ECD SYSTEM(for DPF) Engine Difficult to Start or Stalling

DTC Code DTC Name
Engine Difficult to Start or Stalling

DESCRIPTION

  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

      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
      Table 3. Turbocharger System

      Symptom and Corresponding Main Fault

      • Air leak in the turbocharged air passage

      • ECM not operating well

      • Turbocharger sub-assembly (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.
      Table 4. Exhaust System

      Main fault

      Blockage

      Symptoms

      Lack of power (high engine speed, under heavy load)
      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. 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.
      Table 7. Engine - 1

      Main fault

      Damaged, seized up

      Symptoms

      Cannot crank, crank speed is low, strange noise
      Table 8. 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.
      Table 9. 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. Common Rail (ALL)

      Table 10. 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.

      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 11. 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 12. 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 13. Pressure Discharge Valve

      Main fault

      Does not completely close

      Symptoms

      Difficult to start, engine stall, rough idle, lack of power
      Table 14. 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 15. 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

      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped and check that Fuel Press and Common Rail Pres Sens 2 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Fuel Press or Common Rail Pres Sens 2 decreases to a value less than Target Common Rail Pressure).

      Diagnostic Trouble Code

      When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 16. Irregular Fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 17. 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).

      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 is turned to ON (engine stopped).

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

      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 18. 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 (the engine is 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

    • MAP

    • MAF

    • Intake Air

    • Coolant Temp

    • Battery Voltage

    • Starter Signal

    • Engine Speed of Cyl #1 (to #4)

    • 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.

    • EGR Close Lrn. Status

    • EGR Close Lrn. Val.

WIRING DIAGRAM

Refer to DTC P0088.

Click here

CAUTION / NOTICE / HINT

  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

    A299141E02
    A183464E11
    Note:

    • After replacing the suction control valve, the ECM needs initialization.

      Click here

    • After replacing an injector assembly, the ECM needs registration.

      Click here

    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 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.

      Tip:

      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 hereClick 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.

    4. Check the DTCs.

      Result

      Proceed to

      DTC is not output

      Engine related DTCs are output
      Tip:

      If only DTC P1604 is output, proceed to step 3.

    Engine related DTCs are output

    GO TO RELATED DTC

    Click hereClick here

    DTC is not output

  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 / All Data.

    4. Take a snapshot when idling with no load after the engine is warmed up and when starting trouble is occurring.

      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 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.

    Result

    Proceed to

    NEXT
    NEXT

  4. CHECK SNAPSHOT (FUEL PRESS)

    1. Check Fuel Press in the snapshot taken in procedure 3 when the engine was started.

      A227761E05

      Result

      Result

      Proceed to

      At the point in the illustration labeled "a", Fuel Press is less than 10000 kPa from the value of Fuel Press when cranking started

      A

      At the point in the illustration labeled "c", Fuel Press is below Target Common Rail Pressure by 15000 kPa or higher

      B

      Fuel Press increases to a value that is higher than Target Common Rail Pressure immediately after cranking, and, at the point in the illustration labeled "d", Fuel Press is higher than Target Common Rail Pressure

      C

      Except above

      D
      Tip:

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

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

      • Fuel Press increases rapidly during cranking.

    B

    READ VALUE USING GTS (FUEL PRESS)Click here

    C

    INSPECT INJECTOR DRIVER (EDU)Click here

    D

    INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)Click here

    A

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

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

    2. Operate the priming 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 priming pump is operated.

      Tip:

      • When there is a lack of fuel, fuel pressure drops.

      • Inspect for fuel filter element assembly clogging (check that the fuel filter element assembly is not clogged).

    Result

    Proceed to

    OK

    NG
    NG

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

      B48-1 - B76-41 (PCV+)

      Always

      Below 1 Ω

      B48-2 - B76-81 (PCV-)

      Always

      Below 1 Ω

      B48-1 or B76-41 (PCV+) - Body ground

      Always

      10 kΩ or higher

      B48-2 or B76-81 (PCV-) - Body ground

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. REPLACE SUCTION CONTROL VALVE

    1. Replace the suction control valve.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  8. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  9. PERFORM SUPPLY PUMP INITIALIZATION

    1. Perform supply pump initialization.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  10. READ VALUE USING GTS (FUEL PRESS)

    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 / Fuel Press.

      Powertrain > Engine > Data List

      Tester Display

      Fuel Press

    4. Start the engine.

    5. Read the Fuel Press values while cranking and idling the engine.

      Result

      Result

      Proceed to

      The engine cannot be started or the engine can be started but Fuel Press is below 20000 kPa 2 seconds after the starter signal changes from off to on

      B

      Except above

      A
    A

    END

    B

  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 plug assemblies.

      Tip:

      • If there is fuel on a glow plug assembly, 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 fuel pressure while cranking the engine.

      • If there is fuel on a glow plug assembly, 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.

    Result

    Proceed to

    NEXT
    NEXT

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDERClick here

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

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

    Result

    Proceed to

    NEXT
    NEXT

  13. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  14. READ VALUE USING GTS (FUEL PRESS)

    1. Check Fuel Press in the snapshot taken in procedure 3 when the engine was warmed up.

      Result

      Result

      Proceed to

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

      A

      Except above

      B
    B

    REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERSClick here

    A

  15. REPLACE SUCTION CONTROL VALVE

    1. Replace the suction control valve.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  16. PERFORM SUPPLY PUMP INITIALIZATION

    1. Perform supply pump initialization.

      Click here

    Result

    Proceed to

    NEXT
    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.

    Result

    Proceed to

    NEXT
    NEXT

    REPLACE FUEL FILTER ELEMENT ASSEMBLYClick here

  18. INSPECT INJECTOR DRIVER (EDU)

    1. Even in cases where DTC P062D is not stored even though the engine cannot be started, perform the DTC P062D (No. 1 Fuel Injector Driver Circuit Performance) troubleshooting procedure (Click here).

      When troubleshooting the injector driver (EDU) system, the source of the malfunction is likely to be in one of the following areas, so be sure to inspect these areas carefully.

      • Injector driver (EDU) system power source circuit

      • Injector assembly circuit

      • Injector driver (EDU)

      • ECM

      Tip:

      • When the engine cannot be started due to a malfunction in the injector driver (EDU) system, once the DTCs are cleared, the system cannot store DTC P062D even if it is confirmed that the engine cannot be started when trying to reproduce the problem symptoms.

        As DTC P062D 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 P062D (No. 1 Fuel Injector Driver Circuit Performance) 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.

      • Perform the troubleshooting procedure for DTC P062D and proceed to the diagnostic flow situations where the engine does not start.

      Result

      Proceed to

      Injector driver (EDU) system is normal

      Injector driver (EDU) system is abnormal
    Injector driver (EDU) system is abnormal

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    Injector driver (EDU) system is normal

  19. INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)

    1. When the engine does not start, perform the following procedure.

      1. Stop the engine and leave the vehicle for 4 hours or more.

        Tip:

        It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

      2. Confirm the engine starts.

    2. When the engine starts, perform the following procedure.

      1. Bleed the air from the fuel system.

        Click here

      2. Confirm the engine starts.

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  20. INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)

    1. When the engine does not start, perform the following procedure.

      1. Stop the engine and leave the vehicle for 4 hours or more.

        Tip:

        It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

      2. Check that the engine starts.

        OK

        The engine starts.

    2. When the engine starts, perform the following procedure.

      1. Bleed the air from the fuel system.

        Click here

      2. Check that the engine starts.

        OK

        The engine starts.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  21. 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 10 mm3/st.

      A

      *

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

      Tip:

      There may be a malfunction in the corresponding cylinder.

      B

      Except above

      C
      Tip:

      • *: 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

    PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)Click here

    C

    CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURSClick here

    A

  22. 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

    REPLACE FUEL FILTER ELEMENT ASSEMBLYClick here

  23. PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

    Tip:

    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 / Compression / Engine Speed of Cyl #1 to #4.

      Powertrain > Engine > 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
      Tip:

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

    B

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDERClick here

    A

  24. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    Tip:

    Measure the compression of the cylinder that had a high speed during the "Check the Cylinder Compression" Active Test.

    1. Check the cylinder compression pressure.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  25. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    Tip:

    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.

    Result

    Proceed to

    NEXT
    NEXT

  26. REPLACE FUEL FILTER ELEMENT ASSEMBLY

    1. Replace the fuel filter element assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  27. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  28. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

    1. Register the injector compensation codes.

      Click here

    2. Perform the injector quantity learning.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  29. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  30. CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS

    1. Check the temperature when starting trouble occurs.

      Result

      Proceed to

      Difficult to start only for cold engine.

      Difficult to start both for cold and warmed up engine.
    Difficult to start both for cold and warmed up engine.

    CHECK FUEL QUALITYClick here

    Difficult to start only for cold engine.

  31. READ VALUE USING GTS (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 / All Data / Coolant Temp.

      Powertrain > Engine > Data List

      Tester Display

      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.

    Result

    Proceed to

    OK

    NG
    NG

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR

    Click here

    OK

  32. INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)

    1. Inspect the glow plug assembly.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE GLOW PLUG ASSEMBLY

    Click here

    OK

  33. CHECK FUEL QUALITY

    1. Check that only diesel fuel is being used.

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

    Result

    Proceed to

    NEXT
    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIREDClick here

  34. 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.

      Powertrain > Engine > Trouble Codes

    4. Read the DTCs.

      Result

      Proceed to

      DTC is not output

      Engine related DTCs are output
    Engine related DTCs are output

    GO TO RELATED DTC

    Click hereClick here

    DTC is not output

  35. 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).

      Tip:

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

      OK

      Communication is possible (vehicle can be recognized).

    Result

    Proceed to

    OK

    NG
    NG

    CHECK VC OUTPUT CIRCUIT

    Click here

    OK

  36. 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 / All Data / Starter Signal.

      Powertrain > Engine > Data List

      Tester Display

      Starter Signal

    4. Read the value displayed on the GTS.

      OK

      GTS Display

      Condition

      Specified Condition

      Starter Signal

      Cranking

      ON

    Result

    Proceed to

    OK

    NG
    NG

    INSPECT CLUTCH SWITCH ASSEMBLY

    OK

  37. CHECK STARTING SYSTEM

    1. Inspect the starting system.

      Tip:

      Be sure to inspect the following areas:

      • Starter (ST) relay

      • Starter assembly

      • Immobiliser system

    Result

    Proceed to

    NEXT
    NEXT

  38. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END