СИСТЕМА ECD Engine Difficult to Start or Stalling

DESCRIPTION


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      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
      Turbocharger System
      Main fault

      • Air leak in the turbocharged air passage

      • ECM not operating well

      • Turbocharger (turbine, bearing)
      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


      • 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.
      Exhaust System
      Main fault Blockage
      Symptoms Lack of power (high engine speed, under heavy load)
      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 Measure the resistance of the glow plug
      Battery
      Main fault Battery is depleted
      Symptoms Difficult to start (cannot crank, crank speed is low), horn is quiet
      Data List

      Battery Voltage

      When cranking, battery voltage is below 5 V.
      Engine - 1
      Main fault Damaged, seized up
      Symptoms Cannot crank, crank speed is low, strange noise
      Engine - 2
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      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.
      Start System
      Main fault Starter system malfunction
      Symptoms Difficult to start
      Data List

      Starter Signal


      • Ignition switch (STA) output:

        ON: Starter is operating

        OFF: Starter is not operating

    2. Diesel Injection

      Fuel Supply Pump
      Main fault -
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Common Rail Pressure, Target Common Rail Pressure


      • Common Rail Pressure 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.

      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.
      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


      • Common Rail Pressure 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.

      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.
      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.
      Injector Driver
      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 has a fault, some DTCs may be stored.
      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

      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.
      Irregular Fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      EGR System
      Main fault

      • Does not move smoothly

      • Does not close completely
      Symptoms

      • Rough idle

      • EGR valve stuck closed: A 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 EGR and there is a heavy load, when the vehicle starts moving, a lack of power will be felt).

    4. Diesel Throttle

      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.

  2. Data List Related to Starting Trouble


    • MAP

    • Intake Air

    • Coolant Temp

    • Battery Voltage

    • Starter Signal

    • Target Common Rail Pressure

    • Common Rail Pressure

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

INSPECTION PROCEDURE


  1. Explanation of Symptom

    Starting Trouble

    For good starting it is essential to have:


    • Sufficient cranking speed.

    • Properly operating engine preheating system.

    • Good quality fuel.

    The fuel is ignited by the heat which is generated by compression pressure.

    With problems such as a depleted battery, the crankshaft speed can become low, or if the engine compression is poor due to leakage, the compression pressure will not rise and there will be difficulty starting.

    When the engine is cold, even if there is compression heat, it will escape from the combustion chamber. For this reason, when the engine is started when it is cold, the glow plugs heat the compressed air.

    Also, after starting the engine, by charging the glow plugs for a fixed time set according to the engine coolant temperature, diesel knocking and white smoke are prevented. The quantity of fuel injected is determined by the fuel pressure and also the amount of time the injector assembly is open.

  2. Trouble Area Chart According to Problem Cause

    B007QUCE02
    B007PFHE03

    Note


    • After replacing the ECM, the new ECM needs registration Click here 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.

    Tech Tips

    Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List values may occur depending on the measuring conditions or the vehicle age. Do not assume the vehicle is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

PROCEDURE


  1. CHECK ENGINE CRANKING CONDITION


    1. Check the engine cranking condition.

      Result
      Result Proceed to
      Cranking is OK. A

      Low cranking speed.

      Tech Tips

      When cranking speed is low, especially when the temperature is low, check if the engine oil grade matches the recommendation.

      		 B
      Does not crank at all. C

    B

    CHECK BATTERY CONDITION Click here

    C

    READ OUTPUT DTC (RELATED TO ENGINE) Click here

    A

  2. READ ALL OUTPUT DTCS


    1. Connect the GTS to the DLC3.

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

    3. Enter the following menus: System Select / Health Check.

      Result
      Result Proceed to
      No DTC is output A
      DTCs related to engine are output B

    B

    GO TO RELATED DTC Click here

    A

  3. TAKE SNAPSHOT DURING STARTING AND IDLING (PROCEDURE 3)


    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 / Common rail (All).

    4. Take a snapshot when idling with no load after the engine is warmed up and when starting trouble 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 data in the illustration below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

      • When there is trouble starting with a cold engine, take the snapshot when the engine is cold. Then warm up the engine (engine coolant temperature is 70°C (158°F) or higher) and after idling the vehicle for 1 minute (A/C off, electrical load off), take a snapshot of the data for 15 seconds while idling.

      • 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 and when the engine is started.


    NEXT

  4. CHECK SNAPSHOT (COMMON RAIL PRESSURE)


    1. Check Common Rail Pressure in the snapshot taken in procedure 3 when the engine was started.

      B007UGKE04
      Result
      Result Proceed to
      At the point in the illustration labeled "a", Common Rail Pressure is less than 10000 kPa from the value of Common Rail Pressure when cranking started A
      At the point in the illustration labeled "c", Common Rail Pressure is below Target Common Rail Pressure by 15000 kPa or more B
      Common Rail Pressure increases to a value that is higher than Target Common Rail Pressure immediately after cranking, and, at the point in the illustration labeled "d", Common Rail Pressure is higher than Target Common Rail Pressure C
      Except above D

      Tech Tips


      • Even if Common Rail Pressure is temporarily higher than Target Common Rail Pressure, as shown at the point in the illustration labeled "b", the fuel supply pump is normal.

      • Common Rail Pressure is about 25000 to 35000 kPa when the engine is cranking and the engine coolant temperature is 0°C (32°F) or higher.

      • Common Rail Pressure increases rapidly during cranking.


    B

    READ VALUE USING GTS (COMMON RAIL PRESSURE) Click here

    C

    INSPECT INJECTOR DRIVER Click here

    D

    CHECK DATA LIST Click here

    A

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


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

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

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

      Tech Tips


      • When there is a lack of fuel, Common Rail Pressure drops.

      • Inspect for Fuel Filter clogging (check that the Fuel Filter is not clogged).

    3. Reconnect the inlet hose.


    NG

    CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP) Click here

    OK

  6. 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
      D47-1 - D105-41 (PCV+) Always Below 1 Ω
      D47-2 - D105-81 (PCV-) Always Below 1 Ω
      D47-1 or D105-41 (PCV+) - Body ground Always 10 kΩ or higher
      D47-2 or D105-81 (PCV-) - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT

  8. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  9. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  10. READ VALUE USING GTS (COMMON RAIL 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 / Common Rail Pressure.

    4. Start the engine.

    5. Read the Common Rail Pressure values while cranking and idling the engine.

      Result
      Result Proceed to
      The engine cannot be started or the engine can be started but Common Rail Pressure is below 20000 kPa 2 seconds after the starter signal changes from OFF to ON B
      Except above A

    B

    INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM) Click here

    A

    END

  11. INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)


    1. Remove the glow plug assembly for all the cylinders Click here.

    2. Visually check if there is fuel on the glow plugs.

      Tech Tips


      • If there is fuel on a glow plug, fuel may be leaking from an injector assembly.

      • After replacing an injector assembly, make sure that the common rail pressure (fuel pressure) is within 5000 kPa of the target common rail pressure while cranking the engine.

      • If there is fuel on a glow plug, fuel may have mixed with the engine oil. Check the engine oil amount and whether the engine oil smells of diesel fuel. If the oil level is above the full line or the engine oil smells of diesel fuel, replace the engine oil.

    3. Install the glow plug assembly Click here.


    NEXT

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER Click here

  12. CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)


    1. Check and repair or replace the clogged fuel pipe.


    NEXT

  13. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  14. READ VALUE USING GTS (COMMON RAIL PRESSURE)


    1. Check Common Rail Pressure in the snapshot taken in procedure 3 when the engine was warmed up.

      Result
      Result Proceed to
      Common Rail Pressure is more than 5000 kPa from Target Common Rail Pressure A
      Except above B

    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS Click here

    A

  15. REPLACE SUCTION CONTROL VALVE


    1. Replace the suction control valve Click here.


    NEXT

  16. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

  17. 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.


    NEXT

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER Click here

  18. CHECK DATA LIST


    1. Check Injection Feedback Val # in the snapshot taken in procedure 3 when the engine was idling.

      Result
      Result Proceed to

      Injection Feedback Val #1 to #4 are 3 mm3/st or less.

      Injection Volume is more than 12 mm3/st.

      		 A*

      Injection Feedback Val for at least one cylinder is more than +3 mm3/st

      Tech Tips

      There may be a malfunction in the corresponding cylinder.

      		 B
      Except above C

      Tech Tips


      • *: When this case occurs, usually symptoms may be noticeable, such as difficulty starting, lack of power.

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


    B

    CHECK CYLINDER COMPRESSION PRESSURE Click here

    C

    CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS Click here

    A

  19. 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.


    NEXT

    CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER Click here

  20. 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 may be installed improperly.


    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  21. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tech Tips

    It can be determined that the injector assembly is faulty as the corresponding cylinder is malfunctioning, but has no compression loss.


    1. Replace the injector assembly 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.


    NEXT

  22. CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER


    1. Clean the fuel filter case and replace the fuel filter.

      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 is installed with foreign matter remaining inside the fuel filter case.


    NEXT

  23. BLEED AIR FROM FUEL SYSTEM


    1. Bleed the air from the fuel system Click here.


    NEXT

  24. PERFORM ECM INITIALIZATION AND REGISTER INJECTOR COMPENSATION CODE


    1. Perform the ECM initialization.


      1. Connect terminals 13 (TC) and 4 (CG) of the DLC3.

        B007URJE90

      2. Turn the ignition switch to ON for 50 minutes or more.

        Note


        • Perform ECM initialization only when the injectors for all the cylinders have been replaced.

        • It is necessary to wait for 50 minutes or more. Otherwise, ECM initialization is not completed.

      3. Turn the ignition switch off.

      4. Disconnect terminals 13 (TC) and 4 (CG).

    2. Register the injector compensation codes Click here.


    NEXT

  25. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END

  26. INSPECT INJECTOR DRIVER


    1. Even in cases where DTC P0200 is not stored even though the engine cannot be started, perform the DTC P0200 troubleshooting procedure Click here.

      Tech Tips


      • When the engine cannot be started due to a malfunction in the injector driver system, once the DTCs are cleared, the system cannot store DTC P0200 even if it is confirmed that the engine cannot be started when trying to reproduce the problem symptoms.

        As DTC P0200 cannot be stored when starting the engine, fuel injection signals are output by the ECM, but fuel is not actually injected. Therefore, an excessive amount of fuel is supplied to the common rail by the fuel supply pump assembly, and as a result, the fuel pressure is higher than the target common rail pressure in the data recorded at the time the engine was having trouble starting.

      • If the problem cannot be determined even after performing the DTC P0200 troubleshooting procedure and the fuel pressure is higher than the target common rail pressure when attempting to start the engine, proceed to the next step.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  27. INSPECT INJECTOR ASSEMBLY


    1. Inspect the injector assemblies Click here.

      Tech Tips

      If there is no initial combustion during cranking, there may be air in the injector assemblies.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  28. CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS


    1. Check the temperature when starting trouble occurs.

      Result
      Result Proceed to
      Difficult to start only for cold engine. A
      Difficult to start both for cold and warmed up engine. B

    B

    CHECK FUEL QUALITY Click here

    A

  29. READ VALUE USING ENGINE COOLANT TEMPERATURE SENSOR (COOLANT TEMP)


    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 / Coolant Temp.

    4. Read the value displayed on the GTS.

      OK
      Coolant Temp is not high when the engine is cold, and not low after the engine is warmed up

    NG

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  30. INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)


    1. Inspect the glow plug Click here.


    NG

    REPLACE GLOW PLUG ASSEMBLY Click here

    OK

  31. CHECK FUEL QUALITY


    1. Check that only diesel fuel is being used.

    2. Check that the fuel does not contain any impurities.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  32. READ OUTPUT DTC (RELATED TO ENGINE)


    1. Connect the GTS to the DLC3.

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

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

    4. Read the DTCs.

      Result
      Result Proceed to
      No DTC is output A
      DTCs related to engine are output B

    B

    GO TO RELATED DTC Click here

    A

  33. CHECK COMMUNICATION BETWEEN GTS AND ECM


    1. Connect the GTS to the DLC3.

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

    3. Check if the normal starting screen appears (check whether communication with the ECM is possible).

      Tech Tips

      Use a GTS that is able to communicate with other vehicles.

      OK
      Communication is possible (vehicle can be recognized).

    NG

    CHECK VC OUTPUT CIRCUIT

    OK

  34. READ VALUE USING GTS (STARTER SIGNAL)


    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 / Starter Signal.

    4. Read the value displayed on the GTS.

      OK
      Tester Display Condition Specified Condition
      Starter Signal Cranking ON

    NG

    GO TO PROBLEM SYMPTOMS TABLE Click here

    OK

  35. CHECK STARTING SYSTEM


    1. Inspect the starting system.

      Tech Tips

      Be sure to inspect the following areas:


      • Starter relay

      • Starter


    NEXT

  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END