ECD SYSTEM (w/ EGR Cooler) Rough Idling or Excessive Engine Vibrations

DESCRIPTION

Malfunction Condition Main Trouble Area Related Trouble Area

  • Rough idling or juddering due to abnormal combustion

  • Juddering when vehicle is starting due to clutch system malfunctions

  1. Injector malfunctions


    • Injector sliding malfunction

    • Injector stuck closed

    • Injector stuck open

    • Deposits in injector

    • Injector circuit malfunction

  2. Clutch system malfunctions


    • Clutch system (juddering when starting)

  • Injector compensation code

  • Fuel leak

  • Engine mounting

  • Intake air system leakage

  • Intake air system blockage

  • EGR system

  • Throttle valve system

  • Mass air flow meter

  • Supply pump

  • Fuel pressure sensor

  • EDU (P0200 set simultaneously)

  • Low quality fuel

  • Vehicle modifications

  • Fuel filter air bleed problem

  • Accessory problem (A/C, generator, etc.)

  • ECM

Tech Tips


  • This troubleshooting procedure checks for the cause of rough idling and excessive engine vibrations.

  • Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result 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.


  1. Faults and Symptoms of Common Rail Diesel Components


    1. Engine Control

      Mass Air Flow Meter
      Main fault Decrease in performance (foreign matter is stuck)
      Symptoms Lack of power, black smoke
      Data List MAF

      Tech Tips

      The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
      Glow System
      Main fault Open circuit, glow plug relay fault
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Data List Check the glow plug indicator light
      Diagnostic Point Try to measure the resistance of the glow plug
      Engine
      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


      • If Injection Feedback Val is more than 3 mm3/st, the cylinder may have a fault.

    2. Diesel Injection

      Fuel Supply Pump
      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


      • At a stable condition (e.g. Idling), Fuel Press is within +/-5000 kPa of "Target Common Rail Pressure".

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

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

      Tech Tips


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

      • When Target Pump SCV Current is 3000 mA or more, the suction control valve has a tendency to become stuck.
      Diagnostic Trouble Code Even if Fuel Press is less than 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

      Fuel Press, Target Common Rail Pressure


      • At a stable condition (e.g. Idling), the fuel pressure is within +/-5000 kPa of "Target Common Rail Pressure".

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

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

      Tech Tips

      The fuel pressure changes at engine starting, but is approx. 25000 kPa at engine start after the engine is warmed up.
      Diagnostic Trouble Code Even if Fuel Press is less than Target Common Rail Pressure, a DTC will not be stored.
      Fuel Injector
      Main fault Blockage
      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val


      • When an Injection Feedback Val is more than 3 mm3/st, the cylinder is not normal. This can be read after idling for 1 minute with the engine warmed up (engine coolant temperature is more than 70°C (158°F)).
      Injector Driver (EDU)
      Main fault Circuit fault: The fuel injector does not open.
      Symptoms Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
      Data List Same as fuel injector
      Diagnostic Trouble Code When the EDU 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

      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 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).
      Data List

      Actual EGR Valve Pos., Target EGR Pos.


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

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

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

      • EGR valve opens to the halfway point at idling after the engine 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

      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 is 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 temporarily closed fully.

  2. Data List Related to Rough Idling or Excessive Engine Vibrations


    • Engine Speed

    • MAF

    • Intake Air

    • Coolant Temp

    • 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.

INSPECTION PROCEDURE

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 a fuel injector, the ECM needs registration Click here.

PROCEDURE


  1. CHECK MALFUNCTION CONDITION


    1. Identify when shuddering occurs.

      Result
      Result Proceed to
      When idling A
      When engaging engine clutch at vehicle start

      B

      (Clutch system shudders)

    B

    REPAIR OR REPLACE CLUTCH SYSTEM

    A

  2. CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT


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

      OK
      The wire harnesses and connectors are connected securely.

      Tech Tips

      The engine may have problems when there is an intermittent disconnection in a circuit related to the fuel pressure sensor, crankshaft position sensor, engine coolant temperature sensor, etc.


    NG

    REPAIR OR REPLACE HARNESS AND CONNECTOR Click here

    OK

  3. READ OUTPUT DTC (RELATING TO ENGINE)


    1. Connect the intelligent tester to the DLC3.

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

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

    4. Read pending DTCs.

      Result
      Result Proceed to
      No DTCs are output A
      Engine related DTCs are output B

    B

    GO TO DTC CHART

    A

  4. TAKE SNAPSHOT DURING IDLING (PROCEDURE 4)


    1. A01DUXVE02

      Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Warm up the engine (engine coolant temperature is 70°C (158°F) or higher)

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data.

    5. Take a snapshot when idling with no load after the engine is warmed up.

      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.

      • Graphs can be displayed by transferring the stored snapshot data from the tester to a PC. Intelligent Viewer must be installed on the PC.

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

      • If rough idling occurs when the A/C switch is on, take another snapshot with the A/C switch on.


    NEXT

  5. CHECK WHITE SMOKE


    1. Start the engine.

    2. Fully depress the accelerator pedal and then release it.

    3. Check whether the white smoke is emitted when racing the engine.

      Note

      Be sure not to check for white smoke indoors.

      Tech Tips

      Depending on whether there is oil mixed with the fuel, or whether there is unburned fuel present, the smell of the exhaust gas differs. When oil is mixed in, the exhaust gas smells like burning oil.

      Result
      Result Proceed to
      White smoke is emitted B
      White smoke is not emitted A

    B

    CHECK AND REPAIR ENGINE ASSEMBLY Click here

    A

  6. CHECK DATA LIST (ENGINE SPEED)


    1. Check engine speed in the snapshot taken at procedure 4 when the engine was idling.

      Result
      Result Proceed to
      Change in engine speed coincides with air conditioning system operation B
      Except above A

    B

    CHECK AIR CONDITIONING SYSTEM Click here

    A

  7. CHECK DATA LIST (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)


    1. Check Injection Feedback Val # in the snapshot taken at procedure 4 when the engine was idling.

      Result
      Result Proceed to

      Injection Feedback Val for at least one cylinder is more than 3 mm3/st and engine vibration is abnormally large

      		 A
      Except above B

      Tech Tips


      • When there is a problem with the operation of a fuel injector due to foreign matter in the inside of the fuel injector, 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 fuel injectors are not malfunctioning.


    B

    CHECK DATA LIST (FUEL PRESS AND TARGET COMMON RAIL PRESSURE) Click here

    A

  8. INSPECT INJECTOR COMPENSATION CODE


    1. Read the injector compensation code Click here.

      OK
      Compensation codes stored in the ECM match compensation codes of the installed fuel injectors.

    NG

    REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING Click here

    OK

  9. 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

  10. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  11. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER #1 TO #4 FUEL CUT)

    Tech Tips

    Use this Active Test to determine the malfunctioning cylinder.


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and turn the tester on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Cylinder #1 to #4 Fuel Cut.

      Tech Tips


      • If the engine idle speed does not change when a fuel injector is disabled, the cylinder being tested is malfunctioning.

      • If the cylinder being tested is normal, there will be a significant change in idle speed when the fuel injection is stopped for that cylinder.


    NEXT

  12. REPLACE FUEL INJECTOR OF MALFUNCTIONING CYLINDER


    1. Replace the fuel injector of the malfunctioning cylinder Click here.


    NEXT

  13. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  14. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING


    1. Register the injector compensation code Click here.

    2. Perform the fuel injector pilot quantity learning Click here.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  15. REPAIR OR REPLACE HARNESS AND CONNECTOR


    1. Repair or replace the harness or connector.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  16. CHECK AND REPAIR ENGINE ASSEMBLY


    1. Check the following items, and repair the malfunctioning part if necessary.


      1. Check cylinder compression pressure Click here.

      2. Inspect the glow plug assembly Click here.


    NEXT

    CHECK DATA LIST (FUEL PRESS AND TARGET COMMON RAIL PRESSURE) Click here

  17. CHECK AIR CONDITIONING SYSTEM


    1. Check the air conditioning system.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  18. CHECK DATA LIST (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)


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

      Result
      Result Proceed to
      Fuel Press is outside range of +/-5000 kPa from Target Common Rail Pressure A
      Except above B

    B

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR CUT) Click here

    A

  19. CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

    A01DWE5E13

    1. Disconnect the S8 suction control valve connector.

    2. Disconnect the E8 ECM connector.

    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      S8-1 - PCV+ (E8-2) Always Below 1 Ω
      S8-2 - PCV- (E8-1) Always Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      S8-1 or PCV+ (E8-2) - Body ground Always 10 kΩ or higher
      S8-2 or PCV- (E8-1) - Body ground Always 10 kΩ or higher

      Tech Tips

      When there is an open circuit, Target Pump SCV Current is outside the range of 923 to 1123 mA.


    NG

    REPAIR OR REPLACE HARNESS AND CONNECTOR Click here

    OK

  20. CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP


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

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

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

      Tech Tips


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

      • Inspect for fuel filter clogging.


    NG

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

    OK

  21. REPLACE FUEL SUPPLY PUMP


    1. Replace the fuel supply pump Click here.


    NEXT

  22. BLEED AIR FROM FUEL SYSTEM


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


    NEXT

  23. PERFORM FUEL SUPPLY PUMP INITIALIZATION


    1. Perform fuel supply pump initialization Click here.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  24. REPAIR OR REPLACE HARNESS AND CONNECTOR


    1. Repair or replace the harness or connector.


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  25. 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

  26. 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

  27. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR CUT)


    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and warm it up (engine coolant temperature is 70°C (158°F) or higher), and the A/C switch and all accessory switches should be off.

    3. Turn the ignition switch off. Wait for 30 seconds and then restart the engine.

    4. Turn the tester on.

    5. Select the following menus: Powertrain / Engine and ECT / Data List / MAF.

    6. Read the MAF value displayed on the tester when engine idling.

    7. Select the following menus: Powertrain / Engine and ECT / Active Test / Activate The VSV for EGR Cut.

    8. Read the MAF value when the VSV for EGR cut is turned from off to on using the Active Test function.

      Tech Tips


      • If idling continues for 15 minutes or more, the EGR valve opening angle target becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to run the vehicle or to restart the engine.

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

      Result
      Active Test Result Proceed to

      Activate The VSV for EGR Cut:

      off (Open) to on (Close)

      		 MAF value is not changed A
      MAF value is changed B

      Note

      As the numerical values shown below may differ depending on the conditions such as the differences of measuring environments, and the changes of vehicle condition due to aging, do not determine with these values whether acceptable of not.

      Tech Tips

      The problem may be a temporary one, due to the entry of deposits or foreign matter. Please check that there are no deposits or foreign matter in the E-VRV or mass air flow meter.

      Reference
      EGR Valve Condition (Opening) MAF (Reference) Measuring Condition
      Open 3.0 to 9.0 gm/s

      • Atmosphere pressure: 101 kPa

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

      • Engine coolant temperature: 88°C (190°F)
      Close 15 to 22 gm/s

    B

    CHECK AND REPLACE ENGINE MOUNTING INSULATOR Click here

    A

  28. REMOVE DEPOSIT (EGR VALVE ASSEMBLY)


    1. Remove the EGR valve assembly.

    2. Visually check the EGR valve assembly for deposits.

      If there are deposits, clean the EGR valve assembly.

      Tech Tips


      • If the EGR valve is stuck closed, the intake air amount increases and engine vibration may worsen.

      • If the EGR valve does not operate due to clogging or disconnection of the vacuum hose, repair the hose.

      • 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 EGR valve.

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


    NEXT

    CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Click here

  29. CHECK AND REPLACE ENGINE MOUNTING INSULATOR


    1. Check the following items, and repair or replace the malfunctioning part if necessary.


      1. Check that the engine mounting insulators are installed correctly.

      2. Check that the engine mounting insulators are not twisted.

      3. Check that deformation of an engine mounting insulator is not causing the engine to contact the vehicle body.


    NEXT

  30. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


    NEXT

    END