ECD SYSTEM Black Smoke Emitted

DESCRIPTION

Faults and Symptoms of Common Rail Diesel Components

Engine Control

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

Glow System
Main fault	Glow system malfunction
Symptoms	Difficult to start, rough idle, knocking, white smoke (when cold)
Data List	Check the glow plug indicator light
Diagnostic Point	Measure the resistance of the glow plug assembly

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

Common Rail (ALL)

Supply Pump Assembly
Main fault	-
Symptoms	Difficult to start, engine stalling, rough idle, lack of power
Data List	Fuel Press, Target Common Rail Pressure, Target Pump SCV Current Fuel Press is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)). If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt. If the fuel pressure is below 25000 kPa, then idling will be rough. 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 Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.

Injector Assembly
Main fault	Blockage, increase in fuel injection volume
Symptoms	Rough idle, lack of power, black smoke, white smoke, knocking
Data List	Injection Feedback Val When an Injector Feedback Val is more than 3 mm³/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.

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 quantity will increase at high common rail pressure due to a delay in injector assembly closure.
When black smoke occurs due to contamination of the injector assemblies, there are usually other symptoms, such as engine knocking noise at cold idling, rough idling, difficulty starting, etc. which are also present when the common rail pressure is low.

Injector Driver (EDU)
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 (EDU) 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	Fuel Press, Target Common Rail Pressure Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped and check that Fuel Press and Common Rail Pres Sens 2 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Fuel Press or Common Rail Pres Sens 2 decreases to a value less than Target Common Rail Pressure).
Diagnostic Trouble Code	When the fuel pressure sensor has a fault, some DTCs may be stored.

Irregular Fuel
Main fault	-
Symptoms	Difficult to start, rough idle (especially when cold)

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 Position Generally, Actual EGR Valve Pos. = Target EGR Position +/-5% (fully closed: 0%, fully open: 100%). Using the EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Position (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.

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 0%: Fully open 100%: Fully closed When the ignition switch 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.

Data List Related to Starting Trouble
- Engine Speed
- MAP
- MAF
- Intake Air
- Coolant Temp
- Engine Speed of Cyl #1 (to #4)
- Target Common Rail Pressure
- Fuel Press
- 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.

WIRING DIAGRAM

Refer to DTC P0088.

Click here

CAUTION / NOTICE / HINT

Note

After replacing the ECM, the new ECM needs registration (Click here ) and initialization Click here.
After replacing a suction control valve, 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 to be normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

Explanation of Symptom

Black Smoke

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

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

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

PROCEDURE

READ OUTPUT DTC (RELATING TO ENGINE)

Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS.
Enter the following menus: Powertrain / Engine / Trouble Codes.

Powertrain > Engine > Trouble Codes

Read the pending DTCs.

Result

Proceed to
DTCs are not output
Engine related DTCs are output

Tech Tips

If only DTC P1609 is output, proceed to step 2.

Engine related DTCs are output

GO TO DTC CHART Click here

DTCs are not output

CHECK FOR BLACK SMOKE

Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it [A].
Repeat the above procedure [A] 10 times or more [B].

Check for black smoke emission during 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 number of black smoke emissions if there is any visible smoke.
If the procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.

Result

Proceed to
OK
NG

EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY TO BE REPLACED Click here

RECOVERY TO NORMAL

Tech Tips

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

Result

Proceed to
NEXT

END

EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY TO BE REPLACED

Even though it has been determined that the DPNR catalytic converter (exhaust manifold converter sub-assembly) needs to be replaced, make sure to complete diagnosis for this problem before replacing it.

Click here

Tech Tips

This problem is occurred because an excessive amount of PM has accumulated and resulted in abnormal combustion. It is necessary to diagnose the cause of abnormal PM accumulation and repair the problem. Therefore, do not perform replacement at this time.

Result

Proceed to
NEXT

CHECK INTAKE SYSTEM

Check for air leakage and blockage between the air cleaner case sub-assembly and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.

Tech Tips

Make sure that the air cleaner filter element sub-assembly is not clogged and the intake and exhaust system hoses are not disconnected.
When the vacuum hoses are disconnected.
Check that the intercooler is not clogged with foreign matter.
Check that there are no disconnected, pinched or leaking hoses or pipes.
Check that there are no modifications made by the user.

OK
No leakage or blockage.

Result

Proceed to
OK
NG

REPAIR OR REPLACE MALFUNCTIONING PARTS

CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT

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

GO TO STEP 35 Click here

CHECK INJECTOR COMPENSATION CODE

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

GO TO STEP 19 Click here

PERFORM PILOT QUANTITY LEARNING (DETAIL)

Perform the pilot quantity learning (detail).

Click here

Result

Proceed to
NEXT

CHECK FOR BLACK SMOKE

Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it [A].
Repeat the above procedure [A] 10 times [B].

Check for black smoke emission during 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 number of black smoke emissions if there is any visible smoke.

Result

Proceed to
OK
NG

END

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

Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / All Data.

Take a snapshot of the following Data List items.

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 list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.
Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.

Result

Proceed to
NEXT

READ VALUE USING GTS (MAF AND MAP)

Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).
Enter the following menus: Powertrain / Engine / Data List / All Data / MAP and MAF.

Powertrain > Engine > Data List

Tester Display

MAF

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

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

Result

Result	Proceed to
MAF 85 gm/s or more and MAP 120 kPa or higher	A
Except above	B

Tech Tips

The shift lever should be in neutral and the A/C switch and all accessory switches should be off.
The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.

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

PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE) Click here

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

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

Result

Result	Proceed to
Injection Volume is less than 5 mm³/st at 4000 rpm	A
Injection Feedback Val for at least one cylinder is more than 3 mm³/st	B
Except above	C

PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION) Click here

READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE) Click here

REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

Replace the injector assemblies.

Click here

Note

When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.

Result

Proceed to
NEXT

GO TO STEP 17 Click here

PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

Tech Tips

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

Connect the GTS to the DLC3.
Start the engine and turn the GTS on.

Enter the following menus: Powertrain / Engine / Active Test / Check the Cylinder Compression / Compression / Engine Speed of Cyl #1 to #4.

Powertrain > Engine > 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

Check the engine speed during the Active Test.

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 higher than the other cylinders, there is probably a complete loss of compression in that cylinder.

GO TO STEP 16 Click here

CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

Tech Tips

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

Check the cylinder compression pressure.

Click here

Result

Proceed to
OK
NG

CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

Replace the injector assembly of the malfunctioning cylinder.

Click here

Note

When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.

Result

Proceed to
NEXT

REPLACE FUEL FILTER ELEMENT ASSEMBLY

Replace the fuel filter element assembly.

Click here

Result

Proceed to
NEXT

BLEED AIR FROM FUEL SYSTEM

Bleed the air from the fuel system.

Click here

Result

Proceed to
NEXT

Perform the pilot quantity learning.

Click here

Result

Proceed to
NEXT

CHECK FOR BLACK SMOKE

Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it [A].
Repeat the above procedure [A] 10 times [B].

Check for black smoke emission during 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 number of black smoke emissions if there is any visible smoke.

Result

Proceed to
NEXT

END

READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.

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

Powertrain > Engine > Data List

Tester Display
Atmosphere Pressure
MAP

Compare MAP to Atmosphere Pressure when the ignition switch ON (engine stopped).

Tech Tips

If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 10 kPa (0.1 kgf/cm², 1.5 psi) or more, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.
Standard atmospheric pressure is 101 kPa (1.0 kgf/cm2, 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm2, 0.1 psi). This varies by weather (high atmospheric pressure, low atmospheric pressure).

Result

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

REPLACE ECM Click here

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)

Connect the GTS to the DLC3.
Start the engine and turn the GTS on.

Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak / All Data / Fuel Press, Target Common Rail Pressure.

Powertrain > Engine > Active Test

Active Test Display
Test the Fuel Leak

Data List Display
Target Common Rail Pressure
Fuel Press

Take a snapshot with the GTS during the Active Test.

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

Tech Tips

In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

OK
The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa (102.0 kgf/cm², 1451 psi).

Tech Tips

"Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.
"Fuel Press" is the actual fuel pressure in common rail assembly.
When the pressure discharge valve on the common rail assembly has a malfunction, the actual fuel pressure changes as shown by "Pressure Discharge Valve Abnormal Fuel Press" in the illustration.
The pressure discharge valve operates to discharge fuel pressure when the internal pressure of the common rail exceeds the target fuel pressure.
There are 2 fuel pressure sensor circuits and both of them display the same value. If the difference between Fuel Press and Common Rail Press Sens 2 exceeds 10000 kPa (102 kgf/cm², 1451 psi) for 2 seconds or more, it is necessary to inspect or repair the wiring for the fuel pressure sensor.

Result

Proceed to
OK
NG

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

READ VALUE USING GTS (COOLANT TEMP)

Soak the engine for a long time.
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.

Enter the following menus: Powertrain / Engine / Data List / All Data / Coolant Temp.

Powertrain > Engine > Data List

Tester Display
Coolant Temp

OK
Coolant Temp is the same as the ambient temperature.

Tech Tips

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

Result

Proceed to
OK
NG

CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

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

Soak the engine for a long time.
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.

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

Powertrain > Engine > 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

GO TO STEP 34 Click here

CHECK AND REPLACE MALFUNCTIONING PARTS

Inspect the mass air flow meter assembly.

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

Click here
Replace the mass air flow meter assembly.

Click here

Tech Tips

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

Replace the intake air temperature sensor (turbo).

Click here

Tech Tips

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

Result

Proceed to
NEXT

GO TO STEP 34 Click here

CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor.

Click here

Replace the engine coolant temperature sensor.

Click here

Tech Tips

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

Result

Proceed to
NEXT

GO TO STEP 34 Click here

CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

Disconnect the suction control valve connector.
Disconnect the ECM connector.

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

Standard Resistance

Tester Connection	Condition	Specified Condition
B48-1 - B76-41 (PCV+)	Always	Below 1 Ω
B48-2 - B76-81 (PCV-)	Always	Below 1 Ω
B48-1 or B76-41 (PCV+) - Body ground	Always	10 kΩ or higher
B48-2 or B76-81 (PCV-) - Body ground	Always	10 kΩ or higher

Result

Proceed to
OK
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY

Disconnect the inlet hose from the supply pump assembly.

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, the fuel pressure drops.
Inspect for fuel filter element assembly clogging (Check that the fuel filter element assembly is not clogged).

Result

Proceed to
OK
NG

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

REPLACE SUCTION CONTROL VALVE

Replace the suction control valve.

Click here

Result

Proceed to
NEXT

BLEED AIR FROM FUEL SYSTEM

Bleed the air from the fuel system.

Click here

Result

Proceed to
NEXT

PERFORM SUPPLY PUMP INITIALIZATION

Perform the supply pump initialization.

Click here

Result

Proceed to
NEXT

GO TO STEP 34 Click here

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

Check and replace the clogged fuel pipe.

Result

Proceed to
NEXT

BLEED AIR FROM FUEL SYSTEM

Bleed the air from the fuel system.

Click here

Result

Proceed to
NEXT

CHECK FOR BLACK SMOKE

Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it [A].
Repeat the above procedure [A] 10 times [B].

Check for black smoke emission during 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 number of black smoke emissions if there is any visible smoke.

Result

Proceed to
NEXT

END

REPAIR OR REPLACE HARNESS OR CONNECTOR

Repair or replace the harness or connector.

Result

Proceed to
NEXT

GO TO STEP 34 Click here

REPLACE ECM

Replace the ECM.

Click here

Result

Proceed to
NEXT

GO TO STEP 34 Click here

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

Replace the manifold absolute pressure sensor.

Click here

Result

Proceed to
NEXT

GO TO STEP 34 Click here

PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)

Connect the GTS to the DLC3.
Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
Turn the ignition switch off. Wait for 30 seconds, and then restart the engine.
Turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.

Powertrain > Engine > Data List

Tester Display

MAF
Read the MAF value displayed on the GTS while the engine is idling.
Enter the following menus: Powertrain / Engine / Active Test / Activate the EGR Valve Close / All Data / MAF.

Powertrain > Engine > Active Test

Active Test Display

Activate the EGR Valve Close

Data List Display

MAF

Read the MAF value when the EGR valve is closed using the Active Test function.

Tech Tips

If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.
Before performing the diagnosis, confirm that the EGR valve target opening angle is not 0%.

Result

GTS Display

Result

Proceed to

Activate the EGR Valve Close:

OFF (Open) to Close

MAF value does not change

MAF value changes

Note

As the measured values may differ from those shown below due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.

Tech Tips

The problem may be a temporary one, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the electric EGR control valve assembly or mass air flow meter assembly.

Reference

EGR Valve Condition (Opening)	Measuring Condition	MAF (Reference)
Open (67%)	Atmosphere pressure: 101 kPa Intake air temperature: 30°C (86°F) Engine coolant temperature: 88°C (190°F)	3 to 12 gm/s
Closed (0%)		7 gm/s or more

GO TO STEP 12 Click here

READ VALUE USING GTS (MAF)

Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.

Powertrain > Engine > Data List

Tester Display

MAF

With the ignition switch ON and engine stopped, read the value when 30 seconds has elapsed.

Standard

GTS Display	Condition	Standard
MAF	Ignition switch ON (do not start engine)	0.35 gm/s or less

Result

Proceed to
OK
NG

REPLACE MASS AIR FLOW METER ASSEMBLY Click here

PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

Connect the GTS to the DLC3.
Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
Turn the ignition switch off and wait for 30 seconds.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.

Powertrain > Engine > Data List

Tester Display

MAF
Read the MAF value displayed on the GTS while the engine is idling.

Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for EGR Cooler Bypass / All Data / EGR Cooler Bypass Position and MAF.

Tech Tips

Whether the EGR is passing through the bypass side or cooler side during the Active Test can be confirmed by checking EGR Cooler Bypass Position.

Powertrain > Engine > Active Test

Active Test Display
Activate the VSV for EGR Cooler Bypass

Data List Display
MAF
EGR Cooler Bypass Position

Using the Active Test function, switch the No. 1 vacuum switching valve assembly (for EGR cooler) between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".

Tech Tips

If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

Result

GTS Display

Result

Proceed to

Activate the VSV for EGR Cooler Bypass:

Cooler to Bypass

MAF value does not change

MAF value changes

Tech Tips

If the EGR pipe with cooler sub-assembly is clogged, the MAF changes.

GO TO STEP 42 Click here

REMOVE DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

Remove the electric EGR control valve assembly.

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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.
When cleaning the electric EGR control valve assembly, perform initialization procedure.

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Do not forcibly open the valve, as it may be damaged or deformed.
When cleaning the electric EGR control valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.

Tech Tips

If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.
If the EGR valve does not close properly or is stuck open, EGR becomes excessive and combustion becomes unstable. Also, there may be a lack of power. In this case, clean the electric EGR control valve assembly.

Result

Proceed to
NEXT

REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLY

Replace the EGR pipe with cooler sub-assembly.

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Result

Proceed to
NEXT

GO TO STEP 20 Click here

REPLACE MASS AIR FLOW METER ASSEMBLY

Replace the mass air flow meter assembly.

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Result

Proceed to
NEXT

GO TO STEP 20 Click here