ECD SYSTEM Engine Difficult to Start or Stalling

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

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

      Tech Tips

      The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
      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

      • Target Booster Pressure

        When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.
      Turbocharger System
      Main fault

      • Air leak in the turbocharged air passage

      • ECM not operating well

      • Turbocharger (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, Target Booster Pressure


      • When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.

      • 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.

      VN Turbo Command


      • 0%: Vanes fully open (drive rod contracts)

      • Over 90%: Vanes fully closed (drive rod expands and turbo operates effectively)
      Diagnostic Point

      • Using the "Test the Turbo Charger Step Motor" Active Test, check the drive rod movement.

      • Check the drive rod movement when the ignition switch is turned from ON to off.
      Exhaust System
      Main fault Blockage
      Symptoms Lack of power (high engine speed, under heavy load)
      Data List

      MAP

      When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.
      Glow System
      Main fault Open circuit, glow plug relay fault
      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
      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.
      Engine - 1
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      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.
      Start System
      Main fault Starter system malfunction
      Symptoms Difficult to start
      Data List

      Starter Signal


      • Ignition switch (STA) output:

        ON: Starter is operating

        OFF: Starter is not operating

    2. Diesel Injection

      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


      • In a stable condition (e.g. idling), Common Rail Pressure is within 5000 kPa of "Target Common Rail Pressure".

      • 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.

      Tech Tips


      • 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.
      Fuel Filter Element Sub-assembly
      Main fault Blockage
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure


      • In a stable condition (e.g. idling), the fuel pressure is within 5000 kPa of "Target Common Rail Pressure".

      • 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.

      Tech Tips

      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.
      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 with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).
      Pressure Discharge Valve
      Main fault Does not completely close
      Symptoms Difficult to start, engine stall, rough idle, lack of power
      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.
      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.
      Irregular Fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      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., Target EGR Pos.


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

      • Using the EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR 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. Status


      • When leaving the vehicle idling, when EGR Close Lrn. Status is OK, the normal range of EGR Close Lrn. Val. is 0 to 1 V.

      • In cases when EGR Close Lrn. Status. is NG or EGR Close Lrn. Val. is out of the normal range (0 to 1 V), it is possible that the EGR valve cannot completely close.

    4. Diesel Throttle

      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

        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 #4)

    • Target Common Rail Pressure

    • Common Rail Pressure

    • Target Pump SCV Current

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

    • Actual Throttle Position

    • Target EGR Position

    • Actual EGR Valve Pos.

    • EGR Close Lrn. Status

    • EGR Close Lrn. Val.

CAUTION / NOTICE / HINT


  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. Trouble Area Chart According to Problem Cause

    B001DQTE02
    B001FVHE03

    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.

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

PROCEDURE


  1. CHECK ENGINE CRANKING CONDITION


    1. Check the engine cranking condition.

      Result
      Result Proceed to
      Does not crank at all. A

      Low cranking speed.

      Tech Tips

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

      		 B
      Cranking is OK. C

    B

    CHECK BATTERY CONDITION Click here

    C

    CHECK FUEL RECEIVER GAUGE (AMOUNT OF FUEL) Click here

    A

  2. CHECK BATTERY CONDITION


    1. Check the battery condition Click here.


    NG

    REPLACE BATTERY

    OK

  3. CHECK COMMUNICATION BETWEEN INTELLIGENT TESTER AND ECM


    1. Connect the intelligent tester to the DLC3.

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

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

      Tech Tips

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

      OK
      Communication is possible (vehicle can be recognized).

    NG

    CHECK VC OUTPUT CIRCUIT Click here

    OK

  4. READ VALUE USING INTELLIGENT TESTER (CLUTCH SWITCH)


    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 / All Data / Clutch Switch.

    4. Read the value displayed on the tester.

      OK
      Tester Display Condition Specified Condition
      Clutch Switch Clutch pedal depressed ON
      Result
      Result Proceed to
      OK A
      NG B

    B

    REPLACE CLUTCH SWITCH ASSEMBLY

    A

  5. READ ALL OUTPUT DTCS


    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: Utility / All Codes.

      Result
      Result Proceed to
      No DTC is output A
      DTCs related to engine are output B

    A

    END

    B

    GO TO RELATED DTC Click here

  6. CHECK FUEL RECEIVER GAUGE (AMOUNT OF FUEL)


    1. Check if the fuel level is low.

      Result
      Result Proceed to
      The indicator (fuel warning light) is not illuminated A
      The indicator (fuel warning light) is illuminated B

    B

    ADD FUEL Click here

    A

  7. CHECK INITIALIZATION (FUEL SUPPLY PUMP)


    1. When the engine does not start or another problem such as rough idling is present, perform initialization and check to see if the problem symptoms disappear. If the problem symptoms do not disappear, perform the next procedure.

      Tech Tips

      When replacing the ECM, the fuel supply pump initialization must be performed Click here.


    NEXT

  8. READ OUTPUT DTC (RELATED 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 the DTCs.

      Result
      Result Proceed to
      No DTC is output A
      DTCs related to engine are output B

    B

    REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT Click here

    A

  9. TAKE SNAPSHOT DURING STARTING AND IDLING


    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 / All Data.

    4. B001D63E02
      *1 Snapshot Button

      Take a snapshot of the following Data List items with the intelligent tester during "ignition switch ON (5 seconds) → Starting → Idling (10 seconds)".

      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 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 70°C (158°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.

      • Graphs like the ones shown below can be displayed by transferring the stored snapshot from the tester to a PC. Intelligent Viewer must be installed on the PC.


    NEXT

  10. CHECK SNAPSHOT (COMMON RAIL PRESSURE)


    1. Check Common Rail Pressure in the snapshot taken when the engine was starting.

      Result
      Result Proceed to

      2 seconds after Starter Signal turns from OFF to ON, Common Rail Pressure is below 20000 kPa

      Tech Tips

      As long as the fuel pressure remains below 5000 kPa, the ECM stops sending the injection command signal (IJT) to the injector driver, and then the actual injection duration remains 0 microseconds.

      		 A
      2 seconds after Starter Signal turns from OFF to ON, Common Rail Pressure is 50000 kPa or higher B
      Except above C

      Tech Tips


      • Fuel pressure is about 30000 to 40000 kPa when the engine is cranking and the engine coolant temperature is 0°C (32°F) or higher.

      • Fuel pressure increases rapidly during cranking.


    B

    CHECK SNAPSHOT Click here

    C

    INSPECT INJECTOR COMPENSATION CODE Click here

    A

  11. CHECK ENGINE STARTING CONDITION


    1. Check whether the engine can be started.

      Tech Tips

      If there are deposits in the injector assemblies and they are left for a long time, the injector assemblies for all the cylinders may become stuck.

      Result
      Result Proceed to
      The engine can be started. A
      There is no initial combustion even when the engine can be cranked. B

    B

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

    A

  12. INSPECT COMMON RAIL ASSEMBLY


    1. Inspect the common rail assembly Click here.


    OK

    ADD FUEL Click here

    NG

    REPLACE COMMON RAIL Click here

  13. 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 when the priming pump is operated.

      Tech Tips


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

      • Inspect for fuel filter element sub-assembly clogging (check that the fuel filter element sub-assembly is not clogged).

    3. Reconnect the inlet hose.


    NG

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

    OK

  14. 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 (Check for Open)
      Tester Connection Condition Specified Condition
      C71-1 - C92-23 (PCV+) Always Below 1 Ω
      C71-2 - C92-12 (PCV-) Always Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      C71-1 or C92-23 (PCV+) - Body ground Always 10 kΩ or higher
      C71-2 or C92-12 (PCV-) - Body ground Always 10 kΩ or higher

    4. Reconnect the suction control valve connector.

    5. Reconnect the ECM connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  15. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT

  16. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  17. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  18. READ VALUE USING INTELLIGENT TESTER (COMMON RAIL 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 / Common Rail Pressure.

    4. Start the engine.

    5. Read the Common Rail Pressure values while cranking and idling the engine.

      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

    A

    END

    B

  19. 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.

      Tech Tips


      • 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 (fuel 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.

      Result
      Result Proceed to
      No fuel on glow plugs A
      Fuel on glow plugs B

    3. Install the glow plug assembly Click here.


    B

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

    A

  20. REPLACE COMMON RAIL


    1. Replace the common rail 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 (COMMON RAIL 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 / Common Rail Pressure.

    4. Start the engine.

    5. Read the Common Rail Pressure values while cranking and idling the engine.

      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

    A

    END

    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS Click here

  23. INSPECT INJECTOR COMPENSATION CODE


    1. Read the injector compensation code Click here.

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

    NG

    REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING Click here

    OK

  24. CHECK DATA LIST


    1. B001D63E02
      *1 Snapshot Button

      Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken when the engine was idling.

      Result
      Result Proceed to

      Injection Feedback Val #1 to #4 are more than 3 mm3/st.

      Tech Tips

      There may be a malfunction in the corresponding cylinder.

      		 A

      Injection Feedback Val #1 to #4 are 3 mm3/st or less.

      Injection Volume is more than 10 mm3/st.

      		 B*

      Injection Feedback Val #1 to #4 are 3 mm3/st or less.

      Injection Volume is 10 mm3/st or less.

      		 C

      Tech Tips


      • *: When this case occurs, usually symptoms may be noticeable, such as difficulty starting, rough idling, knocking or black smoke at high common rail pressure.

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


    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS Click here

    C

    CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS Click here

    A

  25. 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.

      • 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

  26. 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. Turn the ignition switch to ON 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.

      OK
      The values of Engine Speed Cyl #1 to #4 are within 10 rpm of each other.

      Tech Tips

      When cranking, if the speed of a cylinder is approximately 100 rpm more than the other cylinders, there is probably a loss of compression in that cylinder.


    OK

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

    NG

  27. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    Tech Tips

    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.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  28. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tech Tips

    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.


    NEXT

    BLEED AIR FROM FUEL SYSTEM Click here

  29. CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS


    1. Check the temperature when starting trouble occurs.

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

    B

    CHECK FUEL QUALITY Click here

    A

  30. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  31. INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)


    1. Inspect the glow plug Click here.


    NG

    REPLACE GLOW PLUG ASSEMBLY Click here

    OK

  32. CHECK FUEL QUALITY


    1. Check that fuel with a low cetane number is used.


    NEXT

  33. CHECK ENGINE STARTING CONDITION


    1. Check whether the engine can be started.

      Tech Tips

      If there are deposits in the injector assemblies and they are left for a long time, the injector assemblies for all the cylinders may become stuck.

      Result
      Result Proceed to
      The engine can be started. A
      There is no initial combustion even when the engine can be cranked. B

    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS Click here

    A

  34. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


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


    NEXT

    END

  35. CHECK SNAPSHOT

    Tech Tips

    When all Data List values are OK and Common Rail Pressure is higher than Target Common Rail Pressure, perform the following inspection.


    NEXT

  36. INSPECT INJECTOR DRIVER (POWER SOURCE)


    1. B001D1PE01
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Injector Driver)

      Disconnect the injector driver connector.

    2. Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      C88-2(+B) - C88-3(GND) Ignition switch ON 11 to 14 V

    3. Reconnect the injector driver connector.


    NG

    GO TO INJECTOR CIRCUIT Click here

    OK

  37. INSPECT INJECTOR ASSEMBLY

    Tech Tips

    If there is no initial combustion during cranking, there may be air in the injector assemblies.


    NEXT

    END

  38. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. Replace the injector assemblies Click here.


    NEXT

  39. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  40. 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

  41. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    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 / Common Rail Pressure.

    4. Start the engine.

    5. Read the Common Rail Pressure values while cranking and idling the engine.

      OK
      The engine can be started and Common Rail Pressure is 20000 kPa or higher 2 seconds after the starter signal changes from OFF to ON.

    NEXT

    END

  42. 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.


    NEXT

    BLEED AIR FROM FUEL SYSTEM Click here

  43. ADD FUEL


    1. Add fuel.


    NEXT

  44. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  45. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    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 / Common Rail Pressure.

    4. Start the engine.

    5. Read the Common Rail Pressure values while cranking and idling the engine.

      OK
      The engine can be started and Common Rail Pressure is 20000 kPa or higher 2 seconds after the starter signal changes from OFF to ON.

    NEXT

    END

  46. CHECK VC OUTPUT CIRCUIT


    1. Check the VC output circuit Click here.


    NEXT

  47. CHECK COMMUNICATION BETWEEN INTELLIGENT TESTER AND ECM


    1. Connect the intelligent tester to the DLC3.

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

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

      Tech Tips

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

      OK
      Communication is possible (vehicle can be recognized).

    OK

    END

    NG

  48. CHECK ECM POWER SOURCE CIRCUIT


    1. Check the ECM power source circuit Click here.


    NEXT

  49. CHECK COMMUNICATION BETWEEN INTELLIGENT TESTER AND ECM


    1. Connect the intelligent tester to the DLC3.

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

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

      Tech Tips

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

      OK
      Communication is possible (vehicle can be recognized).

    OK

    END

    NG

    REPLACE ECM Click here