ECD SYSTEM (for DPF) 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 Glow system malfunction
      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 70°C (158°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.

      • 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 EGR

      EGR System
      Main fault
      • Does not move smoothly

      • Does not close completely

      Symptoms
      • Rough idle

      • EGR valve stuck closed: A loud turbocharger sound.

      • EGR valve stuck open: Difficult to start (does not stall), black smoke, lack of power (if there is an excess in the quantity of EGR and there is a heavy load, when the vehicle starts moving, a lack of power will be felt).

      Data List

      Actual EGR Valve Pos., Target EGR Position


      • Generally, Actual EGR Valve Pos. = Target EGR Position +/-5% (fully closed: 0%, fully open: 100%).

      • Using the EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Position (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).

      • EGR valve is fully closed when the ignition switch is turned to ON (engine stopped).

      • EGR valve opens to the halfway point at idling after the engine is warmed up.

      EGR Close Lrn. Val., EGR Close Lrn. Status


      • When leaving the vehicle idling, when EGR Close Lrn. Status is OK, the normal range of EGR Close Lrn. Val. is 0 to 1 V.

      • In cases when EGR Close Lrn. Status. is NG or EGR Close Lrn. Val. is out of the normal range (0 to 1 V), it is possible that the EGR valve cannot completely close.

    4. 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

        0%: Fully open

        100%: Fully closed

      • When the ignition switch 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

    • MAF

    • 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

    • Target EGR Position

    • Actual EGR Valve Pos.

    • EGR Close Lrn. Status

    • EGR Close Lrn. Val.

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 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 (final injection quantity is limited by MAF).

    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 intelligent tester to the DLC3.

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

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

    4. Read the pending DTCs.

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

      Tech Tips

      If only DTC P1609 is output, proceed to step 2.


    B
    A
  2. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°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
      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.

      • 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.


    OK
    NG
  3. CATALYTIC CONVERTER TO BE REPLACED


    1. Even though it has been determined that the DPF catalytic converter (Exhaust manifold converter sub-assembly) needs to be replaced, make sure to complete diagnosis for this problem before replacing it Click here.

      Tech Tips

      This problem is occurred because an excessive amount of PM has accumulated and resulted in abnormal combustion. It is necessary to diagnose the cause of abnormal PM accumulation and repair the problem. Therefore, do not perform replacement at this time.


    NEXT
  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 the intercooler is not clogged with foreign matter.

      • 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.

    NG
    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.

    NG
    OK
  6. CHECK INJECTOR COMPENSATION CODE


    1. Read the injector compensation codes Click here.

      OK
      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.

    NG
    OK
  7. PERFORM PILOT QUANTITY LEARNING (DETAIL)


    1. Perform the injector pilot quantity learning (Detail) Click here.


    NEXT
  8. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 70°C (158°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.


    OK
    NG
  9. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Enter the following menus: Powertrain / Engine and ECT / 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.

      • Graphs like the ones shown below can be displayed by transferring the stored snapshot data from the tester to a PC. Intelligent Viewer must be installed on the PC.

      • Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.


    NEXT
  10. READ VALUE USING INTELLIGENT TESTER (MAF AND MAP)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).

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

    5. Take a snapshot when the engine speed is maintained at 4000 rpm with no load.

    6. Read the values of "MAP" and "MAF" in the Data List using the snapshot review function.

      Result
      Result Proceed to
      MAF 85 gm/s or more and MAP 140 kPa or higher A
      Except above B

      Tech Tips


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

      • 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.


    A
    B
  11. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE EGR VALVE CLOSE)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off. Wait for 30 seconds, and then restart the engine.

    4. Turn the tester on.

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

    6. Read the MAF value displayed on the tester while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the EGR Valve Close.

    8. Read the MAF value when the EGR valve is closed using the Active Test function.

      Tech Tips


      • If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

      • Before performing the diagnosis, confirm that the EGR valve target opening angle is not 0%.

      Result
      Active Test Result Proceed to

      Activate the EGR Valve Close:

      Off (Open) to On (Closed)

      MAF value does not change A
      MAF value changes B

      Note

      As the measured values may differ from those shown below due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.

      Tech Tips

      The problem may be a temporary one, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the electric EGR control valve assembly or mass air flow meter.

      Reference
      EGR Valve Condition (Opening) Measuring Condition MAF (Reference)
      Open (67%)
      • Atmosphere pressure: 101 kPa

      • Intake air temperature: 30°C (86°F)

      • Engine coolant temperature: 88°C (190°F)

      3 to 12 gm/s
      Closed (0%) 7 gm/s or more

    B
    A
  12. READ VALUE USING INTELLIGENT TESTER (MAF)


    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 and ECT / Data List / MAF.

    4. With the ignition switch ON and engine stopped, read the value when 30 seconds has elapsed.

      Standard
      Tester Display Switch Condition Standard
      MAF Ignition switch ON (do not start engine) Less than 0.3 gm/s

    NG
    OK
  13. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR COOLER BYPASS)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off and wait for 30 seconds.

    4. Start the engine and turn the tester on.

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

    6. Read the MAF value displayed on the tester while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EGR Cooler Bypass / Data List / EGR Cooler Bypass Position.

      Tech Tips

      Whether the EGR is passing through the bypass side or cooler side during the Active Test can be confirmed by checking EGR Cooler Bypass Position.

    8. Using the Active Test function, switch the EGR valve bypass switching valve between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".

      Tech Tips

      If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

      Result
      Tester Display Result Proceed to

      Activate the VSV for EGR Cooler Bypass:

      Cooler to Bypass

      MAF value does not change A
      MAF value changes B

      Tech Tips

      If the EGR cooler is clogged, the mass air flow changes.


    B
    A
  14. REMOVE DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)


    1. Remove the electric EGR control valve assembly Click here.

    2. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.

      Note


      • When cleaning the electric EGR control valve assembly, make sure the valve is completely closed.

      • When cleaning the electric EGR control valve assembly, perform initialization procedure Click here.

      • Do not forcibly open the valve, as it may be damaged or deformed.

      • When cleaning the electric EGR control valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.

      Tech Tips


      • If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.

      • If the EGR valve does not close properly or is stuck open, EGR becomes excessive and combustion becomes unstable. Also, there may be a lack of power. In this case, clean the electric EGR control valve assembly.

    3. Reinstall the electric EGR control valve assembly Click here.


    NEXT
  15. REPLACE EGR COOLER


    1. Replace the EGR cooler Click here.


    NEXT
  16. REPLACE MASS AIR FLOW METER


    1. Replace the mass air flow meter Click here.

      Tech Tips

      If foreign matter is stuck inside the mass air flow meter, the output characteristics of the mass air flow meter may change, resulting in a malfunction.


    NEXT
  17. CHECK SNAPSHOT (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 5 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
    C
    A
  18. 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.


    NEXT
  19. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CHECK THE CYLINDER COMPRESSION)

    Tech Tips

    Use this Active Test to help determine whether a cylinder has compression loss or not.


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #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
    A
  20. 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.


    NG
    OK
  21. 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.


    NEXT
  22. REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. Replace the fuel filter element sub-assembly Click here.


    NEXT
  23. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT
  24. 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.


    NEXT
  25. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°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.


    NEXT
  26. READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE)


    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 and ECT / Data List / MAP and Atmosphere Pressure.

    4. Compare MAP to Atmosphere Pressure when the ignition switch 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 (0.1 kgf/cm2, 1.5 psi) 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 (1.0 kgf/cm2, 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm2, 0.1 psi). This varies by weather (high atmospheric pressure, low atmospheric pressure).

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

    B
    C
    A
  27. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (TEST THE FUEL LEAK)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

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

    4. A010O1XE13
      Text in Illustration
      *1 Snapshot Button
      *a Reference

      Take a snapshot with the intelligent tester during the Active Test.

      Tech Tips

      Detailed graphs can be displayed by transferring the stored snapshot from the tester to a PC (Personal Computer) with Intelligent Viewer installed.

    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.

      A010R02E02
      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 (102.0 kgf/cm2, 1451 psi).

      Tech Tips


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

      • "Common Rail Pressure" is the actual fuel pressure in common rail assembly.

      • When the pressure discharge valve on the common rail assembly has a malfunction, the actual fuel pressure changes as shown by "Pressure Discharge Valve Abnormal Fuel Pressure" in the illustration.

      • The pressure discharge valve operates to discharge fuel pressure when the internal pressure of the common rail exceeds the target fuel pressure.

      • There are 2 fuel pressure sensor circuits and both of them display the same value. If the difference between Common Rail Pressure and Common Rail Press Sens 2 exceeds 10000 kPa (102 kgf/cm2, 1451 psi) for 2 seconds or more, it is necessary to inspect or repair the wiring for the fuel pressure sensor.


    NG
    OK
  28. READ VALUE USING INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE)


    1. Connect the intelligent tester to the DLC3.

    2. Soak the engine for a long time.

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

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


    NG
    OK
  29. READ VALUE USING INTELLIGENT TESTER (INTAKE AIR AND INTAKE AIR TEMP (TURBO))


    1. Connect the intelligent tester to the DLC3.

    2. Soak the engine for a long time.

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

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Intake Air, Intake Air Temp (Turbo).

      OK
      Intake Air is the same as Intake Air Temp (Turbo).

    OK
    NG
  30. 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
      B61-1 (+B) - B39-41 (PCV+) Always Below 1 Ω
      B62-2 (PCV) - B39-81 (PCV-) Always Below 1 Ω
      B61-1 (+B) or B39-41 (PCV+) - Body ground Always 10 kΩ or higher
      B62-2 (PCV) or B39-81 (PCV-) - Body ground Always 10 kΩ or higher
    4. Reconnect the suction control valve connector.

    5. Reconnect the ECM connector.


    NG
    OK
  31. 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.


    NG
    OK
  32. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT
  33. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT
  34. PERFORM SUPPLY PUMP INITIALIZATION


    1. Perform supply pump initialization Click here.


    NEXT
  35. REPLACE ECM


    1. Replace the ECM Click here.


    NEXT
  36. REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Replace the manifold absolute pressure sensor.


    NEXT
  37. 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.


    NEXT
  38. CHECK AND REPLACE MALFUNCTIONING PARTS


    1. Inspect the mass air flow meter Click here.

    2. Inspect the intake air temperature sensor (turbo) Click here.

    3. Replace the mass air flow meter Click here.

      Tech Tips

      It is only necessary to replace the part when the results of the inspection indicate a problem.

    4. Replace the intake air temperature sensor (turbo) Click here.

      Tech Tips

      It is only necessary to replace the part when the results of the inspection indicate a problem.


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  39. REPAIR OR REPLACE HARNESS OR CONNECTOR


    1. Repair or replace the harness or connector.


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


    1. Check and replace the clogged fuel pipe.


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  41. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


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  42. CHECK FOR BLACK SMOKE


    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°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.


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  43. 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.


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