ECD SYSTEM Lack of Power or Hesitation

DTC Code DTC Name
Lack of Power or Hesitation

DESCRIPTION

Malfunction Condition

Main Trouble Area

Related Trouble Area

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

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

(a) Injector assembly malfunctions

  • Injector sliding malfunction

  • Injector stuck closed

  • Injector stuck open

  • Deposits in injector

  • Injector circuit malfunction

(b) Abnormal common rail pressure

  • Suction control valve

(c) Abnormal intake air volume

  • Intake air system leakage or clogged

  • Turbocharger sub-assembly

  • Front exhaust pipe blockage

  • Exhaust manifold converter sub-assembly blockage

  • EGR valve does not close

  • Throttle valve does not open

  • Pressure discharge valve (built into common rail assembly) (P1271 stored simultaneously)

  • Intake air system blockage

  • EGR system

  • Fuel filter element assembly is clogged

  • Throttle valve

  • Mass air flow meter assembly

  • Compression pressure

  • Injector compensation code

  • Fuel leak

  • Glow plug assembly

  • Fuel pressure sensor (built into common rail assembly)

  • Manifold absolute pressure sensor

  • Vacuum hose connection for manifold absolute pressure sensor

  • Injector driver (EDU) (P062D stored simultaneously)

  • Vehicle modifications

  • Clutch disc wear

  • Low quality fuel

  • Frozen 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. 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.

  • This troubleshooting procedure checks for the cause of an obvious lack of engine power while the vehicle is being driven (such as the maximum speed being extremely low).

  1. Faults and Symptoms of Common Rail Diesel Components

    1. Engine Control

      Table 1. Mass Air Flow Meter Assembly

      Main fault

      Decrease in performance (foreign matter is stuck)

      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 assembly.
      Table 2. Intake System

      Symptom and Corresponding Main Fault

      • Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct

      • Black smoke (no lack of power) due to leakage between the turbo and intake manifold

      Data List

      • MAP

      • Target Booster Pressure

        When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.

      • MAF
      Table 3. Turbocharger System

      Main fault

      • Air leak in the turbocharged air passage

      • Turbocharger sub-assembly (turbine, bearing, variable nozzle)

      Symptoms

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

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

      Data List

      MAP, Target Booster Pressure

      • When the accelerator is fully depressed, if MAP is 20 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 decreases by 1 kPa each time elevation increases by 100 m, and is also affected by the current weather conditions.
      Table 4. Exhaust System

      Main fault

      Blockage

      Symptoms

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

      Data List

      MAP, Target Booster Pressure

      When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.
      Table 5. Glow System

      Main fault

      Glow system malfunction

      Symptoms

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

      Data List

      Check the glow plug indicator light

      Diagnostic Point

      Measure the resistance of the glow plug assembly
      Table 6. Engine - 1

      Main fault

      Damaged, seized up

      Symptoms

      Cannot crank, crank speed is low, strange noise
      Table 7. Engine - 2

      Main fault

      Loss of compression

      Symptoms

      Rough idle (lack of power always)

      Data List

      Engine Speed of Cyl

      • When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.

      Injection Feedback Val

      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.

    2. Common Rail (ALL)

      Table 8. 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

      • Fuel Press is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      • If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa, then idling will be rough.

      • If Target Pump SCV Current is 3000 mA or higher, the suction control valve may be stuck.

      Tip:

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

      • When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.

      Diagnostic Trouble Code

      Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.
      Table 9. Fuel Filter Element Assembly

      Main fault

      Blockage

      Symptoms

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

      Data List

      Fuel Press, Target Common Rail Pressure

      • Fuel Press is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      • If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa, then idling will be rough.

      Tip:

      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 Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.
      Table 10. Injector Assembly

      Main fault

      Blockage

      Symptoms

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

      Data List

      Injection Feedback Val

      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.
      Table 11. Injector Driver (EDU)

      Main fault

      Circuit fault: The injector assembly does not open.

      Symptoms

      Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking

      Data List

      Same as injector assembly

      Diagnostic Trouble Code

      When the injector driver (EDU) has a fault, some DTCs may be stored.
      Table 12. Fuel Pressure Sensor

      Main fault

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

      Symptoms

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

      Data List

      Fuel Press, Target Common Rail Pressure

      • Fuel Press is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      Diagnostic Trouble Code

      When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 13. Irregular Fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 14. EGR System

      Main fault

      • Does not move smoothly

      • Does not close fully

      Symptoms

      • Rough idle

      • EGR valve stuck closed: A loud turbocharger sound.

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

      Data List

      Actual EGR Valve Pos., Target EGR Position

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

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

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

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

      • When the EGR valve does not close, mass air flow decreases when the vehicle is accelerated at full throttle. Manifold absolute pressure also decreases in comparison to Target Booster Pressure, however there is not a large difference.

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

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

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

    4. Diesel Throttle

      Table 15. Diesel Throttle System

      Main fault

      Stuck, does not move smoothly

      Symptoms

      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

      • Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.

      Data List

      Actual Throttle Position

      • 0%: Fully open

      • 100%: Fully closed

      • When the ignition switch ON (engine stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

  2. Data List Related to Starting Trouble

    • Engine Speed

    • MAP

    • MAF

    • Intake Air

    • Coolant Temp

    • Target Common Rail Pressure

    • Fuel Press

    • Target Pump SCV Current

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

    • Actual Throttle Position

    • Target EGR Position

    • Actual EGR Valve Pos.

CAUTION / NOTICE / HINT

  1. Explanation of Symptom

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 assembly is open. Basically, the fuel pressure is controlled so that it reaches 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 so that it reaches the Target Booster Pressure when accelerating the vehicle at full throttle. 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.
Note:

  • After replacing the ECM, the new ECM needs registration (Click here) and initialization (Click here).

  • After replacing the suction control valve, the ECM needs initialization (Click here).

  • After replacing an injector assembly, the ECM needs registration (Click here).

  • After replacing the exhaust manifold converter sub-assembly (DPF catalyst), clear the thermal deterioration data stored in the ECM.

PROCEDURE

  1. READ OUTPUT DTC (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 / Trouble Codes.

      Powertrain > Engine > Trouble Codes

    4. Read the pending DTCs.

      Result

      Proceed to

      DTCs are not output

      Engine related DTCs are output
      Tip:

      If only DTC P1608 is output, proceed to step 2.

    Engine related DTCs are output

    GO TO DTC CHART

    Click hereClick here

    DTCs are not output

  2. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 2)

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine / Data List / Diesel Lack of Power.

    4. With no load after the engine is warmed up, take a snapshot when idling and at 4000 rpm.

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

    Result

    Proceed to

    NEXT
    NEXT

  3. TAKE SNAPSHOT DURING LACK OF POWER (PROCEDURE 3)

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

    4. Check for a lack of power during the driving test.

      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.

      • Move the shift lever to 2nd gear and accelerate the vehicle with the accelerator pedal fully depressed (obey all laws and regulations, and pay attention to traffic conditions while driving the vehicle). Then, check the Data List with the engine warmed up and idling (the shift lever should be in neutral and the A/C switch and all accessory switches should be off).

      Result

      Proceed to

      Apparent lack of power is present

      Apparent lack of power is not present
    Apparent lack of power is not present

    COMPARE WITH SIMILAR VEHICLE WITH SAME ENGINEClick here

    Apparent lack of power is present

  4. CHECK SNAPSHOT (MAP AND MAF)

    1. Check MAP and MAF in the snapshot taken in procedure 2 when the engine was running at 4000 rpm with no load.

      Result

      Result

      Proceed to

      MAP is 120 kPa or higher and MAF is 85 gm/s or more*1

      A

      MAP is below 90 kPa*2

      B

      Except above*3

      C
      Tip:

      The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.

      Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.

      *1: There may be a problem in the fuel injection system or intake system.

      *2: There may be a problem in the turbocharger system.

      *3: There may be a problem in the intake system or a problem with the EGR valve (valve stuck open or valve does not close).

    B

    READ VALUE USING GTS (MAP AND ATMOSPHERIC PRESSURE)Click here

    C

    CHECK INTAKE SYSTEMClick here

    A

  5. CHECK SNAPSHOT (FUEL PRESS, TARGET COMMON RAIL PRESSURE, MAP AND TARGET BOOSTER PRESSURE)

    1. Check Fuel Press, Target Common Rail Pressure, MAP and Target Booster Pressure in the snapshot taken in procedure 3 when the vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear.

      Result

      Result

      Proceed to

      MAP is below 160 kPa at an engine speed of 3000 rpm

      A

      Difference between Fuel Press and Target Common Rail Pressure is 20000 kPa or higher

      B

      Except above

      C
      Tip:

      • The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.

        Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.

      • The engine speed must be 1500 rpm or less before performing the inspection in which the accelerator pedal is fully depressed and the engine is accelerated to a speed of 3000 rpm.

      • If the turbocharger sub-assembly movement is not smooth, etc., the value of MAP in the snapshot taken during lack of power will not reach the target value.

        When the accelerator pedal is fully depressed and the engine speed is 3000 rpm, the MAP should be higher than 160 kPa.

    B

    INSPECT CLOGGED FUEL PIPEClick here

    C

    CHECK INTAKE SYSTEMClick here

    A

  6. CHECK INTAKE SYSTEM

    1. Check for air leaks and blockages between the air cleaner case sub-assembly and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.

      Tip:

      • Inspect the intake system, especially hoses and pipes between the air cleaner case sub-assembly and turbocharger sub-assembly.

      • Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.

      • Using your hand, check whether the pipes and hoses in the intake system are securely connected.

      • By applying soapy water and revving up the engine, air leaks from the intake system can be checked by checking for bubbles.

      • Check for any modifications in the intake system made by the user.

      OK

      No leakage or blockage.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE INTAKE SYSTEMClick here

    OK

  7. REPLACE FUEL FILTER ELEMENT ASSEMBLY

    1. Replace the fuel filter element assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  8. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

    1. Replace the injector assemblies.

      Click here

      Note:

      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.

    Result

    Proceed to

    NEXT
    NEXT

  9. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  10. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

    1. Register the injector compensation codes.

      Click here

    2. Perform the injector pilot quantity learning.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  11. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  12. REPAIR OR REPLACE INTAKE SYSTEM

    1. Repair or replace the malfunctioning part in the intake system.

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  13. INSPECT CLOGGED FUEL PIPE

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine / Data List / Common Rail (ALL).

    4. 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.

    5. Check the Target Common Rail Pressure and Fuel Press value.

      A261221E07

      Result

      Result

      Proceed to

      While idling the vehicle, "Fuel Press" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1

      A

      "Fuel Press" is normal while idling the vehicle, but "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear*2

      Except above

      B
      Note:

      • *1: The cause may be a squashed or blocked fuel pipe or hose.

      • *2: The cause may be a clogged fuel filter element assembly.

    B

    REPLACE SUCTION CONTROL VALVEClick here

    A

  14. REPAIR OR REPLACE CLOGGED FUEL LINE

    1. Repair or replace the clogged (including frozen fuel) fuel pipe.

    2. Replace the fuel filter element assembly.

      Click here

      Tip:

      If "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element assembly.

    Result

    Proceed to

    NEXT
    NEXT

  15. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  16. PERFORM SUPPLY PUMP INITIALIZATION

    1. Perform the supply pump initialization.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  17. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

      Powertrain > Engine > Active Test

      Active Test Display

      Test the Fuel Leak

      Data List Display

      Target Common Rail Pressure

      Fuel Press

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

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

      Tip:

      In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

      A227749E06

      OK

      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa.

      Tip:

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

      • "Fuel Press" is the actual fuel pressure.

    Result

    Proceed to

    NEXT
    NEXT

    END

  18. REPLACE SUCTION CONTROL VALVE

    1. Replace the suction control valve.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    BLEED AIR FROM FUEL SYSTEMClick here

  19. READ VALUE USING GTS (MAP AND ATMOSPHERIC 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 / Data List / All Data / MAP and Atmosphere Pressure.

      Powertrain > Engine > Data List

      Tester Display

      Atmosphere Pressure

      MAP

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

      Standard

      Difference between MAP and Atmosphere Pressure is less than 8 kPa.

      Tip:

      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 8 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 elevation, pressure drops by 1 kPa. This varies by weather.

      Result

      Result

      Proceed to

      MAP and Atmosphere Pressure have same value

      A

      MAP is different from actual atmospheric pressure

      B

      Atmosphere Pressure is different from actual atmospheric pressure

      C
    B

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSORClick here

    C

    REPLACE ECMClick here

    A

  20. CHECK INTAKE SYSTEM

    1. Check for air leaks and blockages between the air cleaner case sub-assembly and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.

      Result

      Result

      Proceed to

      Leaks and/or blockages exist in the intake system

      A

      No leaks or blockages in the intake system MAP is different from actual atmospheric pressure

      B
      Tip:

      • Inspect the intake system, especially hoses and pipes between the air cleaner case sub-assembly and turbocharger sub-assembly.

      • Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.

      • Using your hand, check whether the pipes and hoses in the intake system are securely connected.

      • When inspecting for a clogged intake system (cause of low MAP), check the following points:

        • Clogged air cleaner filter element sub-assembly

        • Clogged intake hose

        • Diesel throttle valve stuck in closed position

      • Check for any modifications in the intake system made by the user.

    A

    REPAIR OR REPLACE INTAKE SYSTEMClick here

    B

  21. INSPECT TURBOCHARGER SUB-ASSEMBLY

    1. Inspect the turbocharger sub-assembly.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLYClick here

    OK

  22. CHECK FOR INTERMITTENT PROBLEMS

    1. Check for intermittent problems.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  23. REPLACE TURBOCHARGER SUB-ASSEMBLY

    1. Replace the turbocharger sub-assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  24. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  25. REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

    1. Replace the manifold absolute pressure sensor.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  26. REPLACE ECM

    1. Replace the ECM.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  27. CHECK INTAKE SYSTEM

    1. Check for air leaks and blockages between the air cleaner case sub-assembly and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.

      Result

      Proceed to

      No leaks or blockages in the intake system

      Leaks and/or blockages exist in the intake system
      Tip:

      • Inspect the intake system, especially hoses and pipes between the air cleaner case sub-assembly and turbocharger sub-assembly.

      • Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.

      • Using your hand, check whether the pipes and hoses in the intake system are securely connected.

      • By applying soapy water and revving up the engine, air leaks from the intake system can be checked by checking for bubbles.

      • Make sure that the hose between the manifold absolute pressure sensor and intake manifold is not loose or disconnected.

      • Check for any modifications in the intake system made by the user.

    Leaks and/or blockages exist in the intake system

    REPAIR OR REPLACE INTAKE SYSTEMClick here

    No leaks or blockages in the intake system

  28. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)

    1. Connect the GTS to the DLC3.

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

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

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine > Data List

      Tester Display

      MAF

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

    7. Enter the following menus: Powertrain / Engine / Active Test / Activate the EGR Valve Close / All Data / MAF.

      Powertrain > Engine > Active Test

      Active Test Display

      Activate the EGR Valve Close

      Data List Display

      MAF

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

      Tip:

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

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

      Result

      GTS Display

      Result

      Proceed to

      Activate the EGR Valve Close:

      OFF (Open) to Close

      MAF value does not change

      A

      MAF value changes

      B
      Note:

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

      Tip:

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

      Reference

      EGR Valve Condition (Opening)

      Measuring Condition

      MAF (Reference)

      Open (67%)

      • Atmosphere pressure: 101 kPa

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

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

      3 to 12 gm/s

      Closed (0%)

      7 gm/s or more
    B

    PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)Click here

    A

  29. READ VALUE USING GTS (MAF)

    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 / Data List / All Data / MAF.

      Powertrain > Engine > Data List

      Tester Display

      MAF

    4. Read the value.

      Standard

      GTS Display

      Condition

      Specified Condition

      MAF

      Engine not running

      0.35 gm/s or less

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE MASS AIR FLOW METER ASSEMBLYClick here

    OK

  30. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

    1. Connect the GTS to the DLC3.

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

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

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine > Data List

      Tester Display

      MAF

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

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

      Powertrain > Engine > Active Test

      Active Test Display

      Activate the VSV for EGR Cooler Bypass

      Data List Display

      MAF

      EGR Cooler Bypass Position
      Tip:

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

    8. Using the Active Test function, switch the No. 1 vacuum switching valve assembly (for EGR cooler) between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".

      Tip:

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

      Result

      GTS Display

      Result

      Proceed to

      Activate the VSV for EGR Cooler Bypass:

      Cooler to Bypass

      MAF value does not change

      A

      MAF value changes

      B
      Tip:

      If the EGR pipe with cooler sub-assembly is clogged, the MAF changes.

    B

    REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLYClick here

    A

  31. REMOVE DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    1. Remove the electric EGR control valve assembly.

      Click here

    2. Visually check the electric EGR control valve assembly for deposits.

      If there are deposits, clean the electric EGR control valve assembly.

      Note:

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

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

        Click here

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

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

      Tip:

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

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

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  32. REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLY

    1. Replace the EGR pipe with cooler sub-assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  33. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

    CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLYClick here

  34. REPLACE MASS AIR FLOW METER ASSEMBLY

    1. Replace the mass air flow meter assembly.

      Click here

      Tip:

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

      • Before replacing the mass air flow meter assembly, perform a wire harness inspection and if there are any problems with the wire harness, repair or replace it.

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  35. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

    1. Connect the GTS to the DLC3.

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

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

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine > Data List

      Tester Display

      MAF

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

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

      Powertrain > Engine > Active Test

      Active Test Display

      Activate the VSV for EGR Cooler Bypass

      Data List Display

      MAF

      EGR Cooler Bypass Position
      Tip:

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

    8. Using the Active Test function, switch the No. 1 vacuum switching valve assembly (for EGR cooler) between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".

      Tip:

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

      Result

      GTS Display

      Result

      Proceed to

      Activate the VSV for EGR Cooler Bypass:

      Cooler to Bypass

      MAF value does not change

      A

      MAF value changes

      B
      Tip:

      If the EGR pipe with cooler sub-assembly is clogged, the MAF changes.

    B

    REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLYClick here

    A

  36. CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Remove the DPNR catalytic converter (exhaust manifold converter sub-assembly).

      Click here

    2. Visually check for catalyst clogging or carbon deposits adhering to the inner wall of the exhaust pipe upstream of the catalyst.

      OK

      Less than 10% of the cells are clogged.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLYClick here

    OK

  37. INSPECT TURBOCHARGER SUB-ASSEMBLY

    1. Inspect the turbocharger sub-assembly.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE TURBOCHARGER SUB-ASSEMBLYClick here

    OK

  38. CHECK FOR INTERMITTENT PROBLEMS

    1. Check for intermittent problems.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  39. REPLACE TURBOCHARGER SUB-ASSEMBLY

    1. Replace the turbocharger sub-assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  40. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  41. REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Replace the DPNR catalytic converter (exhaust manifold converter sub-assembly).

      Click here

    2. Perform the initialization procedure for DPF catalyst record clear.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  42. REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLY

    1. Replace the EGR pipe with cooler sub-assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  43. REPAIR OR REPLACE INTAKE SYSTEM

    1. Repair or replace the malfunctioning part in the intake system.

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  44. COMPARE WITH SIMILAR VEHICLE WITH SAME ENGINE

    1. Confirm the situation in which the lack of power was experienced by the customer again, and compare the driving feeling under the same conditions using a similar vehicle with the same engine while collecting data with the GTS.

      Tip:

      Confirm the state of the following conditions when the lack of power was experienced.

      • Accelerator pedal position (vehicle load)

      • Vehicle speed

      • Engine coolant temperature

      • Ambient temperature

      • Driving conditions before the lack of power occurred

      • Climate

      • Road and traffic conditions

      • When (what day) the problem was noticed

      • Whether the problem occurs suddenly or gradually

      • How often the problem occurs

      • Why the customer felt there is a lack of power (e.g. the customer compared their vehicle with another vehicle, somebody told the customer that their vehicle has a lack of power, etc.)

      • Level of lack of power (slight or drastic)

      Result

      Proceed to

      Significant difference is found

      Significant difference is not found
    Significant difference is found

    CHECK SNAPSHOT (FUEL PRESS, TARGET COMMON RAIL PRESSURE, MAP AND TARGET BOOSTER PRESSURE)Click here

    Significant difference is not found

  45. EXPLAIN THE INVESTIGATION RESULT TO CUSTOMER

    1. Vehicle performance is normal.

      There is no problem at this point in time. However, if the problem recurs, ask the customer to explain in detail the situation in which the problem occurred.

      The best course may be to have the customer ride in another vehicle with the same specifications to understand that there is no problem with the customer's vehicle.

    Result

    Proceed to

    NEXT
    NEXT

    END