ECD SYSTEM > Engine Knocking or Rattling

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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. (a) Injector malfunctions
    1. Injector sliding malfunction
    2. Injector stuck closed
    3. Injector stuck open
    4. Deposits in injector
    1. Injector circuit malfunction
  1. (b) Abnormal common rail pressure
    1. Supply pump
    2. Fuel pulsation sound
    3. Air in fuel
  1. (c) Friction between parts
  1. (d) Compression pressure
  1. Injector compensation codes
  2. Fuel leakage
  3. Intake air system leakage
  4. Intake air system blockage
  5. Throttle valve system
  6. Fuel pressure sensor
  7. Manifold absolute pressure sensor
  8. Atmosphere air pressure sensor (built into ECM)
  9. Vehicle modifications
  10. Low quality fuel
  11. Lack of fuel
  12. 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

HINT:
  1. This troubleshooting procedure checks for knocking and rattling.
  2. Knocking is most likely to occur while the engine is idling.

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

1.CHECK SOUND AREA

  1. Find the 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 MALFUNCTION PARTS
A


2.CHECK WIRE HARNESS IN ENGINE COMPARTMENT

  1. Check the wire harness connections.

    OK:
    Wire harnesses are connected securely.



NG
REPAIR OR REPLACE HARNESS AND 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, 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 (25mph) for several tens of seconds.

  1. Decelerate and stop the vehicle.

  1. Repeat steps (d) and (e) 4 times or more.

  1. Stop the engine and wait for at least 10 seconds.

  1. Repeat steps (d) and (g) described above to set DTCs relating to the 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 OUTPUT DTC (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 (Click here)
    		B



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


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

HINT:
By performing this Active Test, the engine speed is maintained at 2,000 rpm and the common rail 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 (Click here).

HINT:
There may be fuel leaks inside components, such as the supply pump.

OK:
No fuel leakage.



NG
REPAIR OR REPLACE FUEL LEAKAGE POINT
OK


6.READ VALUE OF MANIFOLD ABSOLUTE PRESSURE SENSOR AND FUEL PRESSURE SENSOR

  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. Fuel Press

    Standard:

    Item
    		Engine Speed*
    		Standard Range
    		Proceed to
    		Description
    MAP
    		Ignition switch ON (engine stopped)
    		Same as atmospheric pressure
    1. A (standard range)
    2. B (MAP outside standard range)
    		Intake manifold internal pressure detected by intake pressure sensor
    Idling
    		95 to 105 kPa (713 to 788 mmHg, 28.1 to 31 in.Hg)
    3,000 rpm (No engine load)
    		113 to 133 kPa (848 to 998 mmHg, 33.4 to 39.3 in.Hg)
    3,500 rpm (full throttle acceleration)
    		Min.: 175 kPa (1,313 mmHg, 51.7 in.Hg)
    Fuel Press
    		Idling
    		25 to 35 MPa
    1. A (standard range)
    2. C (fuel pressure outside standard range)
    		Common rail internal fuel pressure
    2,000 rpm (No engine load)
    		25 to 35 MPa
    3,000 rpm (No engine load)
    		35 to 45 MPa
    3,500 rpm (full throttle acceleration)
    		Min.: 121 MPa

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



B
GO TO DTC PO105/35, P0107/35 AND P0108/35 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR)

C
Go to step 27
A


7.READ VALUE OF INFECTOR ASSEMBLY (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
    		Proceed to
    		Description
    Injection Feedback Val #1
    		Idling
    		-3.0 to 3.0 mm3
    1. A (standard range)
    2. B (Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range)
    		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 mm3 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
    		3.0 to 10.0 mm3
    		Fuel injection volume value controlled by ECU
    1. Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure
    2. If problems exist, Injection Volume may be outside standard range

    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 installed injector is same as code registered in ECM.



NG
REGISTER INJECTOR COMPENSATION CODE
OK


9.CHECK BATTERY

  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.BASIC INSPECTION

  1. Check the fuel quality.

  1. Check the fuel for air.

  1. Check the fuel system for blockages.

  1. Check the air filter.

  1. Check the engine oil.

  1. Check the engine coolant.

  1. Check the engine idling speed and the maximum engine speed.

  1. Check the vacuum pump.

    OK:
    Each inspection result is normal.



NG
REPAIR OR REPLACE MALFUNCTION PARTS
OK


11.CHECK INTAKE AND EXHAUST 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 MALFUNCTION PARTS
OK


12.INSPECT DIESEL THROTTLE BODY ASSEMBLY

  1. Measure the resistance between the terminal 1 of the diesel throttle body and body ground.

    Standard resistance:
    2 to 10 kΩ at 20°C (68°F)



NG
REPLACE DIESEL THROTTLE BODY ASSEMBLY
OK


13.CHECK COMBUSTION

  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 4 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:
    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 OF LOW COMPRESSION
OK


16.CHECK MALFUNCTIONING CYLINDER INJECTION FOR DEPOSIT

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
A


17.CLEAN INJECTOR

NEXT


18.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 ignition switch ON 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
    		3.0 to 10.0 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
OK

END 

19.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
    		3.0 to 10.0mm3

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


Result:

Injection Volume
Injection Feedback Val #1 to #4
Less than 3.0 mm3
Between 3.0 to 10.0 mm3 (Normal)
More than 10.0 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 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


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. 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

REPLACE INJECTOR ASSEMBLY 

21.CHECK ALL CYLINDER INJECTORS FOR DEPOSIT

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 ASSEMBLY OF ALL CYLINDER
A


22.CLEAN INJECTOR

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 ignition switch ON 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
    		3.0 to 10.0 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 ALL CYLINDER
OK

END 

24.CHECK SOUND AREA

  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 MALFUNCTION PARTS
A


25.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


26.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 

27.INSPECT SUPPLY PUMP ASSEMBLY

  1. Measure the resistance of the suction control valve terminals.

    Standard resistance:
    1.9 to 2.3 Ω at 20°C (68°F)



NG
REPLACE SUPPLY PUMP ASSEMBLY
OK


28.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

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED (PRESSURE LIMITER)