ECD SYSTEM(w/ Glow Plug Controller) Black Smoke Emitted

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      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 heavy load)

      (Black smoke is not emitted when racing the engine while the vehicle 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.
      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
      Engine
      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 assembly breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.

    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.
      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.

      Tech Tips


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

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

      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

Note


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

    Click here

  • When cleaning the electric EGR control valve assembly or diesel throttle body assembly, use a piece of cloth soaked with cleaning solvent. Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

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.


  1. Explanation of Symptom

    Black Smoke

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

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

    Black smoke is emitted either when:


    • A lack of oxygen is present during combustion

    • Too much fuel is injected for a given intake air mass and the air fuel ratio becomes temporarily rich

PROCEDURE


  1. READ OUTPUT DTC (RELATING TO ENGINE)


    1. Connect the GTS to the DLC3.

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

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

    4. Read the pending DTCs.


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

      Tech Tips

      If DTC P1609 is output, proceed to step 2.


    B

    GO TO DTC CHART Click here

    A

  2. PERFORM ENGINE SPEED ACCELERATION (CHECK FOR BLACK SMOKE)


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

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

    3. Fully depress the accelerator pedal for 5 seconds and then release it (A).

    4. Repeat the procedure A 10 times (B).

    5. Check for black smoke emission during the procedures A and B.

      OK
      Black smoke is emitted less than 5 times.

      Tech Tips

      Even if the black smoke is very thin, count the black smoke emission if there is any visible smoke.

      Result
      Proceed to
      OK
      NG

    OK

    END (TEMPORARY SOOT DEPOSITS DUE TO EXTREMELY LOW VEHICLE SPEED OR CONSECUTIVE SHORT TRIPS)

    NG

  3. CHECK HARNESS AND CONNECTOR (ENGINE ROOM)


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

      OK
      The wire harnesses and connectors are connected securely.
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  4. TAKE SNAPSHOT DURING IDLING AND 3000 RPM


    1. Connect the GTS to the DLC3.

    2. Start the engine and allow it to idle until the engine coolant temperature sensor reaches 75°C (167°F) or higher.

      Tech Tips

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

    3. Turn the GTS on.

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

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

      Tech Tips


      • Check the Data List at idling and at 3000 rpm with no load after the engine is warmed up.

      • If black smoke emitted, take a snapshot while the smoke is being emitted.

      Data Condition Idling (Engine Warmed Up, A/C Off, Shift Lever in neutral)
      Data List
      Engine Speed
      MAP
      MAF
      Target Common Rail Pressure
      Common Rail Pressure
      Injection Volume
      Target VN Turbo Position
      Target EGR Valve Pos
      Actual EGR Valve Pos
      Target Throttle Position
      Actual Throttle Position
      Accel Position
      Atmosphere Pressure
      Coolant Temp
      Calculate Load
      Pilot 1 Injection Period
      Pilot 2 Injection Period
      Data Condition at 3000 rpm (Engine Warmed Up, A/C Off, Shift Lever in neutral)
      Data List
      Engine Speed
      Target Booster Pressure
      MAP
      MAF
      Target Common Rail Pressure
      Common Rail Pressure
      Target Pump SCV Current
      Injection Volume
      Target VN Turbo Position
      Target EGR Valve Pos
      Actual EGR Valve Pos
      Target Throttle Position
      Actual Throttle Position
      Accel Position
      Coolant Temp
      Calculate Load
      Pilot 1 Injection Period
      Pilot 2 Injection Period
      Result
      Proceed to
      NEXT

    NEXT

  5. CHECK SNAPSHOT (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)


    1. Check Common Rail Pressure and Target Common Rail Pressure in the snapshot taken when the engine was idling and at 3000 rpm with no load.

      Tech Tips

      If black smoke was emitted, check the snapshot from that moment.

      Result
      Result Proceed to
      Common Rail Pressure is within +/-10000 kPa of Target Common Rail Pressure. A
      Common Rail Pressure is outside range of +/-10000 kPa from Target Common Rail Pressure. B

    B

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

    A

  6. CHECK SNAPSHOT (TARGET PUMP SCV CURRENT)


    1. Check Target Pump SCV Current in the snapshot taken when the engine was idling and at 3000 rpm with no load.

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

    B

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

    A

  7. CHECK INJECTOR COMPENSATION CODE


    1. Read the injector compensation codes.

      Click here

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

    NG

    PERFORM REGISTRATION AND INITIALIZATION Click here

    OK

  8. CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 to #4)


    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken after the engine is warmed up and has idled for 1 minute.

      Tech Tips

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

      Result
      Result Proceed to

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

      		 A

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

      B

      *1

      Injection Feedback Val #1 to #4 is outside the range of +/-2 mm3/st*2

      		 C

      Tech Tips


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

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

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

        In this case, there is a possibility 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

    REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS Click here

    C

    PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT) Click here

    A

  9. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Remove the electric EGR control valve assembly.

    2. Connect the electric EGR control valve assembly connector.

    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 / Control the EGR Step Position / Data List / Actual EGR Valve Pos.


      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Control the EGR Step Position
      Data List Display
      Actual EGR Valve Pos

    6. When changing the Active Test value from 1 to 100%, check that Actual EGR Valve Pos smoothly changes to the set opening angle.

      OK
      Value smoothly changes to the set opening angle.

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

      Note


      • When cleaning the electric EGR control valve assembly, make sure the valve is completely closed.

      • Do not forcibly open the valve, as it may be damaged or deformed.

      • When cleaning the electric EGR control valve assembly and the diesel throttle body assembly, use a piece of cloth with cleaning solvent.

        Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

    8. Hold the electric EGR control valve up to a light and visually check that there is no clearance between the valve and body.

      A01TC2MC06
      *1 Electric EGR Control Valve Assembly - -
      *a Part A *b Clearance
      *c OK *d NG
      OK
      No light passes through (there is no clearance between the valve and body).

      If light passes through (there is clearance between the valve and body), replace the electric EGR control valve assembly.

      Tech Tips

      Light passes through part A shown in the illustration even if the valve is completely closed, this is not a malfunction.

    9. Remove the diesel throttle body assembly, intake air connector and EGR pipe connector.

    10. Remove the deposits from the parts and clean them.

      Note


      • When cleaning the electric EGR control valve assembly and the diesel throttle body assembly, use a piece of cloth with cleaning solvent. Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

      • Extreme care must be taken to prevent the removed deposits from falling into the engine unit during cleaning.

      Tech Tips


      • Remove the intake manifold from the cylinder head when it has to be cleaned.

      • Do not leave any deposits in the electric EGR control valve assembly when cleaning the valve.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY Click here

    OK

  10. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor.

      Click here

      Tech Tips

      Confirm that the engine coolant temperature is 60°C (140°F) or higher using the GTS, and then leave the vehicle overnight (7 hours or more). The engine coolant temperature and atmosphere temperature should be very similar.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  11. READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)


    1. Connect the GTS to the DLC3.

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

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


      Powertrain > Engine and ECT > Data List
      Tester Display
      Atmosphere Pressure
      MAP

    4. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).

      Standard
      The difference between MAP and Atmosphere Pressure is less than 7 kPa.

      Tech Tips


      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 7 kPa or higher, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.

      • Standard atmospheric pressure is 101 kPa. For every 100 m increase in altitude, pressure drops by 1 kPa. Atmosphere pressure varies with the weather (high atmospheric pressure, low atmospheric pressure).

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

    B

    REPLACE DIESEL TURBO PRESSURE SENSOR Click here

    C

    REPLACE ECM Click here

    A

  12. READ VALUE USING GTS (ACCEL POSITION)


    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 / Accel Position.


      Powertrain > Engine and ECT > Data List
      Tester Display
      Accel Position

    4. Read the value.

      Standard
      Condition Standard Value
      Accelerator pedal released 0%
      Accelerator pedal depressed 95% or more
      Accelerator pedal released → depressed*1 0 to 95% or more*1

      Tech Tips

      *1: Make sure the Accel Position opening angle changes smoothly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE ACCELERATOR PEDAL SENSOR ASSEMBLY Click here

    OK

  13. READ VALUE USING GTS (INTAKE AIR AND INTAKE AIR TEMP (TURBO))


    1. Leave the vehicle overnight (7 hours or more).

    2. Connect the GTS to the DLC3.

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

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


      Powertrain > Engine and ECT > Data List
      Tester Display
      Intake Air
      Intake Air Temp (Turbo)
      OK
      Intake Air is the same as Intake Air Temp (Turbo).
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MALFUNCTIONING PARTS

    OK

  14. TAKE SNAPSHOT WHILE ACCELERATING WITH ACCELERATOR FULLY OPEN


    1. Connect the GTS to the DLC3.

    2. Start the engine and allow it to idle until the engine coolant temperature sensor reaches 75°C (167°F) or higher.

      Tech Tips

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

    3. Turn the GTS on.

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

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

      CAUTION:

      Obey all laws and regulations, and pay attention to driving conditions while driving the vehicle.

      Tech Tips

      Accelerate the vehicle with the accelerator fully open in 2nd gear.

      Data Condition with Engine Speed at 2000 rpm
      Data List
      Vehicle Speed
      Engine Speed
      Accel Position
      Target Booster Pressure
      MAP
      MAF
      Calculate Load
      Target Common Rail Pressure
      Common Rail Pressure
      Target Pump SCV Current
      Injection Volume
      Target VN Turbo Position
      Actual EGR Valve Pos
      Actual Throttle Position
      Data Condition with Engine Speed at 3000 rpm
      Data List
      Vehicle Speed
      Engine Speed
      Accel Position
      Target Booster Pressure
      MAP
      MAF
      Calculate Load
      Target Common Rail Pressure
      Common Rail Pressure
      Target Pump SCV Current
      Injection Volume
      Target VN Turbo Position
      Actual EGR Valve Pos
      Actual Throttle Position
      Data Condition with Engine Speed at 3500 rpm
      Data List
      Vehicle Speed
      Engine Speed
      Accel Position
      Target Booster Pressure
      MAP
      MAF
      Calculate Load
      Target Common Rail Pressure
      Common Rail Pressure
      Target Pump SCV Current
      Injection Volume
      Target VN Turbo Position
      Actual EGR Valve Pos
      Actual Throttle Position
      Data Condition with Engine Speed at 4000 rpm
      Data List
      Vehicle Speed
      Engine Speed
      Accel Position
      Target Booster Pressure
      MAP
      MAF
      Calculate Load
      Target Common Rail Pressure
      Common Rail Pressure
      Target Pump SCV Current
      Injection Volume
      Target VN Turbo Position
      Actual EGR Valve Pos
      Actual Throttle Position
      Result
      Proceed to
      NEXT

    NEXT

  15. CHECK SNAPSHOT (MAP AND TARGET BOOSTER PRESSURE)


    1. Check the condition of the vehicle using the snapshot.

      Result
      Result Proceed to
      MAP is less than "Target Booster Pressure - 15 kPa" when accelerating with accelerator fully open A
      MAP and Target Booster Pressure values are almost the same B

    B

    GO TO STEP 19 Click here

    A

  16. INSPECT VACUUM HOSE


    1. Check the vacuum hose connection (diesel turbo pressure sensor).

      OK
      Vacuum hose is connected securely.
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE VACUUM HOSE

    OK

  17. CHECK INTAKE SYSTEM


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

    2. Check for air leakage at intake manifold.

      Tech Tips


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

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

      OK
      No leakage.
      A01TCW0E18
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  18. INSPECT TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM)


    1. Inspect the turbocharger sub-assembly.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY Click here

    OK

  19. PERFORM ENGINE SPEED ACCELERATION (CHECK FOR BLACK SMOKE)


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

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

    3. Fully depress the accelerator pedal for 5 seconds and then release it (A).

    4. Repeat the above procedure A 10 times (B).

    5. Check for black smoke emission during the above procedures A and B.

      OK
      Black smoke is emitted less than 5 times.

      Tech Tips

      Even if the black smoke is very thin, count the black smoke emission if there is any visible smoke.

      Result
      Proceed to
      OK
      NG

    OK

    END

    NG

  20. BASIC INSPECTION


    1. Check the fuel quality.

    2. Check the fuel line for air.

    3. Check the fuel system for blockages.

    4. Check the air filter.

    5. Check the engine oil.

    6. Check the engine coolant.

    7. Check the engine idling speed and maximum engine speed.

    8. Check the vacuum pump.

      OK
      Each inspection result is normal.
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  21. REPLACE NO. 2 EXHAUST MANIFOLD (DPF CATALYTIC CONVERTER)


    1. Replace the No. 2 exhaust manifold (DPF catalytic converter).

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  22. PERFORM INITIALIZATION


    1. Clear the DPF deterioration record using the GTS.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  23. CHECK INTAKE SYSTEM DEPOSIT


    1. Check if 3 mm (0.12 in.) or more of carbon has accumulated on the intake manifold, cylinder head, etc. and if so, clean it off.

      Result
      Proceed to
      NEXT

    NEXT

  24. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  25. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS


    1. Replace the injector assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  26. 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

  27. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  28. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  29. PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)

    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

      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

  30. 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 32 Click here

    A

  31. 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

  32. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  33. 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

  34. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  35. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  36. 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

  37. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  38. 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

  39. 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

    GO TO STEP 44 Click here

    OK

  40. REPLACE SUPPLY PUMP ASSEMBLY


    1. Replace the supply pump assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  41. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  42. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  43. 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

    REPLACE SUPPLY PUMP ASSEMBLY Click here

    OK

  44. 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

  45. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  46. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END

  47. REPLACE SUPPLY PUMP ASSEMBLY


    1. Replace the supply pump assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  48. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

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


    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/ Active Test / Test the Fuel Leak / Data List / Common Rail Pressure and Target Common Rail Pressure.


      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Test the Fuel Leak
      Data List Display
      Target Common Rail Pressure
      Common Rail Pressure

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

    5. Maintain an engine speed of 3500 rpm, and then press the "Start" button.

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

      A01T8B8E03

      Tech Tips


      • The EPS, ABS and SRS warning lights may blink when the engine speed exceeds 3500 rpm during this test.

      • To ensure accurate measurements, perform the Active Test with measurements 5 times or more.

      Standard
      The difference between the target fuel pressure and the actual fuel pressure is less than 15000 kPa when the target fuel pressure reaches the maximum value approximately 2 seconds after the Active Test starts.
      Result
      Result Proceed to
      Difference between target fuel pressure and actual fuel pressure is 15000 kPa or higher A
      Difference between target fuel pressure and actual fuel pressure is less than 15000 kPa B

    B

    GO TO STEP 52 Click here

    A

  50. REPLACE COMMON RAIL ASSEMBLY


    1. Replace the common rail assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  51. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  52. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END