ECD SYSTEM > Black Smoke Emitted

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INSPECTION PROCEDURE

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.

NOTICE:
  1. If the ECM is replaced, the new ECM needs initialization (Click here).
  2. If the supply pump is replaced, the new ECM needs initialization (Click here).

1.CHECK OUTPUT DTC (RELATED TO ENGINE)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch ON and turn the intelligent tester ON.

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

  1. Read the DTCs.

    Result:
    Display (DTC Output)
    		Proceed to
    No output
    		A
    DTCs related to the engine (Click here)
    		B



B
REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT
A


2.READ VALUE OF INJECTOR ASSEMBLY (INJECTION VOLUME AND INJECTION FEED BACK VAL #1 TO #4)

  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 / Data List.

  1. 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 to 10 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 N position, and the A/C switch and all accessory switches should be OFF.



NG
Go to step 10
OK


3.PERFORM ENGINE RPM ACCELERATION

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.

  1. 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.



OK
END
NG


4.CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM

  1. Remove the air cleaner filter.

  1. Inspect the throttle valve operation.

    1. Start the engine.

    2. Check if the throttle valve fully opens when accelerating the engine speed.

      HINT:
      While revving the engine, the throttle valve is fully opened. If the systems are normal, the volume of black smoke will decrease.

      OK:
      Throttle valve operate normally.



NG
CHECK AND REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST
OK


5.CHECK TURBOCHARGING PRESSURE

  1. Check the turbocharger pressure (Click here).

    Standard:
    58.5 to 78.9 kPa (0.60 to 0.80 kgf/cm2, 8.5 to 11.4 psi)



NG
REPLACE TURBOCHARGER SUB-ASSEMBLY
OK


6.PERFORM ACTIVE TEST BY FUEL PRESSURE SENSOR AND INJECTOR ASSEMBLY

  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 / Data List.

  1. 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
    		25 to 35 MPa
    Fuel Pressure
    		2,000 rpm (no engine load)
    		25 to 35 MPa
    Fuel Pressure
    		3,000 rpm (no engine load)
    		35 to 45 MPa
    Injection Volume
    		Idling
    		3 to 10 mm3
    Injection Volume
    		2,000 rpm (no engine load)
    		3 to 10 mm3
    Injection Volume
    		3,000 rpm (no engine load)
    		4 to 12 mm3
    Main Injection
    		Idling
    		525 to 675 μs
    Pilot 2 Injection
    		Idling
    		350 to 450 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



B
REPLACE INJECTOR ASSEMBLY

C
Go to step 10
A


7.INSPECT CYLINDER COMPRESSION PRESSURE

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

    Standard:
    1,230 kPa (12.5 kgf/cm2, 178 psi)
    Minimum pressure:
    880 kPa (9 kgf/cm2, 128 psi)
    Difference between each cylinder:
    98 kPa (1.0 kgf/cm2, 14 psi)



NG
CHECK ENGINE TO DETERMINE CAUSE OR LOW COMPRESSION
OK


8.CHECK HARNESS AND CONNECTOR (INJECTOR ASSEMBLY - EDU)

HINT:
DTC P0200/97 is set if there is an open or short malfunction in the EDU circuit (1 trip detection logic).



    A099847E03

  1. Disconnect the F5, F6, F7 and F8 injector connectors.

  1. Disconnect the I1 EDU connector.

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

    Standard resistance:
    Tester Connection
    		Specified Condition
    F5-1 - I1-4 (INJ#1)
    		Below 1 Ω
    F6-1 - I1-2 (INJ#2)
    		Below 1 Ω
    F7-1 - I1-1 (INJ#3)
    		Below 1 Ω
    F8-1 - I1-3 (INJ#4)
    		Below 1 Ω
    F5-2 - I1-5 (COM1)
    		Below 1 Ω
    F6-2 - I1-6 (COM2)
    		Below 1 Ω
    F7-2 - I1-6 (COM2)
    		Below 1 Ω
    F8-2 - I1-5 (COM1)
    		Below 1 Ω
    F5-1 or I1-4 (INJ#1) - Body ground
    		10 kΩ or higher
    F6-1 or I1-2 (INJ#2) - Body ground
    		10 kΩ or higher
    F7-1 or I1-1 (INJ#3) - Body ground
    		10 kΩ or higher
    F8-1 or I1-3 (INJ#4) - Body ground
    		10 kΩ or higher
    F5-2 or I1-5 (COM1) - Body ground
    		10 kΩ or higher
    F6-2 or I1-6 (COM2) - Body ground
    		10 kΩ or higher
    F7-2 or I1-6 (COM2) - Body ground
    		10 kΩ or higher
    F8-2 or I1-5 (COM1) - Body ground
    		10 kΩ or higher



NG
REPAIR OR REPLACE HARNESS AND CONNECTOR
OK


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

  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 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 rough idling.



B
REPLACE INJECTOR ASSEMBLY
A

REPLACE INJECTOR DRIVER 

10.CHECK AND REPLACE ECM TERMINAL VOLTAGE (THW TERMINAL)


    A066060E49

  1. Start the engine.

  1. Measure the voltage of the ECM connector.

    Standard voltage:
    Tester Connection
    		Condition
    		Specified Condition
    E8-19 (THW) - E8-28 (E2)
    		Idling, engine coolant temperature between 60 and 120°C (140 and 248°F)
    		0.2 to 1.0 V



NG
Go to step 16
OK


11.CHECK ECM TERMINAL VOLTAGE (PIM TERMINAL)


    A066060E50

  1. Turn the ignition switch ON.

  1. Measure the voltage of the ECM connectors.

    Standard voltage:
    Tester Connection
    		Condition
    		Specified Condition
    E7-28 (PIM) - E8-28 (E2)
    		Applied negative pressure of 40 kPa (300 mmHg, 11.8 in.Hg)
    		1.3 to 1.9 V
    E7-28 (PIM) - E8-28 (E2)
    		Same as atmospheric pressure
    		2.4 to 3.1 V
    E7-28 (PIM) - E8-28 (E2)
    		Applied positive pressure of 69 kPa (518 mmHg, 20.4 in.Hg)
    		2.7 to 4.3 V

    HINT:
    Even when the output voltage from the manifold absolute pressure sensor is within the specified voltage range, there may be a problem in the sensor caused by age deterioration.



NG
Go to step 17
OK


12.CHECK ECM TERMINAL VOLTAGE (NE+ AND NE- TERMINALS)


    G034646E03

  1. While idling the engine, check the waveform of the ECM connector using an oscilloscope.

    Standard:
    Tester Connection
    		Specified Condition
    E8-27 (NE+) - E8-34 (NE-)
    		Correct waveform is shown
    Tool Setting
    		Condition
    5 V/DIV., 20 msec./DIV.
    		Idling with warm engine

    HINT:
    The waveform varies depending on the engine revolution.



NG
Go to step 18
OK


13.CHECK ECM TERMINAL VOLTAGE (VPA AND VPA2 TERMINALS)


    A066060E51

  1. Turn the ignition switch ON.

  1. Measure the voltage of the ECM connector.

    Standard voltage:
    Tester Condition
    		Accelerator Pedal Condition
    		Specified Condition
    E5-22 (VPA) - E5-28 (EPA)
    		Released
    		0.6 to 1.0 V
    E5-22 (VPA) - E5-28 (EPA)
    		Depressed
    		2.9 to 4.2 V
    E5-23 (VPA2) - E5-29 (EPA2)
    		Released
    		1.4 to 1.8 V
    E5-23 (VPA2) - E5-29 (EPA2)
    		Depressed
    		3.7 to 5.0 V



NG
Go to step 19
OK


14.CHECK ECM TERMINAL VOLTAGE (THA TERMINAL)


    A066060E52

  1. Start the engine.

  1. Measure the voltage of the ECM connector.

    Standard voltage:
    Tester Connection
    		Condition
    		Specified Condition
    E8-31 (THA) - E8-28 (E2)
    		Idling, intake air temperature at 20°C (68°F)
    		0.5 to 3.4 V



NG
Go to step 16
OK


15.CHECK ECM TERMINAL VOLTAGE (PCR1 TERMINAL)


    A066060E53

  1. Start the engine.

  1. Measure the voltage of the ECM connector.

    Standard voltage:
    Tester Connection
    		Condition
    		Specified Condition
    E8-26 (PCR1) - E8-28 (E2)
    		Idling
    		1.3 to 1.8 V



NG
Go to step 21
OK

REPLACE ECM 

16.INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    A111100E01

  1. Remove the sensor.

  1. 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.



NG
REPLACE ENGINE COOLANT TEMPERATURE SENSOR
OK

REPAIR OR REPLACE HARNESS AND CONNECTOR 

17.CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)


    A099844E03

  1. Disconnect the T9 sensor connector.

  1. Disconnect the E7 and E8 ECM connectors.

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

    Standard resistance:
    Tester Connection
    		Specified Condition
    T9-2 (PIM) - E7-28 (PIM)
    		Below 1 Ω
    T9-3 (VC) - E8-18 (VC)
    		Below 1 Ω
    T9-1 (E2) - E8-28 (E2)
    		Below 1 Ω
    T9-2 (PIM) or E7-28 (PIM) - Body ground
    		10 kΩ or higher
    T9-3 (VC) or E8-18 (VC) - Body ground
    		10 kΩ or higher
    T9-1 (E2) or E8-28 (E2) - Body ground
    		10 kΩ or higher



NG
REPAIR OR REPLACE HARNESS AND CONNECTOR
OK

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR 

18.INSPECT CRANKSHAFT POSITION SENSOR


    A072395E02

  1. Disconnect the C4 sensor connector.

  1. Measure the resistance of the sensor.

    Standard resistance:
    Tester Connection
    		Condition
    		Specified Condition
    1 - 2
    		Cold
    		1,630 to 2,740 Ω
    1 - 2
    		Hot
    		2,065 to 3,225 Ω

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



NG
REPLACE CRANKSHAFT POSITION SENSOR
OK

REPAIR OR REPLACE HARNESS AND CONNECTOR 

19.CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR - ECM)


    A111102E01

  1. Disconnect the A13 sensor connector.

  1. Disconnect the E5 ECM connector.

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

    Standard resistance:
    Tester Connection
    		Specified Condition
    A13-1 (VCP2) - E5-27 (VCP2)
    A13-2 (EPA2) - E5-29 (EPA2)
    A13-3 (VPA2) - E5-23 (VPA2)
    A13-4 (VCP1) - E5-20 (VCPA)
    A13-5 (EP1) - E5-28 (EPA)
    A13-6 (VPA1) - E5-22 (VPA)
    		Below 1 Ω
    A13-1 (VCP2) or E5-27 (VCP2) - Body ground
    A13-2 (EPA2) or E5-29 (EP2) - Body ground
    A13-3 (VPA2) or E5-23 (VPA2) - Body ground
    A13-4 (VCP1) or E5-26 (VCPA) - Body ground
    A13-5 (EP1) or E5-28 (EPA) - Body ground
    A13-6 (VPA1) or E5-22 (VPA) - Body ground
    		10 kΩ or higher



NG
REPAIR OR REPLACE HARNESS AND CONNECTOR
OK

REPLACE ACCELERATOR PEDAL ROD ASSEMBLY 

20.INSPECT INTAKE AIR TEMPERATURE SENSOR


    A111099E01

  1. Remove the sensor.

  1. 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.



NG
REPLACE INTAKE AIR TEMPERATURE SENSOR
OK

REPAIR OR REPLACE HARNESS AND CONNECTOR 

21.INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)


    A062213E06

  1. Disconnect the F9 sensor connector.

  1. Measure the resistance of the sensor.

    Standard resistance:
    Tester Connection
    		Specified Condition
    1 (E2) - 2 (PR)
    		3 kΩ or less
    2 (PR) - 3 (VC)
    		16.4 kΩ or less



NG
REPLACE COMMON RAIL ASSEMBLY
OK


22.CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)


    A099798E07

  1. Disconnect the E8 ECM connector.

  1. Disconnect the F9 sensor connector.

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

    Standard resistance:
    Tester Connection
    		Specified Condition
    E8-26 (PCR1) - F9-2 (PR)
    		Below 1 Ω
    E8-18 (VC) - F9-3 (VCC)
    		Below 1 Ω
    E8-28 (E2) - F9-1 (E2)
    		Below 1 Ω
    E8-26 (PCR1) or F9-2 (PR) - Body ground
    		10 kΩ or higher
    E8-18 (VC) or F9-3 (VC) - Body ground
    		10 kΩ or higher
    E8-28 (E2) or F9-1 (E2) - Body ground
    		10 kΩ or higher



NG
REPAIR OR REPLACE HARNESS AND CONNECTOR
OK


23.REPLACE ECM


NG
REPLACE SUPPLY PUMP ASSEMBLY
OK

END