ECD SYSTEM (w/o 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

  • 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.

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. CHECK HARNESS AND CONNECTOR IN ENGINE COMPARTMENT


    1. Check the harness and connector connections of common rail system components.

      OK
      The wire harnesses and connectors are connected securely.

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. CHECK AIR INDUCTION SYSTEM (PROCEDURE 3)


    1. Check the air induction system (turbocharger, manifold absolute pressure sensor, EGR valve, etc.).

      OK
      All hoses are connected securely and there are no leaks or blockage in air induction system.

    NG

    REPAIR OR REPLACE AIR INDUCTION SYSTEM

    OK

  4. 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 output A
      Engine related DTCs B

    B

    GO TO DTC CHART Click here

    A

  5. 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
      Difference between MAP and Atmosphere Pressure is less than 8 kPa.

      Tech Tips


      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 8 kPa 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. For every 100 m increase in elevation, pressure drops by 1 kPa. 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

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

    Tech Tips

    By performing this Active Test, the engine is ran at high speed 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. Turn the ignition switch to ON and turn the tester on.

    3. A01DLTIE01

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure, and Target Pump SCV Current.

    4. Take a snapshot with the intelligent tester during the Active Test.

      Tech Tips

      Detailed graphs can be displayed by transferring the stored snapshot from the tester to a PC (personal computer) with Intelligent Viewer installed.

    5. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Fuel Press) when the "Test the Fuel Leak" Active Test is performed.

      Tech Tips

      In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

      A01DS4FE10
      OK
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa.

      Tech Tips


      • Target Common Rail Pressure is the target fuel pressure controlled by the ECM.

      • Fuel Press is the actual fuel pressure.

      • If the pressure discharge valve mounted on the common rail is malfunctioning, the actual fuel pressure will change as indicated by "Pressure Discharge Valve Malfunctioning" in the illustration.

      • If the pump is controlled using the "Test the Fuel Leak" Active Test, when the Active Test is stopped, the actual fuel pressure may drop below the target common rail pressure, but this is normal and does not indicate a malfunction.

    6. Read the value of Target Pump SCV Current in the Data List when the "Test the Fuel Leak" Active Test is performed.

      Standard
      Target Pump SCV Current is between 800 mA and 3000 mA.

      Tech Tips

      If the value of Target Pump SCV Current stored in the snapshot is higher than the standard, the intermittent suction control valve is probably stuck.

      Result
      Result Proceed to
      Both results are within standard range A

      Fuel pressure exceeds "Target Common Rail Pressure + 10000 kPa"

      and/or

      Target Pump SCV Current value is out of standard range

      		 B
      Fuel pressure does not reach "Target Common Rail Pressure - 10000 kPa" within 2 seconds C

    B

    CONFIRM IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY Click here

    C

    BLEED AIR FROM FUEL SYSTEM Click here

    A

  7. 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

  8. RESET ECM


    1. Disconnect the cable from the negative (-) battery terminal or remove the EFI fuse from the engine room relay block for at least 2 minutes.

    2. Reconnect the cable to the negative (-) battery terminal or reinstall the EFI fuse.

    3. Check whether the malfunction has been successfully repaired.

      OK
      Malfunction has been repaired successfully.

    NG

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR CUT) Click here

    OK

    END

  9. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR CUT)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off. Wait for 30 seconds, and then restart the engine.

    4. Turn the tester on.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / MAF.

    6. Read the MAF value displayed on the tester while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EGR Cut or Activate the EGR valve Close.

    8. Read the mass air flow meter value when the VSV for EGR Cut or electric vacuum regulating valve assembly is turned from off to on using the Active Test function.

      Tech Tips


      • If idling continues for 15 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or to restart the engine.

      • Before performing the diagnosis, confirm that the EGR valve target opening angle is not 0%.

      • When "Coolant Temp" is 75°C (167°F) or higher during idling, the exhaust gas flows through the EGR cooler. If MAF does not change when the EGR is cut even though the EGR valve is operating normally, the EGR cooler may be clogged.

      • When idling while warming up the engine, the actuator operates and the EGR cooler is bypassed. However, if the connector of the VSV for the EGR cooler is disconnected, the EGR cooler is not bypassed and it is possible to check how clogged the EGR cooler is.

      Result
      Active Test Result Proceed to

      Activate the VSV for EGR Cut:

      Off (Open) to on (Close)

      		 MAF value does not change B
      MAF value changes A

      Note

      As the values shown below may differ due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.

      Tech Tips

      The problem may be a temporary one, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the electric vacuum regulating valve assembly or mass air flow meter.

      Reference
      EGR Valve Condition (Opening) Measuring Condition MAF (Reference)
      Open (55%)

      • Atmosphere pressure: 101 kPa

      • Intake air temperature: 30°C (86°F)

      • Engine coolant temperature: 88°C (190°F)

      		 4.5 to 10.5 g/sec
      Close (0%) 13 to 20 g/sec

    B

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY Click here

    A

  10. READ VALUE USING INTELLIGENT TESTER (EGR CLOSE LEARN VAL. AND EGR CLOSE LRN. STATUS)


    1. Turn the ignition switch to ON.

    2. Turn the ignition switch off and wait for 15 seconds or more.

    3. Connect the intelligent tester to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / EGR Close Learn Val. and EGR Close Lrn. Status.

    6. Read the values.

      Standard
      EGR Close Lrn. Status is OK

      Tech Tips


      • When EGR Close Lrn. Status is NG, the value of EGR Close Learn Val. is unavailable because the EGR fully closed position learned value is out of the standard range.

      • When EGR Close Lrn. Status is NG, the ECM suspends the learning value update. The value indicated on the tester is the past data from when the EGR valve was working properly or the initialized data remaining from when the battery cable was reconnected, i.e., the value is not current data.

      • As the EGR valve opens, the sensor output voltage decreases.

      • If the amount of EGR is insufficient, engine knocking may occur.


    NG

    INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY Click here

    OK

  11. INSPECT DIESEL THROTTLE BODY ASSEMBLY


    1. Inspect the diesel throttle body assembly (using intelligent tester).


      1. Turn the ignition switch to ON.

      2. Turn the ignition switch off and wait for 5 seconds or more.

        Tech Tips

        Be sure to turn off the ignition switch before performing this inspection. The fully closed position of the diesel throttle valve is learned when the ignition switch is turned off.

      3. Connect the intelligent tester to the DLC3.

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

      5. Enter the following menus: Powertrain / Engine and ECT / Data List / Actual Throttle Position.

      6. Read the values.

        Standard
        Engine Condition Specified Condition
        Ignition switch ON -5 to 5%
        Idling (after engine warmed up, at elevation near sea level) 55 to 90%
        Accelerator pedal fully depressed

        -5 to 5%

        and value changes smoothly in transition

        Tech Tips

        Actual Throttle Position in the Data List should be interpreted as follows:

        Throttle Valve Condition Actual Throttle Position
        Fully closed 100%
        Fully open 0%

      7. Enter the following menus: Powertrain / Engine and ECT / Data List / Throttle Close Learning Val. and Diesel Throttle Learn Status.

      8. Read the values when the ignition switch ON.

        OK
        Diesel Throttle Learn Status is OK.

        Note

        Extremely cold conditions might cause the throttle valve movement to be delayed.

        Tech Tips


        • When Diesel Throttle Learn Status is NG, the value of Throttle Close Learning Val. is unavailable because the throttle fully closed position learning value is out of the standard range.

        • When Diesel Throttle Learn Status is NG, the ECM suspends the learning value update. The value indicated on the tester is the past data from when the diesel throttle was working properly or the initialized data remaining from when the battery cable was reconnected, i.e., the value is not current data.

        • If the diesel throttle condition is normal, the fully closed position is learned when the ignition switch is turned off and 5 seconds or more elapse.

    2. Inspect the diesel throttle body assembly (without using intelligent tester).


      1. Inspect throttle valve operation visually.

        OK
        No malfunction.

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY Click here

    OK

  12. 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 MAF) Click here

    A

  13. CHECK ENGINE COOLANT TEMPERATURE SENSOR


    1. After warming up the engine, the engine coolant temperature should be 70°C (158°F) or higher. After leaving the vehicle overnight, the engine coolant temperature should be nearly equal to the intake air temperature.

      OK
      The engine coolant temperature is nearly equal to the intake air temperature.

      Tech Tips

      If the engine coolant temperature sensor output is below the actual engine coolant temperature, engine knocking may occur.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  14. INSPECT GLOW PLUG (RESISTANCE)


    1. Inspect the glow plug Click here.


    NG

    REPLACE GLOW PLUG Click here

    OK

  15. READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL #1 TO #4)

    Tech Tips


    • Read the values of Injector Feedback Val. #1 to #4 when the engine is cold.

    • If the engine coolant temperature is higher than 40°C (104°F), leave the vehicle until the engine coolant reaches almost the same temperature as the ambient temperature.


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / Injector Feedback Val. #1 to #4.

    4. Start the engine.

    5. Read the values during engine idling when the engine is cold and write them down.

      Result
      Result Proceed to

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

      		 B
      Except above A

      Note

      If any of the injector feedback values are outside of the specified range, and there is no problem with the cylinder compression pressure, replace all of the injector assemblies together.


    B

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER #1 TO #4 FUEL CUT) Click here

    A

  16. READ VALUE USING INTELLIGENT TESTER (MAP AND MAF)


    1. Connect the intelligent tester to the DLC3.

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

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

      Standard
      Item Engine Speed*1 Standard Range*2 Description
      MAP Ignition switch ON (engine stopped) Same as atmospheric pressure Intake manifold internal pressure detected by manifold absolute pressure sensor
      Idling 95 to 105 kPa (713 to 788 mmHg, 28.0 to 31.0 in.Hg)
      4000 rpm (no engine load) 100 to 125 kPa (750 to 938 mmHg, 29.5 to 36.9 in.Hg)
      3000 rpm (driving with full throttle acceleration) 175 kPa (1,313 mmHg, 51.7 in.Hg) or higher
      MAF*3 Ignition switch ON (engine stopped) Less than 0.35 g/sec. Intake air volume detected by mass air flow meter
      Idling 5 to 12 g/sec.
      4000 rpm (no engine load) 97 to 117 g/sec.
      3000 rpm (driving with full throttle acceleration) 120 g/sec. or more
      Result
      Item Result Proceed to
      MAP and MAF Within standard range A
      MAP and MAF Outside standard range B
      Only MAP Outside standard range C
      Only MAF Outside standard range D

      Tech Tips


      • *1: The A/C switch and all accessory switches should be off with a fully warm engine.

      • *2: These values are valid when the ambient temperature is 25°C (77°F), the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg) and a stable boost pressure is maintained for approximately 10 seconds.

      • *3: When the mass air flow meter malfunctions, the MAF output may deviate from the standard (reference) range when the engine is idling and when the vehicle is accelerated from 3000 to 4000 rpm with full throttle acceleration.


    B

    CHECK AIR INDUCTION SYSTEM (REFER TO PROCEDURE 3)

    C

    GO TO DTC P0107 AND P0108 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR) Click here

    D

    GO TO DTC P0102 AND P0103 (RELATED TO MASS AIR FLOW METER) Click here

    A

  17. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Remove the electric EGR control valve assembly.

    2. Check that the electric EGR control valve assembly is fully closed.

      OK
      The electric EGR control valve assembly closes.

      Tech Tips


      • Hold the electric EGR control valve assembly to a light and confirm that the valve contacts the valve seat securely.

      • If light leaks out from the valve, the electric EGR control valve assembly is not completely closed.

      • Remove deposits if there is a large amount of deposits in the electric EGR control valve assembly or the passage of the intake manifold.

    3. Reinstall the electric EGR control valve assembly.


    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY Click here

    OK

  18. REMOVE DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY AND INTAKE MANIFOLD)


    1. Remove the electric EGR control valve assembly.

    2. Remove the intake manifold.

    3. Visually check the electric EGR control valve assembly and intake manifold for deposits. If there are deposits, clean the electric vacuum regulating valve assembly and intake manifold.

    4. Reinstall the electric EGR control valve assembly.

    5. Reinstall the intake manifold.


    NEXT

  19. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the knocking has been successfully repaired.


    NG

    READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL #1 TO #4) Click here

    OK

    END

  20. READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL #1 TO #4)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up until the engine coolant temperature reaches 70°C (158°F) or higher.

    3. Allow the engine to idle for 1 minute or more.

      Tech Tips

      The A/C switch and all accessory switches should be off with a fully warm engine.

    4. Turn the tester on.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / Injector Feedback Val. #1 to #4.

    6. Read the values during engine idling.

      Result
      Result Proceed to

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

      		 B
      Except above A

      Note

      If any Injector Feedback Val. is not as specified, replace all of the injector assemblies together.


    A

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER #1 TO #4 FUEL CUT) Click here

    B

    BASIC INSPECTION Click here

  21. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  22. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL LEAK TEST)

    Tech Tips

    By performing this Active Test, the engine is ran at high speed 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. Turn the ignition switch to ON and turn the tester on.

    3. A01DLTIE01

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure, and Target Pump SCV Current.

    4. Take a snapshot with the intelligent tester during the Active Test.

      Tech Tips

      Detailed graphs can be displayed by transferring the stored snapshot from the tester to a PC (personal computer) with Intelligent Viewer installed.

    5. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Fuel Press) when the "Test the Fuel Leak" Active Test is performed.

      Tech Tips

      In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

      A01DS4FE10
      OK
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa.

      Tech Tips


      • Target Common Rail Pressure is the target fuel pressure controlled by the ECM.

      • Fuel Press is the actual fuel pressure.

      • If the pressure discharge valve mounted on the common rail is malfunctioning, the actual fuel pressure will change as indicated by "Pressure Discharge Valve Malfunctioning" in the illustration.

      • If the pump is controlled using the "Test the Fuel Leak" Active Test, when the Active Test is stopped, the actual fuel pressure may drop below the target common rail pressure, but this is normal and does not indicate a malfunction.


    NG

    CONFIRM IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY Click here

    OK

  23. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the knocking has been successfully repaired.


    NEXT

    END

  24. CONFIRM IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY


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

    2. Operate the hand 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 hand pump is operated.

      Tech Tips


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

      • Check that the fuel filter element sub-assembly is not clogged.

    3. Reconnect the inlet hose.


    NG

    REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)

    OK

  25. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT

  26. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  27. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  28. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL LEAK TEST)

    Tech Tips

    By performing this Active Test, the engine is ran at high speed 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. Turn the ignition switch to ON and turn the tester on.

    3. A01DLTIE01

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure, and Target Pump SCV Current.

    4. Take a snapshot with the intelligent tester during the Active Test.

      Tech Tips

      Detailed graphs can be displayed by transferring the stored snapshot from the tester to a PC (personal computer) with Intelligent Viewer installed.

    5. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Fuel Press) when the "Test the Fuel Leak" Active Test is performed.

      Tech Tips

      In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

      A01DS4FE10
      OK
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa.

      Tech Tips


      • Target Common Rail Pressure is the target fuel pressure controlled by the ECM.

      • Fuel Press is the actual fuel pressure.

      • If the pressure discharge valve mounted on the common rail is malfunctioning, the actual fuel pressure will change as indicated by "Pressure Discharge Valve Malfunctioning" in the illustration.

      • If the pump is controlled using the "Test the Fuel Leak" Active Test, when the Active Test is stopped, the actual fuel pressure may drop below the target common rail pressure, but this is normal and does not indicate a malfunction.

      Result
      Result Proceed to
      Outside standard range A
      Within standard range B

    B

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

    A

  29. REPLACE COMMON RAIL ASSEMBLY


    1. Replace the common rail assembly Click here.


    NEXT

  30. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  31. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


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


    NEXT

    END

  32. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER #1 TO #4 FUEL CUT)

    Tech Tips

    Use this Active Test to determine the malfunctioning cylinder.


    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 / Control the Cylinder #1 to #4 Fuel Cut.

      Tech Tips


      • If the engine idle speed does not change when an injector assembly is disabled, the cylinder being tested is malfunctioning. Record any malfunctioning cylinders.

      • If the cylinder being tested is normal, there will be a significant change in idle speed when the fuel injection is stopped for that cylinder.


    NEXT

  33. 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

  34. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  35. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    1. Replace the injector assembly of the malfunctioning cylinder Click here.


    NEXT

  36. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation code Click here.

    2. Perform the injector pilot quantity learning Click here.


    NEXT

  37. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  38. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


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


    NEXT

    END

  39. 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 idling speed and maximum engine speed.

    7. Check the vacuum pump.


    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

    END