ECD SYSTEM Lack of Power or Hesitation

DESCRIPTION

Malfunction Condition Main Trouble Area Related Trouble Area

  • Lack of power caused by abnormal fuel injection volume (fuel supply pump malfunction, injector assembly malfunction, etc.)

  • Lack of power caused by intake air volume shortage (turbocharger malfunction, or front exhaust pipe or exhaust manifold converter blocked)

(a) Injector assembly malfunctions


  • Injector sliding malfunction

  • Injector stuck closed

  • Injector stuck open

  • Deposits in injector

  • Injector circuit malfunction

(b) Abnormal common rail pressure


  • Fuel supply pump

(c) Abnormal intake air volume


  • Intake air system leakage or clogged

  • Turbocharger

  • Front exhaust pipe blockage

  • Exhaust manifold converter blockage

  • Throttle valve does not open

  • Pressure discharge valve (P1271 stored simultaneously)

  • Intake air system blockage

  • Fuel filter element assembly

  • Throttle valve

  • Compression pressure

  • Injector compensation code

  • Fuel leak

  • Glow plug

  • Fuel pressure sensor

  • Manifold absolute pressure sensor

  • Vacuum hose connection for manifold absolute pressure sensor

  • Injector driver (P0200 stored simultaneously)

  • Vehicle modifications

  • Clutch disc wear

  • Low quality fuel

  • Frozen fuel

  • ECM

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's age. Do not judge the vehicle to be normal even when the Data List values indicate a standard level. There are possibly some concealed factors causing the malfunction.

  • Check that the vehicle has not been modified in any way prior to the vehicle inspection.

  • This troubleshooting procedure checks for the cause of an obvious lack of engine power while the vehicle is being driven (such as the maximum speed being extremely low).


  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
      Turbocharger System
      Main fault

      • Air leak in the turbocharged air passage

      • Turbocharger (turbine, bearing)
      Symptoms

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

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

      MAP


      • If there are problems with waste gate valve operation or the valve is stuck closed, the boost pressure increases. When this happens, the fuel injection amount may be reduced to protect the engine, which may result in a lack of power or hesitation.

      • 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 decreases by 1 kPa each time elevation increases by 100 m, and is also affected by the current weather conditions.
      Exhaust System
      Main fault Blockage
      Symptoms Lack of power (high engine speed, under heavy load)
      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 - 1
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      Engine - 2
      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 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.

      • If Target Pump SCV Current is 3000 mA or higher, the suction control valve may be stuck.

      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.
      Fuel Filter
      Main fault Blockage
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure


      • 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 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.
      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
      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.
      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


      • 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)).
      Diagnostic 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 (fully closed: 100%, fully open: 0%)

      • When the ignition switch is ON (engine 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 Lack of Power


    • Engine Speed

    • MAP

    • Intake Air

    • Coolant Temp

    • 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


  1. Explanation of Symptom

    Lack of Power

    The power of the diesel engine is determined by the quantity of injected fuel and the quantity of intake air.

    The quantity of injected fuel is determined by the fuel pressure and the amount of time the injector assembly is open. Basically, the fuel pressure is controlled so that it reaches the target fuel pressure. The throttle valve does not restrict air flow volume, so the manifold absolute pressure is almost the same as atmospheric pressure when idling. At more than approximately 1500 rpm, the turbo starts to operate causing the manifold absolute pressure to become higher than atmospheric pressure.

    Note


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

    • After replacing the fuel supply pump, the ECM needs initialization Click here.

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

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 the 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. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 2)


    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 / Lack of power.

    4. With no load after the engine is warmed up, take a snapshot when idling and at 4000 rpm.

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

      Result
      Proceed to
      NEXT

    NEXT

  3. CHECK SNAPSHOT (MAP)


    1. Check MAP in the snapshot taken in procedure 2 when the engine was running at 4000 rpm with no load.

      Result
      Result Proceed to
      MAP is 210 kPa or higher*1 A
      MAP is below 90 kPa*2 B
      Except above*3 C

      Tech Tips

      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.

      *1: There may be a problem in the turbocharger (waste gate valve) or fuel system.

      *2: There may be a problem in the turbocharger system.

      *3: There may be a problem in the intake system.


    A

    GO TO STEP 15 Click here

    C

    CHECK SNAPSHOT (COMMON RAIL PRESSURE, TARGET COMMON RAIL PRESSURE AND MAP) Click here

    B

  4. READ VALUE USING GTS (MAP AND ATMOSPHERIC 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 (do not start the engine).

      Standard
      Difference between MAP and Atmosphere Pressure is less than 8 kPa.

      Tech Tips


      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 8 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.

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

    B

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

    C

    REPLACE ECM Click here

    A

  5. CHECK AIR INTAKE SYSTEM


    1. Check for air leaks and blockages between the air cleaner case and turbocharger, and between the turbocharger and intake manifold.

      Tech Tips


      • Inspect the air intake system, especially hoses and pipes between the air cleaner and turbocharger.

      • Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.

      • Using your hand, check whether the pipes and hoses in the intake system are securely connected.

      • By applying soapy water and revving up the engine, air leaks from the intake system can be checked by checking for bubbles.

      • Check for any modifications in the intake system made by the user.

      OK
      No leakage or blockage.
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE AIR INTAKE SYSTEM Click here

    OK

  6. CHECK FRONT EXHAUST PIPE ASSEMBLY (CATALYST CONVERTER)


    1. Remove the front exhaust pipe assembly.

    2. Visually check for catalyst clogging or carbon deposits adhering to the inner wall of the exhaust pipe upstream of the catalyst.

      OK
      Less than 10% of the cells are clogged.

    3. Reinstall the front exhaust pipe assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE EXHAUST PIPE ASSEMBLY FRONT (CATALYST CONVERTER) Click here

    OK

  7. CHECK TURBOCHARGER SUB-ASSEMBLY


    1. Inspect the turbine shaft.


      1. Inspect axial play of turbine shaft.

        Click here

      2. Inspect radial pray of turbine shaft.

        Click here

      3. Check turbine shaft rotation.

        Click here

    2. Inspect the turbocharger housing.


      1. Visually check that there are no scratches or chipped areas inside the turbine housing or compressor housing.

      2. Visually check that there are no scratches or chipped areas on the blades of the impeller or turbine wheel.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY Click here

    OK

  8. CHECK FOR INTERMITTENT PROBLEMS


    1. Check for intermittent problems.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  9. REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Replace the manifold absolute pressure sensor.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  10. REPAIR OR REPLACE AIR INTAKE SYSTEM


    1. Repair or replace the malfunctioning part in the air intake system.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  11. REPLACE TURBOCHARGER SUB-ASSEMBLY


    1. Replace the turbocharger sub-assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  12. REPLACE ECM


    1. Replace the ECM.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  13. REPLACE EXHAUST PIPE ASSEMBLY FRONT (CATALYST CONVERTER)


    1. Replace the front exhaust pipe assembly.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  14. CHECK SNAPSHOT (COMMON RAIL PRESSURE, TARGET COMMON RAIL PRESSURE AND MAP)


    1. Check Common Rail Pressure, Target Common Rail Pressure and MAP in the snapshot taken in procedure 3 when the vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear and the engine speed around 3000 rpm.

      Result
      Result Proceed to
      MAP is 230 kPa or higher at an engine speed of 3000 rpm A
      Difference between Common Rail Pressure and Target Common Rail Pressure is 20000 kPa or more B
      Except above C

      Tech Tips


      • The above values are applicable 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.

      • The engine speed must be 1500 rpm or less before performing the inspection in which the accelerator pedal is fully depressed and the engine is accelerated to a speed of 3000 rpm.

      • If "Fuel pressure" follows "Target common rail pressure" during idling or low speed driving but is insufficient during acceleration or high speed driving, the fuel filter may be clogged.


    B

    INSPECT CLOGGED FUEL PIPE Click here

    C

    CHECK INTAKE SYSTEM Click here

    A

  15. CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)


    1. Disconnect the manifold absolute pressure sensor 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
      C89-2 (PIM) - C56-28 (PIM) Always Below 1 Ω
      C89-3 (VC) - C55-18 (VC) Always Below 1 Ω
      C89-1 (E) - C55-28 (E2) Always Below 1 Ω
      C89-2 (PIM) or C56-28 (PIM) - Body ground Always 10 kΩ or higher
      C89-3 (VC) or- C55-18 (VC) - Body ground Always 10 kΩ or higher
      C89-1 (E) or C55-28 (E2) - Body ground Always 10 kΩ or higher

      Tech Tips


      • Make sure that there is no evidence of any wire harnesses being crushed and that there are no wires that are about to snap.

      • Make sure that no terminals are worn down and that there are no bad connections.

      • Make sure there are no shorts between wires in areas where the wires bend or where a clamp might have slid along the wire harness.

      • Make sure there are no shorts to body ground in areas where wire harnesses are attached to metal parts.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  16. CHECK OR REPLACE TURBOCHARGER SUB-ASSEMBLY


    1. Check that the actuator rod moves and that the waste gate valve opens.

      Click here

      Tech Tips

      If the waste gate valve does not open, replace the turbocharger sub-assembly.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 39 Click here

  17. INSPECT CLOGGED FUEL PIPE


    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 / Diesel Injection.

    4. With no load after the engine is warmed up, take a snapshot when idling and vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear.

    5. Check the Target Common Rail Pressure and Common Rail Pressure value.

      B0025O8E24
      Result
      Result Proceed to
      While idling the vehicle, "Common Rail Pressure" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1 A
      "Common Rail Pressure" is normal while idling the vehicle, but "Common Rail Pressure" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear*2
      Except above B

      Note


      • *1: The cause may be a squashed or blocked fuel pipe or hose.

      • *2: The cause may be a clogged fuel filter.


    B

    REPLACE FUEL SUPPLY PUMP (SUCTION CONTROL VALVE) Click here

    A

  18. REPAIR OR REPLACE CLOGGED FUEL LINE


    1. Repair or replace the clogged (including frozen fuel) fuel pipe.

    2. Replace the fuel filter element assembly.

      Tech Tips

      If "Common Rail Pressure" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element assembly.

      Result
      Proceed to
      NEXT

    NEXT

  19. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  20. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  21. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    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.

      B0027UBE15
      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

    OK

    END

    NG

    REPLACE COMMON RAIL ASSEMBLY Click here

  22. REPLACE FUEL SUPPLY PUMP (SUCTION CONTROL VALVE)


    1. Replace the fuel supply pump.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 19 Click here

  23. REPLACE COMMON RAIL ASSEMBLY


    1. Replace the common rail assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  24. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  25. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    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.

      B0027UBE21
      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
      NEXT

    NEXT

    END

  26. CHECK INTAKE SYSTEM


    1. Check for air leaks and blockages between the air cleaner case and turbocharger, and between the turbocharger and intake manifold.

      Tech Tips


      • Inspect the air intake system, especially hoses and pipes between the air cleaner and turbocharger.

      • Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.

      • Using your hand, check whether the pipes and hoses in the intake system are securely connected.

      • When checking whether the intake system is clogged (which causes a low MAP), perform the following checks:


        • Check whether the air cleaner is clogged.

        • Check whether an intake hose is clogged.

        • Check whether the diesel throttle valve is stuck in the closed position.

      • Check for any modifications in the intake system made by the user.

      OK
      No leaks or blockages in the intake system.
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE AIR INTAKE SYSTEM Click here

    OK

  27. CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)


    1. Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the ECM connectors.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      C89-2 (PIM) - C56-28 (PIM) Always Below 1 Ω
      C89-3 (VC) - C55-18 (VC) Always Below 1 Ω
      C89-1 (E) - C55-28 (E2) Always Below 1 Ω
      C89-2 (PIM) or C56-28 (PIM) - Body ground Always 10 kΩ or higher
      C89-3 (VC) or C55-18 (VC) - Body ground Always 10 kΩ or higher
      C89-1 (E) or C55-28 (E2) - Body ground Always 10 kΩ or higher

      Tech Tips


      • Make sure that there is no evidence of any wire harnesses being crushed and that there are no wires that are about to snap.

      • Make sure that no terminals are worn down and that there are no bad connections.

      • Make sure there are no shorts between wires in areas where the wires bend or where a clamp might have slid along the wire harness.

      • Make sure there are no shorts to body ground in areas where wire harnesses are attached to metal parts.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  28. CHECK FRONT EXHAUST PIPE ASSEMBLY (CATALYTIC CONVERTER)


    1. Remove the front exhaust pipe assembly.

    2. Visually check for catalyst clogging or carbon deposits adhering to the inner wall of the exhaust pipe upstream of the catalyst.

      OK
      Less than 10% of the cells are clogged.

    3. Reinstall the front exhaust pipe assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE FRONT EXHAUST PIPE ASSEMBLY (CATALYTIC CONVERTER) Click here

    OK

  29. INSPECT TURBOCHARGER SUB-ASSEMBLY


    1. Check that the actuator rod moves and that the waste gate valve opens.

      Click here

      Tech Tips

      If the waste gate valve does not open, replace the turbocharger sub-assembly.

    2. Inspect the turbine shaft.


      1. Inspect axial play of turbine shaft.

        Click here

      2. Inspect radial pray of turbine shaft.

        Click here

      3. Check turbine shaft rotation.

        Click here

    3. Inspect the turbocharger housing.


      1. Visually check that there are no scratches or chipped areas inside the turbine housing or compressor housing.

      2. Visually check that there are no scratches or chipped areas on the blades of the impeller or turbine wheel.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY Click here

    OK

  30. CHECK FOR INTERMITTENT PROBLEMS


    1. Check for intermittent problems.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  31. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    OK
    NG

    OK

    END

    NG

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY Click here

  32. REPAIR OR REPLACE AIR INTAKE SYSTEM


    1. Repair or replace the malfunctioning part in the air intake system.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 28 Click here

  33. REPLACE FRONT EXHAUST PIPE ASSEMBLY (CATALYTIC CONVERTER)


    1. Replace the front exhaust pipe assembly.

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 31 Click here

  34. REPLACE TURBOCHARGER SUB-ASSEMBLY


    1. Replace the turbocharger sub-assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

    GO TO STEP 31 Click here

  35. 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 fuel injectors may not operate properly if the fuel filter is installed with foreign matter remaining inside the fuel filter case.

      Result
      Proceed to
      NEXT

    NEXT

  36. 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

  37. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  38. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation codes.

      Click here

    2. Perform the injector pilot quantity learning.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  39. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT

    END