Ecd System Engine Difficult To Start Or Stalling

INSPECTION PROCEDURE

CHECK DTC OUTPUT (RELATED TO ENGINE)

CHECK FUEL FILTER ASSEMBLY

CHECK CRANKING

READ VALUE OF INTELLIGENT TESTER

CHECK INITIAL COMBUSTION

CHECK PRE-HEATING SYSTEM (GLOW INDICATOR LIGHTING TIME AND AFTER GLOW TIME)

READ VALUE OF INTELLIGENT TESTER (FUEL PRESSURE)

CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM

READ VALUE OF INTELLIGENT TESTER (FUEL PRESSURE AND INJECTION VOLUME)

CHECK CYLINDER COMPRESSION PRESSURE

CHECK HARNESS AND CONNECTOR (INJECTOR - EDU)

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (CONTROL CYLINDER FUEL CUT)

CHECK FUEL SYSTEM

READ VALUE OF INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE)

CHECK IDLE SPEED

CHECK HARNESS AND CONNECTOR (STARTER RELAY - ECM)

READ VALUE OF INTELLIGENT TESTER

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

INSPECT CRANKSHAFT POSITION SENSOR

INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)

REPLACE ECM

INSPECTION PROCEDURE

NOTICE:

1. After replacing the ECM, the new ECM needs registration (Click here) and initialization (Click here).
   
2. After replacing a supply pump, the ECM needs initialization (Click here).
   
3. After replacing an injector, the ECM needs registration (Click here).
   

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 assume the vehicle is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.
   
2. If the vehicle runs out of fuel while the engine is operating, there is a chance that the engine may be difficult to restart after the fuel is refilled.
   

1. Connect the intelligent tester to the DLC3.
   

2. Turn the engine switch ON (IG) and turn the intelligent tester ON.
   

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

4. Read DTCs.
   
   

   Result:

   
   

   Display (DTC Output)	Proceed to
   No output	A
   DTCs related to engine	B

1. Check that the fuel filter is not clogged.
   

   OK:

   Fuel filter is not clogged.
   

1. Check the engine cranking condition.
   

2. Compare the cranking condition with that of a normal engine of the same model, and carefully check if there is any difference between them.
   

   OK:

   Engine cranking condition is normal.
   

1. Connect the intelligent tester to the DLC3.
   

2. Turn the engine switch ON (IG) and turn the intelligent tester ON.
   

3. Enter the following menus: Powertrain / Engine / Data List / Fuel Press.
   

4. Read the value.
   
   

   Standard:

   
   

   Item	Inspection Condition	Reference Value
   Fuel Press	Cranking, and engine coolant temperature 0°C (32°F) or more	20 to 55 MPa

1. Check if initial combustion occurs.
   
   

   Result:

   
   

   Result	Proceed To
   No initial combustion with cold engine	A
   No initial combustion with hot engine	B
   Initial combustion occurs	C

1. Check the lighting duration of the glow indicator light (Click here).
   

   OK:

   Indicator lighting time is normal.
   

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and turn the intelligent tester ON.
   

3. Enter the following menus: Powertrain / Engine / Data List / Fuel Press.
   

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

   Standard:

   
   

   Engine Speed	Fuel Pressure
   Idling	Approximately 37 to 43 MPa
   3,000 rpm (No engine load)	Approximately 60 to 66 MPa

1. Inspect the engine condition (Click here).
   

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and turn the intelligent tester ON.
   

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

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

   1. Fuel Press
      
   2. Injection Volume
      
   
   

   Standard:

   
   

   Item	Engine Speed*	Reference Value
   Fuel Press	Idling	37 to 43 MPa
   Fuel Press	2,000 rpm (No engine load)	47 to 53 MPa
   Fuel Press	3,000 rpm (No engine load)	60 to 66 MPa
   Injection Volume	Idling	3.9 to 7.0 mm3
   Injection Volume	2,000 rpm (No engine load)	5.6 to 9.1 mm3
   Injection Volume	3,000 rpm (No engine load)	7.9 to 11.4 mm3

   HINT:

   *: If no idling conditions are specified, the shift lever should be in the neutral position, and the A/C switch and all accessory switches should be OFF.

1. Check the cylinder compression pressure (Click here).
   

   Standard:

   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)
   

1. Check the wire harness between the injector and EDU (INJ terminal).
   

   1. Disconnect the E74, E75, E76 and E77 connectors.
      

   2. Disconnect the E84 and E86 EDU connectors.
      

   3. Measure the resistance of the wire harness side connectors.
      

      Standard resistance:

      Tester Connection	Specified Condition
      E74-1 - IJ1+ (E84-2)	Below 1 Ω
      E75-1 - IJ2+ (E84-5)	Below 1 Ω
      E76-1 - IJ3+ (E84-4)	Below 1 Ω
      E77-1 - IJ4+ (E84-1)	Below 1 Ω
      E74-2 - IJ1- (E86-4)	Below 1 Ω
      E75-2 - IJ2- (E86-5)	Below 1 Ω
      E76-2 - IJ3- (E86-6)	Below 1 Ω
      E77-2 - IJ4- (E86-1)	Below 1 Ω
      E74-1 or IJ1+ (E84-2) - Body ground	10 kΩ or higher
      E75-1 or IJ2+ (E84-5) - Body ground	10 kΩ or higher
      E76-1 or IJ3+ (E84-4) - Body ground	10 kΩ or higher
      E77-1 or IJ4+ (E84-1) - Body ground	10 kΩ or higher
      E74-2 or IJ1- (E86-4) - Body ground	10 kΩ or higher
      E75-2 or IJ2- (E86-5) - Body ground	10 kΩ or higher
      E76-2 or IJ3- (E86-6) - Body ground	10 kΩ or higher
      E77-2 or IJ4- (E86-1) - Body ground	10 kΩ or higher

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and turn the intelligent tester ON.
   

3. Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3 and #4 Fuel Cut.
   

4. Check the engine idle speed while the fuel injection to each cylinder is cut using the intelligent tester.
   
   

   Result:

   
   

   Engine Idling Condition	Proceed to
   Becomes unstable	A
   Does not change	B

   HINT:

   Replace the injector mounted on the cylinder that causes no significant idle speed change.

1. Connect the intelligent tester to the DLC3.
   

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

3. Enter the following menus: Powertrain / Engine / Active Test / Activate the Intank Fuel Pump Relay.
   

4. Grip the fuel hose to confirm that fuel is being transferred when the fuel pump relay is OK.
   

   OK:

   Fuel is being transferred.
   

1. Connect the intelligent tester to DLC3.
   

2. Start the engine and warm it up.
   

3. Enter the following menus: Powertrain / Engine / Data List / Coolant Temp.
   

4. Read the value.
   

   Standard:

   80 to 95°C
   

1. Connect the intelligent tester to DLC3.
   

2. Turn the engine switch ON (IG) and turn the intelligent tester ON.
   

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

4. Read the value.
   

   Standard:

   Idling:

   750 to 1,200 rpm
   

1. Disconnect the A49 ECM connector.
   

2. Remove the ST relay from the engine room J/B and R/B No. 1.
   

3. Measure the resistance of the wire harness side connectors.
   

   Standard resistance:

   Tester Connection	Specified Condition
   R/B ST relay terminal 1 - STA (A49-43)	Below 1 Ω
   R/B ST relay terminal 1 or STA (A49-43) - Body ground	10 kΩ or higher

1. Connect the intelligent tester to DLC3.
   

2. Start the engine and turn the intelligent tester ON.
   

3. Enter the following menus: Powertrain / Engine / Data List / Fuel Pressure.
   

4. Read the value.
   

   OK:

   The internal fuel pressure of the common rail is within the specification below.
   

   
   

   Engine Speed	Fuel Pressure
   Idling	Approximately 37 to 43 MPa
   3,000 rpm (No engine load)	Approximately 60 to 66 MPa

1. Remove the sensor.
   

2. Measure the resistance of the sensor.
   

   Standard resistance:

   Connection	Specified Condition
   20°C (68°F)	2.32 to 2.59 kΩ
   80°C (176°F)	0.310 to 0.326 kΩ

   NOTICE:

   When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry.

   HINT:

   Alternative procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values against the resistance/ temperature graph. Change the engine temperature (warm up or cool down) and repeat the test.

1. Disconnect the E81 sensor connector.
   

2. Measure the resistance between terminals 1 and 2.
   

   Standard resistance:

   Tester Connection	Condition	Specified Condition
   1 - 2	Cold	835 to 1,400 Ω
   1 - 2	Hot	1,060 to 1,645 Ω

   NOTICE:

   In the table above, the terms "cold" and "hot" refer to the temperature of the coils in the sensors. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F).

1. Disconnect the E65 fuel sensor connector.
   

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

   Standard resistance:

   Tester Connection	Specified Condition
   PR (E65-5) - E2 (E65-4)	16.4 kΩ or less
   PR2 (E65-2) - E2S (E65-3)	16.4 kΩ or less
   PR (E65-5) - VC (E65-6)	3 kΩ or less
   PR2 (E65-2) - VCS (E65-1)	3 kΩ or less

3. Reconnect the fuel pressure sensor connector.
   

1. Disconnect the E59 ECM connector.
   

2. Disconnect the F65 fuel pressure sensor connector.
   

3. Check the resistance between the wire harness side connectors.
   

   Standard resistance (Check for open):

   Tester Connection	Specified Condition
   PCR1 (E59-67) - PR (E65-5)	Below 1 Ω
   PCR2 (E59-114) - PR2 (E65-2)	Below 1 Ω
   VCS (E59-68) - VCS (E65-1)	Below 1 Ω
   VCM (E59-69) - VC (E65-6)	Below 1 Ω
   E2M (E59-91) - E2 (E65-4)	Below 1 Ω
   E2S (E59-66) - E2S (E65-3)	Below 1 Ω

   Standard resistance (Check for short):

   Tester Connection	Specified Condition
   PCR1 (E59-67) or PR (E65-5) - Body ground	10 kΩ or higher
   PCR2 (E59-114) or PR2 (E65-2) - Body ground	10 kΩ or higher
   VCS (E59-68) or VCS (E65-1) - Body ground	10 kΩ or higher
   VCM (E59-69) or VC (E65-6) - Body ground	10 kΩ or higher
   E2M (E59-91) or E2 (E65-4) - Body ground	10 kΩ or higher
   E2S (E59-66) or E2S (E65-3) - Body ground	10 kΩ or higher

4. Reconnect the ECM connector.
   

5. Reconnect the fuel pressure sensor connector.
   

1. Replace the ECM.
   

   NOTICE:

   After replacing the ECM, the new ECM needs registration (Click here) and initialization (Click here)

2. Check if the engine starts smoothly or if the engine stalls.
   

   OK:

   The engine starts smoothly and does not stall.