СИСТЕМА ECD Black Smoke Emitted

DESCRIPTION

  1. Faults and Symptoms of Common Rail Diesel Components

    1. Engine Control

      Table 1. Intake System
      Symptom and Corresponding Main Fault
      • Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct

      • Black smoke (no lack of power) due to leakage between the turbo and intake manifold

      Data List MAP
      Table 2. Glow System
      Main fault Glow system malfunction
      Symptoms Difficult to start, rough idle, knocking, white smoke (when cold)
      Data List Check the glow plug indicator light
      Diagnostic Point Measure the resistance of the glow plug assembly
      Table 3. Engine
      Main fault Loss of compression
      Symptoms Rough idle (lack of power always)
      Data List

      Engine Speed of Cyl

      • When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.

      Injection Feedback Val

      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.

    2. Common Rail (ALL)

      Table 4. Supply Pump Assembly
      Main fault -
      Symptoms Difficult to start, engine stalling, rough idle, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure, Target Pump SCV Current

      • Fuel Press is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

      • If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.

      • If the fuel pressure is below 25000 kPa, then idling will be rough.

      Tip:
      • The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.

      • When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.

      Diagnostic Trouble Code Even if Fuel Press is below Target Common Rail Pressure, a DTC will not be stored.
      Table 5. Injector Assembly
      Main fault Blockage, increase in fuel injection volume
      Symptoms Rough idle, lack of power, black smoke, white smoke, knocking
      Data List

      Injection Feedback Val

      • When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.

      Tip:
      • When the sliding resistance of the internal parts of the injector assemblies (i.e. armature shaft, command piston and plunger) has increased due to internal contamination, injection quantity will increase at high common rail pressure due to a delay in injector assembly closure.

      • When black smoke occurs due to contamination of the injector assemblies, there are usually other symptoms, such as engine knocking noise at cold idling, rough idling, difficulty starting, etc. which are also present when the common rail pressure is low.

      Table 6. Injector Driver (EDU)
      Main fault Circuit fault: The injector assembly does not open.
      Symptoms Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
      Data List Same as injector assembly
      Diagnostic Trouble Code When the injector driver (EDU) has a fault, some DTCs may be stored.
      Table 7. Fuel Pressure Sensor
      Main fault Open circuit, decrease in performance (foreign matter is attached)
      Symptoms Difficult to start, rough idle, engine stall, lack of power
      Data List

      Fuel Press, Target Common Rail Pressure

      • Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped and check that Fuel Press and Common Rail Pres Sens 2 follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Fuel Press or Common Rail Pres Sens 2 decreases to a value less than Target Common Rail Pressure).

      Diagnostic Trouble Code When the fuel pressure sensor has a fault, some DTCs may be stored.
      Table 8. Irregular Fuel
      Main fault -
      Symptoms Difficult to start, rough idle (especially when cold)
    3. Diesel EGR

      Table 9. EGR System
      Main fault
      • Does not move smoothly

      • Does not close completely

      Symptoms
      • Rough idle

      • EGR valve stuck closed: Loud turbocharger sound.

      • EGR valve stuck open: Difficult to start (does not stall), black smoke, lack of power (if there is an excess in the quantity of recirculated exhaust gas and the engine is under heavy load, when the vehicle starts moving, a lack of power will be felt).

      Data List

      Actual EGR Valve Pos., Target EGR Position

      • Generally, Actual EGR Valve Pos. = Target EGR Position +/-5% (fully closed: 0%, fully open: 100%).

      • Using the EGR valve Active Test, check whether Actual EGR Valve Pos. follows Target EGR Position (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).

      • EGR valve is fully closed when the ignition switch is turned to ON (engine stopped).

      • EGR valve opens to the halfway point at idling after the engine is warmed up.

      EGR Close Lrn. Val., EGR Close Lrn. Status

      • When leaving the vehicle idling, when EGR Close Lrn. Status is OK, the normal range of EGR Close Lrn. Val. is 0 to 1 V.

      • In cases when EGR Close Lrn. Status. is NG or EGR Close Lrn. Val. is out of the normal range (0 to 1 V), it is possible that the EGR valve cannot completely close.

    4. Diesel Throttle

      Table 10. Diesel Throttle System
      Main fault Stuck, does not move smoothly
      Symptoms
      • Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.

      • Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.

      Data List

      Actual Throttle Position

      • 0%: Fully open

      • 100%: Fully closed

      • When the ignition switch ON (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

  2. Data List Related to Starting Trouble

    • Engine Speed

    • MAP

    • MAF

    • Intake Air

    • Coolant Temp

    • Engine Speed of Cyl #1 (to #4)

    • Target Common Rail Pressure

    • Fuel Press

    • Target Pump SCV Current

    • Injection Feedback Val #1 (to #4)

    • Injection Volume

    • Actual Throttle Position

    • Target EGR Position

    • Actual EGR Valve Pos.

    • EGR Close Lrn. Status

    • EGR Close Lrn. Val.

WIRING DIAGRAM

Refer to DTC P0088.

Click hereНажмите здесь

CAUTION / NOTICE / HINT

Note:
Tip:

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 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. Explanation of Symptom

    Black Smoke

    The fuel used in diesel engines has a higher boiling point and evaporates much slower than that used in gasoline engines. Additionally, the fuel is injected directly, so the air fuel mixture in diesel engines is formed in a very short period of time and is less homogenous. This is why diesel engines must operate with a larger air fuel ratio across the entire operating range. An insufficient quantity of air results in imperfect combustion and increased particulate (soot) emissions.

    When the accelerator pedal is depressed, a large amount of fuel is injected. As a result, the air fuel ratio becomes rich. In this relatively rich environment, fuel droplets lacking in oxygen burn imperfectly producing soot, which is emitted as black smoke. In order to prevent black smoke production, the maximum injection quantity for a given intake air mass is limited (final injection quantity is limited by mass air flow).

    Black smoke is emitted when either 1) a lack of oxygen is present during combustion, or 2) Too much fuel is injected for a given intake air mass and the air fuel ratio becomes temporarily rich.

PROCEDURE

  1. READ OUTPUT DTC (RELATING TO ENGINE)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS.

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

    4. Read the pending DTCs.

      Powertrain > Engine and ECT > Trouble Codes
      Result
      ResultProceed to
      DTCs are not outputA
      Engine related DTCs are outputB
      Tip:

      If only DTC P1609 is output, proceed to procedure 2.

    B

    GO TO DTC CHART Click here Нажмите здесь


    A
  2. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times or more [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK
      Black smoke is emitted less than 5 times.
      Tip:
      • Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

      • If the procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  3. RECOVERY TO NORMAL

    Tip:

    If the racing procedure is repeated 10 times or more and black smoke stops being emitted, this probably means that the black smoke was caused by a temporary accumulation of soot which occurred when driving at low speeds, and is not a malfunction.

    Result
    Proceed to
    NEXT
    NEXT

    END


  4. EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY TO BE REPLACED

    1. Even though it has been determined that the DPF catalytic converter (exhaust manifold converter sub-assembly) needs to be replaced, make sure to complete diagnosis for this problem before replacing it.

      Click hereНажмите здесь

      Tip:

      This problem is occurred because an excessive amount of PM has accumulated and resulted in abnormal combustion. It is necessary to diagnose the cause of abnormal PM accumulation and repair the problem. Therefore, do not perform replacement at this time.

      Result
      Proceed to
      NEXT
    NEXT
  5. CHECK INTAKE SYSTEM

    1. Check for air leakage and blockage between the air cleaner case sub-assembly and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.

      Tip:
      • Make sure that the air cleaner filter element sub-assembly is not clogged and the intake and exhaust system hoses are not disconnected.

      • When the vacuum hoses are disconnected.

      • Check that the intercooler is not clogged with foreign matter.

      • Check that there are no disconnected, pinched or leaking hoses or pipes.

      • Check that there are no modifications made by the user.

      OK
      No leakage or blockage.
      Result
      Proceed to
      OK
      NG
    NG

    REPAIR OR REPLACE MALFUNCTIONING PARTS


    OK
  6. CHECK WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT

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

      OK
      The wire harnesses and connectors are connected securely.
      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    GO TO STEP 35


    OK
  7. CHECK INJECTOR COMPENSATION CODE

    1. Check the injector compensation codes.

      Click hereНажмите здесь

      OK
      Compensation codes stored in the ECM match the compensation codes of the installed injector assemblies.
      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    GO TO STEP 19


    OK
  8. PERFORM PILOT QUANTITY LEARNING (DETAIL)

    1. Perform the pilot quantity learning (detail).

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  9. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

      Result
      Proceed to
      OK
      NG
    OK

    END


    NG
  10. TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

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

    4. Take a snapshot of the following Data List items.

      Tip:
      • A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting.

      • Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.

      Result
      Proceed to
      NEXT
    NEXT
  11. READ VALUE USING GTS (MAF AND MAP)

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAP and MAF.

      Powertrain > Engine and ECT > Data List
      Tester Display
      MAF
      MAP
    5. Take a snapshot when the engine speed is maintained at 4000 rpm with no load.

    6. Read the values of "MAP" and "MAF" in the Data List using the snapshot review function.

      Result
      Result Proceed to
      MAF 85 gm/sec or more and MAP 140 kPa or higher A
      Except above B
      Tip:
      • The shift lever should be in neutral and the A/C switch and all accessory switches should be off.

      • The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.

        Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.

    B Нажмите здесь

    A
  12. CHECK SNAPSHOT (INJECTION VOLUME AND INJECTION FEEDBACK VAL #1 TO #4)

    1. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken after the engine is warmed up and idled for 1 minute.

      Result
      Result Proceed to

      Injection Volume is less than 5 mm3/st at 4000 rpm

      A

      Injection Feedback Val for at least one cylinder is more than 3 mm3/st

      B
      Except above C
    B Нажмите здесь

    C Нажмите здесь

    A
  13. REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

    1. Replace the injector assemblies.

      Click here Нажмите здесь

      Note:
      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 17


  14. PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

    Tip:

    Use this Active Test to help determine whether a cylinder has compression loss or not.

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression / Compression / Engine Speed of Cyl #1 to #4.

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Check the Cylinder Compression
      Data List Display
      Engine Speed of Cyl #1
      Engine Speed of Cyl #2
      Engine Speed of Cyl #3
      Engine Speed of Cyl #4
    4. Check the engine speed during the Active Test.

      Result
      Result Proceed to
      Except below A
      The values of Engine Speed Cyl #1 to #4 are within 10 rpm of each other B
      Tip:

      When cranking, if the speed of a cylinder is approximately 100 rpm higher than the other cylinders, there is probably a complete loss of compression in that cylinder.

    B Нажмите здесь

    GO TO STEP 16


    A
  15. CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

    Tip:

    Measure the compression of the cylinder that had a high speed during the Active Test "Check the Cylinder Compression".

    1. Check the cylinder compression pressure.

      Click hereНажмите здесь

      Result
      Proceed to
      OK
      NG
    NG

    CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION


    OK
  16. REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

    1. Replace the injector assembly of the malfunctioning cylinder.

      Click here Нажмите здесь

      Note:
      • When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

      • Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.

      • If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.

      • If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.

      • If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.

      Result
      Proceed to
      NEXT
    NEXT
  17. REPLACE FUEL FILTER ELEMENT SUB-ASSEMBLY

    1. Replace the fuel filter element sub-assembly.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  18. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  19. REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

    1. Register the injector compensation codes.

      Click hereНажмите здесь

    2. Perform the pilot quantity learning.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  20. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

      Result
      Proceed to
      NEXT
    NEXT

    END


  21. READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / MAP and Atmosphere Pressure.

      Powertrain > Engine and ECT > Data List
      Tester Display
      Atmosphere Pressure
      MAP
    4. Compare MAP to Atmosphere Pressure when the ignition switch ON (engine stopped).

      Tip:
      • If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 10 kPa (0.1 kgf/cm2, 1.5 psi) or more, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.

      • Standard atmospheric pressure is 101 kPa (1.0 kgf/cm2, 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm2, 0.1 psi). This varies by weather (high atmospheric pressure, low atmospheric pressure).

      Result
      Result Proceed
      MAP and Atmosphere Pressure have same value A
      Atmosphere Pressure is different from actual atmospheric pressure B
      MAP is different from actual atmospheric pressure C
    B Нажмите здесь

    C Нажмите здесь

    A
  22. PERFORM ACTIVE TEST USING GTS (TEST THE FUEL LEAK)

    1. Connect the GTS to the DLC3.

    2. Start the engine and turn the GTS on.

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak / All Data / Fuel Press and Target Common Rail Pressure.

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Test the Fuel Leak
      Data List Display
      Target Common Rail Pressure
      Fuel Press
    4. Take a snapshot with the GTS during the Active Test.

    5. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Fuel Press) when the "Test the Fuel Leak" Active Test is performed.

      Tip:

      In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

      A012GN8E06
      OK
      The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa (102.0 kgf/cm2, 1451 psi).
      Tip:
      • "Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.

      • "Fuel Press" is the actual fuel pressure in common rail assembly.

      • When the pressure discharge valve on the common rail assembly has a malfunction, the actual fuel pressure changes as shown by "Pressure Discharge Valve Abnormal Fuel Press" in the illustration.

      • The pressure discharge valve operates to discharge fuel pressure when the internal pressure of the common rail exceeds the target fuel pressure.

      • There are 2 fuel pressure sensor circuits and both of them display the same value. If the difference between Fuel Press and Common Rail Press Sens 2 exceeds 10000 kPa (102 kgf/cm2, 1451 psi) for 2 seconds or more, it is necessary to inspect or repair the wiring for the fuel pressure sensor.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  23. READ VALUE USING GTS (COOLANT TEMP)

    1. Soak the engine for a long time.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to ON and turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Coolant Temp.

      Powertrain > Engine and ECT > Data List
      Tester Display
      Coolant Temp
      OK
      Coolant Temp is the same as the ambient temperature.
      Tip:

      When the engine coolant temperature is low even though the engine has been fully warmed up, or when the engine coolant temperature is high even though the engine is cold, inspect the sensor.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  24. READ VALUE USING GTS (INTAKE AIR AND INTAKE AIR TEMP (TURBO))

    1. Soak the engine for a long time.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to ON and turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Intake Air and Intake Air Temp (Turbo).

      Powertrain > Engine and ECT > Data List
      Tester Display
      Intake Air
      Intake Air Temp (Turbo)
      OK
      Intake Air is the same as Intake Air Temp (Turbo).
      Result
      Proceed to
      OK
      NG
    OK Нажмите здесь

    GO TO STEP 34


    NG
  25. CHECK AND REPLACE MALFUNCTIONING PARTS

    1. Inspect the mass air flow meter assembly.

      Click hereНажмите здесь

    2. Inspect the intake air temperature sensor (turbo).

      Click hereНажмите здесь

    3. Replace the mass air flow meter assembly.

      Click hereНажмите здесь

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

    4. Replace the intake air temperature sensor (turbo).

      Click hereНажмите здесь

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 34


  26. CHECK AND REPLACE ENGINE COOLANT TEMPERATURE SENSOR

    1. Inspect the engine coolant temperature sensor.

      Click hereНажмите здесь

    2. Replace the engine coolant temperature sensor.

      Click hereНажмите здесь

      Tip:

      It is only necessary to replace the part when the results of the inspection indicate a problem.

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 34


  27. CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

    Click hereНажмите здесь

    Result
    Proceed to
    OK
    NG
    NG Нажмите здесь

    OK
  28. CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP ASSEMBLY

    1. Disconnect the inlet hose from the supply pump assembly.

    2. Operate the hand pump and check that fuel is being supplied to the supply pump assembly.

      OK
      Fuel is properly supplied to the supply pump assembly when the hand pump is operated.
      Tip:
      • When there is a lack of fuel, the fuel pressure drops.

      • Check that the fuel filter element sub-assembly is not clogged.

      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  29. REPLACE SUCTION CONTROL VALVE

    1. Replace the suction control valve.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  30. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  31. PERFORM SUPPLY PUMP INITIALIZATION

    1. Perform the supply pump initialization.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 34


  32. CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - SUPPLY PUMP ASSEMBLY)

    1. Check and replace the clogged fuel pipe.

      Result
      Proceed to
      NEXT
    NEXT
  33. BLEED AIR FROM FUEL SYSTEM

    1. Bleed the air from the fuel system.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT
  34. CHECK FOR BLACK SMOKE

    1. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.

    2. Stop the vehicle and allow the engine to idle.

    3. Fully depress the accelerator pedal for 5 seconds, and then release it [A].

    4. Repeat the procedure [A] 10 times [B].

    5. Check for black smoke emission during the procedures [A] and [B].

      OK
      Black smoke is emitted less than 5 times.
      Tip:

      Even if the black smoke is very thin, count the number of black smoke emissions if there is any visible smoke.

      Result
      Proceed to
      NEXT
    NEXT

    END


  35. REPAIR OR REPLACE HARNESS OR CONNECTOR

    1. Repair or replace the harness or connector.

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 34


  36. REPLACE ECM

    1. Replace the ECM.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 34


  37. REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

    1. Replace the manifold absolute pressure sensor.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 34


  38. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)

    1. Connect the GTS to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off and wait for 30 seconds.

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine and ECT > Data List
      Tester Display
      MAF
    6. Read the MAF value displayed on the GTS while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the EGR Valve Close / All Data / MAF.

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Activate the EGR Valve Close
      Data List Display
      MAF
    8. Read the MAF value when the EGR valve is closed using the Active Test function.

      Tip:
      • If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

      • Before performing diagnosis, confirm that the EGR valve target opening angle is not 0%.

      • When "Coolant Temp" is 75°C (167°F) or higher during idle, the exhaust gas flows through the EGR pipe with cooler sub-assembly. If MAF does not change when the EGR is cut even though the EGR valve is operating normally, the EGR pipe with cooler sub-assembly may be clogged.

      • When idling while warming up the engine, the actuator operates and the EGR pipe with cooler sub-assembly is bypassed. However, if the connector of the No. 1 vacuum switching valve assembly (for EGR cooler) is disconnected, the EGR pipe with cooler sub-assembly is not bypassed and it is possible to check if the EGR pipe with cooler sub-assembly is clogged.

      Result
      GTS Display Result Proceed to

      Activate the EGR Valve Close:

      OFF (Open) to Close

      MAF value does not change A
      MAF value changes B
      Note:

      As the measured values may differ from those shown below due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.

      Tip:

      The problem may be a temporary, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the electric EGR control valve assembly or mass air flow meter assembly .

      Reference
      EGR Valve Condition (Opening) Measuring Condition MAF (Reference)
      Open (67%)
      • Atmosphere pressure: 101 kPa

      • Intake air temperature: 30°C (86°F)

      • Engine coolant temperature: 88°C (190°F)

      3 to 12 gm/sec
      Closed (0%) 7 gm/sec or more
    B Нажмите здесь

    GO TO STEP 12


    A
  39. READ VALUE USING GTS (MAF)

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

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

      Powertrain > Engine and ECT > Data List
      Tester Display
      MAF
    4. With the ignition switch ON and engine stopped, read the value when 30 seconds has elapsed.

      Standard
      GTS Display Condition Standard
      MAF Ignition switch ON (do not start engine) 0.35 gm/sec or less
      Result
      Proceed to
      OK
      NG
    NG Нажмите здесь

    OK
  40. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

    1. Connect the GTS to the DLC3.

    2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.

    3. Turn the ignition switch off and wait for 30 seconds.

    4. Start the engine and turn the GTS on.

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

      Powertrain > Engine and ECT > Data List
      Tester Display
      MAF
    6. Read the MAF value displayed on the GTS while the engine is idling.

    7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EGR Cooler Bypass / All Data / EGR Cooler Bypass Position and MAF.

      Powertrain > Engine and ECT > Active Test
      Active Test Display
      Activate the VSV for EGR Cooler Bypass
      Data List Display
      MAF
      EGR Cooler Bypass Position
      Tip:

      Whether the EGR is passing through the bypass side or cooler side during the Active Test can be confirmed by checking EGR Cooler Bypass Position.

    8. Using the Active Test function, switch the No. 1 vacuum switching valve assembly (for EGR cooler) between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".

      Tip:

      If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

      Result
      GTS Display Result Proceed to

      Activate the VSV for EGR Cooler Bypass:

      Cooler to Bypass

      MAF value does not change A
      MAF value changes B
      Tip:

      If the EGR pipe with cooler sub-assembly is clogged, the MAF value changes.

    B Нажмите здесь

    GO TO STEP 42


    A
  41. CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    1. Remove the electric EGR control valve assembly.

      Click hereНажмите здесь

    2. Visually check the electric EGR control valve assembly for deposits. If there are deposits, clean the electric EGR control valve assembly.

      Note:
      • When cleaning the electric EGR control valve assembly, make sure the valve is completely closed.

      • When cleaning the electric EGR control valve assembly, perform initialization procedure.

        Click hereНажмите здесь

      • Do not forcibly open the valve, as it may be damaged or deformed.

      • When cleaning the electric EGR control valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying solvent directly onto these parts or soaking the parts in solvent may damage the parts.

      • When cleaning the EGR control valve, care should be taken to prevent the ingress of cleaning solvent into the bearings of valve shaft, and when wiping off deposits on the EGR control valve, care should be taken not to push the deposits into the bearings of valve shaft. These contaminants may adversely affect on the function of EGR control valve.

      Tip:
      • If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.

      • If the EGR valve does not close properly or is stuck open, the amount of recirculated exhaust gas becomes excessive and combustion becomes unstable. Also, there may be a lack of power. In this case, clean the electric EGR control valve assembly.

      Result
      Proceed to
      NEXT
    NEXT
  42. REPLACE EGR PIPE WITH COOLER SUB-ASSEMBLY

    1. Replace the EGR pipe with cooler sub-assembly.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 20


  43. REPLACE MASS AIR FLOW METER ASSEMBLY

    1. Replace the mass air flow meter assembly.

      Click hereНажмите здесь

      Result
      Proceed to
      NEXT
    NEXT Нажмите здесь

    GO TO STEP 20