ECD SYSTEM (w/o DPF) Engine Knocking or Rattling

DESCRIPTION

Malfunction Condition Main Trouble Area Related Trouble Area

  • Knocking and abnormal sound due to extremely rich combustion

  • Abnormal sound due to friction between parts

  1. Fuel injector malfunctions


    • Fuel injector sliding malfunction

    • Fuel injector stuck closed

    • Fuel injector stuck open

    • Deposits in fuel injector

    • Fuel injector circuit malfunction

  2. Abnormal common rail pressure


    • Fuel supply pump

    • Fuel pulsation sound

    • Air in fuel

  3. Friction between parts

  4. Compression pressure

  • Fuel injector compensation codes

  • Fuel leakage

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Throttle valve system

  • Fuel pressure sensor

  • Manifold absolute pressure sensor

  • Atmospheric pressure sensor (built into ECM)

  • Vehicle modifications

  • Low quality fuel

  • Lack of 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 of the malfunction.

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

INSPECTION PROCEDURE

Note


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

  • After replacing a fuel injector, the ECM needs registration Click here.

Tech Tips


  • This troubleshooting procedure checks for knocking and rattling.

  • Knocking is most likely to occur while the engine is idling.

PROCEDURE


  1. CHECK SOUND AREA


    1. Find the source of the abnormal sound using a mechanic's stethoscope.

      Result
      Result Proceed to
      Sound from fuel supply pump A
      Sound from parts other than fuel supply pump B

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    A

  2. CHECK HARNESS AND CONNECTOR IN ENGINE COMPARTMENT


    1. Check the wire harness connections.

      OK
      Wire harnesses are connected securely.

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. PERFORM CONFIRMATION DRIVING PATTERN

    Tech Tips

    Drive the vehicle according to the driving pattern below to allow the ECM to store DTCs relating to malfunctions of the fuel system, EGR system and throttle valve. If DTCs are stored, problem areas can be identified.


    1. Connect the intelligent tester to the DLC3.

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

    3. Enter Check Mode Click here.

    4. Fully warm up the engine.

    5. Allow the engine to idle for 5 minutes or more.

    6. Drive the vehicle at more than 40 km/h (25 mph) for 1 minute or more (procedure "A").

    7. Decelerate and stop the vehicle (procedure "B").

    8. Repeat procedure "A" and procedure "B" 4 times or more.

    9. Stop the engine and wait for at least 10 seconds (procedure "C").

    10. Repeat procedure "A" and procedure "C" described above to store DTCs relating to the EGR system and throttle valve.

    11. Drive the vehicle at more than 70 km/h (43 mph) for at least 1 minute (to store DTCs relating to the fuel supply pump).


    NEXT

  4. READ OUTPUT DTC (RELATING 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 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

  5. READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine, warm it up, and turn the tester on.

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


      • Injection Feedback Val #1 to #8

      • Injection Volume

      Standard Value
      Item Engine Speed* Standard Range Description
      Injection Feedback Val #1 to #8 Idling

      -3.0 to 3.0 mm3/st

      Value of fuel injector injection volume compensates for differences in combustion condition of cylinders


      • Positive values indicate control which corrects combustion degradation

      • Negative values indicate control which corrects excessive combustion pressure

      • If problems exist, Injection Feedback Val may deviate from the -3.0 to 3.0 mm3/st range
      Injection Volume Idling

      3.0 to 10 mm3/st

      Fuel injection volume value controlled by ECU


      • Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure, EGR volume, and MAF

      • If problems exist, Injection Volume may be outside standard range
      Result
      Result Proceed to
      Standard range A
      Injection Feedback Val #1 to #8 and/or Injection Volume outside standard range B

      Tech Tips

      *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.


    B

    IDENTIFY MALFUNCTIONING CYLINDER FUEL INJECTOR Click here

    A

  6. CHECK FUEL INJECTOR COMPENSATION CODE


    1. Read the fuel injector compensation code Click here.

      Tech Tips

      If the fuel injector compensation code is not correctly registered, it may cause malfunctions Click here.

    2. Check the fuel injector compensation code.

      OK
      Compensation code of the installed fuel injector is the same as the code registered in the ECM.

    NG

    REGISTER FUEL INJECTOR COMPENSATION CODE Click here

    OK

  7. RESET ECM


    1. Disconnect the cable from the negative (-) battery terminal for at least 2 minutes.

    2. Reconnect the cable to the negative (-) battery terminal.

    3. Check whether the malfunction has been successfully repaired by performing a driving test using the freeze frame data recorded at the time the malfunction occurred.

      OK
      Malfunction has been repaired successfully.

    NG

    BASIC INSPECTION Click here

    OK

    CHECK FOR INTERMITTENT PROBLEMS Click here

  8. 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 the maximum engine speed.

    8. Check the vacuum pump.

      OK
      Each inspection result is normal.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  9. CHECK INTAKE SYSTEM


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

      OK
      No air leakage or blockage.

    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  10. CHECK EGR VALVE ASSEMBLY (No. 1 or No. 2)

    Tech Tips

    For vehicles without EGR valve, perform troubleshooting from the next step.


    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 / Active Test / Control the EGR Step Position or Control the EGR Step Position #2 / Data List / Actual EGR Valve Pos. or Actual EGR Valve Pos. #2.

    4. When changing the Active Test value from 0 to 100%, check that Actual EGR Valve Pos. or Actual EGR Valve Pos. #2 smoothly changes to the set opening angle.

      OK
      Value smoothly changes to within +/-10% of set opening angle.

      Tech Tips


      • EGR valve closed: Actual EGR Valve Pos. is 0%

      • EGR valve open: Actual EGR Valve Pos. is 94.9%


    NG

    REPLACE EGR VALVE ASSEMBLY (for No. 1 or No. 2) Click here

    OK

  11. READ VALUE USING INTELLIGENT TESTER (ACTUAL THROTTLE POSITION)


    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 / Actual Throttle Position and Actual Throttle Position #2.

    4. Read the value.

      OK
      Ignition switch ON
      -5 to 5%
      Idling (Warmed up engine)
      0 to 90%
      Accelerator pedal fully depressed
      -5 to 5%

    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY (for Bank 1 or Bank 2) Click here

    OK

  12. CHECK COMBUSTION SOUND


    1. Confirm type of sound emitted.

      Result
      Result Proceed to
      Knocking A
      Mechanical sound other than knocking B

    B

    CHECK SOUND AREA Click here

    A

  13. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTION)


    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 8 cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.

      Tech Tips


      • While the engine is idling, if the idling stability variation is small despite cutting off the fuel injection, the cylinder is malfunctioning.

      • With normal cylinders, the engine idles roughly when the fuel injection is cut off.


    NEXT

  14. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure Click here.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  15. CHECK MALFUNCTIONING CYLINDER FUEL INJECTOR FOR DEPOSITS

    Tech Tips

    If a fuel injector is contaminated with deposits, the injection volume deviates from the standard range. This may cause malfunctions.


    1. Check the fuel injector for any deposits.

      Result
      Result Proceed to
      Deposits A
      No deposits B

    B

    REPLACE FUEL INJECTOR OF MALFUNCTIONING CYLINDER Click here

    A

  16. CLEAN FUEL INJECTOR


    1. Wipe away deposits from the tips of the fuel injectors.

      Tech Tips

      Solvent or carbon removal agents help remove the deposits easily.

      Note

      Exercise extreme care not to damage the fuel injectors while wiping off the deposits.


    NEXT

  17. READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)


    1. Reinstall the fuel injector to the cylinder head.

    2. Connect the intelligent tester to the DLC3.

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

    4. Start the engine and warm it up.

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

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


      • Injection Feedback Val #1 to #8

      • Injection Volume

      Standard Value
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #8 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      3.0 to 10 mm3/st

      Tech Tips


      • *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.

      • When the values are outside the standard range, deposits inside the fuel injector may be causing the problem.

      OK
      Values are within the standard range.

    NG

    REPLACE FUEL INJECTOR OF MALFUNCTIONING CYLINDER Click here

    OK

    END

  18. IDENTIFY MALFUNCTIONING CYLINDER FUEL INJECTOR


    1. Follow the instructions in the table below according to the check result of the intelligent tester.

      Tech Tips

      This operation is based on the premise that the common rail pressure is normal.

      Standard Value
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #8 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      3.0 to 10 mm3/st

      Tech Tips

      *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.

      Result
      Injection Feedback Val #1 to #8 Injection Volume Proceed to

      3.0 mm3/st or more, -3.0 mm3/st or less

      Less than 3.0 mm3/st

      		 A

      Between 3.0 and 10 mm3/st (Normal)

      		 B

      More than 10 mm3/st

      		 B

      Between -3.0 and 3.0 mm3/st

      Less than 3.0 mm3/st

      		 -

      Between 3.0 and 10 mm3/st (Normal)

      		 Normal

      More than 10 mm3/st

      		 C*

      Tech Tips

      *: When the Injection Volume displayed on the tester is large despite the Fuel Press and Injection Feedback Val #1 to #8 in the Data List being normal, the fuel injector may be clogged. In this case, there may be deposits inside or outside the tip of the fuel injector.

      Proceed to Inspection Area Description
      A

      Inspect and repair cylinder fuel injector with revised injection volume of less than 3.0 mm3:


      • Perform power balance inspection and identify malfunctioning cylinder

      • Replace malfunctioning cylinder fuel injector

      		 Fuel injector of cylinder with abnormal value injects excessively large quantity of fuel
      B

      Identify malfunctioning cylinders by conducting power balance inspection:


      • Perform power balance inspection to identify malfunctioning cylinders

      • Clean malfunctioning cylinder fuel injector, then check and repair it

      Fuel injector of cylinder with abnormal value injects excessively large quantity of fuel


      • Injection volume too low due to fuel injector nozzle being blocked by deposits

      • Compression of cylinder with abnormal value decreases

      • Fuel injector of cylinder with abnormal value injects excessively large quantity of fuel
      C

      Inspect and repair all cylinder fuel injectors:

      Clean all cylinder fuel injectors, and then inspect and repair them

      All cylinder fuel injectors inject excessively small quantity of fuel:

      Injection volume too low due to all cylinder fuel injector nozzles being blocked by deposits

      Tech Tips


      • Despite the fuel injector functioning normally, the indicated Injection Feedback Val #1 to #8 value may be outside the normal operating range due to compensation for other problems (such as low compression).

      • Injection Feedback Val #1 to #8 is the value used to correct the injection volumes of each cylinder, in order to optimize (compensate for the unevenness between) all the cylinder combustion conditions. If any of the cylinders malfunction, the injection volumes for the normal cylinders are corrected simultaneously. As a result, the Injection Feedback Val #1 to #8 may deviate from the standard range.


    B

    CHECK MALFUNCTIONING CYLINDER FUEL INJECTOR FOR DEPOSITS Click here

    C

    CHECK FUEL INJECTORS FOR DEPOSITS Click here

    A

  19. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)


    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 8 cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.

      Tech Tips


      • If the engine idle speed does not change when a fuel injector is disabled, the cylinder being tested is malfunctioning.

      • 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.


    NEXT

    REPLACE FUEL INJECTOR OF MALFUNCTIONING CYLINDER Click here

  20. CHECK FUEL INJECTORS FOR DEPOSITS

    Tech Tips

    If a fuel injector is contaminated with deposits, the injection volume deviates from the standard range. This may cause malfunctions.


    1. Check the fuel injector for any deposits.

      Result
      Result Proceed to
      Deposits A
      No Deposits B

    B

    REPLACE FUEL INJECTOR OF MALFUNCTIONING CYLINDER Click here

    A

  21. CLEAN FUEL INJECTOR


    1. Wipe away deposits from the tips of the fuel injectors.

      Tech Tips

      Solvent or carbon removal agents help remove the deposits easily.

      Note

      Exercise extreme care not to damage the fuel injectors while wiping off the deposits.


    NEXT

  22. READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)


    1. Reinstall the fuel injector to the cylinder head.

    2. Connect the intelligent tester to the DLC3.

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

    4. Start the engine and warm it up.

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

    6. Select the following menu items in order and read the values displayed on the tester respectively.


      • Injection Feedback Val #1 to #8

      • Injection Volume

      Standard Value
      Item Engine Speed* Reference Value
      Injection Feedback Val #1 to #8 Idling

      -3.0 to 3.0 mm3/st
      Injection Volume Idling

      3.0 to 10 mm3/st

      Tech Tips


      • *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.

      • When the values are outside the standard range, deposits inside the fuel injector may be causing the problem.

      OK
      Values are within the standard range.

    NG

    REPLACE FUEL INJECTOR OF MALFUNCTIONING CYLINDER Click here

    OK

    END

  23. CHECK SOUND AREA


    1. Find the source of the abnormal sound using a mechanic's stethoscope.

      Result
      Result Proceed to
      Sound from fuel supply pump A
      Sound from parts other than fuel supply pump B

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    A

  24. BLEED AIR FROM FUEL SYSTEM


    1. To bleed air from the priming pump, pump the priming pump until it becomes hard and cannot be pumped any more.


    NEXT

  25. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    1. Check whether the knocking has been successfully repaired by performing a driving test.

      OK
      Malfunction has been repaired successfully.

    NEXT

    END