ECD SYSTEM (w/o DPF) Lack of Power or Hesitation

DESCRIPTION

Malfunction Condition Main Trouble Area Related Trouble Area

  • 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 system

  • 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 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 (such as the maximum speed being extremely slow) while the vehicle is being driven.

INSPECTION PROCEDURE

Note


PROCEDURE


  1. CHECK HARNESS AND CONNECTOR IN ENGINE ROOM


    1. Check the wire harness connections.

      OK
      Wire harness and connector 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 an 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 an intelligent tester to the DLC3.

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

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

    4. Read DTCs.

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

    B

    REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT

    A

  4. PERFORM CONFIRMATION DRIVING PATTERN

    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. READ OUTPUT DTCS (RELATING TO ENGINE)


    1. Connect an intelligent tester to the DLC3.

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

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

    4. Read DTCs.

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

    B

    REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT

    A

  6. 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 PART

    OK

  7. 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

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


    1. Connect an 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 / Data List.

    4. Select the following menu items in order and read the values.


      • MAP

      • MAF

      • Fuel Press

      Result
      Item Engine Speed* Standard Range Proceed To Description
      MAP

      Ignition switch ON

      Idling

      		 Same as atmospheric pressure

      • A (standard range)

      • B (both MAP and MAF outside standard range)

      • C (only MAP outside standard range)

      • D (only MAF outside standard range)

      • E ( fuel pressure outside standard range)

      		 Intake manifold internal pressure detected by intake pressure sensor
      Idling 95 to 105 kPa (712.5 to 787.5 mmHg, 28 to 31 in.Hg)
      3,000 rpm (No engine load) 103 to 128 kPa (772.5 to 960 mmHg, 30.4 to 37.7 in.Hg)
      3,000 rpm (Ffull throttle acceleration) Min.: 185 kPa (1387.6 mmHg, 54.6 in.Hg)
      MAF

      Ignition switch ON

      (engine stopped)

      		 0 g/sec Intake air volume detected by mass air flow meter
      Idling 9 to 16 g/sec
      2,000 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 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 (VALVE OPERATION) 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

    CHECK AND REPLACE FUEL FILTER ASSEMBLY Click here

    A

  9. 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/st

      • 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 mm3/st range
      Injection Feedback Val #2 Idling

      -3.0 to 3.0 mm3/st
      Injection Feedback Val #3 Idling

      -3.0 to 3.0 mm3/st
      Injection Feedback Val #4 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      5.0 to 12.0 mm3/st

      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 with a fully warm engine.


    B

    IDENTIFY MALFUNCTIONING CYLINDER INJECTOR Click here

    A

  10. 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.

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

    NG

    REGISTER INJECTOR COMPENSATION CODE

    OK

  11. 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

  12. 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

  13. 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

  14. INSPECT GLOW PLUG


    1. A01BAU1E02

      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 glow plug terminals 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

    REPLACE GLOW PLUG

    OK

  15. 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

    OK

  16. 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 air leakage or blockage.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

    END

  17. IDENTIFY MALFUNCTIONING CYLINDER INJECTOR


    1. Connect an intelligent tester to the DLC3.

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

    3. Start the engine and warm it up.

    4. Select the following menu items: Powertrain / Engine / Data List.


      • Injection Feedback Val #1, #2, #3 and #4

      • Injection Volume

    5. 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 value
      Item Engine Speed* Specified Condition
      Injection Feedback Val #1 to #4 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      5.0 to 12.0 mm3/st

      Tech Tips

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

      Result
      Injection Feedback Val #1 to #4 Injection Volume Proceed To

      3.0 mm3/st or more, -3.0 mm3/st or less

      Less than 5.0 mm3/st

      		 A

      Between 5.0 to 12.0 mm3/st (Normal)

      		 B

      More than 12.0 mm3/st

      		 B

      Between -3.0 and 3.0 mm3/st

      Less than 5.0 mm3/st

      		 -

      Between 5.0 to 12.0 mm3/st (Normal)

      		 Normal

      More than 12.0 mm3/st

      		 C*
      Proceed To Inspection Area Description
      A

      Inspect and repair injector with revised injection volume of less than -3.0 mm3/st:


      • 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 large 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 an intelligent tester is large despite the Fuel Press 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 value may be outside the normal operating range due to compensation for other problems (such as low compression).

      • Injection Feedback Val #1 to #4 is the value 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 ALL CYLINDER INJECTORS FOR DEPOSIT Click here

    A

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


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

    4. Check the 4 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 OF MALFUNCTIONING CYLINDER

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


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

    4. Check the 4 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

  20. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER


    1. Check the cylinder compression pressure Click here.

      Standard
      2,000 kPa (20.39 kgf/cm2, 290 psi)
      Minimum pressure:
      1,630 kPa (16.6 kgf/cm2, 236.4 psi)
      Difference between each cylinder:
      500 kPa (5.0 kgf/cm2, 71 psi)

    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  21. CHECK MALFUNCTIONING CYLINDER INJECTION FOR DEPOSIT

    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 OF MALFUNCTIONING CYLINDER

    A

  22. CLEAN INJECTOR


    NEXT

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


    1. Reinstall the injector to the cylinder head.

    2. Connect an intelligent tester to the DLC3.

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

    4. Start the engine and warm it up.

    5. Select the following menu items: Powertrain / Engine / 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 value
      Item Engine Speed* Specified Condition
      Injection Feedback Val #1 to #4 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      5.0 to 12.0 mm3/st

      Tech Tips

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

    OK

    END

  24. CHECK ALL CYLINDER INJECTORS FOR DEPOSIT

    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 INJECTORS

    A

  25. CLEAN INJECTOR


    NEXT

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


    1. Reinstall the injector to the cylinder head.

    2. Connect an intelligent tester to the DLC3.

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

    4. Start the engine and warm it up.

    5. Select the following menu items: Powertrain / Engine / 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 value
      Item Engine Speed* Specified Condition
      Injection Feedback Val #1 to #4 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      5.0 to 12.0 mm3/st

      Tech Tips

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

    OK

    END

  27. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY (VALVE OPERATION)

    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 E-VRV for EGR connector.

    3. Connect an intelligent tester to the DLC3.

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

    5. Start the engine.

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

    7. Measure the MAF rate while idling the engine.

      Standard rate
      MAF rate is between 14 to 21 g/sec

      Tech Tips


      • Standard MAF rate while idling the engine with the EGR valve operating: 9 to 16 g/sec

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

    8. Reconnect the E-VRV for EGR connector.


    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    OK

  28. INSPECT DIESEL THROTTLE BODY ASSEMBLY (VISUAL AND OPERATIONAL INSPECTIONS)

    OK
    No malfunction

    NG

    REPAIR OR REPLACE DIESEL THROTTLE BODY ASSEMBLY

    OK

  29. 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 air leakage or blockage.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  30. INSPECT INTAKE MANIFOLD (SWIRL CONTROL VALVE OPERATION)


    1. Inspect the swirl control valve system, referring the inspection procedure for DTC P2006 Click here.

      OK
      Swirl control valve operates normally.

    NG

    REPAIR OR REPLACE INTAKE MANIFOLD (SWIRL CONTROL VALVE SYSTEM)

    OK

  31. 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

  32. INSPECT ECM (VNTO VOLTAGE)


    1. A01BDXZE06

      While idling the engine, check the waveform of the ECM connectors using an oscilloscope.

      Standard voltage
      Tester Connection Specified Condition
      VNTO (D1-10) - E1 (D3-7) Correct waveform is as shown

    NG

    REPLACE ECM

    OK

  33. INSPECT ECM (VNTI VOLTAGE)


    1. A01BDQEE01

      While idling the engine, check the waveform of the ECM connectors using an oscilloscope.

      Standard voltage
      Tester Connection Specified Condition
      VNTI (D1-17) - E1 (D3-7) Correct waveform is as shown

    NG

    REPLACE TURBO MOTOR DRIVER

    OK

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


    1. Turn the ignition switch to ON.

    2. Turn the ignition switch to OFF and check the DC motor operation (check the operation link connected to the DC motor movement).

      OK
      When the ignition switch is turned to OFF, the operation link moves as shown in A to D in the illustration below and the operation link contacts the stopper bolt
      A01BC6XE01

    3. Connect an intelligent tester to the DLC3.

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

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

    6. Select the following menu items and read the value.


      • MAP

      • MAF

      Standard value
      Item Engine Speed* Specified Condition
      MAP 3,000 rpm (full throttle acceleration) Min.: 185 kPa (1,387 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 range and malfunction does not recur.
      Result
      Operation Link Condition Tester Display Proceed To
      Operation link moves correctly

      Outside standard range

      (malfunction recurs)

      		 A
      Within standard range C
      Operation link moves not correctly

      Outside standard range

      (malfunction recurs)

      		 B

    B

    INSPECT TURBOCHARGER SUB-ASSEMBLY (DC MOTOR) Click here

    C

    CHECK FOR INTERMITTENT PROBLEMS

    A

  35. 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 blockage

    NG

    REPAIR OR REPLACE FRONT EXHAUST PIPE ASSEMBLY

    OK

  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect an 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 / Data List.

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


      • MAP

      • MAF

      Standard value
      Item Engine Speed* Specified Condition
      MAP 3,000 rpm (full throttle acceleration) Min.: 185 kPa (1,387 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

    INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

    OK

    END

  37. CHECK AND REPLACE FUEL FILTER ASSEMBLY


    NEXT

  38. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect an 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 / Data List.

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


      • Fuel Press

      Standard value
      Item Engine Speed * Specified Condition
      Fuel Press Idling 30 to 40 MPa
      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.

      OK
      The values are within the standard range.

    OK

    END

    NG

  39. INSPECT SUPPLY PUMP ASSEMBLY


    1. Inspect the supply pump assembly, referring to the inspection procedure for DTC P0093 and P0627 Click here Click here.


    NG

    REPLACE SUCTION CONTROL VALVE

    OK

  40. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. Inspect the common rail assembly (fuel pressure sensor), referring to the inspection procedure for DTC P0087 Click here.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

  41. INSPECT COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)


    1. Inspect the common rail assembly (pressure discharge valve), referring to the inspection procedure for DTC P1271 Click here.


    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

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

  42. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Check the vacuum hoses connected to the manifold absolute pressure sensor.


      1. Check that the vacuum hoses connected to the manifold absolute pressure sensor and the gas filter are not clogged.

        OK
        Vacuum hoses and gas filter are not clogged

      2. Check the vacuum hose connection.

        OK
        Vacuum hoses are securely connected to sensor

    2. Inspect the manifold absolute pressure sensor output.


      1. Turn the ignition switch to ON.

        A01BADOE10

      2. Measure the voltage of the ECM connectors.

        Standard voltage
        Tester Connection Condition Specified Condition
        PIM (D3-28) - E2 (D1-28) Applied negative pressure of 40 kPa (300 mmHg, 11.8 in.Hg) 0.1 to 0.7 V
        PIM (D3-28) - E2 (D1-28) Same as atmospheric pressure 0.8 to 1.5 V
        PIM (D3-28) - E2 (D1-28) Applied positive pressure of 170 kPa (1,275 mmHg, 50.2 in.Hg) 1.6 to 2.3 V

        Tech Tips

        Even when the output voltage from the manifold absolute pressure sensor is within the specified voltage range, there may be a problem in the sensor caused by age deterioration.


    NG

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

    OK

  43. INSPECT MASS AIR FLOW METER


    1. Read values using an intelligent tester (MAF).

      Note


      • Turn the ignition switch to OFF.

      • Perform the inspection with the vehicle indoors and on a level surface.

      • Perform the inspection of the mass air flow meter while it is installed in the air cleaner case (installed on the vehicle).

      • During the test, do not use the exhaust air duct to perform suction on the exhaust pipe.


      1. Turn the ignition switch ON (do not run the engine).

      2. Turn the tester ON.

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

      4. Wait 30 seconds, and read the values on the intelligent tester.

        Standard condition
        Less than 0.50 g/sec
    2. A01BBDRE02

      Using a work light, check that the platinum filament (heater portion) in the mass air flow meter has no foreign matter attached.

      Standard
      No foreign matter attached.

    NG

    REPLACE MASS AIR FLOW METER

    OK

    END

  44. INSPECT TURBOCHARGER SUB-ASSEMBLY (DC MOTOR)


    1. A01BC1AE03

      Disconnect the D65 DC motor connector.

    2. Measure the DC motor resistance.

      Standard resistance
      1 to 100 Ω

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  45. CHECK HARNESS AND CONNECTOR (DC MOTOR - TURBO MOTOR DRIVER)


    1. A01BGZ6E03

      Disconnect the D65 DC motor connector.

    2. Disconnect the B43 turbo motor driver connector.

    3. Measure the resistance of the wire harness side connector.

      Standard resistance (Check for open)
      Tester Connection Specified Condition
      M+ (B43-12) - D65-2 Below 1 Ω
      M- (B43-5) - D65-1 Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Specified Condition
      M+ (B43-12) or D65-2 - Body ground 10 kΩ or higher
      M- (B43-5) or D65-1 - Body ground 10 kΩ or higher

    4. Reconnect the turbo motor driver connector.

    5. Reconnect the DC motor connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  46. REPLACE TURBO MOTOR DRIVER


    NEXT

  47. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Connect an 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 / Data List.

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


      • Fuel Press

      Standard value
      Item Engine Speed * Specified Condition
      Fuel Press Idling 30 to 40 MPa
      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.

      OK
      The values are within the standard range and malfunction does not recur.

    B

    END

    A

    REPLACE TURBOCHARGER SUB-ASSEMBLY