AND ECM


    1. Connect the intelligent tester to the DLC3.

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

    3. Check if the normal starting screen appears (check whether communication with the ECM is possible).

      Tech Tips

      Use a tester that is able to communicate with other vehicles.

      OK
      Communication is possible (vehicle can be recognized).

    NG

    CHECK VC OUTPUT CIRCUIT Click here

    OK

  36. READ VALUE USING INTELLIGENT TESTER (STARTER SIGNAL)


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / Starter Signal.

    4. Read the value displayed on the tester.

      OK
      Tester Display Condition Specified Condition
      Starter Signal Cranking ON

    NG

    GO TO STARTER SIGNAL CIRCUIT Click here

    OK

  37. CHECK STARTING SYSTEM


    1. Inspect the starting system.

      Tech Tips

      Be sure to inspect the following areas:


      • Starter relay

      • Starter


    NEXT

  38. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END