ECD SYSTEM(w/o Glow Plug Controller) Lack of Power or Hesitation

DTC Code DTC Name
Lack of Power or Hesitation

DESCRIPTION

Table 1. Description

Malfunction Condition

Main Trouble Area

Related Trouble Area

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

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

  1. Injector assembly

    • Injector assembly sliding malfunction

    • Injector assembly stuck closed

    • Injector assembly stuck open

    • Deposits in injector assembly

  3. Abnormal common rail pressure

    • Supply pump assembly

  5. Abnormal intake air volume

    • Turbocharger sub-assembly

    • Front exhaust pipe blockage

    • Exhaust manifold converter blockage

    • Diesel throttle does not open

    • Electric EGR control valve assembly does not close

  7. Shift position switch malfunction

  • Intake system leakage

  • Intake system blockage

  • Fuel filter element is clogged

  • Fuel is not supplied to supply pump

  • Diesel turbo pressure sensor

  • Mass air flow meter

  • Injector assembly

  • Injector compensation code

  • Vehicle modifications

  • Glow (Poor acceleration when engine is cold)

  • Low quality fuel

  • Shift position switch

  • ECM
Tip:

  • 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 judge the vehicle to be normal even when the Data List values indicate a standard level. Hidden factors of the malfunction are possible.

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

  • This troubleshooting procedure checks for the cause of an obvious lack of engine power (e.g. the vehicle speed does not reach the target speed in the high speed range) while the vehicle is being driven.

  1. Faults and Symptoms of Common Rail Diesel Components

    1. Engine Control

      Table 2. Mass Air Flow Meter

      Component

      Mass air flow meter

      Main fault

      Decrease in performance (foreign matter is attached)

      Symptoms

      Lack of power, black smoke

      Data List

      MAF
      Tip:

      The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
      Table 3. Intake System

      Component

      Intake system

      Symptom: Main fault

      • Lack of power (No black smoke): air filter blockage, Air duct is crushed/leaking

      • Black smoke (No lack of power): Leakage between the turbo and intake manifold

      Data List

      • MAP (intake manifold absolute pressure)

      • Target Booster Pressure

        When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.
      Table 4. Turbocharger System

      Component

      Turbocharger system

      Main fault

      • Air leak in the turbocharger air passage

      • Turbo motor driver not operating well

      • Turbocharger (turbine, bearing)

      Symptoms

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

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

      Data List

      MAP (intake manifold absolute pressure), Target Booster Pressure

      • When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.

      • With the ignition switch ON or during idling, MAP = atmospheric pressure (standard atmospheric pressure = 101 kPa). When the engine speed is about 1500 rpm or more, the turbocharger starts to take effect and MAP becomes higher than atmospheric pressure.

      • Atmospheric pressure increases 1 kPa each time altitude increases by 100 m, and is also affected by the current weather conditions.

      VN Turbo Command

      • 0%: Vanes fully open (drive rod contracts)

      • Over 90%: Vanes fully closed (drive rod expands and turbo operates effectively)

      Diagnostic Point

      • Using the Active Test "Test the Turbo Charger Step Motor", check the drive rod movement.

      • Check the drive rod movement when the ignition switch is turned from ON to off.
      Table 5. Exhaust System

      Component

      Exhaust system

      Main fault

      Blockage

      Symptoms

      Lack of power (high engine speed, when vehicle under heavy load)

      Data List

      MAP (intake manifold absolute pressure)

      When the accelerator is fully depressed, if MAP is 15 kPa lower than Target Booster Pressure for more than 5 seconds then a lack of power will be felt.
      Table 6. Glow System

      Component

      Glow system

      Main fault

      Open circuit, glow plug relay fault

      Symptoms

      Difficult to start, rough idle, knocking, white smoke (when cold)

      Data List

      Check the glow plug indicator light

      Diagnostic Point

      Try to measure the resistance of the glow plug
      Table 7. Engine - 1

      Component

      Engine

      Main fault

      Damaged, seized up

      Symptoms

      Cannot crank, crank speed is low, strange noise
      Table 8. Engine - 2

      Component

      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

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.

    2. Diesel Injection

      Table 9. Fuel Supply Pump

      Component

      Supply pump assembly

      Main fault

      -

      Symptoms

      Difficult to start, engine stalling, rough idle, lack of power

      Data List

      Fuel Press, Target Common Rail Pressure, Target Pump SCV Current

      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel pressure.

      • 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.

      Tip:

      • The fuel pressure changes at engine starting, but is approx. 25000 kPa at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 1530 mA or more, the suction control valve has a tendency to become stuck.

      Diagnostic Trouble Code

      Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 10. Fuel Filter

      Component

      Fuel filter

      Main fault

      Blockage

      Symptoms

      Difficult to start, engine stalling, rough idle, lack of power

      Data List

      Fuel Press, Target Common Rail Pressure

      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel pressure.

      • 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.

      Tip:

      The fuel pressure changes at engine starting, but is approx. 25000 kPa at engine start after the engine is warmed up.

      Diagnostic Trouble Code

      Even if Fuel Press is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 11. Injector Assembly

      Component

      Injector Assembly

      Main fault

      Injection hole blockage

      Nozzle needle or valve piston does not move smoothly

      Symptoms

      Rough idle, lack of power, black smoke, white smoke, knocking

      Data List

      Injection Feedback Val

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.
      Table 12. Pressure Control Valve

      Component

      Pressure control valve

      Main fault

      Does not completely close

      Symptoms

      Difficult to start, engine stall, rough idle, lack of power
      Table 13. Fuel Pressure Sensor

      Component

      Fuel pressure sensor

      Main fault

      Open circuit, decrease in performance (foreign matter is attached)

      Symptoms

      Difficult to start, rough idle, engine stall, lack of power

      Data List

      Fuel Press, Target Common Rail Pressure

      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped, and check that Fuel Press follows Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure. (However, the value may not deviate even when a malfunction is present).

      Diagnostic Trouble Code

      When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 14. Irregular Fuel

      Component

      Irregular fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 15. EGR System

      Component

      EGR system

      Main fault

      • Does not move smoothly

      • Does not close completely

      Symptoms

      • Rough idle

      • EGR valve stuck closed: 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 recirculated exhaust gas and the engine is under heavy load, when the vehicle starts moving, a lack of power will be felt).

      Data List

      Actual EGR Valve Pos., Target EGR Pos.

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

      • Using EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Pos. (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 warmed up.

    4. Diesel Throttle

      Table 16. Diesel Throttle System

      Component

      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, Target Throttle Position

        0%: Fully open

        100%: Fully closed

      • If there is a malfunction of the throttle actuator, compare the target and actual throttle position values for the troubleshooting.

WIRING DIAGRAM

Refer to DTC P1228.

Click here

CAUTION / NOTICE / HINT

  1. Explanation of Symptom

  2. Trouble Area Chart According to Problem Cause

Lack of Power

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

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

The manifold absolute pressure is controlled to reach the Target Booster Pressure. Also, when accelerating the vehicle at full throttle, the throttle is fully open and the EGR valve is fully closed, preserving the mass air flow.
A183894E08
A184474E01
Note:

  • When replacing the ECM, injector assembly and/or DPF catalyst, perform ECM Initialization and Registration.

    Click hereClick here

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

Tip:

  • When the ECM must be replaced, before replacing the ECM, perform the "Learning Values Save" function using the GTS. Then after installing a new ECM, perform all of the initialization and registration procedures for the "Learning Values Write" function by following the instructions shown on the GTS display.

  • Before troubleshooting, conduct the following:

    1. Check the fuel quality.

    2. Check the fuel lines for air.

    3. Check the fuel system for blockage.

    4. Check the air filter.

    5. Check the engine oil.

    6. Check the engine coolant.

    7. Check the engine idling speed and maximum engine speed.

PROCEDURE

  1. READ OUTPUT DTC (RELATED TO ENGINE)

    1. Connect the GTS to the DLC3.

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

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

      Powertrain > Engine and ECT > Trouble Codes

    4. Read pending DTCs.

      Result

      Result

      Proceed to

      No DTCs are output

      A

      Engine related DTCs are output

      B
      Tip:

      If DTC P1608 is output, proceed to step 2.

  2. TAKE SNAPSHOT DURING LACK OF POWER

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

      Tip:

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

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

    4. Take a snapshot of the following Data List items with the GTS during lack of power.

      CAUTION:

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

      Tip:

      • 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 illustration below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

      • Accelerate the vehicle with the accelerator fully open in 2nd or 3rd gear. Then, check the Data List with the engine warmed up and idling.

      A208571E01
      A208572E10
      A208573E03
      A208574E02
      Table 17. Reference Values with Engine Speed at 2000 rpm

      Data List

      Value

      Unit

      Vehicle Speed

      32

      km/h

      Engine Speed

      2000

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      201.46

      kPa

      MAP

      155

      kPa

      MAF

      37.22

      gm/sec

      Calculate Load

      81.9

      %

      Target Common Rail Pressure

      107800

      kPa

      Fuel Press

      109670

      kPa

      Target Pump SCV Current

      1140

      mA

      Injection Volume

      31.28

      mm3/st

      VN Turbo Command

      95

      %

      Actual EGR Valve Pos.

      0.3

      %

      Actual Throttle Position

      -1

      %
      Table 18. Reference Values with Engine Speed at 3000 rpm

      Data List

      Value

      Unit

      Vehicle Speed

      48

      km/h

      Engine Speed

      3000

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      234.25

      kPa

      MAP

      220

      kPa

      MAF

      75.49

      gm/sec

      Calculate Load

      98.8

      %

      Target Common Rail Pressure

      155480

      kPa

      Fuel Press

      156520

      kPa

      Target Pump SCV Current

      965

      mA

      Injection Volume

      45.48

      mm3/st

      VN Turbo Command

      37

      %

      Actual EGR Valve Pos.

      0.3

      %

      Actual Throttle Position

      0

      %
      Table 19. Reference Values with Engine Speed at 3500 rpm (Point A)

      Data List

      Value

      Unit

      Vehicle Speed

      58

      km/h

      Engine Speed

      3500

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      231.75

      kPa

      MAP

      227

      kPa

      MAF

      86.97

      gm/sec

      Calculate Load

      100.0

      %

      Target Common Rail Pressure

      158520

      kPa

      Fuel Press

      159380

      kPa

      Target Pump SCV Current

      952

      mA

      Injection Volume

      42.28

      mm3/st

      VN Turbo Command

      29

      %

      Actual EGR Valve Pos.

      0

      %

      Actual Throttle Position

      0

      %
      Table 20. Reference Values with Engine Speed at 4000 rpm

      Data List

      Value

      Unit

      Vehicle Speed

      66

      km/h

      Engine Speed

      4000

      rpm

      Accel Position

      99.60

      %

      Target Booster Pressure

      223.45

      kPa

      MAP

      219

      kPa

      MAF

      90.16

      gm/sec

      Calculate Load

      100.0

      %

      Target Common Rail Pressure

      158940

      kPa

      Fuel Press

      158720

      kPa

      Target Pump SCV Current

      947

      mA

      Injection Volume

      37.48

      mm3/st

      VN Turbo Command

      19

      %

      Actual EGR Valve Pos.

      0

      %

      Actual Throttle Position

      0

      %
      Table 21. Data Condition Idling (Engine warmed up, A/C Off, Shift Lever in neutral)

      Data List

      Value

      Unit

      Engine Speed

      798

      rpm

      Target Booster Pressure

      100.97

      kPa

      MAP

      99

      kPa

      MAF

      4.3

      gm/sec

      Target Common Rail Pressure

      25000

      kPa

      Fuel Press

      24330

      kPa

      Target Pump SCV Current

      1164

      mA

      Injection Volume

      4.58

      mm3/st

      VN Turbo Command

      90

      %

      Actual EGR Valve Pos.

      65.4

      %

      Actual Throttle Position

      74

      %

      Accel Position

      0.00

      %

      Target EGR Position

      65.4

      %

      Atmosphere Pressure

      99

      kPa

      Coolant Temp

      75

      °C
      Tip:

      Actual Examples of Malfunction

      • Lack of power caused by overly low boost pressure

      • Lack of power caused by overly low MAF

      • EGR valve stuck in open position

    Result

    Proceed to

    NEXT
    NEXT

  3. CHECK SNAPSHOT

    1. Check the condition of the vehicle using the snapshot taken during the lack of power.

      Result

      Result

      Proceed to

      None of the conditions below apply

      A

      Fuel Press is less than "Target Common Rail Pressure - 15000 kPa" when accelerating with accelerator fully open

      B

      Target Pump SCV Current 1530 mA or more

      C

      One of the Injection Feedback Val #1 to 4 values is outside the range of +/-2 mm3/st when idling after warm up

      D

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is more than 8 mm3/st when idling after warm up

      E

      *
      Tip:

      • *: When this result occurs, usually symptoms may be noticeable, such as difficult starting, rough idling, knocking or black smoke at high common rail pressure.

      • If the value of Injection Volume is more than 8 mm3/st and the value Injection Feedback Val #1 to #4 is within the threshold, replace the injector assemblies for all cylinders.

      In this case, there is a possibility that too much recirculated exhaust gas is entering the engine. Therefore, compare the Target EGR Position with the Actual EGR Valve Pos. by entering the following menus using the GTS: Powertrain / Engine and ECT / Data List / Target EGR Position and Actual EGR Valve Pos.

      If the difference between Target EGR Position and Actual EGR Valve Pos. exceeds +/-10%, the EGR system may be malfunctioning.

    B

    BLEED AIR FROM FUEL SYSTEMClick here

    C

    CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)Click here

    D

    CHECK INJECTOR COMPENSATION CODEClick here

    E

    REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERSClick here

    A

  4. CHECK SNAPSHOT

    1. Check the condition of the vehicle using the snapshot taken during the lack of power.

      Result

      Result

      Proceed to

      MAP is less than "Target Booster Pressure - 15 kPa" (MAF is normal) when the engine speed is 3000 rpm or more with accelerator fully open

      A

      MAF is low when accelerating with accelerator fully open (MAP is normal)

      • 3000 rpm: 61 gm/sec or less

      • 3500 rpm: 67 gm/sec or less

      • 4000 rpm: 70 gm/sec or less

      Tip:

      If MAF (Mass Air Flow) decreases, Calculate Load will be 80% or less when accelerating with the accelerator fully open.

      B

      MAP and MAF are both low when accelerating with the accelerator fully open

      C

      None of the above conditions apply

      D
    B

    INSPECT MASS AIR FLOW METERClick here

    C

    READ VALUE USING GTS (ACCEL POSITION)Click here

    D

    READ VALUE USING GTS (PM ACCUMULATION RATIO)Click here

    A

  5. INSPECT VACUUM HOSE

    1. Check the vacuum hose connection (diesel turbo pressure sensor).

      OK

      Vacuum hose is connected securely.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE VACUUM HOSE

    OK

  6. READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

    1. Connect the GTS to the DLC3.

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

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / MAP and Atmosphere Pressure.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Atmosphere Pressure

      MAP

    4. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).

      Standard

      Difference between the MAP and the Atmosphere Pressure is less than 7 kPa.

      Tip:

      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 7 kPa or higher, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.

      • Standard atmospheric pressure is 101 kPa. For every 100 m increase in altitude, pressure drops by 1 kPa. Atmosphere pressure varies with the weather (high atmospheric pressure, low atmospheric pressure).

    Result

    Result

    Proceed to

    Atmosphere Pressure is different from actual atmospheric pressure

    A

    MAP is different from actual atmospheric pressure

    B

    MAP and Atmosphere Pressure have the same value

    C
    A

    REPLACE ECM

    Click here

    B

    REPLACE DIESEL TURBO PRESSURE SENSOR

    Click hereClick here

    C

    READ VALUE USING GTS (ACCEL POSITION)Click here

  7. INSPECT MASS AIR FLOW METER

    1. Inspect the mass air flow meter.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE MASS AIR FLOW METER

    Click here

    OK

  8. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY

    1. Remove the electric EGR control valve assembly.

    2. Connect the electric EGR control valve assembly connector.

    3. Connect the GTS to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position / Data List / Actual EGR Valve Pos.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Control the EGR Step Position

      Data List Display

      Actual EGR Valve Pos.

    6. When changing the Active Test value from 1 to 100%, check that Actual EGR Valve Pos. smoothly changes to the set opening angle.

      OK

      Value smoothly changes to the set opening angle.

    7. 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.

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

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

    8. Hold the electric EGR control valve up to a light and visually check that there is no clearance between the valve and body.

      A200348C06

      *1

      Electric EGR Control Valve Assembly

      -

      -

      *a

      Part A

      *b

      Clearance

      *c

      OK

      *d

      NG

      OK

      No light passes through (there is no clearance between the valve and body).

      If light passes through (there is clearance between the valve and body), replace the electric EGR control valve assembly.

      Tip:

      Light passes through part A shown in the illustration even if the valve is completely closed, this is not a malfunction.

    9. Remove the diesel throttle body assembly, intake air connector and EGR pipe connector.

    10. Remove the deposits from those parts and clean them.

      Note:

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

      • Extreme care must be taken to prevent the removed deposits from falling into the engine unit during cleaning.

      Tip:

      • Remove the intake manifold from the cylinder head when it has to be cleaned.

      • Do not leave any deposits in the electric EGR control valve assembly when cleaning the valve.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

    OK

  9. READ VALUE USING GTS (ACCEL POSITION)

    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 and ECT / Data List / Accel Position.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Accel Position

    4. Read the value.

      Standard

      Condition

      Standard Value

      Accelerator pedal fully released

      0%

      Accelerator pedal fully depressed

      95% or more

      Accelerator pedal fully released → fully depressed*

      0 to 95% or more*
      Tip:

      *: Make sure that Accel Position changes smoothly.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ACCELERATOR PEDAL SENSOR ASSEMBLY

    Click here

    OK

  10. INSPECT DIESEL THROTTLE BODY ASSEMBLY

    1. Inspect the diesel throttle body assembly.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

    Click hereClick here

    OK

  11. CHECK INTAKE SYSTEM

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

      Tip:

      • 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.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  12. INSPECT TURBOCHARGER SUB-ASSEMBLY

    1. Inspect the turbocharger sub-assembly.

      Click hereClick here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLY

    Click hereClick here

    OK

  13. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      OK

      Malfunction has been repaired successfully.

      Tip:

      Symptoms may have appeared due to carbon deposits, etc.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  14. CHECK INTAKE SYSTEM DEPOSIT

    1. Check if 3 mm (0.12 in.) or more of carbon has accumulated on the intake manifold, cylinder head, etc. and if so, clean it off.

    Result

    Proceed to

    NEXT
    NEXT

  15. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  16. READ VALUE USING GTS (PM ACCUMULATION RATIO)

    1. Drive the vehicle at a constant engine speed of 2000 rpm or more (3rd gear) at a vehicle speed between 65 to 100 km/h (40 to 62 mph) for 5 minutes or more.

      CAUTION:

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

    2. Connect the GTS to the DLC3.

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

    4. Start the engine and allow it to idle until the engine coolant temperature reaches 75°C (167°F) or higher.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / PM Accumulation Ratio.

      Powertrain > Engine and ECT > Data List

      Tester Display

      PM Accumulation Ratio

    6. Check the PM Accumulation Ratio at an engine speed of 4000 rpm without load.

      Tip:

      When reading the values of the Data List, confirm that PM regeneration is not activated (value of "After Injection Period" is 0) by entering the following menus: Powertrain / Engine and ECT / Data List / After Injection Period.

      If PM regeneration is activated (value of "After Injection Period" is not 0), drive the vehicle until the PM regeneration is complete (value of "After Injection Period" becomes 0).

      Standard

      PM Accumulation Ratio is less than 40%.

    7. Fully depress the accelerator pedal for 5 seconds and then release it when the vehicle is stopped (A).

    8. Repeat procedure A 10 times (B).

    9. Check for black smoke emission during the above procedures A and B.

      OK

      Black smoke is emitted less than 5 times.

      Tip:

      Even if the black smoke is very thin, count the black smoke emission if there is any visible smoke.

      Result

      Result

      Note

      Proceed to

      Except below

      -

      A

      Black smoke is emitted 5 times or more

      The DPF catalyst cannot trap PM because it is melted or cracked, and therefore must be replaced.

      If a piece of the catalyst breaks off, due to melting or another condition, and enters the exhaust pipe downstream, the exhaust pipe could be blocked, possibly causing a different malfunction.

      Therefore, when replacing the DPF catalyst, visually inspect the rear surface of the DPF filter substrate to determine if replacement of the exhaust pipe is necessary.

      B

      PM Accumulation Ratio 40% or more at 4000 rpm (No engine load)

      An extremely large amount of PM (Particulate Matter) has accumulated in the DPF catalyst.

      If DPF catalyst regeneration is performed in this condition, the heat generated will be excessive, possibly causing another malfunction. Therefore, replace the DPF catalyst.

      C
      Tip:

      • If the PM Accumulation Ratio is more than about 149% at an engine speed of 4000 rpm without load, DTC P2463 (Diesel Particulate Filter Restriction - Soot Accumulation) will be present.

      • If DPF Differential Pressure outputs a negative value when the engine is maintained at an engine speed of 3000 rpm with no load, the hose and pipe connections may be incorrect.

    B

    REPLACE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (DPF CATALYTIC CONVERTER)

    Click hereClick here

    C

    PERFORM ACTIVE TEST USING GTS (FIRST TIME OF ACTIVATE THE DPF REJUVENATE (PM))Click here

    A

  17. CHECK TEMPERATURE WHEN LACK OF POWER OCCURS

    1. Check the temperature when the lack of power occurs.

      Result

      Result

      Proceed to

      Poor acceleration only when engine is cold

      A

      Poor acceleration when engine is cold and warm

      B
    B

    CHECK INJECTOR COMPENSATION CODEClick here

    A

  18. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

    1. Inspect the engine coolant temperature sensor.

      Click here

      Tip:

      Confirm that the engine coolant temperature is 60°C (140°F) or higher using the GTS, and then leave the vehicle overnight (7 hours or more). The actual engine coolant temperature and atmosphere temperature should be about the same.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    Click hereClick here

    OK

  19. CHECK PRE-HEATING CONTROL CIRCUIT

    1. Check the pre-heating control circuit.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  20. 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.

    Result

    Proceed to

    OK

    NG
    NG

    PERFORM REGISTRATION AND INITIALIZATIONClick here

    OK

  21. CHECK FUEL QUALITY

    1. Check that fuel with a low cetane number is used.

    Result

    Proceed to

    NEXT
    NEXT

  22. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

    Result

    Proceed to

    NEXT
    NEXT

    END

  23. PERFORM ACTIVE TEST USING GTS (FIRST TIME OF ACTIVATE THE DPF REJUVENATE (PM))

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the DPF Rejuvenate (PM) / Data List / Exhaust Temperature B1S1, Exhaust Temperature B1S2 and DPNR/DPF Status Reju(PM).

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Activate the DPF Rejuvenate (PM)

      Data List Display

      Exhaust Temperature B1S1

      Exhaust Temperature B1S2

      DPNR/DPF Status Reju(PM)

    4. Perform the Active Test and then drive the vehicle at a constant engine speed of 2000 rpm or more (3rd gear) at a vehicle speed between 65 to 100 km/h (40 to 62 mph).

      CAUTION:

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

      Tip:

      While the Active Test is performed, the accelerator pedal opening angle should be kept as constant as possible.

    5. Confirm that both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher and the DPNR/DPF Status Reju(PM) turns from "Ready" to "Operate".

      Tip:

      • If the DPNR/DPF Status Reju(PM) does not turn from "Ready" to "Operate", drive the vehicle again with increased engine or vehicle speed until both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher.

      • Perform the Active Test until the DPNR/DPF Status Reju(PM) displays "Compl".

    Result

    Proceed to

    NEXT
    NEXT

  24. PERFORM ACTIVE TEST USING GTS (SECOND TIME OF ACTIVATE THE DPF REJUVENATE (PM))

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the DPF Rejuvenate (PM) / Data List / Exhaust Temperature B1S1, Exhaust Temperature B1S2 and DPNR/DPF Status Reju(PM).

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Activate the DPF Rejuvenate (PM)

      Data List Display

      Exhaust Temperature B1S1

      Exhaust Temperature B1S2

      DPNR/DPF Status Reju(PM)

    4. Perform the Active Test and then drive the vehicle at a constant engine speed of 2000 rpm or more (3rd gear) at a vehicle speed between 65 to 100 km/h (40 to 62 mph).

      CAUTION:

      When performing the confirmation driving pattern, obey all speed limits and traffic laws.

      Tip:

      While the Active Test is performed, the accelerator pedal opening angle should be kept as constant as possible.

    5. Confirm that both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher and the DPNR/DPF Status Reju(PM) turns from "Ready" to "Operate".

      Tip:

      • If the DPNR/DPF Status Reju(PM) does not turn from "Ready" to "Operate", drive the vehicle again with increased engine or vehicle speed until both Exhaust Temperature B1S1 and Exhaust Temperature B1S2 reach 250°C (482°F) or higher.

      • Perform the Active Test until the DPNR/DPF Status Reju(PM) displays "Compl".

    Result

    Proceed to

    NEXT
    NEXT

    END

  25. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  26. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      Tip:

      Fuel Press is within +/-10000 kPa of Target Common Rail Pressure.

      OK

      Malfunction has been repaired successfully.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  27. CHECK AND REPLACE FUEL INLET LINE

    1. Check the following items, and repair or replace the malfunctioning part if necessary.

      1. Check that the fuel filter is not clogged.

      2. Check for fuel freezing in the fuel line.

      3. Check for clogs or leaks in the fuel pipe and hose between the fuel tank and supply pump assembly.

    Result

    Proceed to

    NEXT
    NEXT

  28. PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)

    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 and ECT/ Active Test / Test the Fuel Leak / Data List / Fuel Press, Target Common Rail Pressure and Target Pump SCV Current.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Test the Fuel Leak

      Data List Display

      Target Common Rail Pressure

      Fuel Press

      Target Pump SCV Current

    4. Take a snapshot with the GTS during the Active Test.

    5. Maintain an engine speed of 3500 rpm, and then press the "Start" button.

    6. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Fuel Press) when the Active Test is performed.

      A293663E01
      Tip:

      • The EPS, ABS and SRS warning lights may blink when the engine speed exceeds 3500 rpm during this test.

      • To ensure accurate measurements, perform the Active Test with measurements 5 times or more.

      Standard

      The difference between the target fuel pressure and the actual fuel pressure is less than 15000 kPa when the target fuel pressure reaches the maximum value approximately 2 seconds after the Active Test starts.

    7. Read the value of Target Pump SCV Current in the Data List when the "Test the Fuel Leak" Active Test is performed.

      Standard current

      Target Pump SCV Current is less than 1530 mA.

      Tip:

      If the value of Target Pump SCV Current stored in the snapshot is higher than the standard, the intermittent suction control valve is probably stuck.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  29. 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

      B123-2 - B138-12 (PCV)

      Always

      Below 1 Ω

      B123-2 or B138-12 (PCV) - Body ground

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  30. CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY

    1. Disconnect the inlet hose from the supply pump assembly.

    2. Operate the priming pump and check that fuel is being supplied to the supply pump assembly.

      OK

      Fuel is properly supplied to the supply pump assembly when the priming pump is operated.

      Tip:

      • When there is a lack of fuel, fuel pressure drops.

      • Check that the fuel filter is not clogged.

      • Check for fuel freezing in the fuel line.

      • Check for clogs or leaks in the fuel pipe and hose between the fuel tank and supply pump assembly.

    Result

    Proceed to

    OK

    NG
    NG

    CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY)Click here

    OK

  31. REPLACE SUPPLY PUMP ASSEMBLY

    1. Replace the supply pump assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  32. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  33. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

      Tip:

      Fuel Press will be within +/-10000 kPa of Target Common Rail Pressure.

    Result

    Proceed to

    NEXT
    NEXT

    END

  34. CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY)

    1. Check and replace the clogged fuel pipe.

    Result

    Proceed to

    NEXT
    NEXT

  35. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  37. 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.

    Result

    Proceed to

    OK

    NG
    NG

    PERFORM REGISTRATION AND INITIALIZATIONClick here

    OK

  38. 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 and ECT / Active Test / Control the Select Cylinder Fuel Cut.

      Powertrain > Engine and ECT > Active Test

      Tester Display

      Control the Select Cylinder Fuel Cut
      Tip:

      • DTCs may be output after this Active Test. Make sure to check for DTCs after this Active Test. If any DTCs are output, make sure to clear them.

        Click here

      • If the engine idle speed does not change when an injector assembly 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.

    Result

    Proceed to

    NEXT
    NEXT

  39. READ VALUE USING GTS (ENGINE SPEED OF CYL #1 TO #4)

    Tip:

    The speed of each cylinder can be measured (compression test) by using the GTS.

    For the compression test, perform Active Test using GTS (Check the Cylinder Compression) and crank the engine for approximately 10 seconds. At this time, the speed of each cylinder is measured. If the speed of one cylinder is higher than the other cylinders, the compression pressure of that cylinder is determined to be lower than the other cylinders.

    1. Warm up the engine.

    2. Turn the ignition switch off.

    3. Connect the GTS to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Engine Speed of Cyl #1, Engine Speed of Cyl #2, Engine Speed of Cyl #3, Engine Speed of Cyl #4 and Av Engine Speed of All Cyl.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Check the Cylinder Compression

      Data List Display

      Engine Speed of Cyl #1

      Engine Speed of Cyl #2

      Engine Speed of Cyl #3

      Engine Speed of Cyl #4

      Av Engine Speed of All Cyl

    6. Push the snapshot button to turn the snapshot function on.

      Tip:

      Using the snapshot function, data can be recorded during the Active Test.

    7. While the engine is not running, press the ON button to Change the Cylinder Compression to ON.

      Tip:

      After performing the above procedure, Check the Cylinder Compression will start. Fuel injection for all cylinders is prohibited and each cylinder engine speed measurement enters standby mode.

    8. Crank the engine for about 10 seconds.

    9. Monitor the engine speed (Engine Speed of Cyl #1 to #4, Av Engine Speed of All Cyl) displayed on the GTS.

      Tip:

      After approximately 10 seconds of engine cranking, the engine speed measurement of each cylinder will change to the actual engine speed.

      Note:

      • Do not crank the engine continuously for 20 seconds or more.

      • If Check the Cylinder Compression needs to be performed after it is turned ON and performed once, press Exit to return to the Active Test menu screen. Then perform Check the Cylinder Compression again.

      • Use a fully-charged battery.

    10. Stop cranking the engine, and then change "Check the Cylinder Compression" to OFF after the engine stops.

      Note:

      If the Active Test is changed to OFF while the engine is being cranked, the engine will start.

    11. Push the snapshot button to turn the snapshot function off.

    12. Select "Stored Data" on the GTS screen, select the recorded data and display the data as a graph.

      Tip:

      If the data is not displayed as a graph, the change of the values cannot be observed.

    13. Check the change in engine speed values.

      Result

      Result

      Proceed to

      Except below

      A

      The values of Engine Speed Cyl #1 to #4 are within +/-10 rpm of each other.

      B
      Tip:

      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

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDERClick here

    A

  40. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    1. Check the cylinder compression pressure.

      Click hereClick here

    Result

    Proceed to

    OK

    NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  41. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tip:

    The injector assembly is determined to be malfunctioning if the corresponding cylinder is malfunctioning but has no compression loss.

    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  42. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  43. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  44. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  45. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  46. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the lack of power has been successfully repaired.

    Result

    Proceed to

    NEXT
    NEXT

    END

  47. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS

    1. Replace the injector assemblies.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  48. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  49. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  50. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END