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СИСТЕМА ECD Black Smoke Emitted

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DTC Code DTC Name
  Black Smoke Emitted
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DESCRIPTION


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  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Table 1. Intake System
      Symptom and Corresponding Main Fault

      • Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct

      • Black smoke (no lack of power) due to leakage between the turbo and intake manifold
      Data List MAP
      Table 2. Glow System
      Main fault Glow system malfunction
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Data List Check the glow plug indicator light
      Diagnostic Point Measure the resistance of the glow plug
      Table 3. Engine
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      Data List

      Injection Feedback Val


      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.

    2. Diesel Injection

      Table 4. Fuel Supply Pump
      Main fault -
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure


      • Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      • If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa, then idling will be rough.

      Tip:

      The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.
      Diagnostic Trouble Code Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.
      Table 5. Injector Assembly
      Main fault Blockage, increase in fuel injection volume
      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val


      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.
      Tip:

      • When the sliding resistance of the internal parts of the injector assemblies (i.e. armature shaft, command piston and plunger) has increased due to internal contamination, injection quantity will increase at high common rail pressure due to a delay in injector assembly closure.

      • When black smoke occurs due to contamination of the injector assemblies, there are usually other symptoms, such as engine knocking noise at cold idling, rough idling, difficulty starting, etc. which are also present when the common rail pressure is low.

      Table 6. Injector Driver
      Main fault Circuit fault: The injector assembly does not open.
      Symptoms Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
      Data List Same as injector assembly
      Diagnostic Trouble Code When the injector driver has a fault, some DTCs may be stored.
      Table 7. Fuel Pressure Sensor
      Main fault Open circuit, decrease in performance (foreign matter is stuck)
      Symptoms Difficult to start, rough idle, engine stall, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure


      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped, and check that Common Rail Pressure follows Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure. (However, the value may not deviate even when a malfunction is present).
      Diagnostic Trouble Code When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 8. Irregular Fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 9. EGR System
      Main fault

      • Does not move smoothly

      • Does not close completely
      Symptoms

      • Rough idle

      • EGR valve stuck closed: A loud turbocharger sound.

      • EGR valve stuck open: Difficult to start (does not stall), black smoke, lack of power (if there is an excess in the quantity of EGR and there is a heavy load, when the vehicle starts moving, a lack of power will be felt).

    4. Diesel Throttle

      Table 10. Diesel Throttle System
      Main fault Stuck, does not move smoothly
      Symptoms

      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

      • Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.

  2. Data List Related to Black Smoke


    • Engine Speed

    • MAP

    • Intake Air

    • Coolant Temp

    • Target Common Rail Pressure

    • Common Rail Pressure

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

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INSPECTION PROCEDURE

Note:

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

  • After replacing a Fuel Supply Pump, the ECM needs initialization (Click here).

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

Tip:

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 age. Do not assume the vehicle to be normal when the Data List outputs standard values. There may be concealed factors of the malfunction.


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  1. Explanation of Symptom

    Black Smoke

    The fuel used in diesel engines has a higher boiling point and evaporates much slower than that used in gasoline engines. Additionally, the fuel is injected directly, so the air fuel mixture in diesel engines is formed in a very short period of time and is less homogenous. This is why diesel engines must operate with a larger air fuel ratio across the entire operating range. An insufficient quantity of air results in imperfect combustion and increased particulate (soot) emissions.

    When the accelerator pedal is depressed, a large amount of fuel is injected. As a result, the air fuel ratio becomes rich. In this relatively rich environment, fuel droplets lacking in oxygen burn imperfectly producing soot, which is emitted as black smoke. In order to prevent black smoke production, the maximum injection quantity for a given intake air mass is limited (final injection quantity is limited by MAF).

    Black smoke is emitted when either 1) a lack of oxygen is present during combustion, or 2) Too much fuel is injected for a given intake air mass and the air fuel ratio becomes temporarily rich.
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PROCEDURE


  1. Click here

    READ OUTPUT DTC (RELATING TO ENGINE)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

    4. Read the pending DTCs.

      Table 11. Result
      Result Proceed to
      No DTCs are output A
      Engine related DTCs are output B

  2. Click here

    CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it.*1

    4. Repeat the above procedure *1 10 times or more.*2

    5. Check for black smoke emission during procedures *1 and *2.

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      • Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

      • If the procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.


  3. Click here

    CHECK AIR INTAKE SYSTEM


    1. Check for air leakage and blockage between the air cleaner and turbocharger, and between the turbocharger and intake manifold.

      Tip:

      • Make sure that the air cleaner is not clogged and the intake and exhaust system hoses are not disconnected.

      • Check that the intercooler is not clogged with foreign matter.

      • Check that there are no disconnected, pinched or leaking hoses or pipes.

      • Check that there are no modifications made by the user.

      OK
      No leakage or blockage.

  4. Click here

    CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT


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

      OK
      The wire harnesses and connectors are connected securely.

  5. Click here

    CHECK INJECTOR COMPENSATION CODE


    1. Read the injector compensation codes (Click here).

      OK
      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.

  6. Click here

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


    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

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

      Tip:

      • 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 GTS 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.


  7. Click here

    READ VALUE USING GTS (MAP)


    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).

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

    5. Take a snapshot when the engine speed is maintained at 4000 rpm with no load.

    6. Read the values of "MAP" in the Data List using the snapshot review function.

      Table 12. Result
      Result Proceed to
      MAP 151 kPa or higher A
      Except above B
      Tip:

      • The shift lever should be in neutral and the A/C switch and all accessory switches should be off.

      • The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.

        Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.


  8. Click here

    REMOVE DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)


    1. Remove the electric EGR control valve assembly (Click here).

    2. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.

      Tip:

      • If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.

      • If the EGR valve does not operate due to clogging or disconnection of the vacuum hose, repair the hose.

      • If the EGR valve does not close properly or is stuck open, EGR becomes excessive and combustion becomes unstable. Also, there may be a lack of power. In this case, clean the electric EGR control valve assembly.

      • When cleaning the electric vacuum regulating valve assembly, use a piece of cloth soaked with non-residue solvent. Spraying the solvent directly onto these parts or soaking the parts in solvent may damage the parts.

    3. Reinstall the electric EGR control valve assembly (Click here).


  9. Click here

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


    1. Check Injection Feedback Val # and Injection Volume in the snapshot taken after the engine is warmed up and idled for 1 minute.

      Table 13. Result
      Result Proceed to

      Injection Volume is less than 8 mm3/st at 4000 rpm

      		 A

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

      		 B
      Except above C

  10. Click here

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. Replace the injector assemblies (Click here).

      Note:

      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.


  11. Click here

    CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure (Click here).

      Tip:

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


  12. Click here

    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.


  13. Click here

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER


    1. Clean the fuel filter case and replace the fuel filter.

      Tip:

      Be sure to clean the inside of the fuel filter case as the fuel injectors may not operate properly if the fuel filter is installed with foreign matter remaining inside the fuel filter case.


  14. Click here

    BLEED AIR FROM FUEL SYSTEM


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


  15. Click here

    PERFORM ECM INITIALIZATION AND REGISTER INJECTOR COMPENSATION CODE


    1. Perform the ECM initialization.


      1. A003DF8E90

        Connect terminals 13 (TC) and 4 (CG) of the DLC3.

      2. Turn the ignition switch to ON for 50 minutes or more.

        Note:

        • Perform ECM initialization only when the injectors for all the cylinders have been replaced.

        • It is necessary to wait for 50 minutes or more. Otherwise, ECM initialization is not completed.

      3. Turn the ignition switch off.

      4. Disconnect terminals 13 (TC) and 4 (CG).

    2. Register the injector compensation code (Click here).


  16. Click here

    CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it.*1

    4. Repeat the above procedure *1 10 times.*2

    5. Check for black smoke emission during procedures *1 and *2.

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.


  17. Click here

    READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS 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 to ON (engine stopped).

      Tip:

      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 10 kPa (0.1 kgf/cm2, 1.5 psi) 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 (1.0 kgf/cm2, 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm2, 0.1 psi). This varies by weather (high atmospheric pressure, low atmospheric pressure).

      Table 14. Result
      Result Proceed to
      MAP and Atmosphere Pressure have same value A
      Atmosphere Pressure is different from actual atmospheric pressure B
      MAP is different from actual atmospheric pressure C

  18. Click here

    PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)


    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

    4. Take a snapshot with the GTS during the Active Test.

    5. A003GFWE05

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

      Tip:

      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.

      OK
      The difference between the target Common Rail Pressure and the Common Rail Pressure 2 seconds after the Active Test starts is less than 10000 kPa (102.0 kgf/cm2, 1451 psi).
      Tip:

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

      • "Common Rail Pressure" is the actual fuel pressure in common rail assembly.


  19. Click here

    READ VALUE USING GTS (ENGINE COOLANT TEMPERATURE)


    1. Connect the GTS to the DLC3.

    2. Soak the engine for a long time.

    3. Turn the ignition switch to ON and turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Coolant Temp.

      OK
      Coolant Temp is the same as the ambient temperature.
      Tip:

      When the engine coolant temperature is low even though the engine has been fully warmed up, or when the engine coolant temperature is high even though the engine is cold, inspect the sensor.


  20. Click here

    READ VALUE USING GTS (INTAKE AIR)


    1. Connect the GTS to the DLC3.

    2. Soak the engine for a long time.

    3. Turn the ignition switch to ON and turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Intake Air.

      OK
      Intake Air is the same as the ambient temperature.

  21. Click here

    CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY


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

    2. Operate the priming 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 priming pump is operated.
      Tip:

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

      • If "Common rail pressure" follows "Target common rail pressure" during idling or low speed driving but is insufficient during acceleration or high speed driving, the fuel filter may be clogged.

      • Inspect for fuel filter clogging (Check that the fuel filter is not clogged).

    3. Reconnect the inlet hose.


  22. Click here

    REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve (Click here).


  23. Click here

    BLEED AIR FROM FUEL SYSTEM


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


  24. Click here

    PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform supply pump initialization (Click here).


  25. Click here

    REPLACE ECM


    1. Replace the ECM (Click here).


  26. Click here

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Replace the manifold absolute pressure sensor.


  27. Click here

    CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor (Click here).

    2. Replace the engine coolant temperature sensor (Click here).

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.


  28. Click here

    CHECK AND REPLACE MALFUNCTIONING PARTS


    1. Inspect the intake air temperature sensor (Click here).

    2. Inspect the intake air temperature sensor (turbo) (Click here).

    3. Replace the intake air temperature sensor (Click here).

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

    4. Replace the intake air temperature sensor (turbo) (Click here).

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.


  29. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR


    1. Repair or replace the harness or connector.


  30. Click here

    CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)


    1. Check and replace the clogged fuel pipe.


  31. Click here

    BLEED AIR FROM FUEL SYSTEM


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


  32. Click here

    CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it.*1

    4. Repeat the above procedure *1 10 times.*2

    5. Check for black smoke emission during procedures *1 and *2.

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.


  33. Click here

    RECOVERY TO NORMAL

    Tip:

    If the racing procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.


  34. Click here

    END

  35. Click here

    GO TO DTC CHARTClick here

  36. Click here

    REPAIR OR REPLACE MALFUNCTIONING PARTS

  37. Click here

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION