ECD SYSTEM (w/o DPF) Black Smoke Emitted

INSPECTION PROCEDURE

Note


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

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

  • After replacing a fuel injector, 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.

PROCEDURE


  1. READ OUTPUT DTC (RELATED TO ENGINE)


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine / DTC.

    4. Read the DTCs.

      Result
      Result Proceed to
      No DTC is output A
      DTCs related to the engine are output B

    B

    REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT Click here

    A

  2. READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #8)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

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

    4. Select the following menu items in order and read the values.


      • Injection Volume

      • Injection Feedback Val #1, #2, #3, #4, #5, #6, #7 and #8

      Standard Value
      Item Engine Speed* Reference Value
      Injection Volume Idling (No engine load)

      3.0 to 10 mm3/st
      Injection Feedback Val #1 to #8 Idling (No engine load)

      -3.0 to 3.0 mm3/st

      Tech Tips

      *: If no idling conditions are specified, the shift lever should be in N, and the A/C switch and all accessory switches should be off.


    NG

    READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP) Click here

    OK

  3. PERFORM ENGINE SPEED ACCELERATION

    Tech Tips

    If the exhaust gas contains excessive black smoke, perform the following operations.


    1. Accelerate the engine to the maximum speed with no load 20 times.

    2. Check the volume of black smoke in the exhaust gas.

      Result
      Result Proceed to
      Black smoke is not present OK
      Black smoke remains in the exhaust gas NG

      Tech Tips

      Soot deposits in the exhaust system may cause excessive black smoke.


    NG

    CHECK INTAKE AIR CONTROL SYSTEM AND EXHAUST SYSTEM Click here

    OK

    END

  4. CHECK INTAKE AIR CONTROL SYSTEM AND EXHAUST SYSTEM


    1. Inspect the engine condition Click here.


    NG

    REPAIR OR REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST

    OK

  5. INSPECT MASS AIR FLOW METER


    1. Inspect the mass air flow meter Click here.


    NG

    REPLACE MASS AIR FLOW METER Click here

    OK

  6. CHECK TURBOCHARGING PRESSURE


    1. Check the turbocharging pressure Click here.

      OK
      The turbocharger pressure is within the standard range.

    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY (for Bank 1 or Bank 2) Click here

    OK

  7. READ VALUE USING INTELLIGENT TESTER (DATA LIST)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

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

    4. Select the following menu items in order and read the values.


      • Fuel Press

      • Injection Volume

      • Main Injection Period

      • Pilot 2 Injection Period

      • Injection Feedback Val #1, #2, #3, #4, #5, #6, #7 and #8

      Reference
      Item Engine Speed* Reference Value
      Fuel Press Idling 27 to 37 MPa
      Fuel Press 2000 rpm (no engine load) 50 to 70 MPa
      Fuel Press 3000 rpm (no engine load) 52 to 76 MPa
      Injection Volume Idling

      3.0 to 10 mm3/st
      Injection Volume 2000 rpm (no engine load)

      3.5 to 11 mm3/st
      Injection Volume 3000 rpm (no engine load)

      6.5 to 13 mm3/st
      Main Injection Period Idling 430 to 730 μs
      Pilot 2 Injection Period Idling 390 to 490 μs
      Injection Feedback Val #1 to #8 Idling

      -3.0 to 3.0 mm3

      Tech Tips

      *: If no idling conditions are specified, the shift lever should be in N, and the A/C switch and all accessory switches should be off.

      Result
      Result Proceed to
      Within reference value A
      One of Injection Feedback Val #1 to #8 is not within reference value B
      Other result C

    B

    REPLACE MALFUNCTIONING FUEL INJECTOR Click here

    C

    READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP) Click here

    A

  8. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  9. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - EDU)

    A01586VE01

    1. Disconnect the fuel injector connectors.

    2. Disconnect the No. 1 EDU connector.

    3. A01586VE02

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

      Standard Resistance (Check for Open)
      No. 1
      Tester Connection Condition Specified Condition
      C5-2 - C74-4 (INJ1) Always Below 1 Ω
      C14-2 - C74-3 (INJ4) Always Below 1 Ω
      C69-2 - C74-2 (INJ6) Always Below 1 Ω
      C68-2 - C74-1 (INJ7) Always Below 1 Ω
      C5-1 - C74-5 (COM1) Always Below 1 Ω
      C14-1 - C74-5 (COM1) Always Below 1 Ω
      C69-1 - C74-6 (COM2) Always Below 1 Ω
      C68-1 - C74-6 (COM2) Always Below 1 Ω
      Standard Resistance (Check for Short)
      No. 1
      Tester Connection Condition Specified Condition
      C5-2 or C74-4 (INJ1) - Body ground Always 10 kΩ or higher
      C14-2 or C74-3 (INJ4) - Body ground Always 10 kΩ or higher
      C69-2 or C74-2 (INJ6) - Body ground Always 10 kΩ or higher
      C68-2 or C74-1 (INJ7) - Body ground Always 10 kΩ or higher
      C5-1 or C74-5 (COM1) - Body ground Always 10 kΩ or higher
      C14-1 or C74-5 (COM1) - Body ground Always 10 kΩ or higher
      C69-1 or C74-6 (COM2) - Body ground Always 10 kΩ or higher
      C68-1 or C74-6 (COM2) - Body ground Always 10 kΩ or higher

    4. Disconnect the fuel injector connectors.

    5. Disconnect the No. 2 EDU connector.

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

      Standard Resistance (Check for Open)
      No. 2
      Tester Connection Condition Specified Condition
      C70-2 - C76-4 (INJ2) Always Below 1 Ω
      C9-2 - C76-3 (INJ5) Always Below 1 Ω
      C67-2 - C76-1 (INJ3) Always Below 1 Ω
      C54-2 - C76-2 (INJ8) Always Below 1 Ω
      C70-1 - C76-5 (COM4) Always Below 1 Ω
      C9-1 - C76-5 (COM4) Always Below 1 Ω
      C67-1 - C76-6 (COM5) Always Below 1 Ω
      C54-1 - C76-6 (COM5) Always Below 1 Ω
      Standard Resistance (Check for Short)
      No. 2
      Tester Connection Condition Specified Condition
      C70-2 or C76-4 (INJ2) - Body ground Always 10 kΩ or higher
      C9-2 or C76-3 (INJ5) - Body ground Always 10 kΩ or higher
      C67-2 or C76-1 (INJ3) - Body ground Always 10 kΩ or higher
      C54-2 or C76-2 (INJ8) - Body ground Always 10 kΩ or higher
      C70-1 or C76-5 (COM4) - Body ground Always 10 kΩ or higher
      C9-1 or C76-5 (COM4) - Body ground Always 10 kΩ or higher
      C67-1 or C76-6 (COM5) - Body ground Always 10 kΩ or higher
      C54-1 or C76-6 (COM5) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  10. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER FUEL CUT)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3, #4, #5, #6, #7 and #8 Fuel Cut.

    4. Check the engine idling condition while the fuel injection of each cylinder is cut using the tester.

      Result
      Engine Idling Condition Proceed to
      Becomes unstable A
      Does not change B

      Tech Tips

      Replace the fuel injector mounted on the cylinder that causes no significant idle speed change.


    B

    REPLACE MALFUNCTIONING FUEL INJECTOR Click here

    A

    REPLACE INJECTOR DRIVER (No. 1 and/or No. 2) Click here

  11. READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP)


    1. Connect the intelligent tester to the DLC3.

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

    3. Start the engine and warm it up.

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

    5. Read the value.

      Standard Value
      Item Inspection Condition Reference Value
      Coolant Temp Idling with warm engine (A/C switch off) 75 to 90°C (167 to 194°F)

    NG

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  12. READ VALUE USING INTELLIGENT TESTER (MAP)


    1. Connect the intelligent tester to the DLC3.

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

    3. Start the engine and warm it up.

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

    5. Read the value.

      OK
      Same value as the actual atmospheric pressure.

    NG

    CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM) Click here

    OK

  13. READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)


    1. Connect the intelligent tester to the DLC3.

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

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

    4. Read the value.

      Standard Value
      Item Inspection Condition Reference Value
      Engine Speed Idling with warm engine (A/C switch off)

      • 500 to 600 rpm (M/T)

      • 550 to 650 rpm (A/T)

    NG

    INSPECT CRANKSHAFT POSITION SENSOR Click here

    OK

  14. READ VALUE USING INTELLIGENT TESTER (ACCEL SENS. NO.# VOLT %)


    1. A015CLQE02

      Connect the intelligent tester to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine / Data List / Accel Sens. No.1 Volt % and Accel Sens. No.2 Volt %.

    4. Read the values.

      Standard
      Accelerator Pedal Accel Sens. No.1 Volt % Accel Sens. No.2 Volt %
      Released 10 to 22% 24 to 40%
      Depressed 52 to 90% 68 to 99%

    NG

    CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM) Click here

    OK

  15. READ VALUE USING INTELLIGENT TESTER (INTAKE AIR)


    1. Connect the intelligent tester to the DLC3.

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

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

    4. Read the value.

      OK
      Same as air temperature near intake manifold.

    NG

    INSPECT INTAKE AIR TEMPERATURE SENSOR Click here

    OK

  16. READ VALUE USING INTELLIGENT TESTER (FUEL PRESS)


    1. Connect the intelligent tester to the DLC3.

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

    3. Start the engine and warm it up.

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

    5. Read the value.

      Standard Value
      Item Inspection Condition Reference Value
      Fuel Press Idling 27 to 37 MPa

    NG

    INSPECT COMMON RAIL (for Bank 1) (FUEL PRESSURE SENSOR) Click here

    OK

    REPLACE ECM Click here

  17. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

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


    1. A0158VYE01

      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 (Check for Open)
      for LHD
      Tester Connection Condition Specified Condition
      C80-2 (PIM) - C45-114 (PIM) Always Below 1 Ω
      C80-3 (VC) - C45-66 (VCPM) Always Below 1 Ω
      C80-1 (E) - C45-75 (E2) Always Below 1 Ω
      for RHD
      Tester Connection Condition Specified Condition
      C80-2 (PIM) - C46-114 (PIM) Always Below 1 Ω
      C80-3 (VC) - C46-66 (VCPM) Always Below 1 Ω
      C80-1 (E) - C46-75 (E2) Always Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Condition Specified Condition
      C80-2 (PIM) or C45-114 (PIM) - Body ground Always 10 kΩ or higher
      C80-3 (VC) or C45-66 (VCPM) - Body ground Always 10 kΩ or higher
      C80-1 (E) or C45-75 (E2) - Body ground Always 10 kΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      C80-2 (PIM) or C46-114 (PIM) - Body ground Always 10 kΩ or higher
      C80-3 (VC) or C46-66 (VCPM) - Body ground Always 10 kΩ or higher
      C80-1 (E) or C46-75 (E2) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

  19. INSPECT CRANKSHAFT POSITION SENSOR


    1. A015ALBE01

      Disconnect the crankshaft position sensor connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      1 (NE+) - 2 (NE-) Cold 1630 to 2740 Ω
      1 (NE+) - 2 (NE-) Hot 2065 to 3225 Ω

      Tech Tips

      In the table above, the terms "Cold" and "Hot" refer to the temperature of the coils in the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F).


    NG

    REPLACE CRANKSHAFT POSITION SENSOR Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  20. CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM)


    1. A0157YZE35

      Disconnect the accelerator pedal position sensor connector.

    2. Disconnect the ECM connector.

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

      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Condition Specified Condition
      A31-1 (VCP2) - A38-56 (VCP2) Always Below 1 Ω
      A31-2 (EPA2) - A38-58 (EPA2) Always Below 1 Ω
      A31-3 (VPA2) - A38-54 (VPA2) Always Below 1 Ω
      A31-4 (VCPA) - A38-55 (VCPA) Always Below 1 Ω
      A31-5 (EPA) - A38-57 (EPA) Always Below 1 Ω
      A31-6 (VPA) - A38-53 (VPA) Always Below 1 Ω
      for RHD
      Tester Connection Condition Specified Condition
      A31-1 (VCP2) - A52-56 (VCP2) Always Below 1 Ω
      A31-2 (EPA2) - A52-58 (EPA2) Always Below 1 Ω
      A31-3 (VPA2) - A52-54 (VPA2) Always Below 1 Ω
      A31-4 (VCPA) - A52-55 (VCPA) Always Below 1 Ω
      A31-5 (EPA) - A52-57 (EPA) Always Below 1 Ω
      A31-6 (VPA) - A52-53 (VPA) Always Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Condition Specified Condition
      A31-1 (VCP2) or A38-56 (VCP2) - Body ground Always 10 kΩ or higher
      A31-2 (EPA2) or A38-58 (EPA2) - Body ground Always 10 kΩ or higher
      A31-3 (VPA2) or A38-54 (VPA2) - Body ground Always 10 kΩ or higher
      A31-4 (VCPA) or A38-55 (VCPA) - Body ground Always 10 kΩ or higher
      A31-5 (EPA) or A38-57 (EPA) - Body ground Always 10 kΩ or higher
      A31-6 (VPA) or A38-53 (VPA) - Body ground Always 10 kΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      A31-1 (VCP2) or A52-56 (VCP2) - Body ground Always 10 kΩ or higher
      A31-2 (EPA2) or A52-58 (EPA2) - Body ground Always 10 kΩ or higher
      A31-3 (VPA2) or A52-54 (VPA2) - Body ground Always 10 kΩ or higher
      A31-4 (VCPA) or A52-55 (VCPA) - Body ground Always 10 kΩ or higher
      A31-5 (EPA) or A52-57 (EPA) - Body ground Always 10 kΩ or higher
      A31-6 (VPA) or A52-53 (VPA) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE ACCELERATOR PEDAL ROD ASSEMBLY (ACCELERATOR PEDAL POSITION SENSOR) Click here

  21. INSPECT INTAKE AIR TEMPERATURE SENSOR


    1. Remove the mass air flow meter Click here.

      A015AJRE01

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      4 (THA) - 5 (E2) -20°C (-4°F) 13.6 to 18.4 kΩ
      20°C (68°F) 2.21 to 2.69 kΩ
      60°C (140°F) 0.49 to 0.67 kΩ

    NG

    REPLACE MASS AIR FLOW METER Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  22. INSPECT COMMON RAIL (for Bank 1) (FUEL PRESSURE SENSOR)


    1. Inspect the fuel pressure sensor Click here.


    NG

    REPLACE COMMON RAIL (for Bank 1) Click here

    OK

  23. CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)


    1. A0159JAE03

      Disconnect the fuel pressure sensor connector.

    2. Disconnect the ECM connector.

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

      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Condition Specified Condition
      C82-2 (PR) - C45-69 (PCR1) Always Below 1 Ω
      C82-3 (VG) - C45-70 (VCM) Always Below 1 Ω
      C82-1 (E2) - C45-75 (E2) Always Below 1 Ω
      for RHD
      Tester Connection Condition Specified Condition
      C82-2 (PR) - C46-69 (PCR1) Always Below 1 Ω
      C82-3 (VG) - C46-70 (VCM) Always Below 1 Ω
      C82-1 (E2) - C46-75 (E2) Always Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Condition Specified Condition
      C82-2 (PR) or C45-69 (PCR1) - Body ground Always 10 kΩ or higher
      C82-3 (VG) or C45-70 (VCM) - Body ground Always 10 kΩ or higher
      C82-1 (E2) or C45-75 (E2) - Body ground Always 10 kΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      C82-2 (PR) or C46-69 (PCR1) - Body ground Always 10 kΩ or higher
      C82-3 (VG) or C46-70 (VCM) - Body ground Always 10 kΩ or higher
      C82-1 (E2) or C46-75 (E2) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  24. REPLACE ECM


    1. Replace the ECM Click here.

      Note

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

    2. Check if the engine starts smoothly or if the engine stalls.

      OK
      The engine starts smoothly and does not stall.

    NG

    REPLACE FUEL SUPPLY PUMP Click here

    OK

    END