ECD SYSTEM (w/ DPF) Engine Knocking or Rattling

DESCRIPTION

Malfunction Condition Main Trouble Area Related Trouble Area

  • Knocking and abnormal sound due to extremely rich combustion

  • Abnormal sound due to friction between parts

  • (a) Injector assembly malfunctions


    • Injector sliding malfunction

    • Injector stuck closed

    • Injector stuck open

    • Deposits in injector


    • Injector circuit malfunction


  • (b) Abnormal common rail pressure


    • Suction control valve

    • Fuel pulsation sound

    • Air in fuel


  • (c) Friction between parts


  • (d) Compression pressure

  • Injector compensation codes

  • Fuel leakage

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Throttle valve system

  • Fuel pressure sensor (common rail assembly)

  • Manifold absolute pressure sensor

  • Mass air flow meter

  • Atmospheric pressure sensor (built into ECM)

  • Vehicle modifications

  • Low quality fuel

  • Lack of 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.

INSPECTION PROCEDURE

Tech Tips


  • This troubleshooting procedure checks for knocking and rattling.

  • Knocking is most likely to occur while the engine is idling.

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.

PROCEDURE


  1. CHECK SOUND AREA


    1. Find the source of the abnormal sound using a mechanic's stethoscope.

      Result
      Result Proceed to
      Combustion noise from engine A
      Noise from specific part B

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    A

  2. READ OUTPUT DTCS (RELATING 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 DTC CHART Click here

    A

  3. CHECK INJECTOR COMPENSATION CODE

    Note

    Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head portion of each injector assembly. If an incorrect injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.


    1. Check the injector compensation code Click here.

      OK
      Compensation codes of the installed injector assemblies are the same as the compensation codes registered in the ECM.

    NG

    REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING Click here

    OK

  4. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)


    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 / Data List / All Data.

    4. Take a snapshot of the following Data List items.

      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 list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

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

      • Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.


    NEXT

  5. CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)


    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken when the engine was idling and at 4000 rpm with no load.

      Result
      Result Proceed to
      Except below A

      Injection Volume is 10 mm3/st or less at 4000 rpm

      		 B

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

      		 C

      Tech Tips


      • When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.

      • The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not malfunctioning.


    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS Click here

    C

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

    A

  6. CHECK SNAPSHOT (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)


    1. Check Fuel Press and Target Common Rail Pressure in the snapshot taken when the engine was warmed up and idling.

      OK
      Fuel Press is within +/-5000 kPa (50.9 kgf/cm2, 725 psi) of Target Common Rail Pressure.

    NG

    REPLACE SUCTION CONTROL VALVE Click here

    OK

  7. CHECK THE TEMPERATURE WHEN KNOCKING OCCURS


    1. Check the temperature when knocking trouble occurs.

      Result
      Result Proceed to
      Knocking occurs only in cold engine A
      Knocking occurs both in cold and warmed up engine B

    B

    READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE) Click here

    A

  8. INSPECT GLOW PLUG (RESISTANCE)


    1. Inspect the glow plug Click here.


    NG

    REPLACE GLOW PLUG Click here

    OK

  9. TAKE SNAPSHOT DURING IDLING (WHEN ENGINE COLD)


    1. Make sure that the engine is cold so that the snapshot can be taken under the correct conditions.

    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 / All Data.

    5. Take a snapshot of the following Data List items.

      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 list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

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


    NEXT

  10. CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4)


    1. Check Injection Feedback Val #1 to #4 in the snapshot taken when the engine was idling.

      Result
      Result Proceed to

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

      		 A
      Except above B

      Tech Tips


      • When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.

      • The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not malfunctioning.


    A

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

    B

    READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE) Click here

  11. 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

  12. 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

  13. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.

      Tech Tips

      When compression is low, there may be cracks in the piston or the injector may be installed improperly.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  14. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    1. Replace the injector assembly of the malfunctioning cylinder 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

  15. 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

  16. 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

  17. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  18. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the knocking has been successfully repaired.


    NEXT

    END

  19. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.

      Tech Tips

      If the common rail pressure becomes too high when transitioning due to problems with suction control valve operation, knocking noise worsens.


    NEXT

  20. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  21. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  22. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the knocking has been successfully repaired by starting the engine.


    NEXT

    END

  23. READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE)


    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 / MAP and Atmosphere Pressure.

    4. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).

      Standard value
      Difference between MAP and Atmosphere Pressure is less than 8 kPa (60 mmHg, 2.4 in.Hg).

      Tech Tips


      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 8 kPa (60 mmHg, 2.4 in.Hg) or more, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.

      • Standard atmospheric pressure is 101 kPa (758 mmHg, 29.8 in.Hg). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (7.5 mmHg, 0.3 in.Hg). This varies by weather.

      Result
      Result Proceed to
      MAP and Atmosphere Pressure have same value A
      MAP is different from actual atmospheric pressure B
      Atmosphere Pressure is different from actual atmospheric pressure C

    B

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

    C

    REPLACE ECM Click here

    A

  24. BASIC INSPECTION


    1. Check the fuel quality.

    2. Check the fuel for air.

    3. Check the fuel system for blockages.

    4. Check the air cleaner filter element sub-assembly.

    5. Check the engine oil.

    6. Check the engine coolant.

    7. Check the engine idling speed and maximum engine speed.

    8. Check the vacuum pump.


    NEXT

    END