INSPECTION PROCEDURE
READ OUTPUT DTC (RELATED TO ENGINE)
READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #8)
PERFORM ENGINE SPEED ACCELERATION
CHECK INTAKE AIR CONTROL SYSTEM AND EXHAUST SYSTEM
INSPECT MASS AIR FLOW METER
CHECK TURBOCHARGING PRESSURE
READ VALUE USING INTELLIGENT TESTER (DATA LIST)
CHECK CYLINDER COMPRESSION PRESSURE
CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - EDU)
PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER FUEL CUT)
READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP)
READ VALUE USING INTELLIGENT TESTER (MAP)
READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)
READ VALUE USING INTELLIGENT TESTER (ACCEL SENS. NO.# VOLT %)
READ VALUE USING INTELLIGENT TESTER (INTAKE AIR)
READ VALUE USING INTELLIGENT TESTER (FUEL PRESS)
INSPECT ENGINE COOLANT TEMPERATURE SENSOR
CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)
INSPECT CRANKSHAFT POSITION SENSOR
CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM)
INSPECT INTAKE AIR TEMPERATURE SENSOR
INSPECT COMMON RAIL (for Bank 1) (FUEL PRESSURE SENSOR)
CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)
REPLACE ECM
ECD SYSTEM (w/o DPF) - Black Smoke Emitted
INSPECTION PROCEDURE
After replacing the ECM, the new ECM needs registration () and initialization ().
After replacing a fuel supply pump, the ECM needs initialization ().
After replacing a fuel injector, 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.
| 1.READ OUTPUT DTC (RELATED TO ENGINE) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / DTC.
Read the DTCs.
Result| Result | Proceed to |
| No DTC is output | A |
| DTCs related to the engine are output | B |
| | REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT ()
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| 2.READ VALUE USING INTELLIGENT TESTER (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #8) |
Connect the intelligent tester to the DLC3.
Start the engine and turn the tester on.
Enter the following menus: Powertrain / Engine / Data List.
Select the following menu items in order and read the values.
Injection Volume
Injection Feedback Val #1, #2, #3, #4, #5, #6, #7 and #8
- Standard Value:
| Item | Engine Speed* | Reference Value |
| Injection Volume | Idling (No engine load) | 3.0 to 10 mm3/st |
| Injection Feedback Val #1 to #8 | Idling (No engine load) | -3.0 to 3.0 mm3/st |
- *: If no idling conditions are specified, the shift lever should be in N, and the A/C switch and all accessory switches should be off.
| 3.PERFORM ENGINE SPEED ACCELERATION |
- If the exhaust gas contains excessive black smoke, perform the following operations.
Accelerate the engine to the maximum speed with no load 20 times.
Check the volume of black smoke in the exhaust gas.
Result| Result | Proceed to |
| Black smoke is not present | OK |
| Black smoke remains in the exhaust gas | NG |
- Soot deposits in the exhaust system may cause excessive black smoke.
| 4.CHECK INTAKE AIR CONTROL SYSTEM AND EXHAUST SYSTEM |
Inspect the engine condition ().
| | REPAIR OR REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST |
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| 5.INSPECT MASS AIR FLOW METER |
Inspect the mass air flow meter ().
| | REPLACE MASS AIR FLOW METER ()
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| 6.CHECK TURBOCHARGING PRESSURE |
Check the turbocharging pressure ().
- OK:
- The turbocharger pressure is within the standard range.
| | REPLACE TURBOCHARGER SUB-ASSEMBLY (for Bank 1 or Bank 2) ()
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| 7.READ VALUE USING INTELLIGENT TESTER (DATA LIST) |
Connect the intelligent tester to the DLC3.
Start the engine and turn the tester on.
Enter the following menus: Powertrain / Engine / Data List.
Select the following menu items in order and read the values.
Fuel Press
Injection Volume
Main Injection Period
Pilot 2 Injection Period
Injection Feedback Val #1, #2, #3, #4, #5, #6, #7 and #8
- Reference:
| Item | Engine Speed* | Reference Value |
| Fuel Press | Idling | 27 to 37 MPa |
| Fuel Press | 2000 rpm (no engine load) | 50 to 70 MPa |
| Fuel Press | 3000 rpm (no engine load) | 52 to 76 MPa |
| Injection Volume | Idling | 3.0 to 10 mm3/st |
| Injection Volume | 2000 rpm (no engine load) | 3.5 to 11 mm3/st |
| Injection Volume | 3000 rpm (no engine load) | 6.5 to 13 mm3/st |
| Main Injection Period | Idling | 430 to 730 μs |
| Pilot 2 Injection Period | Idling | 390 to 490 μs |
| Injection Feedback Val #1 to #8 | Idling | -3.0 to 3.0 mm3 |
- *: If no idling conditions are specified, the shift lever should be in N, and the A/C switch and all accessory switches should be off.
Result| Result | Proceed to |
| Within reference value | A |
| One of Injection Feedback Val #1 to #8 is not within reference value | B |
| Other result | C |
| | REPLACE MALFUNCTIONING FUEL INJECTOR ()
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| 8.CHECK CYLINDER COMPRESSION PRESSURE |
Check the cylinder compression pressure ().
| | CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION |
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| 9.CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - EDU) |
Disconnect the fuel injector connectors.
Disconnect the No. 1 EDU connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance (Check for Open):
No. 1| Tester Connection | Condition | Specified Condition |
| C5-2 - C74-4 (INJ1) | Always | Below 1 Ω |
| C14-2 - C74-3 (INJ4) | Always | Below 1 Ω |
| C69-2 - C74-2 (INJ6) | Always | Below 1 Ω |
| C68-2 - C74-1 (INJ7) | Always | Below 1 Ω |
| C5-1 - C74-5 (COM1) | Always | Below 1 Ω |
| C14-1 - C74-5 (COM1) | Always | Below 1 Ω |
| C69-1 - C74-6 (COM2) | Always | Below 1 Ω |
| C68-1 - C74-6 (COM2) | Always | Below 1 Ω |
- Standard Resistance (Check for Short):
No. 1| Tester Connection | Condition | Specified Condition |
| C5-2 or C74-4 (INJ1) - Body ground | Always | 10 kΩ or higher |
| C14-2 or C74-3 (INJ4) - Body ground | Always | 10 kΩ or higher |
| C69-2 or C74-2 (INJ6) - Body ground | Always | 10 kΩ or higher |
| C68-2 or C74-1 (INJ7) - Body ground | Always | 10 kΩ or higher |
| C5-1 or C74-5 (COM1) - Body ground | Always | 10 kΩ or higher |
| C14-1 or C74-5 (COM1) - Body ground | Always | 10 kΩ or higher |
| C69-1 or C74-6 (COM2) - Body ground | Always | 10 kΩ or higher |
| C68-1 or C74-6 (COM2) - Body ground | Always | 10 kΩ or higher |
Disconnect the fuel injector connectors.
Disconnect the No. 2 EDU connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance (Check for Open):
No. 2| Tester Connection | Condition | Specified Condition |
| C70-2 - C76-4 (INJ2) | Always | Below 1 Ω |
| C9-2 - C76-3 (INJ5) | Always | Below 1 Ω |
| C67-2 - C76-1 (INJ3) | Always | Below 1 Ω |
| C54-2 - C76-2 (INJ8) | Always | Below 1 Ω |
| C70-1 - C76-5 (COM4) | Always | Below 1 Ω |
| C9-1 - C76-5 (COM4) | Always | Below 1 Ω |
| C67-1 - C76-6 (COM5) | Always | Below 1 Ω |
| C54-1 - C76-6 (COM5) | Always | Below 1 Ω |
- Standard Resistance (Check for Short):
No. 2| Tester Connection | Condition | Specified Condition |
| C70-2 or C76-4 (INJ2) - Body ground | Always | 10 kΩ or higher |
| C9-2 or C76-3 (INJ5) - Body ground | Always | 10 kΩ or higher |
| C67-2 or C76-1 (INJ3) - Body ground | Always | 10 kΩ or higher |
| C54-2 or C76-2 (INJ8) - Body ground | Always | 10 kΩ or higher |
| C70-1 or C76-5 (COM4) - Body ground | Always | 10 kΩ or higher |
| C9-1 or C76-5 (COM4) - Body ground | Always | 10 kΩ or higher |
| C67-1 or C76-6 (COM5) - Body ground | Always | 10 kΩ or higher |
| C54-1 or C76-6 (COM5) - Body ground | Always | 10 kΩ or higher |
| | REPAIR OR REPLACE HARNESS OR CONNECTOR |
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| 10.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE CYLINDER FUEL CUT) |
Connect the intelligent tester to the DLC3.
Start the engine and turn the tester on.
Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3, #4, #5, #6, #7 and #8 Fuel Cut.
Check the engine idling condition while the fuel injection of each cylinder is cut using the tester.
Result| Engine Idling Condition | Proceed to |
| Becomes unstable | A |
| Does not change | B |
- Replace the fuel injector mounted on the cylinder that causes no significant idle speed change.
| | REPLACE MALFUNCTIONING FUEL INJECTOR ()
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| A | |
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| REPLACE INJECTOR DRIVER (No. 1 and/or No. 2) ()
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| 11.READ VALUE USING INTELLIGENT TESTER (COOLANT TEMP) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Start the engine and warm it up.
Enter the following menus: Powertrain / Engine / Data List / Coolant Temp.
Read the value.
- Standard Value:
| Item | Inspection Condition | Reference Value |
| Coolant Temp | Idling with warm engine (A/C switch off) | 75 to 90°C (167 to 194°F) |
| 12.READ VALUE USING INTELLIGENT TESTER (MAP) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Start the engine and warm it up.
Enter the following menus: Powertrain / Engine / Data List / MAP.
Read the value.
- OK:
- Same value as the actual atmospheric pressure.
| 13.READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / Data List / Engine Speed.
Read the value.
- Standard Value:
| Item | Inspection Condition | Reference Value |
| Engine Speed |
Idling with warm engine (A/C switch off) | 500 to 600 rpm (M/T)
550 to 650 rpm (A/T)
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| 14.READ VALUE USING INTELLIGENT TESTER (ACCEL SENS. NO.# VOLT %) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / Data List / Accel Sens. No.1 Volt % and Accel Sens. No.2 Volt %.
Read the values.
- Standard:
| Accelerator Pedal | Accel Sens. No.1 Volt % | Accel Sens. No.2 Volt % |
| Released | 10 to 22% | 24 to 40% |
| Depressed | 52 to 90% | 68 to 99% |
| 15.READ VALUE USING INTELLIGENT TESTER (INTAKE AIR) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / Data List / Inlet Air.
Read the value.
- OK:
- Same as air temperature near intake manifold.
| 16.READ VALUE USING INTELLIGENT TESTER (FUEL PRESS) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Start the engine and warm it up.
Enter the following menus: Powertrain / Engine / Data List / Fuel Press.
Read the value.
- Standard Value:
| Item | Inspection Condition | Reference Value |
| Fuel Press | Idling | 27 to 37 MPa |
| 17.INSPECT ENGINE COOLANT TEMPERATURE SENSOR |
Inspect the engine coolant temperature sensor ().
| | REPLACE ENGINE COOLANT TEMPERATURE SENSOR ()
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| OK | |
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| REPAIR OR REPLACE HARNESS OR CONNECTOR |
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| 18.CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM) |
Disconnect the manifold absolute pressure sensor connector.
Disconnect the ECM connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance (Check for Open):
for LHD| Tester Connection | Condition | Specified Condition |
| C80-2 (PIM) - C45-114 (PIM) | Always | Below 1 Ω |
| C80-3 (VC) - C45-66 (VCPM) | Always | Below 1 Ω |
| C80-1 (E) - C45-75 (E2) | Always | Below 1 Ω |
for RHD| Tester Connection | Condition | Specified Condition |
| C80-2 (PIM) - C46-114 (PIM) | Always | Below 1 Ω |
| C80-3 (VC) - C46-66 (VCPM) | Always | Below 1 Ω |
| C80-1 (E) - C46-75 (E2) | Always | Below 1 Ω |
- Standard Resistance (Check for Short):
for LHD| Tester Connection | Condition | Specified Condition |
| C80-2 (PIM) or C45-114 (PIM) - Body ground | Always | 10 kΩ or higher |
| C80-3 (VC) or C45-66 (VCPM) - Body ground | Always | 10 kΩ or higher |
| C80-1 (E) or C45-75 (E2) - Body ground | Always | 10 kΩ or higher |
for RHD| Tester Connection | Condition | Specified Condition |
| C80-2 (PIM) or C46-114 (PIM) - Body ground | Always | 10 kΩ or higher |
| C80-3 (VC) or C46-66 (VCPM) - Body ground | Always | 10 kΩ or higher |
| C80-1 (E) or C46-75 (E2) - Body ground | Always | 10 kΩ or higher |
| | REPAIR OR REPLACE HARNESS OR CONNECTOR |
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| OK | |
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| REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR ()
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| 19.INSPECT CRANKSHAFT POSITION SENSOR |
Disconnect the crankshaft position sensor connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
| Tester Connection | Condition | Specified Condition |
| 1 (NE+) - 2 (NE-) | Cold | 1630 to 2740 Ω |
| 1 (NE+) - 2 (NE-) | Hot | 2065 to 3225 Ω |
- In the table above, the terms "Cold" and "Hot" refer to the temperature of the coils in the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F).
| | REPLACE CRANKSHAFT POSITION SENSOR ()
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| OK | |
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| REPAIR OR REPLACE HARNESS OR CONNECTOR |
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| 20.CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM) |
Disconnect the accelerator pedal position sensor connector.
Disconnect the ECM connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance (Check for Open):
for LHD| Tester Connection | Condition | Specified Condition |
| A31-1 (VCP2) - A38-56 (VCP2) | Always | Below 1 Ω |
| A31-2 (EPA2) - A38-58 (EPA2) | Always | Below 1 Ω |
| A31-3 (VPA2) - A38-54 (VPA2) | Always | Below 1 Ω |
| A31-4 (VCPA) - A38-55 (VCPA) | Always | Below 1 Ω |
| A31-5 (EPA) - A38-57 (EPA) | Always | Below 1 Ω |
| A31-6 (VPA) - A38-53 (VPA) | Always | Below 1 Ω |
for RHD| Tester Connection | Condition | Specified Condition |
| A31-1 (VCP2) - A52-56 (VCP2) | Always | Below 1 Ω |
| A31-2 (EPA2) - A52-58 (EPA2) | Always | Below 1 Ω |
| A31-3 (VPA2) - A52-54 (VPA2) | Always | Below 1 Ω |
| A31-4 (VCPA) - A52-55 (VCPA) | Always | Below 1 Ω |
| A31-5 (EPA) - A52-57 (EPA) | Always | Below 1 Ω |
| A31-6 (VPA) - A52-53 (VPA) | Always | Below 1 Ω |
- Standard Resistance (Check for Short):
for LHD| Tester Connection | Condition | Specified Condition |
| A31-1 (VCP2) or A38-56 (VCP2) - Body ground | Always | 10 kΩ or higher |
| A31-2 (EPA2) or A38-58 (EPA2) - Body ground | Always | 10 kΩ or higher |
| A31-3 (VPA2) or A38-54 (VPA2) - Body ground | Always | 10 kΩ or higher |
| A31-4 (VCPA) or A38-55 (VCPA) - Body ground | Always | 10 kΩ or higher |
| A31-5 (EPA) or A38-57 (EPA) - Body ground | Always | 10 kΩ or higher |
| A31-6 (VPA) or A38-53 (VPA) - Body ground | Always | 10 kΩ or higher |
for RHD| Tester Connection | Condition | Specified Condition |
| A31-1 (VCP2) or A52-56 (VCP2) - Body ground | Always | 10 kΩ or higher |
| A31-2 (EPA2) or A52-58 (EPA2) - Body ground | Always | 10 kΩ or higher |
| A31-3 (VPA2) or A52-54 (VPA2) - Body ground | Always | 10 kΩ or higher |
| A31-4 (VCPA) or A52-55 (VCPA) - Body ground | Always | 10 kΩ or higher |
| A31-5 (EPA) or A52-57 (EPA) - Body ground | Always | 10 kΩ or higher |
| A31-6 (VPA) or A52-53 (VPA) - Body ground | Always | 10 kΩ or higher |
| | REPAIR OR REPLACE HARNESS OR CONNECTOR |
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| OK | |
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| REPLACE ACCELERATOR PEDAL ROD ASSEMBLY (ACCELERATOR PEDAL POSITION SENSOR) ()
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| 21.INSPECT INTAKE AIR TEMPERATURE SENSOR |
Remove the mass air flow meter ().
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
| Tester Connection | Condition | Specified Condition |
| 4 (THA) - 5 (E2) | -20°C (-4°F) | 13.6 to 18.4 kΩ |
| 20°C (68°F) | 2.21 to 2.69 kΩ |
| 60°C (140°F) | 0.49 to 0.67 kΩ |
| | REPLACE MASS AIR FLOW METER ()
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| OK | |
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| REPAIR OR REPLACE HARNESS OR CONNECTOR |
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| 22.INSPECT COMMON RAIL (for Bank 1) (FUEL PRESSURE SENSOR) |
Inspect the fuel pressure sensor ().
| | REPLACE COMMON RAIL (for Bank 1) ()
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| 23.CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM) |
Disconnect the fuel pressure sensor connector.
Disconnect the ECM connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance (Check for Open):
for LHD| Tester Connection | Condition | Specified Condition |
| C82-2 (PR) - C45-69 (PCR1) | Always | Below 1 Ω |
| C82-3 (VG) - C45-70 (VCM) | Always | Below 1 Ω |
| C82-1 (E2) - C45-75 (E2) | Always | Below 1 Ω |
for RHD| Tester Connection | Condition | Specified Condition |
| C82-2 (PR) - C46-69 (PCR1) | Always | Below 1 Ω |
| C82-3 (VG) - C46-70 (VCM) | Always | Below 1 Ω |
| C82-1 (E2) - C46-75 (E2) | Always | Below 1 Ω |
- Standard Resistance (Check for Short):
for LHD| Tester Connection | Condition | Specified Condition |
| C82-2 (PR) or C45-69 (PCR1) - Body ground | Always | 10 kΩ or higher |
| C82-3 (VG) or C45-70 (VCM) - Body ground | Always | 10 kΩ or higher |
| C82-1 (E2) or C45-75 (E2) - Body ground | Always | 10 kΩ or higher |
for RHD| Tester Connection | Condition | Specified Condition |
| C82-2 (PR) or C46-69 (PCR1) - Body ground | Always | 10 kΩ or higher |
| C82-3 (VG) or C46-70 (VCM) - Body ground | Always | 10 kΩ or higher |
| C82-1 (E2) or C46-75 (E2) - Body ground | Always | 10 kΩ or higher |
| | REPAIR OR REPLACE HARNESS OR CONNECTOR |
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Replace the ECM ().
- After replacing the ECM, the new ECM needs registration () and initialization ().
Check if the engine starts smoothly or if the engine stalls.
- OK:
- The engine starts smoothly and does not stall.
| | REPLACE FUEL SUPPLY PUMP ()
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