ECD SYSTEM(w/ Glow Plug Controller) Rough Idling or Excessive Engine Vibrations

DTC Code DTC Name
Rough Idling or Excessive Engine Vibrations

DESCRIPTION

Malfunction Condition

Main Trouble Area

Related Trouble Area

  • Rough idling or shuddering due to abnormal combustion

  • Shuddering when starting vehicle due to clutch system malfunctions

  1. Injector assembly malfunctions

    • Injector assembly sliding malfunction

    • Injector assembly stuck closed

    • Injector assembly stuck open

    • Deposit in injector assembly

    • Injector circuit malfunction

  3. Clutch system malfunctions

    • Clutch system (shuddering when starting)

  • Injector assembly

  • Injector compensation code

  • Fuel leak

  • Engine mounting insulator

  • Intake system leakage

  • Intake system blockage

  • EGR system

  • Throttle valve system

  • Supply pump assembly

  • Low quality fuel

  • Vehicle modifications

  • Fuel filter air bleed problem

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

  • ECM
Tip:

  • Rough idling and excessive engine vibrations are checked in this troubleshooting procedure.

  • 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 age. Do not judge the vehicle to be normal even when the Data List values indicate a standard level. Hidden factors of the malfunction are possible.

  • 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

      Table 1. Mass Air Flow Meter

      Component

      Mass air flow meter

      Main fault

      Decrease in performance (foreign matter is attached)

      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.
      Table 2. Glow System

      Component

      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
      Table 3. Engine

      Component

      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

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.

    2. Diesel Injection

      Table 4. Fuel Supply Pump

      Component

      Supply pump assembly

      Main fault

      -

      Symptoms

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

      Data List

      Common Rail Pressure, Target Common Rail Pressure, Target Pump SCV Current

      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel 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.

      Tip:

      • 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 1530 mA or more, the suction control valve has a tendency to become stuck.

      Diagnostic Trouble Code

      Even if Common Rail Pressure is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 5. Fuel Filter

      Component

      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

      • When in a stable condition such as when idling, the fuel pressure is within +/-10000 kPa of the target fuel 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.

      Tip:

      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 Common Rail Pressure is less than Target Common Rail Pressure, a DTC may not be stored.
      Table 6. Injector Assembly

      Component

      Injector assembly

      Main fault

      Injection hole blockage

      Nozzle needle or valve piston does not move smoothly

      Symptoms

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

      Data List

      Injection Feedback Val

      • "Injection Feedback Val" more than 2.0 mm3/st: Injector assembly breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.
      Table 7. Pressure Control Valve

      Component

      Pressure control valve (common rail assembly)

      Main fault

      Does not completely close

      Symptoms

      Difficult to start, engine stall, rough idle, lack of power
      Table 8. Fuel Pressure Sensor

      Component

      Fuel pressure sensor (common rail assembly)

      Main fault

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

      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 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.
      Table 9. Irregular Fuel

      Component

      Irregular fuel

      Main fault

      -

      Symptoms

      Difficult to start, rough idle (especially when cold)

    3. Diesel EGR

      Table 10. EGR System

      Component

      EGR system

      Main fault

      • Does not move smoothly

      • Does not close completely

      Symptoms

      • Rough idle

      • EGR valve stuck closed: 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 recirculated exhaust gas and the engine is under heavy load, when the vehicle starts moving, a lack of power will be felt).

      Data List

      Actual EGR Valve Pos, Target EGR Valve Pos

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

      • Using EGR valve Active Test, check whether Actual EGR Valve Pos follows Target EGR Valve 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 warmed up.

    4. Diesel Throttle

      Table 11. Diesel Throttle System

      Component

      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, Target Throttle Position

        100%: Fully open

        0%: Fully closed

      • If there is a malfunction of the throttle actuator, compare the target and actual throttle position values for the troubleshooting.

WIRING DIAGRAM

Refer to DTC P0001.

Click here

CAUTION / NOTICE / HINT

Note:

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

  • When replacing the ECM and/or injector assembly, perform ECM Initialization and Registration.

    Click here

Tip:

Before troubleshooting, conduct the following:

  • (a) Check the fuel quality.

  • (b) Check the fuel line for air.

  • (c) Check the fuel system for blockage.

  • (d) Check the air filter.

  • (e) Check the engine oil.

  • (f) Check the engine coolant.

  • (g) Check the engine idling speed and maximum engine speed.

  • (h) Check the vacuum pump.

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 HARNESS AND CONNECTOR (IN ENGINE ROOM)

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

      OK

      The wire harnesses and connectors are connected securely.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. READ OUTPUT DTC (RELATING TO ENGINE)

    1. Connect the GTS to the DLC3.

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

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

    4. Read the DTCs.

      Powertrain > Engine and ECT > Trouble Codes

      Result

      Result

      Proceed to

      DTC is not output

      A

      Engine related DTCs are output

      B
      Tip:

      If DTC P1605 is output, proceed to step 4.

    B

    GO TO DTC CHART

    Click hereClick here

    A

  4. TAKE SNAPSHOT DURING IDLING AND 3000 RPM

    1. Connect the GTS to the DLC3.

    2. Start the engine and allow it to idle until the engine coolant temperature sensor reaches 75°C (167°F) or higher.

      Tip:

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

    3. Turn the GTS on.

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

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

      Tip:

      Check the Data List at idling and at 3000 rpm with no load after the engine is warmed up.

    Table 12. Data Condition Idling (Engine Warmed Up, A/C Off, Shift Lever in neutral)

    Data List

    Engine Speed

    MAP

    MAF

    Target Common Rail Pressure

    Common Rail Pressure

    Target Pump SCV Current

    Injection Volume

    Target VN Turbo Position

    Target EGR Valve Pos

    Actual EGR Valve Pos

    Target Throttle Position

    Actual Throttle Position

    Accel Position

    Atmosphere Pressure

    Coolant Temp

    Calculate Load

    Pilot 1 Injection Period

    Pilot 2 Injection Period
    Table 13. Data Condition at 3000 rpm (Engine Warmed Up, A/C Off, Shift Lever in neutral)

    Data List

    Engine Speed

    Target Booster Pressure

    MAP

    MAF

    Target Common Rail Pressure

    Common Rail Pressure

    Target Pump SCV Current

    Injection Volume

    Target VN Turbo Position

    Target EGR Valve Pos

    Actual EGR Valve Pos

    Target Throttle Position

    Actual Throttle Position

    Accel Position

    Coolant Temp

    Calculate Load

    Pilot 1 Injection Period

    Pilot 2 Injection Period

    Result

    Proceed to

    NEXT
    NEXT

  5. CHECK SNAPSHOT (COMMON RAIL PRESSURE 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

      Common Rail Pressure is within +/-10000 kPa of Target Common Rail Pressure.

      A

      Common Rail Pressure is outside range of +/-10000 kPa from Target Common Rail Pressure.

      B
    B

    CHECK AND REPLACE FUEL INLET LINEClick here

    A

  6. CHECK SNAPSHOT (TARGET PUMP SCV CURRENT)

    1. Check Target Pump SCV Current in the snapshot taken when the engine was idling and at 3000 rpm with no load.

      Result

      Result

      Proceed to

      Target Pump SCV Current is less than 1530 mA

      A

      Target Pump SCV Current is 1530 mA or more

      B
    B

    CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)Click here

    A

  7. CHECK INJECTOR COMPENSATION CODE

    1. Read the injector compensation codes.

      Click here

      OK

      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.

    Result

    Proceed to

    OK

    NG
    NG

    PERFORM REGISTRATION AND INITIALIZATIONClick here

    OK

  8. CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 to #4)

    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken after the engine is warmed up and has idled for 1 minute.

      Tip:

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

      Result

      Result

      Proceed to

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is 8 mm3/st or less

      A

      Injection Feedback Val #1 to #4 is within the range of +/-2 mm3/st and Injection Volume is more than 8 mm3/st

      B

      *1

      Injection Feedback Val #1 to #4 is outside the range of +/-2 mm3/st*2

      C
      Tip:

      • *1: When this result occurs, usually symptoms may be noticeable, such as difficult starting, rough idling, knocking or black smoke at high common rail pressure.

      • *2: There may be a malfunction in the corresponding cylinder.

      • If the value of Injection Volume is more than 8 mm3/st and the value of Injection Feedback Val #1 to #4 is within the threshold, replace the injector assemblies for all cylinders.

        In this case, there is a possibility that too much recirculated exhaust gas is entering the engine. Therefore, you should compare the Target EGR Valve Pos with the Actual EGR Valve Pos by entering the following menus using the GTS: Powertrain / Engine and ECT / Data List / Target EGR Valve Pos and Actual EGR Valve Pos.

        If the difference between Target EGR Valve Pos and Actual EGR Valve Pos exceeds +/-10%, the EGR system may be malfunctioning.

    C

    PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)Click here

    B

    REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERSClick here

    A

  9. CHECK TEMPERATURE WHEN ROUGH IDLING TROUBLE OCCURS

    1. Check the temperature when rough idling trouble occurs.

      Result

      Result

      Proceed to

      Rough idling only for cold engine.

      A

      Rough idling both for cold and warmed up engine.

      B
    B

    INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLYClick here

    A

  10. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

    1. Inspect the engine coolant temperature sensor.

      Click here

      Tip:

      Confirm that the engine coolant temperature is 60°C (140°F) or higher using the GTS, and then leave the vehicle overnight (7 hours or more). The actual engine coolant temperature and atmospheric temperature should be very similar.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

    OK

  11. INSPECT GLOW PLUG ASSEMBLY

    1. Inspect the glow plug assembly.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE GLOW PLUG ASSEMBLY

    Click here

    OK

  12. INSPECT ELECTRIC EGR CONTROL VALVE ASSEMBLY

    1. Remove the electric EGR control valve assembly.

    2. Connect the electric EGR control valve assembly connector.

    3. Connect the GTS to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position / Data List / Actual EGR Valve Pos.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Control the EGR Step Position

      Data List Display

      Actual EGR Valve Pos

    6. When changing the Active Test value from 1 to 100%, check that Actual EGR Valve Pos smoothly changes to the set opening angle.

      OK

      Value smoothly changes to the set opening angle.

    7. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.

      Note:

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

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

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

    8. Hold the electric EGR control valve assembly up to a light and visually check that there is no clearance between the valve and body.

      A200348C06

      *1

      Electric EGR Control Valve Assembly

      -

      -

      *a

      Part A

      *b

      Clearance

      *c

      OK

      *d

      NG

      OK

      No light passes through (there is no clearance between the valve and body).

      If light passes through (there is clearance between the valve and body), replace the electric EGR control valve assembly.

      Tip:

      Light passes through part A shown in the illustration even if the valve is completely closed, this is not a malfunction.

    9. Remove the diesel throttle body assembly, intake air connector and EGR pipe connector.

    10. Remove the deposits from the parts and clean them.

      Note:

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

      • Extreme care must be taken to prevent the removed deposits from falling into the engine unit during cleaning.

      Tip:

      • Remove the intake manifold from the cylinder head when it has to be cleaned.

      • Do not leave any deposits in the electric EGR control valve assembly when cleaning the valve.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

    OK

  13. PERFORM ACTIVE TEST USING GTS (DIESEL THROTTLE TARGET ANGLE)

    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 / Diesel Throttle Target Angle / Data List / Actual Throttle Position.

      Powertrain > Engine and ECT > Active Test

      Active Test Display

      Diesel Throttle Target Angle

      Data List Display

      Actual Throttle Position

    4. When continuously changing the Active Test value to 100, 70, 40, 10, 40, 70 and 100%, check that Actual Throttle Position smoothly changes to the set opening angle.

      OK

      Value smoothly changes to the set opening angle.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE DIESEL THROTTLE BODY ASSEMBLY

    Click here

    OK

  14. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    1. Check whether the malfunction has been successfully repaired.

      OK

      Malfunction has been repaired successfully.

    Result

    Proceed to

    OK

    NG
    OK

    CHECK FOR INTERMITTENT PROBLEMS

    Click here

    NG

  15. BASIC INSPECTION

    1. Check the fuel quality.

    2. Check the fuel line for air.

    3. Check the fuel system for blockages.

    4. Check the air filter.

    5. Check the engine oil.

    6. Check the engine coolant.

    7. Check the engine idling speed and maximum engine speed.

    8. Check the vacuum pump.

      OK

      Each inspection result is normal.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS

    OK

  16. CHECK ENGINE MOUNTING INSULATOR

    1. Visually check that the engine mounting insulator is installed correctly and is not crooked or twisted.

      OK

      No abnormalities.

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE ENGINE MOUNTING INSULATOR

    OK

  17. CHECK INTAKE SYSTEM DEPOSIT

    1. Check if 3 mm (0.12 in.) or more of carbon has accumulated on the intake manifold, cylinder head, etc. and if so, clean it off.

    Result

    Proceed to

    NEXT
    NEXT

  18. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  19. PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)

    Tip:

    Use this Active Test to determine the malfunctioning cylinder.

    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 / Control the Select Cylinder Fuel Cut.

      Powertrain > Engine and ECT > Active Test

      Tester Display

      Control the Select Cylinder Fuel Cut
      Tip:

      • DTCs may be output after this Active Test. Make sure to check for DTCs after this Active Test. If any DTCs are output, make sure to clear them.

        Click here

      • If the engine idle speed does not change when a injector assembly 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.

    Result

    Proceed to

    NEXT
    NEXT

  20. READ VALUE USING GTS (ENGINE SPEED OF CYL #1 TO #4)

    Tip:

    The speed of each cylinder can be measured (compression test) by using the GTS.

    For the compression test, perform Active Test using GTS (Check the Cylinder Compression) and crank the engine for approximately 10 seconds. At this time, the speed of each cylinder is measured. If the speed of one cylinder is higher than the other cylinders, the compression pressure of that cylinder is determined to be lower than the other cylinders.

    1. Warm up the engine.

    2. Turn the ignition switch off.

    3. Connect the GTS to the DLC3.

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

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Engine Speed of Cyl #1, Engine Speed of Cyl #2, Engine Speed of Cyl #3, Engine Speed of Cyl #4 and Av Engine Speed of All Cyl.

      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

      Av Engine Speed of All Cyl

    6. Push the snapshot button to turn the snapshot function on.

      Tip:

      Using the snapshot function, data can be recorded during the Active Test.

    7. While the engine is not running, press the Active button to Change the Cylinder Compression to ON.

      Tip:

      After performing the above procedure, Check the Cylinder Compression will start. Fuel injection for all cylinders is prohibited and each cylinder engine speed measurement enters standby mode.

    8. Crank the engine for about 10 seconds.

    9. Monitor the engine speed (Engine Speed of Cyl #1 to #4, Av Engine Speed of All Cyl) displayed on the GTS.

      Tip:

      After approximately 10 seconds of engine cranking, the engine speed measurement of each cylinder will change to the actual engine speed.

      Note:

      • Do not crank the engine continuously for 20 seconds or more.

      • If Check the Cylinder Compression needs to be performed after it is turned ON and performed once, press Exit to return to the Active Test menu screen. Then perform Check the Cylinder Compression again.

      • Use a fully-charged battery.

    10. Stop cranking the engine, and then change "Check the Cylinder Compression" to OFF after the engine stops.

      Note:

      If the Active Test is changed to OFF while the engine is being cranked, the engine will start.

    11. Push the snapshot button to turn the snapshot function off.

    12. Select "Stored Data" on the GTS screen, select the recorded data and display the data as a graph.

      Tip:

      If the data is not displayed as a graph, the change of the values cannot be observed.

    13. Check the change in engine speed values.

      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 more than the other cylinders, there is probably a complete loss of compression in that cylinder.

    B

    REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDERClick here

    A

  21. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    1. Check the cylinder compression pressure.

      Click here

    Result

    Proceed to

    OK

    NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

    OK

  22. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    1. Replace the injector assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  23. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    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. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  26. REPLACE INJECTOR ASSEMBLY OF ALL CYLINDERS

    1. Replace the injector assemblies.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  27. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  28. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  29. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  30. PERFORM REGISTRATION AND INITIALIZATION

    1. Register the injector compensation codes.

      Click here

    2. Perform Pilot Quantity Learning Values Reset.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  31. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  32. 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

      B123-2 - B212-30 (PCV)

      Always

      Below 1 Ω

      B123-2 or B212-30 (PCV) - Body ground and other terminals

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  33. 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.

      • Check that the fuel filter is not clogged.

    Result

    Proceed to

    OK

    NG
    OK

    REPLACE SUPPLY PUMP ASSEMBLYClick here

    NG

  34. CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP ASSEMBLY)

    1. Check and replace the clogged fuel pipe.

    Result

    Proceed to

    NEXT
    NEXT

  35. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  36. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  37. CHECK AND REPLACE FUEL INLET LINE

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

      1. Check that the fuel filter is not clogged.

      2. Check for fuel freezing in the fuel line.

      3. Check for clogs or leaks in the fuel pipe and hose between the fuel tank and supply pump assembly.

    Result

    Proceed to

    NEXT
    NEXT

  38. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

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

    1. Connect the GTS to the DLC3.

    2. Start the engine.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail Pressure and Target Common Rail Pressure.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Target Common Rail Pressure

      Common Rail Pressure

    5. Check that the fuel pressure of the common rail is within the specification below.

      Standard

      Common Rail Pressure is within +/-10000 kPa of Target Common Rail Pressure when engine is idling and running at 3000 rpm without load.

    Result

    Proceed to

    OK

    NG
    OK

    END

    NG

  40. REPLACE SUPPLY PUMP ASSEMBLY

    1. Replace the supply pump assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  41. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

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

    1. Connect the GTS to the DLC3.

    2. Start the engine.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail Pressure and Target Common Rail Pressure.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Target Common Rail Pressure

      Common Rail Pressure

    5. Check that the fuel pressure of the common rail is within the specification below.

      Standard

      Common Rail Pressure is within +/-10000 kPa of Target Common Rail Pressure when engine is idling and running at 3000 rpm without load.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE COMMON RAIL ASSEMBLYClick here

    OK

  43. CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

    Result

    Proceed to

    NEXT
    NEXT

    END

  44. REPLACE COMMON RAIL ASSEMBLY

    1. Replace the common rail assembly.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  45. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

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

    1. Connect the GTS to the DLC3.

    2. Start the engine.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail Pressure and Target Common Rail Pressure.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Target Common Rail Pressure

      Common Rail Pressure

    5. Check that the fuel pressure of the common rail is within the specification below.

      Standard

      Common Rail Pressure is within +/-10000 kPa of Target Common Rail Pressure when engine is idling and running at 3000 rpm without load.

    Result

    Proceed to

    NEXT
    NEXT

    END