2AD-FHV Engine Knocking or Rattling

2AD-FHV problems
Engine Knocking or Rattling

Description

Malfunction Condition Main Trouble Areas Related Trouble Areas
  1. Knocking and abnormal sound due to extremely rich combustion
  2. Abnormal sound due to friction between parts
  1. Injector malfunctions
    1. Injector sliding malfunction
    2. Injector stuck closed
    3. Injector stuck open
    4. Deposits in injector
    5. Injector circuit malfunction
  2. Abnormal common rail pressure
    1. Supply pump
    2. Fuel pulsation sound
    3. Air in fuel
  3. Friction between parts
  4. Compression pressure
  1. Injector compensation codes
  2. Fuel leakage
  3. Intake air system leakage
  4. Intake air system blockage
  5. EGR system
  6. Throttle valve system
  7. Fuel pressure sensor
  8. Manifold absolute pressure sensor
  9. Atmosphere air pressure sensor (built into ECM)
  10. Vehicle modifications
  11. Low quality fuel
  12. Lack of fuel
  13. ECM

HINT:

  1. 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'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 of the malfunction.
  2. Check that the vehicle has not been modified in any way prior to the vehicle inspection.

Inspection procedure

NOTICE:

  1. After replacing the supply pump, the ECM needs initialization.
  2. After replacing an injector, the ECM needs registration.

HINT:

  1. This troubleshooting procedure checks for knocking and rattling.
  2. Knocking is most likely to occur while the engine is idling.
1.CHECK SOUND AREA

  1. Find source of the abnormal sound using a mechanic's stethoscope.

    Result:
    Result Proceed to
    Sound from supply pump A
    Sound from parts other than supply pump B
  B  
REPAIR OR REPLACE MALFUNCTION PARTS
 
A  
   
2.CHECK WIRE HARNESS IN ENGINE COMPARTMENT

  1. Check the wire harness connections.

    OK:

    Wire harnesses are connected securely.

  NG  
REPAIR OR REPLACE HARNESS AND CONNECTOR
 
OK  
   
3.PERFORM CONFIRMATION DRIVING PATTERN

HINT:

Drive the vehicle according to the driving pattern below to allow the ECM to set DTCs relating to malfunctions of the fuel system, EGR system and throttle valve. If DTCs are set, problem areas can be identified.

  1. Connect the intelligent tester to the DLC3.

  2. Turn the ignition switch on (IG) and turn the tester ON.

  3. Enter CHECK MODE.

  4. Fully warm up the engine.

  5. Allow the engine to idle for 5 minutes or more.

  6. Drive the vehicle at more than 40 km/h (25 mph) for 1 minute or more (procedure "A").

  7. Decelerate and stop the vehicle (procedure "B").

  8. Repeat procedure "A" and procedure "B" 4 times or more.

  9. Stop the engine and wait for at least 10 seconds (procedure "C").

  10. Repeat procedure "A" and procedure "C" described above to set DTCs relating to the EGR system and throttle valve.

  11. Drive the vehicle at more than 70 km/h (43 mph) for at least 1 minute (to set DTCs relating to the supply pump).

NEXT  
   
4.READ OUTPUT DTC (RELATING TO ENGINE)

  1. Connect the intelligent tester to the DLC3.

  2. Turn the ignition switch on (IG) and turn the tester ON.

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

  4. Read pending DTCs.

    Result:
    Display (DTC Output) Proceed to
    No output A
    Engine related DTCs B
  B  
REPAIR OR REPLACE MALFUNCTION PARTS
 
A  
   
5.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TEST THE FUEL LEAK)

HINT:

By performing this Active Test, the engine speed is maintained. As a result, a fuel leak check can be conducted while retaining the high common rail pressure.

  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 / Test the Fuel Leak.

  4. Visually check the supply pump, injector, and fuel line located between the supply pump and common rail for fuel leaks and fuel pressure leaks. Also, perform the same check on the fuel line between the common rail and the injector.

    HINT:

    There may be fuel leaks inside components, such as the supply pump.

    OK:

    No fuel leakage.

  NG  
REPAIR OR REPLACE FUEL LEAKAGE POINT
 
OK  
   
6.READ VALUE OF MANIFOLD ABSOLUTE PRESSURE SENSOR, MAF METER, AND FUEL PRESSURE SENSOR

  1. Connect the intelligent tester to the DLC3.

  2. Start the engine, warm it up, and turn the tester ON.

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

  4. Select the following menu items in order and read the values.

    1. MAP
    2. MAF
    3. Fuel Press
     

    Standard value:

     
    Item Engine Speed*1 Standard Range Description
    MAP*2 Ignition switch on (IG) (engine stopped) Same as atmospheric pressure Intake manifold internal pressure detected by manifold absolute pressure sensor
    Idling 85 to 93 kPa (690 to 765 mmHg, 27.17 to 30.13 in.Hg)
    3,000 rpm (no engine load) 120 to 140 kPa (803 to 878 mmHg, 31.60 to 34.56 in.Hg)
    3,000 rpm (driving with full throttle acceleration)*5 239 to 259 kPa (1,795 to 1,945 mmHg, 70.67 to 76.57 in.Hg)
    3600 rpm (driving with full throttle acceleration)*5 245 to 265 kPa (1,840 to 1,990 mmHg, 57.00 to 62.91 in.Hg)
    MAF*2, *4 Ignition switch on (IG) (engine stopped) 0 g/sec. Intake air volume detected by mass air flow meter
    Idling 2.5 to 5.52 g/sec.
    3,000 rpm (no engine load) 49 to 57 g/sec.
    3,000 rpm (driving with full throttle acceleration)*5 124 to 136 g/sec.
    3,600 rpm (driving with full throttle acceleration)*5 151 to 163 g/sec.
    Common Rail Pressure*3 Idling 37 to 43 MPa Common rail internal fuel pressure
    2,000 rpm (no engine load) 47 to 53 MPa
    3,000 rpm (no engine load) 60 to 66 MPa
    3,000 rpm (driving with full throttle acceleration)*5 150 to 156 MPa
    3,600 rpm (driving with full throttle acceleration)*5 175 to 185 MPa
     
    Result:
     
    Item Result Proceed to
    MAP, MAF, and Fuel press Standard range A
    MAP and MAF Outside standard range B
    Only MAP Outside standard range C
    Only MAF Outside standard range D
    Only Fuel Press Outside standard range E

    HINT:

    *1: The A/C switch and all accessory switches should be OFF with a fully warm engine.

    *2: This value is indicated when the ambient temperature is 25°C (77°F), the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and the stable boost pressure is maintained for approximately 10 seconds.

    *3: This value is indicated when the ambient temperature is 25°C (77°F), the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and the vehicle is accelerated for approximately 10 seconds.

    *4: When the mass air flow meter malfunctions, the MAF output may deviate from the standard (referential) range when the engine idles and is accelerated from 3,000 to 4,000 rpm with full throttle acceleration.

    *5: Fully depress the accelerator pedal with the vehicle creeping at idle speed in 2nd gear.

  B  
Go to step 10
 
  C  
GO TO DTC P0105, P0107 AND P0108 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR)
 
  D  
GO TO DTC P0100, P0102 AND P0103 (RELATED TO MAF METER)
 
  E  
Go to step 26
 
A  
   
7.READ VALUE OF INJECTOR ASSEMBLY (INJECTION FEED BACK VAL AND INJECTION VOLUME)

  1. Connect the intelligent tester to the DLC3.

  2. Start the engine, warm it up, and turn the tester ON.

  3. Select the following menu items in order and read the values.

    1. Injection Feedback Val #1, #2, #3, and #4
    2. Injection Volume
     

    Standard value:

     
    Item Engine Speed* Standard Range Description
    Injection Feedback Val #1 Idling -3.0 to 3.0 mm3 Value of injector fuel injection volume compensates for differences in combustion condition of cylinders
    1. Positive values indicate control which corrects combustion degradation
    2. Negative values indicate control which corrects excessive combustion pressure
    3. If problems exist, Injection Feedback Val may deviate from -3.0 and 3.0 mm3 range
    Injection Feedback Val #2 Idling -3.0 to 3.0 mm3
    Injection Feedback Val #3 Idling -3.0 to 3.0 mm3
    Injection Feedback Val #4 Idling -3.0 to 3.0 mm3
    Injection Volume Idling 3.9 to 7.0 mm3 Fuel injection volume value controlled by ECU
    1. Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure, and EGR volume
    2. If problems exist, Injection Volume may be outside standard range
     
    Result:
     
    Result Proceed to
    Standard range A
    Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range B

    HINT:

    *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.

  B  
Go to step 19
 
A  
   
8.CHECK INJECTOR COMPENSATION CODE

HINT:

If the injector compensation code is not correctly registered, it may cause malfunctions.

OK:

Compensation code of the installed injector is the same as the code registered in the ECM.

  NG  
REGISTER INJECTOR COMPENSATION CODE
 
OK  
   
9.RESET ECM

  1. Disconnect the cable from the negative (-) battery terminal for at least 2 minutes.

  2. Reconnect the cable to the negative (-) battery terminal.

  3. Check whether the malfunction has been successfully repaired by performing a driving test using the freeze frame data recorded at the time the malfunction occurred.

    OK:

    Malfunction has been repaired successfully.

  OK  
CHECK FOR INTERMITTENT PROBLEMS
 
NG  
   


10.CHECK INTAKE SYSTEM

  1. Check for air leakage and blockage between the air cleaner and turbocharger.

  2. Check for air leakage and blockage between the turbocharger and intake manifold.

    OK:

    No air leakage or blockage.

  NG  
REPAIR OR REPLACE MALFUNCTION PARTS
 
OK  
   


11.CHECK EGR VALVE ASSEMBLY

  1. Check the EGR valve assembly.

  NG  
REPLACE EGR VALVE ASSEMBLY
 
OK  
   
12.INSPECT DIESEL THROTTLE BODY ASSEMBLY

  1. Connect the intelligent tester to the DLC3.

  2. Turn the ignition switch on (IG) and turn the tester ON.

  3. Enter the following menus: Powertrain / Engine and ECT / Diesel Throttle Angle.

  4. Read the value.

    Standard value:

    Ignition switch on (IG):

    0%

    Idling (Warmed up engine):

    95%

    Accelerator pedal fully depressed:

    0%

  NG  
REPLACE DIESEL THROTTLE BODY ASSEMBLY
 
OK  
   
13.CHECK COMBUSTION SOUND

  1. Confirm type of sound emitted.

    Result:
    Result Proceed to
    Knocking A
    Mechanical sound other than knocking B
  B  
Go to step 24
 
A  
   
14.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTION)

  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, #2, #3, and #4 Fuel Cut.

  4. Check the four cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.

    HINT:

    1. While the engine is idling, if the idling stability variation is small despite cutting off the fuel injection, the cylinder is malfunctioning.
    2. With normal cylinders, the engine idles roughly when the fuel injection is cut off.
NEXT  
   
15.CHECK CYLINDER COMPRESSION PRESSURE

  1. Check the cylinder compression pressure.

    Standard pressure:

    2,700 kPa (27.5 kgf/cm2, 392 psi)

    Minimum pressure:

    2,200 kPa (22.4 kgf/cm2, 319 psi)

    Difference between each cylinder:

    500 kPa (5.1 kgf/cm2, 73 psi)

  NG  
CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION
 
OK  
   


16.CHECK MALFUNCTIONING CYLINDER'S INJECTOR FOR DEPOSITS

HINT:

If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This may cause malfunctions.

  1. Check the injector for any deposits.

    Result:
    Result Proceed to
    Deposits A
    No deposits B
  B  
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
 
A  
   
17.CLEAN INJECTOR

  1. Wipe away deposits from the tips of the injectors.

    HINT:

    1. Solvent or carbon removal agents help remove the deposits easily.
    2. Exercise extreme care not to damage the injectors while wiping off the deposits.
NEXT  
   


18.READ VALUE OF INJECTOR ASSEMBLY (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

  1. Reinstall the injector to the cylinder head.

  2. Connect the intelligent tester to the DLC3.

  3. Turn the ignition switch on (IG) and turn the tester ON.

  4. Start the engine and warm it up.

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

  6. Select the following menu items in order and read the values.

    1. Injection Feedback Val #1, #2, #3, and #4
    2. Injection Volume
     

    Standard value:

     
    Item Engine Speed* Reference Value
    Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm3
    Injection Volume Idling 3.9 to 7.0 mm3

    HINT:

    1. *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
    2. When the values are outside the standard range, deposits inside the injector may be causing the problem.

    OK:

    Values are within the standard range.

  NG  
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
 
OK  
   
END 


19.IDENTIFY MALFUNCTIONING CYLINDER INJECTOR

  1. Follow the instructions in the table below according to the check result of the intelligent tester.

    HINT:

    This operation is based on the premise that the common rail pressure is normal.

     

    Standard value:

     
    Item Engine Speed* Reference Value
    Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm3
    Injection Volume Idling 3.9 to 7.0 mm3

    HINT:

    *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.

     
    Result:
     
    Injection Volume Injection Volume
    Injection Feedback Val #1 to #4 Less than 3.9 mm3 Between 3.9 to 7.0 mm3 (Normal) More than 7.0 mm3
    3.0 mm3 or more, -3.0 mm3 or less A B B
    Between -3.0 to 3.0 mm3 - Normal C*
    Proceed to Inspection Areas Descriptions
    A Inspect and repair cylinder injector with revised injection volume of less than -3.0 mm3:
    1. Perform power balance inspection and identify malfunctioning cylinder
    2. Replace malfunctioning cylinder injector
    		 Abnormal value cylinder injector injects excessively large quantity of fuel
    B Identify malfunctioning cylinders by conducting power balance inspection:
    1. Perform power balance inspection to identify malfunctioning cylinders
    2. Clean malfunctioning cylinder injector, then check and repair it
    		 Abnormal value cylinder injector injects excessively large quantity of fuel:
    1. Fuel injection volume too low due to injector nozzle being blocked by deposits
    2. Abnormal value cylinder injector compression decreases
    3. Abnormal value cylinder injector injects excessively large quantity of fuel
    C Inspect and repair all cylinder injectors:
    Clean all cylinder injectors, and then inspect and repair them    		 All cylinder injectors inject excessively small quantity of fuel:
    Fuel injection volume too low due to all cylinder injector nozzles being blocked by deposits

    HINT:

    *: When the Injection Volume displayed on the intelligent tester is large despite the Fuel Press and Injection Feedback Val #1 to #4 in the Data List being normal, the injector may be clogged. In this case, there may be deposits inside or outside the injector.

    1. Despite the injector functioning normally, the indicated Injection Feedback Val #1 to #4 values may be outside the normal operating range due to compensation for other problems (such as low compression).
    2. Injection Feedback Val #1 to #4 is the value used to correct the fuel injection volumes of each cylinder, in order to optimize (compensate for the unevenness between) all the cylinder combustion conditions. If any of the cylinders malfunction, the fuel injection volumes for the normal cylinders are corrected simultaneously. As a result, the Injection Feedback Val #1 to #4 may deviate from the standard range.
  B  
Go to step 16
 
  C  
Go to step 21
 
A  
   
Go to step 18
20.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING 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, #2, #3, and #4 Fuel Cut.

  4. Check the four cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.

    HINT:

    1. If the engine idle does not change when and injector is disabled, the cylinder being tested is malfunctioning.
    2. If the cylinder being tested is normal, there will be a significant change of idle speed when the fuel injection is stopped for that cylinder.
NEXT  
   
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER 


21.CHECK INJECTORS FOR DEPOSITS (EXCEPT FUEL ADDITION INJECTOR)

HINT:

If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This may cause malfunctions.

  1. Check the injector for any deposits.

    Result:
    Injector Condition Proceed to
    Deposits A
    No deposits B
  B  
REPLACE INJECTORS
 
A  
   
22.CLEAN INJECTOR

  1. Wipe away deposits from the tips of the injectors.

    HINT:

    1. Solvent or carbon removal agents help remove the deposits easily.
    2. Exercise extreme care not to damage the injectors while wiping off the deposits.
NEXT  
   
23.READ VALUE OF INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

  1. Reinstall the injector to the cylinder head.

  2. Connect the intelligent tester to the DLC3.

  3. Turn the ignition switch on (IG) and turn the tester ON.

  4. Start the engine and warm it up.

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

  6. Select the following menu items in order and read the values displayed on the tester respectively.

    1. Injection Feedback Val #1, #2, #3, and #4
    2. Injection Volume
     

    Standard value:

     
    Item Engine Speed* Reference Value
    Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm3
    Injection Volume Idling 3.9 to 7.0 mm3

    HINT:

    1. *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
    2. When the values are outside the standard range, deposits inside the injector may be causing the problem.

    OK:

    Values are within the standard range.

  NG  
REPLACE INJECTORS
 
OK  
   
END 


24.BLEED AIR FROM FUEL SYSTEM

  1. To bleed air from the priming pump, pump the priming pump until it becomes hard and cannot be pumped any more.

NEXT  
   
25.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

  1. Check whether the knocking has been successfully repaired by performing a driving test.

    OK:

    Malfunction has been repaired successfully.

NEXT  
   
END 


26.INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

2ad-fhv problems Disconnect the B60 fuel pressure sensor connector.

  1. Disconnect the B60 fuel pressure sensor connector.

  2. Measure the resistance of each terminal of the fuel pressure sensor.

    Standard resistance:

    Tester Connection Specified Condition
    B60-5 (PR) - B60-4 (E2) 16.4 k? or less
    B60-2 (PR2) - B60-3 (E2S) 16.4 k? or less
    B60-5 (PR) - B60-6 (VC) 3 k? or less
    B60-2 (PR2) - B60-1 (VC2) 3 k? or less

  3. Reconnect the fuel pressure sensor connector.

  NG  
REPLACE COMMON RAIL ASSEMBLY
 
OK  
   
27.INSPECT SUPPLY PUMP ASSEMBLY

  1. Measure the resistance of the suction control valve terminals.

    Standard resistance:

    Condition Specified Condition
    20°C (68°F) 1.9 to 2.3 ?
  NG  
REPLACE SUPPLY PUMP ASSEMBLY
 
OK  
   
REPAIR OR REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)

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