ECD SYSTEM Black Smoke Emitted

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. 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 Open circuit, glow plug relay fault
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Data List Check the glow plug indicator light
      Diagnostic Point Measure the resistance of the glow plug
      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.

    2. Diesel Injection

      Fuel Supply Pump
      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


      • Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 75°C (167°F)).

      • If the Common Rail Pressureure is 20000 kPa below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa, then idling will be rough.

      Tech Tips


      • The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.
      Diagnostic Trouble Code Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.
      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
      Main fault Circuit fault: The injector assembly does not open.
      Symptoms Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
      Data List Same as injector assembly
      Diagnostic Trouble Code When the injector driver has a fault, some DTCs may be stored.
      Fuel Pressure Sensor
      Main fault Open circuit, decrease in performance (foreign matter is stuck)
      Symptoms Difficult to start, rough idle, engine stall, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure


      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped and check that Common Rail Pressure 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 Common Rail Pressure 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)

    3. Diesel Throttle

      Diesel Throttle System
      Main fault Stuck, does not move smoothly
      Symptoms

      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

      • Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.
      Data List

      • Actual Throttle Position

        100%: Fully open

        0%: Fully closed

      • When the ignition switch is ON (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

  2. Data List Related to Black Smoke


    • Engine Speed

    • MAP

    • Intake Air

    • Coolant Temp

    • Engine Speed of Cyl #1 (to #4)

      (Output only when the "Check the Cylinder Compression" Active Test is performed)

    • Target Common Rail Pressure

    • Common Rail Pressure

    • Target Pump SCV Current

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

    • Actual Throttle Position

CAUTION / NOTICE / HINT

Note


  • After replacing the ECM, the new ECM needs registration (See page ) and initialization Click here.

  • After replacing a Fuel Supply Pump, 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.


  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 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.

    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


  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 / Trouble Codes.


      Powertrain > Engine > Trouble Codes

    4. Read pending DTCs.

      Result
      Result Proceed to
      No DTCs are output A
      Engine related DTCs are output B

    B

    GO TO DTC CHART Click here

    A

  2. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 75°C (167°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.*1

    4. Repeat the above procedure *1 10 times or more.*2

    5. Check for black smoke emission during procedures *1 and *2.

      OK
      After repeating 10 times or more, black smoke stops being emitted.

      Tech Tips

      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

    NG

    CHECK AIR INTAKE SYSTEM Click here

    OK

  3. 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

    NEXT

    END

  4. CHECK AIR INTAKE SYSTEM


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

      Tech Tips


      • Make sure that the air cleaner is not clogged and the intake and exhaust system hoses are not disconnected.

      • When the vacuum hoses are disconnected (the swirl control valve is always fully open) or the valve is stuck open, smoke may increase without feeling a lack of power (visually check the operation of the swirl control valve when starting the engine).

      • 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

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  5. CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT


    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

    GO TO STEP 31 Click here

    OK

  6. CHECK INJECTOR COMPENSATION CODE


    1. Read the injector compensation codes.

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

    NG

    GO TO STEP 16 Click here

    OK

  7. PERFORM PILOT QUANTITY LEARNING (DETAIL)


    1. Perform the pilot quantity learning (detail).

      Click here

      Result
      Proceed to
      NEXT

    NEXT

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


    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

    4. 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

    NEXT

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


    1. Check Injection Feedback Val # 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 10 mm3/st at 4000 rpm

      		 A

      Injection Feedback Val for at least one cylinder is more than +3 mm3/st

      		 B
      Except above C

    B

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

    C

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

    A

  10. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. 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

    NEXT

    GO TO STEP 14 Click here

  11. 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. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine / Active Test / Check the Cylinder Compression / Data List / 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

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


    B

    GO TO STEP 13 Click here

    A

  12. 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 the cylinder compression pressure.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  13. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    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 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

    NEXT

  14. 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 is installed with foreign matter remaining inside the fuel filter case.

      Result
      Proceed to
      NEXT

    NEXT

  15. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  16. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation code.

      Click here

    2. Perform the injector pilot quantity learning.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  17. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 75°C (167°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.*1

    4. Repeat the above procedure *1 10 times.*2

    5. Check for black smoke emission during procedures *1 and *2.

      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

    NEXT

    END

  18. 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 / Data List / MAP and Atmosphere Pressure.


      Powertrain > Engine > Data List
      Tester Display
      Atmosphere Pressure
      MAP

    4. Compare MAP to Atmosphere Pressure when the ignition switch is 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 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. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather (high atmospheric pressure, low atmospheric pressure).

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

    B

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

    C

    PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK) Click here

    A

  19. REPLACE ECM


    1. Replace the ECM.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 34 Click here

  20. REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Replace the manifold absolute pressure sensor.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 34 Click here

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


    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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


      Powertrain > Engine > 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. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Common Rail Pressure) 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.

      B003LE3E56
      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.

      Tech Tips


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

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

      Result
      Proceed to
      OK
      NG

    NG

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

    OK

  22. READ VALUE USING GTS (ENGINE COOLANT TEMPERATURE)


    1. Connect the GTS to the DLC3.

    2. Soak the engine for a long time.

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

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

    NG

    CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  23. READ VALUE USING GTS (INTAKE AIR)


    1. Connect the GTS to the DLC3.

    2. Soak the engine for a long time.

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

    4. Enter the following menus: Powertrain / Engine / Data List / Intake Air.


      Powertrain > Engine > Data List
      Tester Display
      Intake Air
      OK
      Intake Air is the same as the ambient temperature.
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 34 Click here

    NG

    CHECK AND REPLACE MALFUNCTIONING PARTS Click here

  24. CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor.

      Click here

    2. 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

    NEXT

    GO TO STEP 34 Click here

  25. CHECK AND REPLACE MALFUNCTIONING PARTS


    1. Inspect the intake air temperature sensor.

      Click here

    2. Replace the intake air 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

    NEXT

    GO TO STEP 34 Click here

  26. 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
      C127-1 - C114-2 (PCV+) Always Below 1 Ω
      C127-2 - C114-1 (PCV-) Always Below 1 Ω
      C127-1 or C114-2 (PCV+) - Body ground Always 10 kΩ or higher
      C127-2 or C114-1 (PCV-) - Body ground Always 10 kΩ or higher

    4. Reconnect the suction control valve connector.

    5. Reconnect the ECM connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  27. CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP


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

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

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

      Tech Tips


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

      • Inspect for fuel filter clogging (Check that the fuel filter is not clogged).

    3. Reconnect the inlet hose.

      Result
      Proceed to
      OK
      NG

    NG

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

    OK

  28. REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)


    1. Replace the fuel supply pump assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  29. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  30. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform supply pump initialization.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 34 Click here

  31. REPAIR OR REPLACE HARNESS OR CONNECTOR


    1. Repair or replace the harness or connector.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 34 Click here

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


    1. Check and replace the clogged fuel pipe.

      Result
      Proceed to
      NEXT

    NEXT

  33. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  34. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 75°C (167°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.*1

    4. Repeat the above procedure *1 10 times.*2

    5. Check for black smoke emission during procedures *1 and *2.

      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

    OK

    END

    NG

  35. BASIC INSPECTION


    1. Check the fuel quality.

    2. Check the fuel 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.

      Result
      Proceed to
      NEXT

    NEXT

    END