ECD SYSTEM(w/o EGR Cooler) White Smoke Emitted

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Turbocharger System
      Main fault Turbocharger Sub-assembly (compressor side seal ring, turbine side seal ring, shaft, oil drain)
      Symptoms

      White smoke

      Excessive oil consumption
      Glow System
      Main fault Glow system malfunction
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Diagnostic Point

      • Measure the resistance of the glow plug

      • Check the glow plug indicator light
      Engine
      Main fault Loss of compression
      Symptoms Rough idle (constant lack of power)
      Data List

      Engine Speed of Cyl #1 to #4


      • 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 #1 to #4


      • If Injection Feedback Val #1 to #4 is more than 3 mm3/st, the cylinder may have a fault.

    2. Diesel Injection

      Injector Assembly
      Main fault Blockage
      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val #1 to #4


      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. Injection Feedback Val #1 to #4 can be read after idling for 1 minute with the engine warmed up (engine coolant temperature is higher than 75°C (167°F)).

      Tech Tips

      When the sliding resistance of the internal parts of the injector assemblies (nozzle needle, controlvalve) has increased due to internal contamination, injection quantity will increase at high common rail pressure due to a delay in injector assembly closure.

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

    3. Diesel EGR

      EGR System
      Main fault

      • Does not move smoothly

      • Does not close fully
      Symptoms

      • Rough Idle

      • EGR valve stuck closed: A loud turbocharger sound.

      • EGR valve stuck open: Difficult to start (does not stall), black smoke, white smoke (when engine is cold), lack of power, jerking (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. Also, when racing the engine, there will be some black smoke).
      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 the EGR valve Active Test, check whether Actual EGR Valve Pos follows Target EGR Valve Pos (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).

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

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

      • When the EGR valve does not close, MAF (Mass Air Flow Sub-assembly) decreases when the vehicle is accelerated at full throttle. MAP also decreases in comparison to Target Booster Pressure, however there is not a large difference.

      EGR Close Lrn. Val.


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

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

CAUTION / NOTICE / HINT

Note

After replacing an injector assembly, the ECM requires registration Click here.


  1. Explanation of Symptom

    White Smoke When the engine is misfiring, any fuel that has been injected but remains unburned is emitted as white smoke.

    Turbocharger internal oil leak Click here

    If oil leak occurs from turbine side seal, large amount of white smoke will be emitted from exhaust pipe.

    Internal oil leak is not visible from outside of turbocharger sub-assembly.

PROCEDURE


  1. CONFIRM CONDITIONS PRESENT WHEN WHITE SMOKE APPEARED WITH CUSTOMER


    1. Ask the customer about the conditions when the white smoke was emitted.

      - What were the driving conditions when the white smoke was generated.

      - Is the white smoke constantly emitted, or only occasionally?

      - Does the white smoke occur only when the vehicle is cold, or when the vehicle is both cold and hot?

      - Is the white smoke emitted just after starting the vehicle only, or does it continue while the vehicle is idling?

    2. Determine the symptoms of the problem to narrow down the possible causes.

      Result
      Proceed to
      NEXT

    NEXT

  2. READ OUTPUT DTCS (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 / Troubles.

    4. Read pending DTCs.


      Powertrain > Engine and ECT > Trouble Codes
      Result
      Result Proceed to
      No DTCs are output A
      Engine related DTCs are output B

    B

    GO TO DTC CHART Click here

    A

  3. CHECK WHEN WHITE SMOKE IS EMITTED


    1. Start the engine.

    2. Fully depress the accelerator pedal, and then release it.

    3. B003NVVC03
      *a Example

      Check whether white smoke is emitted or not when racing the engine.

      Note

      Be sure not to check for white smoke indoors.

      Tech Tips


      • If the white smoke is emitted only just after engine start and disappears later, the smoke is not from the turbocharger.

      • If the turbocharger is the cause of the problem, regardless of whether the engine is cold or warmed up, there will be a large amount of white smoke to the extent that visibility is obstructed for a few meters in the area of the smoke (as shown in the illustration).

      • Depending on whether there is oil mixed with the fuel, or whether there is unburned fuel present, the smell of the exhaust gas differs. When oil is mixed in, the exhaust gas smells such as burning oil.

      Result
      Result Proceed to
      White smoke is emitted just after engine start only A
      White smoke is always and continuously emitted B

      There is oil on the exhaust pipe, etc.

      Tech Tips

      The oil on the exhaust pipe may be from the transmission, etc.

      		 C

    B

    CHECK IDLING CONDITION Click here

    C

    CHECK FOR OIL LEAKAGE Click here

    A

  4. CHECK TEMPERATURE WHEN WHITE SMOKE IS EMITTED


    1. Check whether the white smoke is emitted only when the engine coolant temperature is below 0°C (32°F).

      Tech Tips


      • If so, the smoke is not from the turbocharger and may be the smoke of unburned fuel.

      • If misfiring occurs, unburned fuel is emitted.

      Result
      Result Proceed to
      White smoke is emitted when the temperature is below 0°C (32°F) A
      White smoke is emitted regardless of temperature B

    B

    GO TO STEP 6 Click here

    A

  5. INSPECT GLOW PLUG (RESISTANCE)


    1. Inspect the glow plug.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE GLOW PLUG Click here

    OK

  6. READ VALUE USING GTS (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)


    1. Connect the GTS to the DLC3.

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

    3. Start the engine

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail Pressure and Target Common Rail Pressure.


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

    5. Take a snapshot with the GTS.

    6. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Common Rail Pressure) when racing the engine with the accelerator pedal fully depressed.

      Result
      Result Proceed to
      Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure A
      Except above B

      Tech Tips


      • "Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.

      • "Common Rail Pressure" is the actual fuel pressure.


    B

    CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY 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

    REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING Register the injector compensation codes. Click here Perform the injector pilot quantity learning. Click here

    OK

  8. READ VALUE USING GTS (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)


    1. 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 with the A/C off.

      Tech Tips

      Engine coolant temperature is 75°C (167°F) or higher.

      Result
      Result Proceed to

      Injection Feedback Val #1 to #4 are 3 mm3/st or less and Injection Volume is 4.5 to 10.0 mm3/st

      		 A
      Other than above B

    B

    PERFORM PILOT QUANTITY LEARNING (DETAIL) Click here

    A

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


    1. Connect the GTS to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off. Wait for 30 seconds, and then restart the engine.

    4. Turn the GTS on.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / MAF.


      Powertrain > Engine and ECT > Data List
      Tester Display
      MAF

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

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the EGR Valve Close / Data List / MAF.


      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Activate the EGR Valve Close
      Data List Display
      MAF

    8. 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
      Active Test Result Proceed to

      Activate the EGR Valve Close:

      Off (Open) to On (Closed)

      		 MAF value does not change A
      MAF value changes B

      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.

      Reference
      EGR Valve Condition (Opening) Measuring Condition MAF (Reference)
      Open (55%)

      • Atmosphere pressure: 101 kPa

      • Engine coolant temperature: 75°C (167°F)

      		 3 to 7 gm/sec
      Closed (0%) 11 to 16 gm/sec

    A

    CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    B

  10. CHECK ENGINE ASSEMBLY


    1. Inspect the engine to see whether white smoke is being emitted due to defects in the engine itself.


      1. Check for oil leaking into the combustion chamber due to a faulty valve stem oil seal.

      2. Check for oil leaking into the combustion chamber due to a faulty injector assembly nozzle sheet.

      3. Check for low compression.

        Tech Tips

        If the engine runs too rough, Injection Feedback Val #1 to #4 cannot be corrected and the readout will (incorrectly) show that Injection Feedback Val #1 to #4 are within the normal range.

        Tech Tips

        If defects are found, perform repairs, and then check that the symptoms are no longer present.

      Result
      Proceed to
      NEXT

    NEXT

    END

  11. PERFORM PILOT QUANTITY LEARNING (DETAIL)


    1. Perform the pilot quantity learning (detail).

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  12. CHECK WHEN WHITE SMOKE IS EMITTED


    1. B003NVVC01
      *a Example

      Start the engine.

    2. Fully depress the accelerator pedal, and then release it.

    3. Check whether white smoke is emitted or not when racing the engine.

      Note

      Be sure not to check for white smoke indoors.

      Result
      Result Proceed to
      White smoke is not emitted A
      White smoke is emitted B

    A

    END

    B

  13. 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.

      Tech Tips

      If the engine idle speed does not change when an injector assembly is disabled, the cylinder being tested is malfunctioning. Record any malfunctioning cylinders.


      Powertrain > Engine and ECT > Active Test
      Tester Display
      Control the Select Cylinder Fuel Cut
      Result
      Proceed to
      NEXT

    NEXT

  14. 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.


    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 / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #4.


      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

    4. Crank the engine.

    5. Check the engine speed during the Active Test.

      Result
      Result Proceed to
      The values of Engine Speed Cyl #1 to #4 are within 10 rpm of each other A
      Other than above 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.


    A

    GO TO STEP 21 Click here

    B

    CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER Click here

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


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

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

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

      Tech Tips


      • A lack of fuel causes the fuel pressure to drop.

      • Check that the fuel filter element assembly is not clogged.

    3. Reconnect the inlet hose.

      Result
      Proceed to
      NEXT

    NEXT

  16. CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY


    1. Clean the fuel filter case and replace the fuel filter element assembly.

      Tech Tips

      Be sure to clean the inside of the fuel filter case as the injector assemblies may not operate properly if the fuel filter element assembly is installed with foreign matter remaining inside the fuel filter case.

      Result
      Proceed to
      NEXT

    NEXT

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


    1. Check and replace the clogged fuel pipe.

      Result
      Proceed to
      NEXT

    NEXT

  18. BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    If the fuel filter element assembly or fuel pipe has been replaced, be sure to remove any air in the system.


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  19. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the white smoke problem has been successfully repaired by starting the engine.

      Result
      Proceed to
      NEXT

    NEXT

    END

  20. 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".


    1. Check cylinder compression pressure.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  21. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tech Tips

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


    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here

      Note


      • When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection pipe sub-assembly and a new No. 2 injection pipe sub-assembly.

      • Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, 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 sub-assembly may become incomplete, resulting in a fuel leak.

      Result
      Proceed to
      NEXT

    NEXT

  22. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  23. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation codes.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Injector Compensation

    2. Perform the injector pilot quantity learning.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Pilot Quantity Learning
      Result
      Proceed to
      NEXT

    NEXT

  24. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the white smoke problem has been successfully repaired by starting the engine.

      Result
      Proceed to
      OK
      NG

    OK

    END

    NG

  25. CHECK FUEL QUALITY


    1. Check that only diesel fuel is being used.

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

      Result
      Proceed to
      NEXT

    NEXT

    END

  26. CHECK IDLING CONDITION


    1. Start the engine.

    2. Check the idling condition.

      Result
      Result Proceed to
      Engine run smoothly at idle, however white smoke is emitted. A

      There are problems such as rough idling or engine stall, and white smoke is emitted.

      Tech Tips

      If the pressure in the crank case has risen, white smoke will be produced just after the engine is started. In this case, if blow-by gas is ejected when the oil level gauge is slightly removed*, it is possible that the piston is damaged.

      Note

      *Do not completely remove the oil level gauge as oil may spray from the opening.

      		 B

      Tech Tips

      It is possible to determine the faulty cylinder by carrying out the "Check the Cylinder Compression" Active Test.


    A

    GO TO TURBOCHARGER OIL LEAK AND WHITE SMOKE Click here

    B

    REPAIR ENGINE ASSEMBLY

  27. CHECK FOR OIL LEAKAGE


    1. Remove any oil in the front exhaust pipe assembly.

      Tech Tips

      Oil in the exhaust pipe is producing white smoke.

    2. If there is an oil leak, repair the leak.

      Result
      Proceed to
      NEXT

    NEXT

    END