DESCRIPTION
Malfunction Condition | Main Trouble Area | Related Trouble Area |
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(a) Injector assembly malfunctions
(b) Clutch system malfunctions
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Tech Tips
This troubleshooting procedure checks for the cause of rough idling and excessive engine vibrations.
Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result 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 causing the malfunction.
Check that the vehicle has not been modified in any way prior to the vehicle inspection.
Faults and Symptoms of Common Rail Diesel Components
Engine Control
Main fault | Decrease in performance (foreign matter is stuck) |
Symptoms | Lack of power, black smoke |
Data List | MAF |
Tech Tips The maximum fuel injection volume is controlled according to the output from the mass air flow meter. |
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 | Measure the resistance of the glow plug |
Main fault | Loss of compression |
Symptoms | Rough idle (lack of power always) |
Data List | Engine Speed of Cyl
Injection Feedback Val
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Diesel Injection
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
Tech Tips
|
Diagnostic Trouble Code | Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored. |
Main fault | Blockage |
Symptoms | Difficult to start, engine stalling, rough idle, lack of power |
Data List | Common Rail Pressure, Target Common Rail Pressure
Tech Tips The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up. |
Diagnostic Trouble Code | Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored. |
Main fault | Blockage |
Symptoms | Rough idle, lack of power, black smoke, white smoke, knocking |
Data List | Injection Feedback Val
|
Main fault | Circuit fault: The fuel 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. |
Symptoms | Difficult to start, rough idle, engine stall, lack of power |
Data List | Common Rail Pressure, Target Common Rail Pressure
|
Diagnostic Trouble Code | When the fuel pressure sensor has a fault, some DTCs may be stored. |
Main fault | - |
Symptoms | Difficult to start, rough idle (especially when cold) |
Diesel Throttle
Main fault | Stuck, does not move smoothly |
Symptoms |
|
Data List |
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Data List Related to Rough Idling
Engine Speed
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
CAUTION / NOTICE / HINT
Note
After replacing the ECM, the new ECM needs registration (See page ) and initialization Click here.
After replacing the fuel supply pump, the ECM needs initialization Click here.
After replacing an injector assembly, the ECM needs registration Click here.
PROCEDURE
CHECK MALFUNCTION CONDITION
Identify when shuddering occurs.
Result | ||||||
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B |
REPAIR OR REPLACE CLUTCH SYSTEM |
A |
CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT
Check the wire harness and connector connections of common rail system components.
OK |
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The wire harnesses and connectors are connected securely. |
Tech Tips
The engine may have problems when there is an intermittent disconnection in a circuit related to the fuel pressure sensor, crankshaft position sensor, engine coolant temperature sensor, etc.
Result | |||
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NG |
REPAIR OR REPLACE HARNESS AND CONNECTOR Click here |
OK |
READ OUTPUT DTC (RELATING TO ENGINE)
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Enter the following menus: Powertrain / Engine / Trouble Codes.
Read pending DTCs.
Result | ||||||
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B |
GO TO DTC CHART Click here |
A |
TAKE SNAPSHOT DURING IDLING (PROCEDURE 4)
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Warm up the engine (engine coolant temperature is 75°C (167°F) or higher).
Enter the following menus: Powertrain / Engine / Data List / All Data.
Take a snapshot when idling with no load after the engine is warmed up and when the problem is occurring.
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 shift lever should be in neutral and the A/C switch and all accessory switches should be off.
If rough idling occurs when the A/C switch is on, take another snapshot with the A/C switch on.
Take a snapshot when the problem is occurring, such as when the engine is cold. However, if the problem does not reoccur, it is acceptable to only take a snapshot after the engine is warmed up.
Result | ||
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NEXT |
CHECK WHITE SMOKE
Start the engine.
Fully depress the accelerator pedal, and then release it.
Check whether white smoke is emitted when racing the engine.
Note
Be sure not to check for white smoke indoors.
Tech Tips
Depending on whether there is oil mixed with the fuel, or whether there is unburned fuel present, the smell of the exhaust gas differs. When oil is mixed in, the exhaust gas smells like burning oil.
Result | ||||||
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B |
CHECK AND REPAIR ENGINE ASSEMBLY Click here |
A |
CHECK DATA LIST (ENGINE SPEED)
Check engine speed in the snapshot taken in procedure 4 when the engine was idling.
Result | ||||||
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B |
CHECK AIR CONDITIONING SYSTEM Click here |
A |
CHECK DATA LIST (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)
Check Injection Feedback Val # in the snapshot taken in procedure 4 when the engine was idling.
Result | ||||||
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Tech Tips
When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.
The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm3/st, as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not malfunctioning.
B |
CHECK DATA LIST (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE) Click here |
A |
INSPECT INJECTOR COMPENSATION CODE
Read the injector compensation code.
OK |
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Compensation codes stored in the ECM match compensation codes of the installed injector assemblies. |
Result | |||
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NG |
GO TO STEP 13 Click here |
OK |
PERFORM ACTIVE TEST USING GTS (CONTROL THE CYLINDER #1 TO #4 FUEL CUT)
Tech Tips
Use this Active Test to determine the malfunctioning cylinder.
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1 to #4 Fuel Cut.
Tester Display |
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Control the Select Cylinder Fuel Cut |
Tech Tips
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 | ||
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NEXT |
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
Replace the injector assembly of the malfunctioning cylinder.
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.
Result | ||
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NEXT |
CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY
Clean the fuel filter case and replace the fuel filter element assembly.
Tech Tips
Be sure to clean the inside of the fuel filter case as the fuel injectors may not operate properly if the fuel filter element assembly is installed with foreign matter remaining inside the fuel filter case.
Result | ||
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NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Result | ||
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NEXT |
REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING
Register the injector compensation code.
Perform the injector pilot quantity learning.
Result | ||
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NEXT |
GO TO STEP 27 Click here |
CHECK AND REPAIR ENGINE ASSEMBLY
Check the following items and repair the malfunctioning part if necessary.
Check cylinder compression pressure.
Result | ||
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NEXT |
GO TO STEP 27 Click here |
CHECK AIR CONDITIONING SYSTEM
Check the air conditioning system.
Tech Tips
Be sure to check the air conditioning hoses and pipes.
Check the refrigerant pressure.
Result | ||
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NEXT |
GO TO STEP 27 Click here |
REPAIR OR REPLACE HARNESS AND CONNECTOR
Repair or replace the harness or connector.
Result | ||
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NEXT |
GO TO STEP 27 Click here |
CHECK DATA LIST (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)
Check engine speed in the snapshot taken in procedure 4 when the engine was idling after having been warmed up.
Result | ||||||
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B |
PERFORM PILOT QUANTITY LEARNING (DETAIL) Click here |
A |
INSPECT CLOGGED FUEL PIPE
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / Diesel Injection.
With no load after the engine is warmed up, take a snapshot when idling and vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear.
Check the Target Common Rail Pressure and Common Rail Pressure value.
Result | |||||||
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Note
*1: The cause may be a squashed or blocked fuel pipe or hose.
*2: The cause may be a clogged fuel filter.
B |
REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE) Click here |
A |
REPAIR OR REPLACE CLOGGED FUEL LINE
Repair or replace the clogged (including frozen fuel) fuel pipe.
Replace the fuel filter element assembly.
Tech Tips
If "Common Rail Pressure" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element assembly.
Result | ||
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NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Result | ||
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NEXT |
GO TO STEP 27 Click here |
REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)
Replace the fuel supply pump assembly.
Result | ||
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NEXT |
BLEED AIR FROM FUEL SYSTEM
Bleed the air from the fuel system.
Result | ||
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NEXT |
PERFORM FUEL SUPPLY PUMP INITIALIZATION
Perform fuel supply pump initialization.
Result | ||
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NEXT |
GO TO STEP 27 Click here |
PERFORM PILOT QUANTITY LEARNING (DETAIL)
Perform the pilot quantity learning (detail).
Result | ||
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NEXT |
CHECK ROUGH IDLING OR EXCESSIVE ENGINE VIBRATIONS
Check rough idling or excessive engine vibrations.
Result | ||||||
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A |
END |
B |
CHECK AND REPLACE ENGINE MOUNTING INSULATOR
Check the following items and repair or replace the malfunctioning part if necessary.
Check that the engine mounting insulators are installed correctly.
Check that the engine mounting insulators are not twisted.
Check that deformation of an engine mounting insulator is not causing the engine to contact the vehicle body.
Result | ||
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NEXT |
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
Result | ||
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NEXT |
END |