Ecd System Engine Knocking Or Rattling

Engine. Lexus Is250, Is220D. Gse20 Ale20
2Ad-Fhv Engine Control System. Lexus Is250, Is220D. Gse20 Ale20

DESCRIPTION

INSPECTION PROCEDURE

CHECK ENGINE SOUND

CHECK HARNESS AND CONNECTOR (ENGINE WIRE HARNESS)

PERFORM CONFIRMATION DRIVING PATTERN

READ DTC OUTPUT (RELATING TO ENGINE)

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TEST THE FUEL LEAK)

READ VALUE OF INTELLIGENT TESTER (MAP, MAF AND FUEL PRESSURE)

READ VALUE OF INTELLIGENT TESTER (INJECTION FEED BACK VAL AND INJECTION VOLUME)

CHECK INJECTOR COMPENSATION CODE

RESET ECM

CHECK INTAKE SYSTEM

CHECK EGR VALVE ASSEMBLY

INSPECT DIESEL THROTTLE BODY ASSEMBLY

CHECK ENGINE SOUND

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTION)

CHECK CYLINDER COMPRESSION PRESSURE

CHECK INJECTOR (MALFUNCTIONING CYLINDER'S INJECTOR FOR DEPOSITS)

CLEAN INJECTOR

READ VALUE OF INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

CHECK INJECTOR ASSEMBLY (IDENTIFY MALFUNCTIONING CYLINDER INJECTOR)

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)

CHECK INJECTORS FOR DEPOSITS (EXCEPT FUEL ADDITION INJECTOR)

CLEAN INJECTOR

READ VALUE OF INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

BLEED AIR FROM FUEL SYSTEM

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

INSPECT SUPPLY PUMP ASSEMBLY

ECD SYSTEM - 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 (Click here).
  2. After replacing an injector, the ECM needs registration (Click here).
HINT:
  1. This troubleshooting procedure checks for knocking and rattling.
  2. Knocking is most likely to occur while the engine is idling.
1.CHECK ENGINE SOUND

  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 MALFUNCTIONING PARTS, COMPONENT AND AREA
A


2.CHECK HARNESS AND CONNECTOR (ENGINE WIRE HARNESS)

  1. Check the wire harness connections.

    OK:
    Wire harnesses are connected securely.


NG
REPAIR OR REPLACE HARNESS OR 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. Enter CHECK MODE (Click here).

  1. Fully warm up the engine.

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

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

  1. Decelerate and stop the vehicle (Procedure "B").

  1. Repeat (See procedure "A") and (See procedure "B") 4 times or more.

  1. Stop the engine and wait for at least 10 seconds (Procedure "C").

  1. Repeat steps (See procedure "A") and (See procedure "C") described above (to set DTCs relating to the EGR system and throttle valve).

  1. 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 DTC OUTPUT (RELATING TO ENGINE)

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

  1. Read pending DTCs.

    Result:

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


B
GO TO DTC CHART
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.

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

  1. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.

  1. 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 SYSTEM
OK


6.READ VALUE OF INTELLIGENT TESTER (MAP, MAF AND FUEL PRESSURE)

  1. Connect the intelligent tester to the DLC3.

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

  1. Enter the following menus: "Powertrain / Engine / Data List".

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

    1. MAP
    2. MAF
    3. Fuel Press

    Standard:

    Item
    		Engine Speed *1
    		Standard Range
    		Description
    MAP *2
    		Engine switch ON (IG) (engine stopped)
    		Same as atmospheric pressure
    		Intake manifold internal pressure detected by manifold absolute pressure sensor
    Idling
    		85 to 93 kPa
    3,000 rpm (no engine load)
    		120 to 140 kPa
    3,000 rpm (driving with full throttle acceleration)*5
    		239 to 259 kPa
    3600 rpm (driving with full throttle acceleration)*5
    		245 to 265 kPa
    MAF *2, *4
    		Engine switch ON (IG) (engine stopped)
    		0 g/s
    		Intake air volume detected by mass air flow meter
    Idling
    		2.5 to 5.52 g/s
    3,000 rpm (no engine load)
    		49 to 57 g/s
    3,000 rpm (driving with full throttle acceleration)*5
    		124 to 136 g/s
    3,600 rpm (driving with full throttle acceleration)*5
    		151 to 163 g/s
    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
    		177 to 183 MPa
    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) and 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) and 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.

    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


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 INTELLIGENT TESTER (INJECTION FEED BACK VAL AND INJECTION VOLUME)

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

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

    Standard:

    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 mm 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 (Click here).
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.

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

  1. 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
END
NG


10.CHECK INTAKE SYSTEM

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

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

    OK:
    No air leakage or blockage.


NG
REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
OK


11.CHECK EGR VALVE ASSEMBLY

  1. Check the EGR valve assembly (Click here).



NG
REPLACE EGR VALVE ASSEMBLY
OK


12.INSPECT DIESEL THROTTLE BODY ASSEMBLY

  1. Connect the intelligent tester to the DLC3.

  1. Turn the engine switch ON (IG) and tester ON.

  1. Enter the following menus: Powertrain / Engine / Diesel Throttle Angle.

  1. Read the value.

    Standard:
    Engine switch ON (IG):
    0%
    Idling (Warmed up engine):
    95%
    Accelerator pedal fully depressed:
    0%


NG
REPLACE DIESEL THROTTLE BODY ASSEMBLY
OK


13.CHECK ENGINE 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.

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

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

  1. 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 (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)


NG
CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION
OK


16.CHECK INJECTOR (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 INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

  1. Reinstall the injector to the cylinder head.

  1. Connect the intelligent tester to the DLC3.

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

  1. Start the engine and warm it up.

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

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

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

    Standard:

    Item
    		Engine Speed*
    		Reference Value
    Injection Feedback Val #1 to #4
    		Idling
    		-3.0 to 3.0 mm3
    Injection Volume
    		Idling
    		3.5 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.CHECK INJECTOR ASSEMBLY (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:

    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


20.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)

  1. Connect the intelligent tester to the DLC3.

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

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

  1. 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 INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

  1. Reinstall the injector to the cylinder head.

  1. Connect the intelligent tester to the DLC3.

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

  1. Start the engine and warm it up.

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

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

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

    Standard:

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


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Engine Control System.Ecd System.Ecd System Engine Knocking Or Rattling

  1. Disconnect the E65 fuel sensor connector.

  1. 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

  1. 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 Ω


NG
REPLACE SUPPLY PUMP ASSEMBLY
OK

REPAIR OR REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)