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ECD SYSTEM(w/ Urea SCR System), Diagnostic DTC:P0093

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DTC Code DTC Name
P0093 Fuel System Leak Detected - Large Leak
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DESCRIPTION

The fuel pressure sensor mounted on the common rail assembly converts the fuel pressure inside the common rail assembly into an electrical signal and outputs the signal to the ECM. The ECM controls the fuel supply pump assembly in order to maintain the fuel pressure inside the common rail assembly at a target pressure calculated by the ECM. Refer to System Description (Click here).

Tip:

  • If the drop in the internal fuel pressure is large when injecting fuel, the ECM interprets this as a fault and stores P0093.

  • If P0093 is present, refer to "Diagnostic Trouble Code (DTC) Table for Common Rail System" (Click here).

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Memory
P0093 Fuel System Leak Detected - Large Leak Fuel pressure drop before and after the fuel injection is larger than the threshold a certain number of times (0.2 seconds or more) (1 trip detection logic).

  • Fuel line between fuel supply pump assembly and common rail assembly

  • Fuel line between common rail assembly and each injector assembly

  • Common rail assembly

  • Injector assembly

  • Pressure discharge valve (common rail assembly)

  • Fuel pressure sensor (common rail assembly)

  • Crankshaft position sensor

  • Fuel filter element assembly

  • Open or short in injector assembly circuit

  • ECM

 Comes on DTC stored
Table 1. Related Data List
DTC No. Data List
P0093

  • Common Rail Pressure

  • Target Common Rail Pressure
Tip:

When DTC P0093 is set, check the internal fuel pressure of the common rail by entering the following menus on the GTS: Powertrain / Engine / Data List / Common Rail Pressure.

Reference
Engine Speed Common Rail Pressure
Idling Approximately 25000 to 45000 kPa
3000 rpm (No engine load) Approximately 60000 to 95000 kPa
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CONFIRMATION DRIVING PATTERN

DTC No. DTC Detection Drive Pattern
P0093

After idling for 60 seconds, run engine at 2500 rpm for 30 seconds.

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

Rev the engine to 3000 rpm and fully release the accelerator pedal immediately after the engine reaches 3000 rpm. (*B)

Repeat procedures (*A) and (*B) 5 times.
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MONITOR DESCRIPTION

This DTC indicates that fuel leaks exist in high pressure areas in the common rail system. The ECM constantly monitors the internal fuel pressure of the common rail after the engine is started. The ECM stores this DTC if the drop in the internal fuel pressure is large when injecting fuel.

In the common rail system, high-pressure fuel is always supplied to the high-pressure areas including the fuel supply pump assembly, common rail assembly, injector assemblies and piping.

The ECM adjusts the timing of when the pre-stroke control valve is closed to obtain the target internal fuel pressure.

If this DTC is stored, the ECM enters fail-safe mode. In fail-safe mode, PM forced regeneration and fuel supply pump assembly operation is prohibited. The ECM continues operating in fail-safe mode until the ignition switch is turned off.

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CAUTION / NOTICE / HINT

Note:

  • Soon after starting the engine, visually check for fuel leaks in the fuel line.

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

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

Tip:

Read freeze frame data using the GTS. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, and other data from the time the malfunction occurred.

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PROCEDURE


  1. Click here

    CHECK FOR FUEL LEAKS (IN HIGH-PRESSURE AREAS)


    1. Before starting the engine, visually check for fuel leaks from the fuel supply pump assembly, injector assembly, common rail assembly, and the fuel pipes in high-pressure areas.

      OK
      No fuel leaks in high-pressure areas.
      Result
      Proceed to
      OK
      NG

  2. Click here

    CHECK FOR ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0093) AND RECORD STORED DTC AND FREEZE FRAME DATA (PROCEDURE 2)


    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.

    4. Read the DTCs and freeze frame data.


      1. Powertrain > Engine > Trouble Codes


      Result
      Result Proceed to
      DTC P0093 and "P0190, P0192 and/or P0193" are output C
      DTC P0093 and "P0335, P0337, P0338 and/or P0339" are output B
      Except above A

  3. Click here

    CHECK FUEL RECEIVER GAUGE (AMOUNT OF FUEL)


    1. Check if the fuel level is low.

      Result
      Result Proceed to
      The indicator (fuel warning light) is illuminated A
      The indicator (fuel warning light) is not illuminated B

  4. Click here

    ADD FUEL


    1. Add fuel.

      Result
      Proceed to
      NEXT

  5. Click here

    CHECK WHETHER DTC OUTPUT RECURS (DTC P0093)


    1. B0024CA

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note:

      • Hand pump pumping speed: Max. 2 strokes/sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the priming pump does not become harder to push even after pumping continuously 200 times or more, the pipe between the fuel tank and the fuel filter may have a leak, there may be an insufficient amount of fuel or the priming pump may be malfunctioning.

      • If a large amount of air remains inside the fuel system, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note:

      • Even if air bleeding completes with the priming pump, the vehicle may take 10 seconds or more to start.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases. Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the GTS to the DLC3.

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

    6. Clear the DTCs.


      1. Powertrain > Engine > Clear DTCs


    7. Start the engine. (*A)

    8. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak. (*B)

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak. (*C)


      1. Powertrain > Engine > Active Test
        Tester Display
        Test the Fuel Leak




    10. B002704E03

      Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time. (*D)

    11. Enter the following menus: Powertrain / Engine / Trouble Codes.

    12. Read Current DTCs.


      1. Powertrain > Engine > Trouble Codes



      1. When no DTCs are output, the air bleeding is completed.

      2. If any DTCs are output, proceed to the next step.

    13. Repeat steps (*A) to (*D).

    14. Clear the DTCs.


      1. Powertrain > Engine > Clear DTCs


    15. Start the engine and warm it up.

    16. Confirm that the shift lever is in neutral and securely apply the parking brake.

    17. Fully depress the accelerator pedal for 5 seconds, and then release it. (*E)

    18. Rev the engine to 3000 rpm and fully release the accelerator pedal immediately after the engine reaches 3000 rpm. (*F)

    19. B0025MJE08

      Repeat procedures (*E) and (*F) 5 times.

    20. Enter the following menus: Powertrain / Engine / Trouble Codes.

    21. Read Current DTCs.


      1. Powertrain > Engine > Trouble Codes


      Result
      Result Proceed to
      DTC is output A
      No DTC is output B

  6. Click here

    CHECK FREEZE FRAME DATA (INJECTION FEEDBACK VAL #1 TO #4)


    1. Read the value of Injection Feedback Val #1 to #4 in the freeze frame data recorded in Procedure 2.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is 5 mm3/st in at least 1 set of freeze frame data

      		 B
      Except above A
      Tip:

      When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.


  7. Click here

    READ VALUE USING GTS (COMMON RAIL PRESSURE)


    1. Connect the GTS to the DLC3.

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

    3. Clear the DTCs.


      1. Powertrain > Engine > Clear DTCs


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


      1. Powertrain > Engine > Data List
        Tester Display
        Common Rail Pressure




    5. Start the engine.

    6. Read the value of Common Rail Pressure while cranking and idling the engine.

      Result
      Result Proceed to
      The engine cannot be started or the engine can be started but Common Rail Pressure is below 20000 kPa 2 seconds after the starter signal changes from OFF to ON B
      Except above A

  8. Click here

    READ VALUE USING GTS (INJECTION FEEDBACK VAL #1 TO #4)


    1. Connect the GTS to the DLC3.

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

    3. Start the engine and warm it up.

    4. Enter the following menus: Powertrain / Engine / Data List / Injection Feedback Val #1 to #4.


      1. Powertrain > Engine > Data List
        Tester Display
        Injection Feedback Val #1
        Injection Feedback Val #2
        Injection Feedback Val #3
        Injection Feedback Val #4







    5. Read the values.

      Standard
      GTS Display Engine Condition* Normal Value

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

      		 Idling

      -3.0 mm3/st to 3.0 mm3/st
      Tip:

      *: The A/C switch and all accessory switches should be off, the engine coolant temperature should be 75°C (167°F) or higher and the engine should be idled for 1 minute or more.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3 mm3/st and engine vibration is abnormally large

      		 B
      Except above A
      Tip:

      • When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.

      • The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not malfunctioning.


  9. Click here

    CHECK ENGINE SPEED


    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. While checking the tachometer, fully depress the accelerator pedal for 5 seconds, and then release it.*1

    4. Repeat procedure *1 5 times.

      Result
      Result Proceed to
      No problems such as sluggishness or variations in the tachometer reading A
      Except above B

  10. Click here

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY


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

      Click here

      Tip:

      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

  11. Click here

    BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

  12. Click here

    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 and Target Common Rail Pressure.


      1. 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. B0027UBE55

      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.

      Click here

      Tip:

      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.

      Standard
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa.
      Tip:

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

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

      Result
      Result Proceed to
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa A
      Except above B

  13. Click here

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

    Tip:

    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 / Active Test / Control the Select Cylinder Fuel Cut.


      1. Powertrain > Engine > Active Test
        Tester Display
        Control the Select Cylinder Fuel Cut




      Tip:

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

      • If the cylinder being tested is normal, there will be a significant change in idle speed when the fuel injection is stopped for that cylinder.

      Result
      Proceed to
      NEXT

  14. Click here

    INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)


    1. Remove the glow plug for all the cylinders.

      Click here

    2. Visually check if there is fuel on the glow plugs.

      Tip:

      • If there is fuel on a glow plug, fuel may be leaking from an injector assembly.

      • After replacing an injector assembly, make sure that the common rail pressure (fuel pressure) is within 5000 kPa (51.0 kgf/cm2, 725 psi) of the target fuel pressure while cranking the engine.

      • If there is fuel on a glow plug, fuel may have mixed with the engine oil. Check the engine oil amount and whether the engine oil smells of diesel fuel. If the oil level is above the full line or the engine oil smells of diesel fuel, replace the engine oil.

    3. Install the glow plug.

      Click here

      Result
      Proceed to
      NEXT

  15. Click here

    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 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

  16. Click here

    BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

  17. Click here

    REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation code.

      Click here


      1. Powertrain > Engine > Utility
        Tester Display
        Injector Compensation




    2. Perform the injector pilot quantity learning.

      Click here


      1. Powertrain > Engine > Utility
        Tester Display
        Pilot Quantity Learning




      Result
      Proceed to
      NEXT

  18. Click here

    READ VALUE USING GTS (ENGINE SPEED)


    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 / Engine Speed.


      1. Powertrain > Engine > Data List
        Tester Display
        Engine Speed




    4. Read the value while cranking and idling the engine.

      Standard
      GTS Display Engine Condition Specified Condition
      Engine Speed Cranking 50 to 400 rpm
      Idling with warm engine 800 to 900 rpm
      Tip:

      The value should be the same as the actual engine speed and displayed with no interruption on the GTS.

      Result
      Proceed to
      OK
      NG

  19. Click here

    INSPECT ECM (FUEL PRESSURE SENSOR OUTPUT VOLTAGE)


    1. B002636C25
      *a

      Component with harness connected

      (ECM)

      Connect the positive (+) probe of an oscilloscope to the fuel pressure sensor input terminal of the ECM connector and the negative (-) probe to the body ground.

    2. Turn the ignition switch to ON.

    3. B00277OE07
      B0027YSC01
      *1 Engine *2 Engine Wire
      *3 Common Rail Assembly (Fuel Pressure Sensor) *4 Wire to Wire
      *5 ECM - -
      *a Vibration Method (Reference) - -

      Check for any noise in the waveform when vibration is applied to the wire harness and connectors between the fuel pressure sensor and ECM.

      Standard Voltage
      Tester Connection Condition Specified Condition
      C59-18 (PCR1) - Body ground Vibration is applied to the wire harness and connectors No noise in the waveform
      Result
      Result Proceed to
      MIL comes on or noise present in the waveform B
      Except above A

  20. Click here

    CHECK FOR INTERMITTENT PROBLEMS


    1. Check for intermittent problems.

      Click here

      Result
      Proceed to
      NEXT

  21. Click here

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    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.

    4. Clear the DTCs.


      1. Powertrain > Engine > Clear DTCs


    5. Start the engine.

    6. Warm up the engine (engine coolant temperature is 75°C (167°F) or higher).

    7. Confirm that the shift lever is in neutral and securely apply the parking brake.

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

    9. Rev the engine to 3000 rpm and fully release the accelerator pedal immediately after the engine reaches 3000 rpm. (*B)

    10. B0025MJE08

      Repeat procedures (*A) and (*B) 5 times.

    11. Enter the following menus: Powertrain / Engine / Trouble Codes.

    12. Read the DTCs.


      1. Powertrain > Engine > Trouble Codes


      OK
      No DTCs are output.
      Result
      Proceed to
      NEXT

    • NEXT

      END

  22. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - FUEL PRESSURE SENSOR)


    1. Repair or replace the harness or connector.

      Result
      Proceed to
      NEXT

  23. Click here

    INSPECT ECM (FUEL PRESSURE SENSOR OUTPUT VOLTAGE)


    1. B002636C25
      *a

      Component with harness connected

      (ECM)

      Connect the positive (+) probe of an oscilloscope to the fuel pressure sensor input terminal of the ECM connector and the negative (-) probe to the body ground.

    2. Turn the ignition switch to ON.

    3. Check for any noise in the waveform when vibration is applied to the wire harness and connectors between the fuel pressure sensor and ECM.

      Standard Voltage
      Tester Connection Condition Specified Condition
      C59-18 (PCR1) - Body ground Vibration is applied to the wire harness and connectors No noise in the waveform
      Result
      Result Proceed to
      MIL comes on or noise present in the waveform A
      Except above B

  24. Click here

    REPLACE COMMON RAIL ASSEMBLY


    1. Replace the common rail assembly.

      Click here

      Tip:

      Before replacing the common rail assembly, perform a wire harness inspection and if there are any problems with the wire harness, repair or replace it.

      Result
      Proceed to
      NEXT

  25. Click here

    BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

  26. Click here

    REPLACE CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor.

      Click here

      Tip:

      Before replacing the crankshaft position sensor, perform a wire harness inspection and if there are any problems with the wire harness, repair or replace it.

      Result
      Proceed to
      NEXT