ECD SYSTEM Fuel Injection System

CAUTION / NOTICE / HINT

Note


  • After replacing the ECM, the new ECM needs registration (See page ) and initialization Click here.

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

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

PROCEDURE


  1. CHECK INJECTOR COMPENSATION CODE


    1. Check the injector compensation code Click here.

      Result
      Result Proceed to
      Except below A
      Compensation codes of the installed injector assemblies are the same as the compensation codes registered in the ECM B

    B
    A
  2. 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
  3. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 3)


    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. A004PIUE13
      Text in Illustration
      *1 Snapshot Button
      *a Reference

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


    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken in procedure 3 when the engine was idling and at 4000 rpm with no load.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3.0 mm3/st

      A

      Injection Volume is 5 mm3/st or less at 4000 rpm

      B
      Except above 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
    C
    A
  5. 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
    A
  6. 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 assembly may be installed improperly.


    NG
    OK
  7. PERFORM PILOT QUANTITY LEARNING (DETAIL)


    1. Perform the injector pilot quantity learning (Detail) Click here.


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


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

    5. Read the values.

      Standard
      Tester Display Engine Condition* Normal Value

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

      Idling

      -3.0 mm3/st to 3.0 mm3/st

      Tech Tips

      *: The A/C switch and all accessory switches should be off, the engine coolant temperature should be 75°C (167°F) or more and the engine should be idled for 1 minute or more.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3.0 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.


    B
    A
  9. 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
  10. READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME)


    1. Check Injection Volume in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Injection Volume while idling after engine warm up is 15 mm3/st or more

      A
      Except above B

      Tech Tips

      Check that PM forced regeneration is not being performed.


    B
    A
  11. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. Replace the injector assemblies of all cylinders 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
  12. REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. Replace the fuel filter element sub-assembly Click here.


    NEXT
  13. BLEED AIR FROM FUEL SYSTEM


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


    NEXT
  14. 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
  15. CHECK AND REPLACE ENGINE ASSEMBLY


    1. Check and replace the engine assembly.


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


    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 / Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure, and Target Pump SCV Current.

    4. Start the engine.

    5. A004PIUE45
      Text in Illustration
      *1 Snapshot Button
      *a Reference

      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.

    6. 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.

      A004U3OE02
      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 (102.0 kgf/cm2, 1451 psi).
      Result
      Result Proceed to
      NG A
      OK* B

      Note

      *: Even when the results of the Active Test are normal, take a snapshot of vehicle data when the vehicle is accelerating. If "Fuel Press" does not follow "Target Common Rail Pressure", proceed to step 17.

      If "Fuel Press" does not follow "Target Common Rail Pressure", the fuel filter may be clogged.

      Tech Tips


      • "Target Fuel Press" means target fuel pressure controlled by the ECM.

      • "Fuel Press" means actual fuel pressure in common rail assembly.

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

      • The pressure discharge valve operates to discharge fuel pressure when the internal pressure of the common rail exceeds the target fuel pressure.

      • There are 2 fuel pressure sensor circuits and both of them display the same value. If the difference between Fuel Press and Common Rail Press Sens 2 exceeds 10000 kPa (102 kgf/cm2, 1451 psi) for 2 seconds or more, it is necessary to inspect or repair the wiring for the fuel pressure sensor.


    B
    A
  17. INSPECT COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)


    1. Enter the following menus: Powertrain / Engine and ECT / Utility / Pressure Discharge Valve Check Click here.

    2. Select "Always Closed Check".

    3. Press "Next".

    4. Read the Value of fuel pressure values.

      OK
      Fuel pressure is properly maintained.

      Tech Tips


      • If the fuel pressure cannot be maintained, the pressure discharge valve may not have a tight seal.

      • If the fuel pressure is being properly maintained, there are no problems with the sealing properties of the high-pressure fuel system. Therefore, an insufficient supply of fuel due to the fuel filter being clogged, or squashed or blocked low-pressure fuel pipes or hoses may be causing the reduction in common rail pressure.


    NG
    OK
  18. INSPECT CLOGGED FUEL PIPE


    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 / Diesel Injection.

    4. With no load after the engine is warmed up, take a snapshot when idling and vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear.

    5. Check the Target Common Rail Pressure and Fuel Press value.

      A004P29E29
      Result
      Result Proceed to
      While idling the vehicle, "Fuel Press" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1 A
      "Fuel Press" is normal while idling the vehicle, but "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear*2
      Except above B

      Note


      • *1: The cause may be a squashed or blocked fuel pipe or hose.

      • *2: The cause may be a clogged fuel filter.


    B
    A
  19. REPAIR OR REPLACE CLOGGED FUEL LINE


    1. Repair or replace the clogged (including frozen fuel) fuel pipe.

    2. Replace the fuel filter element sub-assembly.

      Tech Tips

      If "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element sub-assembly.


    NEXT
  20. REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)


    1. Replace the common rail assembly Click here.


    NEXT
  21. BLEED AIR FROM FUEL SYSTEM


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


    NEXT
  22. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)


    1. Check Fuel Press and Target Common Rail Pressure in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Difference between Fuel Press and Target Common Rail Pressure is 5000 kPa (51.0 kgf/cm2, 725 psi) or more

      B
      Except above A

    A
    B
  23. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT
  24. BLEED AIR FROM FUEL SYSTEM


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


    NEXT
  25. PERFORM SUPPLY PUMP INITIALIZATION


    1. Perform supply pump initialization Click here.


    NEXT
  26. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT