DESCRIPTION
INSPECTION PROCEDURE
READ OUTPUT DTC (RELATING TO ENGINE)
CHECK FOR BLACK SMOKE
CONFIRM EXHAUST PIPE ASSEMBLIES (DPF CATALYTIC CONVERTERS) TO BE
REPLACED
CHECK AIR INTAKE SYSTEM
CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT
CHECK INJECTOR COMPENSATION CODE
PERFORM PILOT QUANTITY LEARNING (DETAIL)
CHECK FOR BLACK SMOKE
TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)
READ VALUE USING GTS (MAF AND MAP)
INSPECT EGR VALVE ASSEMBLY
PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)
READ VALUE USING GTS (MAF)
REMOVE DEPOSIT (EGR VALVE ASSEMBLY)
REPLACE EGR COOLER
REPLACE MASS AIR FLOW METER
CHECK SNAPSHOT (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #8)
REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS
PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)
CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER
BLEED AIR FROM FUEL SYSTEM
REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING
CHECK FOR BLACK SMOKE
READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)
PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)
READ VALUE USING GTS (ENGINE COOLANT TEMPERATURE)
READ VALUE USING GTS (INTAKE AIR AND INTAKE AIR TEMP (TURBO))
CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)
CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY
REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)
BLEED AIR FROM FUEL SYSTEM
PERFORM SUPPLY PUMP INITIALIZATION
REPLACE ECM
REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR
CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR
CHECK AND REPLACE MALFUNCTIONING PARTS
REPAIR OR REPLACE HARNESS OR CONNECTOR
CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)
BLEED AIR FROM FUEL SYSTEM
CHECK FOR BLACK SMOKE
RECOVERY TO NORMAL
ECD SYSTEM (w/ DPF) - Black Smoke Emitted
DESCRIPTION
| Faults and Symptoms of Common Rail Diesel Components |
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 turbocharger and intake manifold
|
| Data List | MAP |
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 |
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
When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.
|
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, Target Pump SCV Current
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 common rail pressure, then a lack of power will be felt.
If the fuel pressure is below 25000 kPa, then idling will be rough.
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 Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored. |
Injector Assembly| Main fault | Blockage, increase in fuel injection volume |
| 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.
|
When the sliding resistance of the internal parts of the injector assemblies (i.e. armature shaft, command piston and plunger) has increased due to internal contamination, injection quantity will increase at high common rail pressure due to a delay in injector assembly closure.
When black smoke occurs due to contamination of the injector assemblies, there are usually other symptoms, such as engine knocking noise at cold idling, rough idling, difficulty starting, etc. which are also present when the common rail pressure is low.
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 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual common rail pressure may deviate from the target common rail pressure (either Common Rail Pressure 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. |
Irregular Fuel| Main fault | - |
| Symptoms | Difficult to start, rough idle (especially when cold) |
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, Actual EGR Valve Pos #2, Target EGR Valve Pos, Target EGR Valve Pos. #2
Generally, Actual EGR Valve Pos = Target EGR Valve Pos +/-5% (fully closed: 0%, fully open: 100%).
Using the 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 engine switch is turned to on (IG) (engine stopped).
EGR valve opens to the halfway point at idling after the engine is warmed up.
EGR Close Lrn. Val., EGR Close Lrn. Val. #2
When leaving the vehicle idling, the normal range of EGR Close Lrn. Val. is 3.5 to 4.5 V.
In cases when EGR Close Lrn. Val. is out of the normal range (3.5 to 4.5 V), it is possible that the EGR valve cannot completely close.
|
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, Actual Throttle Position #2
100%: Fully open
0%: Fully closed
When the engine switch on (IG) (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the engine switch is turned from on (IG) to off, the throttle is fully closed temporarily.
|
| Data List Related to Black Smoke |
Engine Speed
MAP
MAF
Intake Air
Coolant Temp
Engine Speed of Cyl #1 (to #8)
Target Common Rail Pressure
Common Rail Pressure
Target Pump SCV Current
Injection Feedback Val #1 (to #8)
Injection Volume
Actual Throttle Position
Actual Throttle Position #2
Target EGR Valve Pos
Target EGR Valve Pos #2
Actual EGR Valve Pos
Actual EGR Valve Pos #2
EGR Close Lrn. Val.
EGR Close Lrn. Val. #2
INSPECTION PROCEDURE
After replacing the ECM, the new ECM needs registration () and initialization ().
After replacing a fuel supply pump assembly, the ECM needs initialization ().
After replacing an injector assembly, the ECM needs registration ().
- 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 to be normal when the Data List outputs standard values. There may be concealed factors of the malfunction.
| Black Smoke | The fuel used in diesel engines has a higher boiling point and evaporates much slower than that used in gasoline engines. Additionally, the fuel is injected directly, so the air fuel mixture in diesel engines is formed in a very short period of time and is less homogenous. This is why diesel engines must operate with a larger air fuel ratio across the entire operating range. An insufficient quantity of air results in imperfect combustion and increased particulate (soot) emissions.
When the accelerator pedal is depressed, a large amount of fuel is injected. As a result, the air fuel ratio becomes rich. In this relatively rich environment, fuel droplets lacking in oxygen burn imperfectly producing soot, which is emitted as black smoke. In order to prevent black smoke production, the maximum injection quantity for a given intake air mass is limited (final injection quantity is limited by MAF).
Black smoke is emitted when either 1) a lack of oxygen is present during combustion, or 2) too much fuel is injected for a given intake air mass and the air fuel ratio becomes temporarily rich. |
| 1.READ OUTPUT DTC (RELATING TO ENGINE) |
Connect the GTS to the DLC3.
Turn the engine switch on (IG) and turn the GTS on.
Enter the following menus: Engine and ECT / Trouble Codes.
Read the pending DTCs.
Result| Result | Proceed to |
| No DTCs are output | A |
| Engine related DTCs are output | B |
- If only DTC P1609 is output, proceed to step 2.
Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it.*1
Repeat the above procedure *1 10 times or more.*2
Check for black smoke emission during procedures *1 and *2.
- OK:
- Black smoke is emitted less than 5 times.
Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.
If the procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.
| 3.CONFIRM EXHAUST PIPE ASSEMBLIES (DPF CATALYTIC CONVERTERS) TO BE
REPLACED |
Even though it has been determined that the exhaust pipe assemblies (DPF catalytic converters) need to be replaced, make sure to complete diagnosis for this problem before replacing them ().
Replace the DPF catalytic converter for bank 1 and bank 2 at the same time.
After the DPF catalytic converter is replaced, perform "catalyst record clear" ().
This problem occurred because an excessive amount of PM has accumulated and resulted in abnormal combustion. It is necessary to diagnose the cause of abnormal PM accumulation and repair the problem. Therefore, do not perform replacement at this time.
| 4.CHECK AIR INTAKE SYSTEM |
Check for air leakage and blockage between the air cleaner and turbocharger, and between the turbocharger and intake manifold.
Make sure that the air cleaner is not clogged and the intake and exhaust system hoses are not disconnected.
When the vacuum hoses are disconnected.
Check that the intercooler is not clogged with foreign matter.
Check that there are no disconnected, pinched or leaking hoses or pipes.
Check that there are no modifications made by the user.
- OK:
- No leakage or blockage.
| | REPAIR OR REPLACE MALFUNCTIONING PARTS |
|
|
| 5.CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT |
Check the wire harness and connector connections of common rail system components.
- OK:
- The wire harnesses and connectors are connected securely.
| 6.CHECK INJECTOR COMPENSATION CODE |
Read the injector compensation codes ().
- OK:
- Injector compensation codes stored in the ECM match the injector compensation codes of the installed injector assemblies.
| 7.PERFORM PILOT QUANTITY LEARNING (DETAIL) |
Perform the injector pilot quantity learning (Detail) ().
Start the engine and drive the vehicle until the engine coolant temperature reaches 70°C (158°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it.*1
Repeat the above procedure *1 10 times.*2
Check for black smoke emission during procedures *1 and *2.
- OK:
- Black smoke is emitted less than 5 times.
- Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.
| 9.TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP) |
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Engine and ECT / Data List / All Data.
Take a snapshot of the following Data List items.
A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting. The data in the list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.
Graphs like the ones shown below can be displayed by transferring the stored snapshot data from the GTS to a PC. Intelligent Viewer must be installed on the PC.
Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.
| 10.READ VALUE USING GTS (MAF AND MAP) |
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).
Enter the following menus: Engine and ECT / Data List / MAP and MAF.
Take a snapshot when the engine speed is maintained at 4000 rpm with no load.
Read the values of "MAP" and "MAF" in the Data List using the snapshot review function.
Result| Result | Proceed to |
| MAF 84 gm/sec or more and MAP 105 kPa or higher | A |
| Except above | B |
The shift lever should be in neutral and the A/C switch and all accessory switches should be off.
The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.
Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.
| 11.INSPECT EGR VALVE ASSEMBLY |
Connect the GTS to the DLC3.
Turn the engine switch on (IG) and turn the GTS on.
Enter the following menus: Engine and ECT / Active Test / Control the EGR Step Position or Control the EGR Step Position #2.
While continuously changing the Active Test value to 0, 30, 60, 90, 60, 30 and 0%, check that Actual EGR Valve Pos or Actual EGR Valve Pos #2 smoothly changes to the set opening lift amount.
- OK:
- Value smoothly changes to within +/- 10% of set opening lift amount.
EGR valve closed: 0%.
EGR valve open: 95.2%.
Next, after the engine is warmed up, stop the engine and wait for 15 seconds. After that, start the engine again and idle it for 30 seconds. Then stop the engine and wait for 15 seconds. After starting the engine again, read the Data List values while idling.
Enter the following menus: Data List / EGR Close Lrn. Val. and EGR Close Lrn. Val. #2.
| 12.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE) |
Connect the GTS to the DLC3.
Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
Turn the engine switch off. Wait for 30 seconds, and then restart the engine.
Enter the following menus: Engine and ECT / Data List / MAF.
Read the MAF value displayed on the GTS while the engine is idling.
Enter the following menus: Engine and ECT / Active Test / Activate the EGR Valve Close.
Read the MAF value when the EGR valve is closed using the Active Test function.
If idling continues for 20 minutes or more, the EGR valve target opening lift amount becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.
Before performing the diagnosis, confirm that the EGR valve target opening lift amount is not 0%.
Result| Active Test | Result | Proceed to |
Activate the EGR Valve Close:
Off (Open) to On (Closed) | MAF value does not change | A |
| MAF value changes | B |
- As the measured values may differ from those shown below due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.
- The problem may be a temporary one, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the EGR valve assembly or mass air flow meter.
- Reference:
| EGR Valve Condition (Opening) | Measuring Condition | MAF (Reference) |
| Open (40%) | Atmosphere pressure: 101 kPa
Intake air temperature: 30°C (86°F)
Engine coolant temperature: 88°C (190°F)
| 3 to 10 gm/sec |
| Closed (0%) | 14 to 23 gm/sec |
| 13.READ VALUE USING GTS (MAF) |
Connect the GTS to the DLC3.
Turn the engine switch on (IG) and turn the GTS on.
Enter the following menus: Engine and ECT / Data List / MAF.
With the engine switch on (IG) and engine stopped, read the value when 30 seconds has elapsed.
- Standard:
| GTS Display | Switch Condition | Standard |
| MAF | Engine switch on (IG) (do not start engine) | Less than 0.5 gm/sec |
| 14.REMOVE DEPOSIT (EGR VALVE ASSEMBLY) |
Remove the No. 1 and No. 2 EGR valve assembly ().
Visually check the EGR valve assembly for deposits. If there are deposits, clean the EGR valve assembly.
When cleaning the EGR valve assembly, make sure the valve is completely closed.
When cleaning the EGR valve assembly, perform initialization procedure ().
Do not forcibly open the valve, as it may be damaged or deformed.
When cleaning the EGR valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.
If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.
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 assembly.
Reinstall the EGR valve assembly ().
Replace the EGR cooler ().
| 16.REPLACE MASS AIR FLOW METER |
Replace the mass air flow meter ().
- If foreign matter is stuck inside the mass air flow meter, the output characteristics of the mass air flow meter may change, resulting in a malfunction.
| 17.CHECK SNAPSHOT (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #8) |
Check Injection Feedback Val # and Injection Volume in the snapshot taken after the engine is warmed up and idled for 1 minute.
Result| Result | Proceed to |
| Injection Volume is less than 9 mm3/st at 4000 rpm | A |
| Injection Feedback Val for at least one cylinder is more than +3 mm3/st | B |
| Except above | C |
| 18.REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS |
Replace the injector assemblies ().
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.
| 19.PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION) |
- Use this Active Test to help determine whether a cylinder has compression loss or not.
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #8.
Check the engine speed during the Active Test.
Result| Result | Proceed to |
| Except below | A |
| The values of Engine Speed Cyl #1 to #8 are within 10 rpm of each other | B |
- 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.
| 20.CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER |
- Measure the compression of the cylinder that had a high speed during the Active Test "Check the Cylinder Compression".
Check the cylinder compression pressure ().
| | CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION |
|
|
| 21.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER |
Replace the injector assembly of the malfunctioning cylinder ().
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.
| 22.CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER |
Clean the fuel filter case and replace the fuel filter.
- 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.
| 23.BLEED AIR FROM FUEL SYSTEM |
Bleed the air from the fuel system ().
Perform PM forced regeneration ().
- When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.
| 24.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING |
Register the injector compensation code ().
Perform the injector pilot quantity learning ().
Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it.*1
Repeat the above procedure *1 10 times.*2
Check for black smoke emission during procedures *1 and *2.
- OK:
- Black smoke is emitted less than 5 times.
- Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.
| 26.READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE) |
Connect the GTS to the DLC3.
Turn the engine switch on (IG) and turn the GTS on.
Enter the following menus: Engine and ECT / Data List / MAP and Atmosphere Pressure.
Compare MAP to Atmosphere Pressure when the engine switch is on (IG) (engine stopped).
If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 10 kPa (0.1 kgf/cm2, 1.5 psi) or more, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.
Standard atmospheric pressure is 101 kPa (1.0 kgf/cm2, 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm2, 0.1 psi). This varies by weather (high atmospheric pressure, low atmospheric pressure).
Result| Result | Proceed to |
| MAP and Atmosphere Pressure have same value | A |
| Atmosphere Pressure is different from actual atmospheric pressure | B |
| MAP is different from actual atmospheric pressure | C |
| 27.PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK) |
Connect the GTS to the DLC3.
Start the engine and turn the GTS on.
Enter the following menus: Engine and ECT / Active Test / Test the Fuel Leak / Data List / Common Rail Pressure, Target Common Rail Pressure.
Take a snapshot with the GTS during the Active Test.
Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Common Rail Pressure) when the "Test the Fuel Leak" Active Test is performed.
- In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.
- OK:
- The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa (102.0 kgf/cm2, 1451 psi).
"Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.
"Common Rail Pressure" is the actual fuel pressure in common rail assembly.
When the pressure discharge valve on the common rail assembly has a malfunction, the actual fuel pressure changes as shown by "Pressure Discharge Valve Abnormal Common Rail Pressure" in the illustration.
The pressure discharge valve operates to discharge fuel pressure when the internal pressure of the common rail exceeds the target fuel pressure.
| 28.READ VALUE USING GTS (ENGINE COOLANT TEMPERATURE) |
Connect the GTS to the DLC3.
Soak the engine for a long time.
Turn the engine switch on (IG) and turn the GTS on.
Enter the following menus: Engine and ECT / Data List / Coolant Temp.
- OK:
- Coolant Temp is the same as the ambient temperature.
- When the engine coolant temperature is low even though the engine has been fully warmed up, or when the engine coolant temperature is high even though the engine is cold, inspect the sensor.
| 29.READ VALUE USING GTS (INTAKE AIR AND INTAKE AIR TEMP (TURBO)) |
Connect the GTS to the DLC3.
Soak the engine for a long time.
Turn the engine switch on (IG) and turn the GTS on.
Enter the following menus: Engine and ECT / Data List / Intake Air, Intake Air Temp (Turbo).
- OK:
- Intake Air is the same as Intake Air Temp (Turbo).
| 30.CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM) |
Disconnect the suction control valve connector.
Disconnect the ECM connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
for LHD| Tester Connection | Condition | Specified Condition |
| z64-1 (+B) - C45- 104 (PCV+) | Always | Below 1 Ω |
| z64-2 (PCV) - C45-105 (PCV-) | Always | Below 1 Ω |
| z64-1 (+B) or C45- 104 (PCV+) - Body ground | Always | 10 kΩ or higher |
| z64-2 (PCV) or C45-105 (PCV-) - Body ground | Always | 10 kΩ or higher |
- Standard Resistance:
for RHD| Tester Connection | Condition | Specified Condition |
| z64-1 (+B) - C46- 104 (PCV+) | Always | Below 1 Ω |
| z64-2 (PCV) - C46-105 (PCV-) | Always | Below 1 Ω |
| z64-1 (+B) or C46- 104 (PCV+) - Body ground | Always | 10 kΩ or higher |
| z64-2 (PCV) or C46-105 (PCV-) - Body ground | Always | 10 kΩ or higher |
Reconnect the suction control valve connector.
Reconnect the ECM connector.
| 31.CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY |
Disconnect the inlet hose from the fuel supply pump assembly.
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.
When there is a lack of fuel, the fuel pressure drops.
Inspect for fuel filter clogging (check that the fuel filter is not clogged).
Reconnect the inlet hose.
| 32.REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE) |
Replace the fuel supply pump assembly ().
| 33.BLEED AIR FROM FUEL SYSTEM |
Bleed the air from the fuel system ().
Perform PM forced regeneration ().
- When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.
| 34.PERFORM SUPPLY PUMP INITIALIZATION |
Perform supply pump initialization ().
| 36.REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR |
Replace the manifold absolute pressure sensor ().
| 37.CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR |
Inspect the engine coolant temperature sensor ().
Replace the engine coolant temperature sensor ().
- It is only necessary to replace the part when the results of the inspection indicate a problem.
| 38.CHECK AND REPLACE MALFUNCTIONING PARTS |
Inspect the mass air flow meter ().
Inspect the intake air temperature sensor (turbo) ().
Replace the mass air flow meter ().
- It is only necessary to replace the part when the results of the inspection indicate a problem.
Replace the intake air temperature sensor (turbo) ().
- It is only necessary to replace the part when the results of the inspection indicate a problem.
| 39.REPAIR OR REPLACE HARNESS OR CONNECTOR |
Repair or replace the harness or connector.
| 40.CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP) |
Check and replace the clogged fuel pipe.
| 41.BLEED AIR FROM FUEL SYSTEM |
Bleed the air from the fuel system ().
Perform PM forced regeneration ().
- When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.
Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
Stop the vehicle and allow the engine to idle.
Fully depress the accelerator pedal for 5 seconds, and then release it.*1
Repeat the above procedure *1 10 times.*2
Check for black smoke emission during procedures *1 and *2.
- OK:
- Black smoke is emitted less than 5 times.
- Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.
- If the racing procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.