Ecd System Black Smoke Emitted

INSPECTION PROCEDURE

CHECK DTC OUTPUT (RELATED TO ENGINE)

READ VALUE OF INTELLIGENT TESTER (INJECTION VOLUME AND INJECTION FEED BACK VAL #1 TO #4)

CHECK EXHAUST GAS

CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM

CHECK TURBOCHARGING PRESSURE

PERFORM ACTIVE TEST BY INTELLIGENT TESTER

CHECK CYLINDER COMPRESSION PRESSURE

CHECK HARNESS AND CONNECTOR (INJECTOR ASSEMBLY - EDU)

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

READ VALUE OF INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE)

READ VALUE OF INTELLIGENT TESTER (MANIFOLD ABSOLUTE PRESSURE)

CHECK IDLE SPEED

READ VALUE OF INTELLIGENT TESTER (ACCELERATOR PEDAL POSITION)

READ VALUE OF INTELLIGENT TESTER (INTAKE AIR TEMPERATURE)

READ VALUE OF INTELLIGENT TESTER (FUEL PRESSURE)

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 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 a injector, the ECM needs registration (Click here).
   

HINT:

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 to be normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

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 the DTCs.
   
   

   Result:

   
   

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

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

   Standard:

   
   

   Item	Engine Speed*	Reference Value
   Injection Volume	Idling (No engine load)	3.9 to 7.0 mm3
   Injection Feedback Val #1	Idling (No engine load)	-3.0 to 3.0 mm3
   Injection Feedback Val #2	Idling (No engine load)	-3.0 to 3.0 mm3
   Injection Feedback Val #3	Idling (No engine load)	-3.0 to 3.0 mm3
   Injection Feedback Val #4	Idling (No engine load)	-3.0 to 3.0 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.

HINT:

If the exhaust gas contains excessive black smoke, perform the following operations:

1. Accelerate the engine speed to the maximum rpm with no load 20 times.
   

2. 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

   HINT:

   Soot deposits in the exhaust system may cause excessive black smoke.

1. Inspect the engine condition (Click here).
   

1. Check the turbocharger pressure (Click here).
   

   Standard:

   48 to 53 kPa (0.49 to 0.54 kgf/cm², 6.9 to 7.7 psi)
   

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 Pressure
      
   2. Injection Volume
      
   3. Main Injection
      
   4. Pilot 2 Injection
      
   5. Injection Feedback Val #1, #2, #3, and #4
      
      

      Reference:

      Item	Engine Speed*	Reference Value
      Fuel Pressure	Idling	37 to 43 MPa
      Fuel Pressure	2,000 rpm (no engine load)	47 to 53 MPa
      Fuel Pressure	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
      Main Injection	Idling	110 to 368 μs
      Pilot 2 Injection	Idling	50 to 210 μs
      Injection Feedback Val #1	Idling	-3.0 to 3.0 mm3
      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

   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.

   
   

   Result:

   
   

   Result	Proceed to
   Within reference value	A
   One of Injection Feedback Val #1 to #4 is not within reference value	B
   Other result	C

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 idling condition while the fuel injection of 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 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 an intelligent tester to the DLC3.
   

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

3. Select the following menu items: Powertrain / Engine and ECT / Data List / Map and Atmosphere Pressure.
   

4. Read the value displayed on the tester.
   

   OK:

   MAP:

   Same as atmospheric pressure.
   

   HINT:

   1 bar of atmospheric pressure is 101 kPa.

5. Apply negative pressure of 40 kPa (300 mmHg, 11.8 in.Hg) to the manifold absolute pressure sensor.
   

   OK:

   MAP:

   MAP decreases 40 kPa from atmospheric pressure.
   

6. Apply positive pressure of 69 kPa (518 mmHg, 20.4 in.Hg) to the manifold absolute pressure sensor.
   

   OK:

   MAP:

   MAP increases 69 kPa from atmospheric pressure.
   

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. 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 / Accel Position 1 and Accele Position 2.
   

4. Read the value.
   

   Standard voltage:

   Accelerator Pedal Condition	Specified Condition
   Released	0.6 to 1.0 V
   Depressed	3.4 to 3.8 V
   Released	1.4 to 1.8 V
   Depressed	4.2 to 4.6 V

1. Connect the intelligent tester to DLC3.
   

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

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

4. Read the value.
   

   Standard:

   Same value as the actual air temperature.
   

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. Read the values.
   

   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 ECT 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 E67 sensor connector.
   

2. Disconnect the E59 ECM connector.
   

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

   Standard resistance:

   Tester Connection	Specified Condition
   PIM (E67-2) - PIM (E59-117)	Below 1 Ω
   VC (E67-3) - VCPM (E59-71)	Below 1 Ω
   E (E67-1) - EPIM (E59-94)	Below 1 Ω
   PIM (E67-2) or PIM (E59-117) - Body ground	10 kΩ or higher
   VC (E67-3) or VCPM (E59-71) - Body ground	10 kΩ or higher
   E (E67-1) or EPIM (E59-94) - Body ground	10 kΩ or higher

1. Disconnect the E81 sensor connector.
   

2. Measure the resistance of the sensor.
   

   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 A26 sensor connector.
   

2. Disconnect the A49 ECM connector.
   

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

   Standard resistance:

   Tester Connection	Specified Condition
   VCP2 (A26-1) - VCP2 (A49-56)	Below 1 Ω
   EPA2 (A26-2) - EPA2 (A49-58)	Below 1 Ω
   VPA2 (A26-3) - VPA2 (A49-54)	Below 1 Ω
   VCPA (A26-4) - VCPA (A49-55)	Below 1 Ω
   EPA (A26-5) - EPA (A49-57)	Below 1 Ω
   VPA (A26-6) - VPA (A49-53)	Below 1 Ω
   VCP2 (A26-1) or VCP2 (A49-56) - Body ground	10 kΩ or higher
   EPA2 (A26-2) or EPA2 (A49-58) - Body ground	10 kΩ or higher
   VPA2 (A26-3) or VPA2 (A49-54) - Body ground	10 kΩ or higher
   VCPA (A26-4) or VCPA (A49-55) - Body ground	10 kΩ or higher
   EPA (A26-5) or EPA (A49-57) - Body ground	10 kΩ or higher
   VPA (A26-6) or VPA (A49-53) - Body ground	10 kΩ or higher

1. Remove the sensor.
   

2. Measure the resistance of the sensor.
   

   Standard resistance:

   Tester Connection	Condition	Specified Condition
   1 - 2	20°C (68°F)	2.21 to 2.69 kΩ

   NOTICE:

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

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) - VC2 (E65-1)	3 kΩ or less

3. Reconnect the fuel pressure sensor connector.
   

1. Disconnect the E59 ECM connector.
   

2. Disconnect the E65 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 the volume of black smoke in the exhaust gas.
   

   OK:

   Black smoke is not present.