ECD SYSTEM Fuel Injection System

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. CHECK INJECTOR COMPENSATION CODE


    1. Check the injector compensation code.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Injector Compensation
      Result
      Result Proceed to
      Except below A
      Compensation codes of the installed injector assemblies are the same as the compensation codes registered in the ECM B

    B
    A
  2. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation codes.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Injector Compensation
    2. Perform the injector pilot quantity learning.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Pilot Quantity Learning
      Result
      Proceed to
      NEXT

    NEXT
  3. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (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 and ECT / Data List / Common Rail (All).

    4. Take a snapshot of the following Data List items.

      Tech Tips


      • A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting. The data in the list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

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

      Result
      Proceed to
      NEXT

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


    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken in procedure 3 when the engine was idling and at 4000 rpm with no load.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3.0 mm3/st

      A

      Injection Volume is less than 10 mm3/st at 4000 rpm

      B
      Except above C

      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 (-3.0 mm3/st is the lowest normal value), 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
    C
    A
  5. PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

    Tech Tips

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


    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 / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #4.


      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
    4. Check the engine speed during the Active Test.

      Result
      Result Proceed to
      Except below A
      The values of Engine Speed Cyl #1 to #4 are within 10 rpm of each other. B

      Tech Tips

      When cranking, if the speed of a cylinder is approximately 100 rpm more than the other cylinders, there is probably a complete loss of compression in that cylinder.


    B
    A
  6. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the cylinder compression pressure.

      Click here

      Tech Tips

      When compression is low, there may be cracks in the piston or the injector assembly may be installed improperly.

      Result
      Proceed to
      OK
      NG

    NG
    OK
  7. PERFORM PILOT QUANTITY LEARNING


    1. Perform the injector pilot quantity learning.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Pilot Quantity Learning
      Result
      Proceed to
      NEXT

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


    1. Connect the GTS to the DLC3.

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

    3. Start the engine and warm it up.

    4. 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
    5. Read the values.

      Standard
      GTS Display Engine Condition* Normal Value

      Injection Feedback Val #1

      Injection Feedback Val #2

      Injection Feedback Val #3

      Injection Feedback Val #4

      Idling

      -3.0 mm3/st to 3.0 mm3/st

      Tech Tips

      *: The A/C switch and all accessory switches should be off, the engine coolant temperature should be 75°C (167°F) or more and the engine should be idled for 1 minute or more.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3.0 mm3/st

      A
      Except above B

      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 (-3.0 mm3/st is the lowest normal value), 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
    A
  9. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER


    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here

      Note


      • When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection pipe sub-assembly and a new No. 2 injection pipe sub-assembly.

      • Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, 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 sub-assembly may become incomplete, resulting in a fuel leak.

      Result
      Proceed to
      NEXT

    NEXT
  10. CHECK AND REPLACE PARTIAL ENGINE ASSEMBLY


    1. Check and replace the engine assembly.

      Result
      Proceed to
      NEXT

    NEXT
  11. 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. Start the engine.

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

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

      Tech Tips

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

      B0027UBE55
      OK
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa (102.0 kgf/cm2, 1451 psi).
      Result
      Result Proceed to
      NG A
      OK* B

      Note

      *: Even when the results of the Active Test are normal, take a snapshot of vehicle data when the vehicle is accelerating. If "Common Rail Pressure" does not follow "Target Common Rail Pressure", proceed to step 12.

      If "Common Rail Pressure" does not follow "Target Common Rail Pressure", the fuel filter may be clogged.

      Tech Tips


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

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

      • If the pressure discharge valve mounted on the common rail assembly is malfunctioning, the actual fuel pressure may change as indicated by "Pressure Discharge Valve Abnormal Common Rail Pressure" in the illustration.

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

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


    B
    A
  12. INSPECT COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)


    1. Enter the following menus: Powertrain / Engine and ECT / Utility / Pressure Discharge Valve Check.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Pressure Discharge Valve Check
    2. Select "Always Closed Check".

    3. Press "Next".

    4. Read the Value of fuel pressure values.

      OK
      Fuel pressure is properly maintained.

      Tech Tips


      • If the fuel pressure cannot be maintained, the pressure discharge valve may not have a tight seal.

      • If the fuel pressure is being properly maintained, there are no problems with the sealing properties of the high-pressure fuel system. Therefore, an insufficient supply of fuel due to the fuel filter being clogged, or squashed or blocked low-pressure fuel pipes or hoses may be causing the reduction in common rail pressure.

      Result
      Proceed to
      OK
      NG

    NG
    OK
  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 and ECT / Data List / Target Common Rail Pressure and Common Rail Pressure.


      Powertrain > Engine and ECT > Data List
      Tester Display
      Target Common Rail Pressure
      Common Rail Pressure
    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 Common Rail Pressure value.

      B0025O8E21
      Result
      Result Proceed to
      While idling the vehicle, "Common Rail Pressure" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1 A
      "Common Rail Pressure" is normal while idling the vehicle, but "Common Rail Pressure" 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
    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.

      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
      Proceed to
      NEXT

    NEXT
  15. REPLACE FUEL SUPPLY PUMP ASSEMBLY (PRE-STROKE CONTROL VALVE)


    1. Replace the fuel supply pump assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT
  16. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT
  17. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result
    Proceed to
    NEXT

    NEXT
  18. REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)


    1. Replace the common rail assembly.

      Click here

      Result
      Proceed to
      NEXT

    NEXT
  19. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT
  20. READ VALUE USING GTS (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)


    1. Check Common Rail Pressure and Target Common Rail Pressure in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Difference between Common Rail Pressure and Target Common Rail Pressure is 5000 kPa (51.0 kgf/cm2, 725 psi) or more

      B
      Except above A

    A
    B
  21. READ VALUE USING GTS (INJECTION VOLUME)


    1. Check Injection Volume in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Injection Volume while idling after engine warm up is more than 10 mm3/st

      A
      Except above B

    B
    A
  22. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS


    1. Replace the injector assemblies of all cylinders.

      Click here

      Note


      • When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection pipe sub-assembly and a new No. 2 injection pipe sub-assembly.

      • Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, 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 sub-assembly may become incomplete, resulting in a fuel leak.

      Result
      Proceed to
      NEXT

    NEXT
  23. CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY


    1. 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 injector assemblies may not operate properly if the fuel filter element assembly is installed with foreign matter remaining inside the fuel filter case.

      Result
      Proceed to
      NEXT

    NEXT
  24. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system.

      Click here

      Result
      Proceed to
      NEXT

    NEXT
  25. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation codes.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Injector Compensation
    2. Perform the injector pilot quantity learning.

      Click here


      Powertrain > Engine and ECT > Utility
      Tester Display
      Pilot Quantity Learning
      Result
      Proceed to
      NEXT

    NEXT