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ECD SYSTEM(w/ DPF) Engine Difficult to Start or Stalling

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DTC Code DTC Name
  Engine Difficult to Start or Stalling
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DESCRIPTION


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  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Table 1. Mass Air Flow Meter
      Main fault Decrease in performance (foreign matter is stuck)
      Symptoms Lack of power, black smoke
      Data List MAF
      Tip:

      The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
      Table 2. 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 3. Turbocharger System
      Main fault

      • Air leak in the turbocharged air passage

      • ECM not operating well

      • Turbocharger sub-assembly (turbine, bearing)
      Symptoms

      Lack of power (when vehicle is starting, under heavy load)

      (Black smoke is not emitted when racing while vehicle is stopped)
      Data List

      MAP


      • With the ignition switch ON or during idling, MAP = atmospheric pressure (standard atmospheric pressure = 101 kPa). When the engine speed is about 1500 rpm or more, the turbocharger starts to take effect and MAP becomes higher than atmospheric pressure.

      • Atmospheric pressure decreases by 1 kPa each time elevation increases by 100 m, and is also affected by the current weather conditions.
      Table 4. Exhaust System
      Main fault Blockage
      Symptoms Lack of power (high engine speed, under heavy load)
      Table 5. 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 6. Battery
      Main fault Battery is depleted
      Symptoms Difficult to start (cannot crank, crank speed is low), horn is quiet
      Data List

      Battery Voltage

      When cranking, battery voltage is below 5 V.
      Table 7. Engine - 1
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      Table 8. Engine - 2
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      Data List

      Engine Speed of Cyl


      • When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.

      Injection Feedback Val


      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.
      Table 9. Start System
      Main fault Starter system malfunction
      Symptoms Difficult to start
      Data List

      Starter Signal


      • Ignition switch (STA) output:

        Open: Starter is operating

        Close: Starter is not operating

    2. Diesel Injection

      Table 10. Fuel Supply Pump Assembly
      Main fault -
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure, Target Pump SCV Current


      • 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 75°C (167°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.

      • When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.
      Diagnostic Trouble Code Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.
      Table 11. Fuel Filter
      Main fault Blockage
      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 75°C (167°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 12. Injector Assembly
      Main fault Blockage
      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.
      Table 13. Pressure Discharge Valve
      Main fault Does not completely close
      Symptoms Difficult to start, engine stall, rough idle, lack of power
      Table 14. 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 15. 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 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Common Rail Pressure decreases to a value less than Target Common Rail Pressure).
      Diagnostic Trouble Code When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 16. Irregular Fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 17. 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).
      Data List

      Actual EGR Valve Pos, Actual EGR Valve Pos #2, Target EGR Valve Pos, Target EGR Valve Pos #2


      • Generally, Actual EGR Valve Pos = Target EGR Valve Pos +/-5% (fully closed: 0%, fully open: 100%).

      • Using the EGR valve Active Test, check whether Actual EGR Valve Pos follows Target EGR Valve Pos (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).

      • EGR valve is fully closed when the ignition switch is turned to ON (engine stopped).

      • EGR valve opens to the halfway point at idling after the engine is warmed up.

      EGR Close Lrn. Val., EGR Close Lrn. Val. #2


      • When leaving the vehicle idling, the normal range of EGR Close Lrn. Val. is 3.5 to 4.5 V.

      • In cases when EGR Close Lrn. Val. is out of the normal range (3.5 to 4.5 V), it is possible that the EGR valve cannot completely close.

    4. Diesel Throttle

      Table 18. 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.
      Data List

      • Actual Throttle Position, Actual Throttle Position #2

        100%: Fully open

        0%: Fully closed

      • When the ignition switch is ON (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

  2. Data List Related to Starting Trouble


    • MAP

    • MAF

    • Intake Air

    • Coolant Temp

    • Battery Voltage

    • Starter Signal

    • Engine Speed of Cyl #1 (to #8)

    • Target Common Rail Pressure

    • Common Rail Pressure

    • Target Pump SCV Current

    • Injection Feedback Val #1 (to #8)

    • Injection Volume

    • Actual Throttle Position

    • Actual Throttle Position #2

    • Target EGR Valve Pos.

    • Target EGR Valve Pos #2

    • Actual EGR Valve Pos

    • Actual EGR Valve Pos #2

    • EGR Close Lrn. Val.

    • EGR Close Lrn. Val #2

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CAUTION / NOTICE / HINT


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  1. Explanation of Symptom

    Starting Trouble

    For good starting it is essential to have:


    • Sufficient cranking speed.

    • Properly operating engine preheating system.

    • Good quality fuel.

    The fuel is ignited by the heat which is generated by compression pressure.

    With problems such as a depleted battery, the crankshaft speed can become low, or if the engine compression is poor due to leakage, the compression pressure will not rise and there will be difficulty starting.

    When the engine is cold, even if there is compression heat, it will escape from the combustion chamber. For this reason, when the engine is started when it is cold, the glow plugs heat the compressed air.

    Also, after starting the engine, by charging the glow plugs for a fixed time set according to the engine coolant temperature, diesel knocking and white smoke are prevented. The quantity of fuel injected is determined by the fuel pressure and also the amount of time the injector assembly is open.
  2. A01X2XZE03
    A01X31UE02

    Trouble Area Chart According to Problem Cause

    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).

    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 is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

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PROCEDURE


  1. Click here

    CHECK ENGINE CRANKING CONDITION


    1. Check the engine cranking condition.

      Table 19. Result
      Result Proceed to
      Cranking is OK. A

      Low cranking speed.

      Tip:

      When cranking speed is low, especially when the temperature is low, check if the engine oil grade matches the recommendation.

      		 B
      Does not crank at all. C

  2. Click here

    READ ALL OUTPUT DTCS


    1. Connect the GTS to the DLC3.

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

    3. Enter the following menus: Utility / All Codes.

      Table 20. Result
      Result Proceed to
      No DTC is output A
      Engine related DTCs are output B
      Tip:

      If only DTC P1604 is output, proceed to step 3.


  3. Click here

    TAKE SNAPSHOT DURING STARTING AND IDLING (PROCEDURE 3)


    1. Connect the GTS to the DLC3.

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

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

    4. Take a snapshot when idling with no load after the engine is warmed up and when starting trouble is occurring.

      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 illustration below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

      • When there is trouble starting with a cold engine, take the snapshot when the engine is cold. Then warm up the engine (engine coolant temperature is 75°C (167°F) or higher) and after idling the vehicle for 1 minute (A/C off, electrical load off), take a snapshot of the data for 15 seconds while idling.

      • Take a snapshot when the problem is occurring, such as when the engine is cold. However, if the problem does not reoccur, it is acceptable to only take a snapshot after the engine is warmed up and when the engine is started.


  4. Click here

    CHECK SNAPSHOT (COMMON RAIL PRESSURE)


    1. A01XAABE04

      Check Common Rail Pressure in the snapshot taken in procedure 3 when the engine was started.

      Table 21. Result
      Result Proceed to
      At the point in the illustration labeled "a", Common Rail Pressure is less than 10000 kPa from the value of Common Rail Pressure when cranking starts A
      At the point in the illustration labeled "c", Common Rail Pressure is below Target Common Rail Pressure by 15000 kPa or more B
      Common Rail Pressure increases to a value that is higher than Target Common Rail Pressure immediately after cranking, and, at the point in the illustration labeled "d", Common Rail Pressure is higher than Target Common Rail Pressure C
      Except above D
      Tip:

      • Even if Common Rail Pressure is temporarily higher than Target Common Rail Pressure, as shown at the point in the illustration labeled "b", the fuel supply pump assembly is normal.

      • Common Rail Pressure is about 25000 to 35000 kPa when the engine is cranking and the engine coolant temperature is 0°C (32°F) or higher.

      • Common Rail Pressure increases rapidly during cranking.


  5. 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, fuel pressure drops.

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

    3. Reconnect the inlet hose.


  6. Click here

    CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)


    1. Disconnect the suction control valve connector.

    2. Disconnect the ECM connector.

    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Table 22. for LHD
      Tester Connection Condition Specified Condition
      z64-1 (+B) - C45- 104 (PCV+) Always Below 1 Ω
      z64-2 (PCV) - C45-105 (PCV-) Always Below 1 Ω
      z64-1 (+B) or C45- 104 (PCV+) - Body ground Always 10 kΩ or higher
      z64-2 (PCV) or C45-105 (PCV-) - Body ground Always 10 kΩ or higher
      Standard Resistance
      Table 23. for RHD
      Tester Connection Condition Specified Condition
      z64-1 (+B) - C46- 104 (PCV+) Always Below 1 Ω
      z64-2 (PCV) - C46-105 (PCV-) Always Below 1 Ω
      z64-1 (+B) or C46- 104 (PCV+) - Body ground Always 10 kΩ or higher
      z64-2 (PCV) or C46-105 (PCV-) - Body ground Always 10 kΩ or higher

    4. Reconnect the suction control valve connector.

    5. Reconnect the ECM connector.


    • OKClick here
    • NG

      REPAIR OR REPLACE HARNESS OR CONNECTOR

  7. Click here

    REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)


    1. Replace the supply pump assembly (Click here).


  8. Click here

    BLEED AIR FROM FUEL SYSTEM


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

    2. Perform PM forced regeneration (Click here).

      Tip:

      When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.


  9. Click here

    PERFORM SUPPLY PUMP INITIALIZATION


    1. Perform supply pump initialization (Click here).


  10. Click here

    READ VALUE USING GTS (COMMON RAIL 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: Engine and ECT / Data List / Common Rail Pressure.

    4. Start the engine.

    5. Read the Fuel Press values while cranking and idling the engine.

      Table 24. Result
      Result Proceed to
      The engine cannot be started or the engine can be started but Common Rail Pressure is below 20000 kPa 2 seconds after the starter signal changes from OFF to ON B
      Except above A

  11. Click here

    INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)


    1. Remove the glow plug assembly for all the cylinders (Click here).

    2. Visually check if there is fuel on the glow plugs.

      Tip:

      • If there is fuel on a glow plug, fuel may be leaking from an injector assembly.

      • After replacing an injector assembly, make sure that the common rail pressure is within 5000 kPa of the target fuel pressure while cranking the engine.

      • If there is fuel on a glow plug, fuel may have mixed with the engine oil. Check the engine oil amount and whether the engine oil smells of diesel fuel. If the oil level is above the full line or the engine oil smells of diesel fuel, replace the engine oil.

    3. Install the glow plug assembly (Click here).


  12. Click here

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


    1. Check and repair or replace the clogged fuel pipe.


  13. Click here

    BLEED AIR FROM FUEL SYSTEM


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

    2. Perform PM forced regeneration (Click here).

      Tip:

      When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.


  14. Click here

    READ VALUE USING GTS (COMMON RAIL PRESSURE)


    1. Check Common Rail Pressure in the snapshot taken in procedure 3 when the engine was warmed up.

      Table 25. Result
      Result Proceed to

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

      		 A
      Except above B

  15. Click here

    REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)


    1. Replace the fuel supply pump assembly (Click here).


  16. Click here

    PERFORM SUPPLY PUMP INITIALIZATION


    1. Perform supply pump initialization (Click here).


  17. 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.


  18. Click here

    INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)


    1. When the engine does not start, perform the following procedure.


      1. Stop the engine and leave the vehicle for 4 hours or more.

        Tip:

        It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

      2. Check that the engine starts.

        OK
        The engine starts.

    2. When the engine starts, perform the following procedure.


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

      2. Check that the engine starts.

        OK
        The engine starts.

  19. Click here

    CHECK DATA LIST


    1. Check Injection Feedback Val # in the snapshot taken in procedure 3 when the engine was idling.

      Table 26. Result
      Result Proceed to

      Injection Feedback Val #1 to #8 are 3 mm3/st or less.

      Injection Volume is more than 13 mm3/st.

      		 A*

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

      Tip:

      There may be a malfunction in the corresponding cylinder.

      		 B
      Except above C
      Tip:

      • *: When this case occurs, usually symptoms may be noticeable, such as difficulty starting or lack of power.

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


  20. 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.


  21. Click here

    PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

    Tip:

    Use this Active Test to help determine whether a cylinder has compression loss or not.


    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #8.

    4. Check the engine speed during the Active Test.

      Table 27. Result
      Result Proceed to
      Except below A
      The values of Engine Speed Cyl #1 to #8 are within +/-10 rpm of each other. B
      Tip:

      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.


  22. Click here

    CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    Tip:

    Measure the compression of the cylinder that had a high speed during the "Check the Cylinder Compression" Active Test.


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


    • OKClick here
    • NG

      CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

  23. Click here

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tip:

    It can be determined that the injector assembly is faulty as the corresponding cylinder is malfunctioning, but has no compression loss.


    1. Replace the injector assembly (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.


  24. 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.


  25. Click here

    BLEED AIR FROM FUEL SYSTEM


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

    2. Perform PM forced regeneration (Click here).

      Tip:

      When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.


  26. Click here

    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).


  27. Click here

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    • NEXT

      END

  28. Click here

    INSPECT INJECTOR DRIVER


    1. Even in cases where DTC P062D and P062E are not stored even though the engine cannot be started, perform the DTC P062D troubleshooting procedure (Click here).

      Tip:

      • When the engine cannot be started due to a malfunction in the injector driver system, once the DTCs are cleared, the system cannot store DTC P062D and P062E even if it is confirmed that the engine cannot be started when trying to reproduce the problem symptoms.

        As DTC P062D and P062E cannot be stored when starting the engine, fuel injection signals are output by the ECM, but fuel is not actually injected. Therefore, an excessive amount of fuel is supplied to the common rail by the fuel supply pump assembly, and as a result, the fuel pressure is higher than the target common rail pressure in the data recorded at the time the engine was having trouble starting.

      • If the problem cannot be determined even after performing the DTC P062D and P062E troubleshooting procedure and the fuel pressure is higher than the target common rail pressure when attempting to start the engine, proceed to the next step.

      Table 28. Result
      Result Proceed to
      Injector driver (EDU) circuit is normal A
      Injector driver (EDU) circuit is abnormal B

    • AClick here
    • B

      REPAIR OR REPLACE MALFUNCTIONING PARTS

  29. Click here

    INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)


    1. When the engine does not start, perform the following procedure.


      1. Stop the engine and leave the vehicle for 4 hours or more.

        Tip:

        It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

      2. Confirm the engine starts.

    2. When the engine starts, perform the following procedure.


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

      2. Confirm the engine starts.


  30. Click here

    CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS


    1. Check the temperature when starting trouble occurs.

      Table 29. Result
      Result Proceed to
      Difficult to start only for cold engine. A
      Difficult to start both for cold and warmed up engine. B

  31. Click here

    READ VALUE USING ENGINE COOLANT TEMPERATURE SENSOR (COOLANT TEMP)


    1. Connect the GTS to the DLC3.

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

    3. Enter the following menus: Engine and ECT / Data List / All Data / Coolant Temp.

    4. Read the value displayed on the GTS.

      OK
      Coolant Temp is not high when the engine is cold, and not low after the engine is warmed up

  32. Click here

    INSPECT GLOW PLUG (RESISTANCE)


    1. Inspect the glow plug (Click here).


  33. Click here

    CHECK FUEL QUALITY


    1. Check that only diesel fuel is being used.

    2. Check that the fuel does not contain any impurities.


  34. Click here

    READ OUTPUT DTC (RELATED 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: Engine and ECT / Trouble Codes.

    4. Read the DTCs.

      Table 30. Result
      Result Proceed to
      No DTC is output A
      Engine related DTCs are output B

  35. Click here

    CHECK COMMUNICATION BETWEEN GTS AND ECM


    1. Connect the GTS to the DLC3.

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

    3. Check if the normal starting screen appears (check whether communication with the ECM is possible).

      Tip:

      Use a GTS that is able to communicate with other vehicles.

      OK
      Communication is possible (vehicle can be recognized).

  36. Click here

    READ VALUE USING GTS (STARTER SIGNAL AND NEUTRAL POSITION SW SIGNAL)


    1. Connect the GTS to the DLC3.

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

    3. Enter the following menus: Engine and ECT / Data List / All Data / Starter Signal and Neutral Position SW Signal.

    4. Read the value displayed on the GTS.

      OK
      GTS Display Condition Specified Condition
      Starter Signal Cranking ON
      Neutral Position SW Signal Shift lever in neutral ON

    • OKClick here
    • NG

      INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY

  37. Click here

    CHECK STARTING SYSTEM


    1. Inspect the starting system.

      Tip:

      Be sure to inspect the following areas:


      • Starter relay

      • Starter assembly

      • Immobiliser system


  38. Click here

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    • NEXT

      END