Ecd System Rough Idling Or Excessive Engine Vibrations

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

DESCRIPTION

INSPECTION PROCEDURE

CHECK CLUTCH SYSTEM

CHECK HARNESS AND CONNECTOR (IN ENGINE ENGINE COMPARTMENT)

PERFORM CONFIRMATION DRIVING PATTERN

CHECK DTC OUTPUT (RELATING TO ENGINE)

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL LEAK TEST)

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

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

CHECK INJECTOR COMPENSATION CODE

RESET ECM

CHECK ENGINE MOUNTING INSULATOR

CHECK INTAKE SYSTEM

CHECK EGR VALVE ASSEMBLY

INSPECT DIESEL THROTTLE BODY ASSEMBLY

CHECK INJECTOR ASSEMBLY (IDENTIFY MALFUNCTIONING CYLINDER INJECTOR)

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

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 INJECTOR ASSEMBLY (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

CHECK INJECTORS FOR DEPOSITS (EXCEPT FUEL ADDITION INJECTOR)

CLEAN INJECTOR

READ VALUE OF INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

INSPECT SUPPLY PUMP ASSEMBLY

ECD SYSTEM - Rough Idling or Excessive Engine Vibrations


DESCRIPTION


Malfunction Condition
Main Trouble Areas
Related Trouble Areas
  1. Rough idling or shuddering due to abnormal combustion
  2. Shuddering when vehicle starting due to clutch system malfunctions
  1. Injector malfunctions
    1. Injector sliding malfunction
    2. Injector stuck closed
    3. Injector stuck open
    4. Deposit in injector
    5. Injector circuit malfunction
  2. Clutch system malfunctions
    1. Clutch system (shuddering when starting)
  1. Injector compensation code
  2. Fuel leak
  3. Engine mounting insulator
  4. Intake air system leakage
  5. Intake air system blockage
  6. EGR system
  7. Throttle valve system
  8. Supply pump
  9. Pressure limiter
  10. Fuel pressure sensor
  11. EDU (P0200/97 set simultaneously)
  12. Low quality fuel
  13. Vehicle modifications
  14. Fuel filter air bleed problem
  15. Accessory problem (A/C, generator, etc.)
  16. ECM
HINT:
  1. Rough idling and excessive engine vibrations are checked in this troubleshooting procedure.
  2. Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result 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.
  3. 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 the injector, the ECM needs registration (Click here).
HINT:
  1. Before troubleshooting, conduct the following:
    1. Check the fuel quality.
    2. Check the fuel for air.
    3. Check the fuel system for blockages.
    4. Check the air filter.
    5. Check the engine oil.
    6. Check the engine coolant.
    7. Check the engine idling speed and the maximum engine speed.
    8. Check the vacuum pump.
1.CHECK CLUTCH SYSTEM

  1. Identify when shuddering occurs.

    Result:

    Driving Condition
    		Proceed to
    When idling
    		A
    When engaging engine clutch at vehicle start
    		B
    (Clutch system shudders)


B
REPAIR OR REPLACE CLUTCH SYSTEM
A


2.CHECK HARNESS AND CONNECTOR (IN ENGINE ENGINE COMPARTMENT)

  1. Check the wire harness and connector connections of common rail system components.

    HINT:
    Check the following components and system:
    1. Sensors
    2. Supply pump
    3. Common rail
    4. Injectors
    5. EDU
    6. Turbocharger system
    7. Intake and exhaust system
    OK:
    The wire harnesses and connectors 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. Start the engine (Procedure "A").

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

  1. Perform steps (See procedure "A") and (See procedure "B") again described above (to allow the ECM to set pressure discharge valve malfunction DTCs).

  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 "C").

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

  1. Repeat (See procedure "C") and (See procedure "D") 4 times or more.

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

  1. Repeat (See procedure "C") and (See procedure "E") 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.CHECK DTC OUTPUT (RELATING TO ENGINE)

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

  1. Read pending DTCs.

    Result:

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


B
GO TO DTC CHART
A


5.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL LEAK TEST)
HINT:
By performing this Active Test, the engine speed is maintained at 2,000 rpm and the common rail internal fuel pressure is raised to the maximum operating pressure. 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 the components, such as the supply pump.
    OK:
    No fuel leakage.


NG
REPAIR OR REPLACE FUEL LEAKAGE PARTS
OK


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

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and 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 11

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 24
A


7.READ VALUE OF INTELLIGENT TESTER (INJECTION FEEDBACK 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 the -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 the 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 with a fully warm engine.


B
Go to step 14
A


8.CHECK INJECTOR COMPENSATION CODE

  1. Read the injector compensation code (Click here).

    HINT:
    If the injector compensation code is not correctly registered, it may cause malfunctions (Click here).

  1. Check the injector compensation code.

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


NG
INPUT 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
CHECK FOR INTERMITTENT PROBLEMS
NG


10.CHECK ENGINE MOUNTING INSULATOR

  1. Visually check that the engine mounting insulator is installed correctly and is not crooked or twisted.

    OK:
    No abnormalities.


NG
REPAIR OR REPLACE ENGINE MOUNTING INSULATOR
OK


11.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


12.CHECK EGR VALVE ASSEMBLY

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



NG
REPLACE ELECTRIC EGR CONTROL VALVE ASSEMBLY
OK


13.INSPECT DIESEL THROTTLE BODY ASSEMBLY

  1. Connect the intelligent tester to the DLC3.

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


OK
Go to step 16
NG

REPLACE DIESEL THROTTLE BODY ASSEMBLY

14.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 Feedback Val #1 to #4
    		Injection volume
    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, 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 tip of the injector.
    1. Despite the injector functioning normally, the indicated Injection Feedback Val #1 to #4 value 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


15.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 speed does not change when an 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 OF MALFUNCTIONING CYLINDER

16.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. If the engine idle speed does not change when an 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


17.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


18.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:

    Injector Condition
    		Proceed to
    Deposits
    		A
    No deposits
    		B


B
REPLACE INJECTOR OF MALFUNCTIONING CYLINDER
A


19.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


20.READ VALUE OF INJECTOR ASSEMBLY (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
    		3.9 to 7.0 mm3
    HINT:
    *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up. 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 OF MALFUNCTIONING CYLINDER
OK

END

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.

  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
    		3.9 to 7.0 mm3
    HINT:
    *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up. 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.INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Engine Control System.Ecd System.Ecd System Rough Idling Or Excessive Engine Vibrations

  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


25.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

CHECK AND REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)