ECD SYSTEM(w/ Glow Plug Controller) Engine Knocking or Rattling

DTC Code DTC Name
Engine Knocking or Rattling

DESCRIPTION

Malfunction Condition

Main Trouble Area

Related Trouble Area

Combustion in diesel engines takes place by means of self-ignition. If the timing of the ignition is delayed, the pressure inside the combustion chamber will increase too fast, which leads to uncontrolled combustion and can be heard as diesel knocking.

If any of the following conditions are met, engine knocking may occur due to the fact that

  • Diesel fuel self-ignition timing taking place too late

  • Engine coolant temperature low

  • Intake air temperature low

  • Self-ignition temperature of the diesel fuel high (e.g., low cetane number)

  • Fuel injected into a cold combustion chamber (compression temperature too low)

  • Inadequate fuel vaporization (air-fuel mixture formation is unsatisfactory)

  • Pilot injection deterioration due to an injector assembly sticking or contamination

  1. Injector assembly malfunctions

    • Injector assembly

    • Injector assembly stuck closed

    • Injector assembly stuck open

    • Deposits in injector assembly

    • Injector circuit malfunction

  3. Abnormal common rail pressure

    • Supply pump assembly

    • Fuel pulsation sound

    • Air in fuel

  5. Friction between parts

  6. Compression pressure

  • Injector assembly

  • Injector compensation codes

  • Fuel leakage

  • Intake system leakage

  • Intake system blockage

  • EGR system

  • Throttle valve system

  • Fuel pressure sensor (common rail assembly)

  • Diesel turbo pressure sensor

  • Atmospheric pressure sensor (built into ECM)

  • Vehicle modifications

  • Low quality fuel

  • Lack of fuel

  • 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's 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.

  1. Faults and Symptoms of Common Rail Diesel Components

    1. Engine Control

      Table 1. 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 2. 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

    2. Diesel Injection

      Table 3. Fuel Supply Pump

      Component

      Supply pump assembly

      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

      • 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 Common Rail Pressure is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 4. Fuel Filter

      Component

      Fuel filter

      Main fault

      Blockage

      Symptoms

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

      Data List

      Common Rail Pressure, 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 Common Rail Pressure is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 5. 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 6. 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

      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 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 7. Irregular Fuel

      Component

      Irregular fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 8. 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 Valve Pos

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

      • Using EGR valve Active Test, check whether Actual EGR Valve Pos follows Target EGR Valve 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 9. 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

        100%: Fully open

        0%: 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 P0001.

Click here

CAUTION / NOTICE / HINT

Note:

  • 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.

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

    Click here

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.

  • This troubleshooting procedure checks for knocking and rattling.

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

  1. Explanation of Symptom

    Engine knocking or rattling

    Combustion in diesel engines takes place by means of self-ignition. If the timing of the ignition is delayed, the pressure inside the combustion chamber will increase too fast, which leads to uncontrolled combustion and can be heard as diesel knocking.

    If one of the following conditions are met, engine knocking may occur due to the fact that

    • Diesel fuel self ignition timing taking place too late

    • Engine temperature low

    • Intake air temperature low

    • Self-ignition temperature of the diesel fuel high (e.g., low cetane number)

    • Fuel injected into a cold combustion chamber (compression temperature too low)

    • Inadequate fuel vaporization (air-fuel mixture formation unsatisfactory)

    • Pilot injection deterioration due to an injector sticking or contamination

PROCEDURE

  1. CHECK FOR KNOCKING SOUND

    1. Open the hood and check for knocking.

      Result

      Result

      Proceed to

      Knocking

      A

      No knocking

      B
    B

    CHECK FOR INTERMITTENT PROBLEMS

    Click here

    A

  2. CHECK HARNESS AND CONNECTOR (IN ENGINE ROOM)

    1. Check the harness and connector connections of common rail system components.

      OK

      The wire harnesses and connectors are connected securely.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. CHECK INTAKE SYSTEM (PROCEDURE 3)

    1. Check the intake system (turbocharger, diesel turbo pressure sensor, EGR valve, etc.).

      OK

      All hoses are connected securely and there are no leaks or blockage in the intake system.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE INTAKE SYSTEM

    OK

  4. READ OUTPUT DTCS (RELATING 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.

    4. Read the DTCs.

      Powertrain > Engine and ECT > Trouble Codes

      Result

      Result

      Proceed to

      DTC is not output

      A

      Engine related DTCs are output

      B
    B

    GO TO DTC CHART

    Click hereClick here

    A

  5. 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 MAP and 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

      MAP and Atmosphere Pressure have the same value

      A

      MAP is different from actual atmospheric pressure

      B

      Atmosphere Pressure is different from actual atmospheric pressure

      C
    B

    REPLACE DIESEL TURBO PRESSURE SENSOR

    Click here

    C

    REPLACE ECM

    Click here

    A

  6. 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 / Common Rail Pressure, 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

      Common Rail Pressure

      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 (Common Rail Pressure) when the Active Test is performed.

      A285606E03
      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

      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

      Result

      Proceed to

      Both results are within standard

      A

      Fuel pressure exceeds "Target Common Rail Pressure + 15000 kPa"

      and/or

      Target Pump SCV Current value is out of standard range

      B

      Fuel pressure does not reach "Target Common Rail Pressure - 15000 kPa"

      C
    B

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

    C

    BLEED AIR FROM FUEL SYSTEMClick here

    A

  7. CHECK INJECTOR COMPENSATION CODE

    1. Check the injector compensation codes.

      Click here

      OK

      Compensation codes of the installed injectors are the same as the compensation codes registered in the ECM.

    Result

    Proceed to

    OK

    NG
    NG

    PERFORM REGISTRATION AND INITIALIZATIONClick here

    OK

  8. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the malfunction has been successfully repaired.

      OK

      Malfunction has been repaired successfully.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  9. READ VALUE USING GTS (CONTROL THE EGR STEP POSITION)

    1. Turn the ignition switch to ON.

    2. Turn the ignition switch off and wait for 30 seconds or more.

    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.

      Tip:

      Under normal conditions, Actual EGR Valve Pos is indicated as follows.

      EGR Valve Condition

      Actual EGR Valve Pos

      Fully closed

      0%

      Fully open

      About 100%

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

    OK

  10. PERFORM ACTIVE TEST USING GTS (DIESEL THROTTLE TARGET ANGLE)

    1. Connect the GTS to the DLC3.

    2. Turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Diesel Throttle Target Angle / Data List / Actual Throttle Position.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Diesel Throttle Target Angle

      Data List Display

      Actual Throttle Position

    4. When continuously changing the Active Test value to 100, 70, 40, 10, 40, 70 and 100%, check that Actual Throttle Position smoothly changes to the set opening angle.

      OK

      Value smoothly changes to the set opening angle.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

    Click here

    OK

  11. CHECK THE TEMPERATURE WHEN KNOCKING OCCURS

    1. Check the temperature when knocking trouble occurs.

      Result

      Result

      Proceed to

      Knocking only for cold engine

      A

      Knocking both for cold and warmed up engine

      B
    B

    READ VALUE USING GTS (MAP AND MAF)Click here

    A

  12. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

    1. After warming up the engine, the engine coolant temperature should be 60°C (140°F) or higher. After leaving the vehicle overnight, the engine coolant temperature should be nearly equal to the intake air temperature.

      OK

      The engine coolant temperature is nearly equal to the intake air temperature.

      Tip:

      If the engine coolant temperature sensor output is less than the actual engine coolant temperature, engine knocking may occur.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

    OK

  13. INSPECT GLOW PLUG ASSEMBLY

    1. Inspect the glow plug assembly.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE GLOW PLUG ASSEMBLY

    Click here

    OK

  14. READ VALUE USING GTS (INJECTION FEEDBACK VAL #1 TO #4)

    Tip:

    • Read the values of Injection Feedback Val #1 to #4 when the engine is cold.

    • If the engine coolant temperature is more than 40°C (104°F), leave the vehicle until the engine coolant reaches almost the same temperature as the atmospheric temperature.

    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 / Injection Feedback Val #1 to #4.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

    4. Start the engine.

    5. Read the values during engine idling when the engine is cold, and write them down.

      Standard

      GTS Display

      Condition

      Specified Condition

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

      Idling with cold engine

      Between -2.0 and 2.0 mm3/st
      Tip:

      If any Injection Feedback Val is out of the specified range, replace all of the injector assemblies.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE INJECTOR ASSEMBLYClick here

    OK

  15. READ VALUE USING GTS (MAP AND MAF)

    1. Connect the GTS to the DLC3.

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

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

      Powertrain > Engine and ECT > Data List

      Tester Display

      MAF

      MAP

      Standard

      Item

      Engine Speed*1

      Standard Range

      Description

      MAP*2

      Ignition switch ON (engine stopped)

      Same as atmospheric pressure

      Intake manifold internal pressure detected by manifold absolute pressure sensor

      Idling

      90 to 105 kPa (675 to 788 mmHg, 26.58 to 31.01 in.Hg)

      3000 rpm (no engine load)

      110 to 150 kPa (825 to 1125 mmHg, 32.48 to 44.29 in.Hg)

      3500 rpm (driving with full throttle acceleration)

      Min. 180 kPa (1350 mmHg, 53.15 in.Hg)

      MAF*2, *3

      Ignition switch ON (engine stopped)

      Less than 0.5 gm/sec

      Intake air volume detected by mass air flow meter

      Idling

      3 to 11 gm/sec

      2000 rpm (no engine load)

      10 to 40 gm/sec

      3500 rpm (driving with full throttle acceleration)

      Min. 67 gm/sec
      Tip:

      *1: The A/C switch and all accessory switches should be off with a fully warm engine.

      *2: This value is indicated when the ambient temperature is 25°C (77°F), the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and a stable boost pressure is maintained for approximately 10 seconds.

      *3: When the mass air flow meter malfunctions, the MAF output may deviate from the standard (referential) range when the engine idles and is accelerated from 3000 to 4000 rpm with full throttle acceleration.

      Result

      Item

      Result

      Proceed to

      MAP and MAF

      Within standard range

      A

      MAP and MAF

      Outside standard range

      B

      Only MAP

      Outside standard range

      C

      Only MAF

      Outside standard range

      D
    B

    CHECK INTAKE SYSTEM (PROCEDURE 3)

    C

    GO TO DTC P0107 (RELATED TO DIESEL TURBO PRESSURE SENSOR)

    Click here

    D

    GO TO DTC P0100 (RELATED TO MASS AIR FLOW METER)

    Click here

    A

  16. INSPECT 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.

      • 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 solvent directly onto these parts or soaking the parts in solvent may damage the parts.

    3. Hold the electric EGR control valve assembly 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.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

    OK

  17. BASIC INSPECTION

    1. Check the fuel quality.

    2. Check the fuel line for air.

    3. Check the fuel system for blockages.

    4. Check the air filter.

    5. Check the engine oil.

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

    7. Check the vacuum pump.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  18. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the malfunction has been successfully repaired.

      OK

      Malfunction has been repaired successfully.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  19. READ VALUE USING GTS (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #4)

    1. Connect the GTS to the DLC3.

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

    3. Allow the engine to idle for 1 minute or more.

      Tip:

      The A/C switch and all accessory switches should be off with a fully warm engine.

    4. Turn the GTS on.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / Injection Volume and Injection Feedback Val #1 to #4.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Injection Volume

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

    6. Read the values during engine idling.

      Tip:

      When reading the values of 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

      GTS Display

      Condition

      Specified Condition

      Injection Volume

      Idling

      8 mm3/st or less

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

      Idling

      Between -2.0 and 2.0 mm3/st
      Tip:

      • Cylinders that have a compensation value which is more than the value specified above are considered to be malfunctioning. Use the following steps to inspect and repair the cylinder.

      • If the value of Injection Volume is more than 8 mm3/st and the values of 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, you should compare the Target EGR Valve Pos with the Actual EGR Valve Pos by entering the following menus using the GTS: Powertrain / Engine and ECT / Data List / Target EGR Valve Pos and Actual EGR Valve Pos.

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

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  20. REPLACE INJECTOR ASSEMBLY

    1. Replace the injector assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  21. 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

  22. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  23. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  24. 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

  25. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  26. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  27. 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 / Common Rail Pressure and Target Common Rail Pressure.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Test the Fuel Leak

      Data List Display

      Target Common Rail Pressure

      Common Rail Pressure

    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 (Common Rail Pressure) when the Active Test is performed.

      A285606E03
      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.

    Result

    Result

    OK

    NG
    NG

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

    OK

  28. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  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 - B212-30 (PCV)

      Always

      Below 1 Ω

      B123-2 or B212-30 (PCV) - Body ground and other terminals

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  30. CHECK IF FUEL BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY

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

    2. Operate the hand 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 hand 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

    REPAIR OR REPLACE FUEL FILTER OR CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING, FUEL TANK - SUPPLY PUMP ASSEMBLY)

    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 here

    Result

    Proceed to

    NEXT
    NEXT

  33. 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 / Common Rail Pressure and Target Common Rail Pressure.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Test the Fuel Leak

      Data List Display

      Target Common Rail Pressure

      Common Rail Pressure

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

    5. Maintain the 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 (Common Rail Pressure) when the Active Test / Test the Fuel Leak is performed.

      A285606E03
      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.

    Result

    Proceed to

    OK

    NG
    OK

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

    NG

  34. REPLACE COMMON RAIL ASSEMBLY

    1. Replace the common rail assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  35. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END