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 limiter

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Fuel filter element is clogged

  • Throttle valve

  • Compression pressure

  • Injector compensation code

  • Fuel leak

  • Glow plug

  • Fuel pressure sensor

  • EDU (P0200/97 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


  • After replacing the supply pump, the ECM needs initialization Click here.

  • After replacing the injector, the ECM needs registration Click here.

PROCEDURE


  1. CHECK WIRE HARNESS IN ENGINE ROOM


    1. Check the wire harness and connector connections.

      OK
      Wire harnesses are connected securely.

    NG

    REPAIR OR REPLACE HARNESS AND CONNECTOR

    OK

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


    1. Enter 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

  3. READ OUTPUT DTC (RELATING TO ENGINE)


    1. Enter the following menus: Power train / Engine / DTC.

    2. Read pending DTCs.

      Result
      Display (DTC Output) Proceed to
      No DTCs A

      Engine related DTCs Click here

      		B

    B

    REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT

    A

  4. 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 the intelligent tester to the DLC3.

    2. Start the engine and turn the intelligent tester ON.

    3. Enter the following menus: Power train / 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 leakage.

    NG

    REPAIR OR REPLACE FUEL LEAKAGE POINT

    OK

  5. 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

    CHECK TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM) Click here

    A

  6. READ VALUE USING MANIFOLD ABSOLUTE PRESSURE SENSOR AND FUEL PRESSURE SENSOR (MAP AND FUEL PRESS)


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Power train / Engine / Data List.

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


      • MAP

      • 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 (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) 113 to 133 kPa (848 to 998 mmHg, 33.4 to 39.3 in.Hg)
      3,500 rpm (full throttle acceleration) Min.: 175 kPa (1,313 mmHg, 51.7 in.Hg)
      Fuel Press Idling 25 to 35 MPa

      • A (standard range)

      • C ( fuel pressure outside standard range)

      		 Common rail internal fuel pressure
      2,000 rpm (No engine load) 25 to 35 MPa
      3,000 rpm (No engine load) 35 to 55 MPa
      3,500 rpm (full throttle acceleration) Min.: 121 MPa

      Tech Tips

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


    B

    GO TO DTC P0105/35, P0107/35 AND P0108/35 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR)

    C

    CHECK AND REPLACE FUEL FILTER ASSEMBLY Click here

    A

  7. READ VALUE USING INJECTOR (INJECTION FEED BACK VAL AND 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 mm range
      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 3.0 to 10.0 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

    IDENTIFY MALFUNCTIONING CYLINDER INJECTOR Click here

    A

  8. 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.

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

    NG

    REGISTER INJECTOR COMPENSATION CODE

    OK

  9. 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

  10. 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

  11. 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

  12. INSPECT GLOW PLUG ASSEMBLY


    1. A01BAU1

      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.


    NG

    REPAIR OR REPLACE GLOW PLUG ASSEMBLY

    OK

  13. 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 MALFUNCTION PARTS

    OK

  14. 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 MALFUNCTION PARTS

    OK

  15. CHECK ECM TERMINAL VOLTAGE (EGLS TERMINAL)

    Tech Tips

    The lifting amount of the EGR valve can be checked using the output of the EGR position sensor.


    1. A01BF68E11

      Turn the ignition switch ON.

    2. Measure the voltage of the ECM connector.

      Standard voltage
      Tester Connection Specified Condition
      D3-33 (EGLS) - D1-28 (E2) A (0.3 to 1.3 V)

    3. Turn the ignition switch ON.

    4. Engine start.

    5. Measure the voltage of the ECM connector.

      Standard voltage
      Tester Connection Condition Specified Condition
      D3-33 (EGLS) - D1-28 (E2) Idling: 750 rpm A + (1.91 to 2.70 V)

      Tech Tips

      In the chart above, "Idling" means that the engine should be idled under the following conditions:


      • Idle the engine, turn the A/C switch OFF and move the shift lever to N.

      • After the engine warms up, the engine should have no load.


    NG

    REPAIR OR REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    OK

  16. INSPECT DIESEL THROTTLE BODY ASSEMBLY


    1. Measure the resistance between the terminal 1 of the diesel throttle body and body ground.

      Standard resistance
      2 to 10 kΩ at 20°C (68°F)

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

    OK

  17. 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

      3.0 to 10.0mm3

      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 Volume
      Injection Feedback Val #1 to #4

      Less than 3.0 mm3

      Between 3.0 to 10.0 mm3(Normal)

      More than 10.0 mm3

      3.0 mm3or more, -3.0 mm3or less

      		 A B B

      Between -3.0 to 3.0 mm3

      		- Normal C*
      Proceed to Proceed to 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 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 the intelligent tester to the DLC3.

    2. Start the engine and turn the intelligent tester ON.

    3. Enter the following menus: Power train / Engine / 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

  19. 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 intelligent tester ON.

    3. Enter the following menus: Power train / Engine / 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

  20. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure. Click here

      Standard
      1,230 kPa (12.5 kgf/cm2, 178 psi)
      Minimum pressure
      880 kPa (9 kgf/cm2, 128 psi)
      Difference between each cylinder
      98 kPa (1.0 kgf/cm2, 14 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 ASSEMBLY

    A

  22. CLEAN INJECTOR


    NEXT

  23. READ VALUE USING INJECTOR (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 intelligent tester ON.

    4. Start the engine and warm it up.

    5. Enter the following menus: Power train / 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
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #4 Idling

      -3.0 to 3.0 mm3

      Injection Volume Idling

      3.0 to 10.0 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 INJECTOR ASSEMBLY

    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 INJECTOR ASSEMBLY OF ALL CYLINDER

    A

  25. CLEAN INJECTOR


    NEXT

  26. READ VALUE USING INJECTOR (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 intelligent tester ON.

    4. Start the engine and warm it up.

    5. Enter the following menus: Power train / 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
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #4 Idling

      -3.0 to 3.0 mm3

      Injection Volume #1 to #4 Idling

      3.0 to 10.0 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 INJECTOR ASSEMBLY OF ALL CYLINDER

    OK

    END

  27. CHECK 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
      Impellor rotates smoothly and is not damaged.

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  28. INSPECT TURBOCHARGER ACTUATOR


    1. Inspect the actuator and waste gate valve.

      OK
      The valve has no contamination and move smoothly.

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    OK

  29. 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 intelligent tester ON.

    3. Enter the following menus: Power train / Engine / Data List.

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


      • MAP

      Standard
      Item Engine Speed* Reference Value
      MAP 3,500 rpm (full throttle acceleration) Min.: 175 kPa (1,313 mmHg, 51.7 in.Hg)

      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

  30. CHECK AND REPLACE FUEL FILTER ASSEMBLY


    NEXT

  31. 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 intelligent tester ON.

    3. Enter the following menus: Power train / Engine / Data List.

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


      • Fuel Press

      Standard
      Item Engine Speed * Reference Value
      Fuel Press Idling 25 to 35 MPa
      Fuel Press 2,000 rpm (no engine load) 25 to 35 MPa
      Fuel Press 3,000 rpm (no engine load) 35 to 45 MPa
      Fuel Press 3,500 rpm (full throttle acceleration) Min.: 121 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

  32. INSPECT SUPPLY PUMP ASSEMBLY


    1. Measure the resistance of the suction control valve terminals.

      Standard resistance
      1.9 to 2.3 Ω at 20°C (68°F)

    NG

    REPLACE SUCTION CONTROL VALVE

    OK

  33. INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    1. A01BDUBE03

      Disconnect the D45 sensor connector.

    2. Measure the resistance of the sensor.

      Standard resistance
      Tester Connection Specified Condition
      D45-1 (E2) - D45-2 (PR) 3 kΩ or less
      D45-2 (PR) - D45-3 (VC) 16.4 kΩ or less

    NG

    REPLACE COMMON RAIL ASSEMBLY

    OK

    INSPECT COMMON RAIL ASSEMBLY (PRESSURE LIMITER)