ECD SYSTEM(w/ Glow Plug Controller) Engine Difficult to Start or Stalling

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Mass Air Flow Meter
      Component Mass air flow meter
      Main fault Decrease in performance (foreign matter is attached)
      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
      Component Intake system
      Symptom: Main fault

      • Lack of power (No black smoke): Air filter blockage, Air duct is crushed/leaking

      • Black smoke (No lack of power): Leakage between the turbo and intake manifold
      Data List

      • MAP (inside manifold absolute pressure)

      • Target Booster Pressure

        When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.
      Turbocharger System
      Component Turbocharger system
      Main fault

      • Air leak in the turbocharger air passage

      • Turbo motor driver not operating well

      • Turbocharger (turbine, bearing)
      Symptoms

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

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

      MAP (inside manifold absolute pressure), Target Booster Pressure


      • When the accelerator is fully depressed, if MAP is 15 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 increases 1 kPa each time altitude increases by 100 m, and is also affected by the current weather conditions.

      Target VN Turbo Position


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

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

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

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

      MAP (inside manifold absolute pressure)

      When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.
      Glow System
      Component 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 Try to measure the resistance of the glow plug
      Battery
      Component 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 less than 5 V
      Engine - 1
      Component Engine
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      Engine - 2
      Component Engine
      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


      • "Injection Feedback Val" more than 2.0 mm3/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.
      Start System
      Component Entry and start system
      Main fault Starter system malfunction
      Symptoms Difficult to start
      Data List

      Starter Signal


      • Ignition switch (STA) operation

        ON: Starter is operating

        OFF: Starter is not operating
      Immobiliser system
      Component Engine immobiliser system
      Main fault

      Engine immobiliser system (w/ entry and start system) / Problem Symptoms Table

      Click here

      Engine immobiliser system (w/o entry and start system) / Problem Symptoms Table

      Click here

      Symptoms

      Engine does not start (w/o entry and start system)

      Engine does not crank (w/ entry and start system)
      Data List

      Immobiliser Communication


      • ON: Normal

      • OFF: GND short or immobiliser is set

      Engine immobiliser system (w/ entry and start system) / Data List

      Click here

      Engine immobiliser system (w/o entry and start system) / Data List

      Click here

    2. Diesel Injection

      Fuel Supply Pump
      Component 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


      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel 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 starting, but is approx. 25000 kPa at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 1530 mA or more, the suction control valve has a tendency to become stuck.
      Diagnostic Trouble Code Even if Common Rail Pressure is less than Target Common Rail Pressure, a DTC may not be stored.
      Fuel Filter
      Component 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


      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel 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 starting, but is approx. 25000 kPa at engine start after the engine is warmed up.
      Diagnostic Trouble Code Even if Common Rail Pressure is less than Target Common Rail Pressure, a DTC may not be stored.
      Injector Assembly
      Component Injector assembly
      Main fault

      Injection hole blockage

      Nozzle needle or valve piston does not move smoothly
      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val


      • "Injection Feedback Val" more than 2.0 mm3/st: Injector assembly breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.
      Pressure Control Valve
      Component Pressure control valve (common rail assembly)
      Main fault Does not completely close
      Symptoms Difficult to start, engine stall, rough idle, lack of power
      Fuel Pressure Sensor
      Component Fuel pressure sensor (common rail assembly)
      Main fault Open circuit, decrease in performance (foreign matter is attached)
      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
      Component Irregular fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      EGR System
      Component EGR system
      Main fault

      • Does not move smoothly

      • Does not close completely
      Symptoms

      • Rough idle

      • EGR valve stuck closed: 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 recirculated exhaust gas and the engine is under heavy load, when the vehicle starts moving, a lack of power will be felt).
      Data List

      Actual EGR Valve Pos, Target EGR Valve Pos


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

      • Using 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 warmed up.

    4. Diesel Throttle

      Diesel Throttle System
      Component 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, Target Throttle Position

        100%: Fully open

        0%: Fully closed

      • If there is a malfunction of the throttle actuator, compare the target and actual throttle position values for the troubleshooting.

WIRING DIAGRAM

Refer to DTC P0001.

Click here

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 with compression pressure.

    With problems such as a depleted battery, the crankshaft speed can become low, or if the engine compression is leaking, 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

    A01M2KSE02
    A01LXBYE09

    Note

    When replacing the ECM and/or injector assembly, perform ECM Initialization and Registration.

    Click here

    Tech Tips


    • When the ECM must be replaced, before replacing the ECM, perform the "Learning Values Save" function using the GTS. Then after installing a new ECM, perform all of the initialization and registration procedures for the "Learning Values Write" function by following the instructions shown on the GTS display.

    • 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.

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*
      Cranking is OK B

      Tech Tips

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


    B

    CHECK FUEL RECEIVER GAUGE (AMOUNT OF FUEL) Click here

    A

  2. CHECK BATTERY CONDITION


    1. Check the battery condition.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE BATTERY

    OK

  3. 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).

      Tech Tips

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

      OK
      Communication is possible (vehicle can be recognized).
      Result
      Proceed to
      OK
      NG

    NG

    CHECK VC OUTPUT CIRCUIT Click here

    OK

  4. 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: System Select / Health Check.

    4. Check the DTCs.

      Result
      Result Proceed to
      DTC is not output (w/ entry and start system) A
      DTC is not output (w/o entry and start system) B
      Engine related DTCs are output C

    B

    CHECK STARTER SIGNAL CIRCUIT OR CRANKING HOLDING FUNCTION CIRCUIT Click here

    C

    GO TO RELATED DTC

    A

  5. CHECK DOOR CONTROL TRANSMITTER FUNCTION (W/ ENTRY AND START SYSTEM)


    1. Check if the "Door Control Transmitter" function of each key functions properly.

      Tech Tips


      • Check if the engine starts properly with another key.

      • If the doors cannot be opened/closed by using the "Door Control Transmitter" function of the key, the battery inside the key may be depleted. In such a case, the engine cannot be started by pushing the engine switch.

      • When the door control transmitter battery is depleted, the engine can only be started by holding the door control transmitter against the engine switch.

      • If the inspection result is that the problem only occurs in certain locations or times of day, the possibility of wave interference is high. Also, added vehicle components may cause wave interference. If any optional components are installed, remove them and perform the operation check.

        Near broadcasting stations, large screens, airports, transformer stations, gasoline stations, etc., the door control transmitter may not operate due to wave interference.

      Result
      Proceed to
      NEXT

    NEXT

  6. CHECK STARTER SIGNAL CIRCUIT OR CRANKING HOLDING FUNCTION CIRCUIT

    Tech Tips

    Check that "Starter Signal" in the Data List changes to ON when the engine is started.


    1. Inspect the Starter Signal Circuit (w/o entry and start system).

      Click here

    2. Inspect the Cranking Holding Function Circuit (w/ entry and start system).

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    END

  7. CHECK VC OUTPUT CIRCUIT


    1. Check the VC output circuit.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  8. 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).

      Tech Tips

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

      OK
      Communication is possible (vehicle can be recognized).
      Result
      Proceed to
      OK
      NG

    OK

    END

    NG

  9. CHECK ECM POWER SOURCE CIRCUIT


    1. Check the ECM power source circuit.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  10. 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).

      Tech Tips

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

      OK
      Communication is possible (vehicle can be recognized).
      Result
      Proceed to
      OK
      NG

    OK

    END

    NG

    REPLACE ECM Click here

  11. CHECK FUEL RECEIVER GAUGE (AMOUNT OF FUEL)


    1. Check if the fuel level is low.

      Result
      Proceed to
      OK
      NG

    NG

    ADD FUEL Click here

    OK

  12. 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: Powertrain / Engine and ECT / Trouble Codes / Pending.

    4. Read the pending DTCs.


      Powertrain > Engine and ECT > Trouble Codes
      Result
      Result Proceed to
      DTC is not output A
      Engine related DTCs are output B

    B

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

    A

  13. TAKE SNAPSHOT DURING STARTING AND IDLING


    1. Connect the GTS to the DLC3.

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

      Tech Tips

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

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

    4. Take a snapshot of the following Data List items with the GTS during the following sequence: ignition switch ON (5 seconds) → Starting → Idling (60 seconds).

    5. Warm up the engine until the engine coolant temperature reaches 75°C (167°F) or higher and after idling the vehicle for 1 minute.

      Tech Tips

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

    6. Take a snapshot of the following Data List items with the GTS during the following sequence: ignition switch ON (5 seconds) → Starting → Idling (60 seconds).

      Data List
      Starter Signal
      Engine Speed
      Common Rail Pressure
      Target Common Rail Pressure
      Target Pump SCV Current
      Injection Volume
      Main Injection Period
      Battery Voltage
      Actual EGR Valve Pos
      Target EGR Valve Pos
      Actual Throttle Position
      Target Throttle Position
      MAF
      Target Booster Pressure
      MAP

      Tech Tips

      Actual Examples of Malfunction


      • Starting is not possible


        • Fuel is not supplied to supply pump.

          Common Rail Pressure: Approximately 1000 kPa or less during cranking.

        • Air in injectors.

          Common Rail Pressure: 60000 to 70000 kPa during cranking.

      • Cranking time is long


        • Suction control valve is stuck.

          Target Pump SCV Current intermittently reaches 1530 mA or more. The suction control valve plunger intermittently becomes stuck. If there is difficulty starting when the engine is cold, cool the engine and inspect it.

        • Injector assembly clogging or internal contamination:

          Injection Feedback Val # of one or more of the cylinders is 2 mm3/st or more.

          Injection Feedback Val # can be read when the engine is idling after being warmed up.

      Result
      Proceed to
      NEXT

    NEXT

  14. CHECK SNAPSHOT (TARGET PUMP SCV CURRENT)


    1. Check Target Pump SCV Current in the snapshot taken when the engine had been idling more than 10 seconds after the engine was started.

      Result
      Result Proceed to
      Target Pump SCV Current is less than 1530 mA A
      Target Pump SCV Current is 1530 mA or more B

      Tech Tips

      If the engine could not be started, proceed to A.


    B

    CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM) Click here

    A

  15. CHECK SNAPSHOT (COMMON RAIL PRESSURE)


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

      Result
      Result Proceed to
      Fuel Press is less than 20000 kPa A
      Fuel Press is 20000 kPa or higher B

      Tech Tips


      • Fuel pressure is about 20000 to 35000 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 INJECTOR COMPENSATION CODE Click here

    A

  16. PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)


    1. A01M24SC01
      *1 Hand pump

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases (A).

      Note


      • Hand pump pumping speed: Maximum of 2 strokes/second.

      • Be sure to push the hand pump with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure will not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note


      • Just after starting the engine, visually check for fuel leaks from the supply pump assembly, injector assemblies, common rail, and the fuel pipes in high-pressure areas.

      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to step B.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to step A). Then start the engine.

    3. Turn the ignition switch off (B).

    4. Connect the GTS to the DLC3.

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

    6. Clear the DTCs.


      Powertrain > Engine and ECT > Clear DTCs

    7. Start the engine (C).

    8. Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak (D).


      Powertrain > Engine and ECT > Active Test
      Tester Display
      Test the Fuel Leak

    9. Maintain an engine speed of 3500 rpm, and then press the "Start" button (E).

    10. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak (F).

    11. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time (G).

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off. This is normal and does not indicate a pump malfunction.

      A01M1BTE01

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


      Powertrain > Engine and ECT > Trouble Codes

    13. Read the DTCs.


      1. When no DTCs are output, the air bleeding is complete. Proceed to step I.

      2. If any DTCs are output, proceed to step H.

    14. Clear the DTCs (H).


      Powertrain > Engine and ECT > Clear DTCs

    15. Repeat steps C to G.

    16. Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail Pressure (I).


      Powertrain > Engine and ECT > Data List
      Tester Display
      Common Rail Pressure

    17. Start the engine.

    18. Read the Common Rail Pressure value while cranking and idling the engine.

      Result
      Result Proceed to
      The engine can be started and Common Rail Pressure is 20000 kPa or higher. A
      The engine cannot be started or the engine can be started but the Common Rail Pressure is less than 20000 kPa during cranking. B

    A

    END

    B

    GO TO STEP 33 Click here

  17. CHECK INJECTOR COMPENSATION CODE


    1. Read the injector compensation codes.

      Click here

      OK
      Compensation codes stored in the ECM match compensation codes on the installed injector assemblies.
      Result
      Proceed to
      OK
      NG

    NG

    PERFORM REGISTRATION AND INITIALIZATION Click here

    OK

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


    1. 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 is outside the range of +/-2 mm3/st*1

      A

      *2

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is more than 8 mm3/st

      B

      *3

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is 8 mm3/st or less

      		 C

      Tech Tips


      • *1: There may be a malfunction in the corresponding cylinder.

      • *2: If there is an open or short in a glow plug, this result occurs only with a cold engine.

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

      • If the value of Injection Volume is more than 8 mm3/st and the value of all of the Injection Feedback Val #1 to #4 is within the threshold, replace the injector assembly for all cylinders.

        In this case, it is possible that too much recirculated exhaust gas is entering the engine. Therefore, you should compare the Target EGR Valve Pos with the Actual EGR Valve Pos by entering the following menus using the GTS:

        Powertrain / Engine and ECT / Data List / Target EGR Valve Pos and Actual EGR Valve Pos.

        If the difference between Target EGR Valve Pos and Actual EGR Valve Pos exceeds +/-10%, the EGR system may be malfunctioning.


    B

    GO TO STEP 29 Click here

    C

    CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS Click here

    A

  19. PERFORM ACTIVE TEST USING GTS (FUEL CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)

    Tech Tips

    Use this Active Test to determine the malfunctioning cylinder.


    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 / Control the Select Cylinder Fuel Cut.


      Powertrain > Engine and ECT > Active Test
      Tester Display
      Control the Select Cylinder Fuel Cut

    4. Check the 4 cylinders in sequence to identify the malfunctioning cylinder by performing the Active Test inspection.

      Tech Tips


      • DTCs may be output after this Active Test. Make sure to check for DTCs after this Active Test. If any DTCs are output, make sure to clear them.

        Click here

      • 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.

      Result
      Proceed to
      NEXT

    NEXT

  20. READ VALUE USING GTS (ENGINE SPEED OF CYL #1 TO #4)

    Tech Tips

    The speed of each cylinder can be measured (compression test) by using the GTS.

    For the compression test, perform Active Test using GTS (Check the Cylinder Compression) and crank the engine for approximately 10 seconds. At this time, the speed of each cylinder is measured. If the speed of one cylinder is higher than the other cylinders, the compression pressure of that cylinder is determined to be lower than the other cylinders.


    1. Warm up the engine.

    2. Turn the ignition switch off.

    3. Connect the GTS to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Engine Speed of Cyl #1, Engine Speed of Cyl #2, Engine Speed of Cyl #3, Engine Speed of Cyl #4 and Av Engine Speed of All Cyl.


      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Check the Cylinder Compression
      Data List Display
      Engine Speed of Cyl #1
      Engine Speed of Cyl #2
      Engine Speed of Cyl #3
      Engine Speed of Cyl #4
      Av Engine Speed of All Cyl

    6. Push the snapshot button to turn the snapshot function on.

      Tech Tips

      Using the snapshot function, data can be recorded during the Active Test.

    7. While the engine is not running, press the Active button to Change the Cylinder Compression to ON.

      Tech Tips

      After performing the above procedure, Check the Cylinder Compression will start. Fuel injection for all cylinders is prohibited and each cylinder engine speed measurement enters standby mode.

    8. Crank the engine for about 10 seconds.

    9. Monitor the engine speed (Engine Speed of Cyl #1 to #4, Av Engine Speed of All Cyl) displayed on the GTS.

      Tech Tips

      After approximately 10 seconds of engine cranking, the engine speed measurement of each cylinder will change to the actual engine speed.

      Note


      • Do not crank the engine continuously for 20 seconds or more.

      • If Check the Cylinder Compression needs to be performed after it is turned ON and performed once, press Exit to return to the Active Test menu screen. Then perform Check the Cylinder Compression again.

      • Use a fully-charged battery.

    10. Stop cranking the engine, and then change "Check the Cylinder Compression" to OFF after the engine stops.

      Note

      If the Active Test is changed to OFF while the engine is being cranked, the engine will start.

    11. Push the snapshot button to turn the snapshot function off.

    12. Select "Stored Data" on the GTS screen, select the recorded data and display the data as a graph.

      Tech Tips

      If the data is not displayed as a graph, the change of the values cannot be observed.

    13. Check the change in engine speed values.

      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

    GO TO STEP 22 Click here

    A

  21. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER


    1. Check the cylinder compression pressure.

      Click here

      OK
      The cylinder compression pressure is within the standard range.
      Result
      Proceed to
      OK
      NG

    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  22. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tech Tips

    The injector assembly is determined to be malfunctioning the corresponding cylinder is malfunctioning but has no compression loss.


    1. Replace the injector assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 43 Click here

  23. 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

    GO TO STEP 26 Click here

    A

  24. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  25. INSPECT GLOW PLUG ASSEMBLY


    1. Inspect the glow plug assembly.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE GLOW PLUG ASSEMBLY Click here

    OK

  26. CHECK FUEL QUALITY


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

      Result
      Proceed to
      NEXT

    NEXT

  27. 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 ASSEMBLY OF ALL CYLINDERS Click here

    A

  28. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  29. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS


    1. Replace the injector assemblies.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 43 Click here

  30. PERFORM REGISTRATION AND INITIALIZATION


    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  31. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  32. 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
      Tester Connection Condition Specified Condition
      B123-2 - B212-30 (PCV) Always Below 1 Ω
      B123-2 or B212-30 (PCV) - Body ground and other terminals Always 10 kΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  33. CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY


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

    2. Operate the priming pump and check that fuel is being supplied to the supply pump assembly.

      OK
      Fuel is properly supplied to the supply pump assembly when the priming pump is operated.

      Tech Tips


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

      • Check that the fuel filter is not clogged.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY) Click here

    OK

  34. REPLACE SUPPLY PUMP ASSEMBLY


    1. Replace the supply pump assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  35. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  36. 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: Powertrain / Engine and ECT / Data List / Common Rail Pressure.


      Powertrain > Engine and ECT > Data List
      Tester Display
      Common Rail Pressure

    4. Start the engine.

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

      Result
      Result Proceed to
      The engine can be started and Common Rail Pressure is 20000 kPa or higher. A
      The engine cannot be started or the engine can be started but the Common Rail Pressure is less than 20000 kPa during cranking. B

    A

    END

    B

    INSPECT INJECTOR ASSEMBLY (INSPECTION FOR NOZZLE NEEDLE CLOSING PROBLEM) Click here

  37. CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY)


    1. Check and replace the clogged fuel pipe.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 47 Click here

  38. INSPECT INJECTOR ASSEMBLY (INSPECTION FOR NOZZLE NEEDLE CLOSING PROBLEM)


    1. Remove the glow plug assemblies for all the cylinders.

      Click here

    2. Visually check if there is fuel on the glow plug assemblies.

      Tech Tips


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

      • After replacing an injector assembly, make sure that the common rail pressure (fuel pressure) is within +/- 10000 kPa of the target fuel pressure while cranking the engine.

      • If there is fuel on a glow plug assembly, fuel may have mixed with the engine oil. Check the engine oil level 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 plug assemblies A
      Fuel on glow plug assemblies B

    B

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

    A

  39. REPLACE COMMON RAIL ASSEMBLY


    1. Replace the common rail assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  40. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  41. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  42. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    1. Replace the injector assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  43. PERFORM REGISTRATION AND INITIALIZATION


    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  44. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  45. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  46. ADD FUEL


    1. Add fuel.

      Result
      Proceed to
      NEXT

    NEXT

  47. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  48. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END