ECD SYSTEM > Lack of Power or Hesitation

for Preparation Click here

DESCRIPTION

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.
   
3. This troubleshooting procedure checks for the cause of an obvious lack of engine power (such as the maximum speed being extremely slow) while the vehicle is being driven.
   

INSPECTION PROCEDURE

NOTICE:

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

1. Check the wire harness and connector connections.
   

   OK:

   Wire harnesses are connected securely.
   

NG	REPAIR OR REPLACE HARNESS AND CONNECTOR

OK

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).
   

2. Fully warm up the engine.
   

3. Allow the engine to idle for 5 minutes or more.
   

4. Drive the vehicle at more than 40 km/h (25 mph) for several tens of seconds.
   

5. Decelerate and stop the vehicle.
   

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

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

8. Repeat steps (d) and (g) described above (to set DTCs relating to the throttle valve).
   

9. 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

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

2. Read pending DTCs.
   
   

   Result:

   
   

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

B	REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT

A

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.
   

2. Start the engine and turn the intelligent tester ON.
   

3. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.
   

4. 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 leakage.
   

NG	REPAIR OR REPLACE FUEL LEAKAGE POINT

OK

1. Rev up the engine from idling to 3,000 rpm several times to check whether white smoke is emitted from the exhaust pipe.
   

2. Check that the intake system pipes and hoses are not excessively contaminated with oil.
   

Result:

Result	Proceed to
No problems described above	A
White smoke emitted, or intake system pipes and hoses excessively contaminated with oil	B

B	Go to step 26

A

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up 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. MAP
      
   2. Fuel Press
      
   
   

   Standard:

   
   

   Item	Engine Speed*	Standard Range	Proceed to	Description
   MAP	Ignition switch ON (engine stopped)	Same as atmospheric pressure	A (standard range) 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	A (standard range) 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 P0105/35, P0107/35 AND P0108/35 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR)
C	Go to step 29

A

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	A (standard range) 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 Positive values indicate control which corrects combustion degradation Negative values indicate control which corrects excessive combustion pressure 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 Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure and EGR volume. 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 16

A

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

HINT:

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

2. Check the injector compensation code (Click here).
   

   OK:

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

NG	REGISTER INJECTOR COMPENSATION CODE

OK

1. Disconnect the cable from the negative (-) battery terminal for at least 2 minutes.
   

2. Reconnect the cable to the negative (-) battery terminal.
   

3. 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

1. To bleed air from the priming pump, pump the priming pump until it becomes hard and cannot be pumped any more.
   

NEXT

1. Check whether the lack of power has been successfully repaired by performing a driving test. Use the freeze frame data recorded at the time the malfunction occurred.
   

   OK:

   Malfunction has been repaired successfully.
   

OK	END

NG

1. Disconnect the glow plug wire.
   

2. Measure the resistance of the glow plug.
   

3. Check other glow plugs in the same way.
   

   Standard resistance:

   Tester Connection	Specified Condition
   Glow plug terminal - Body ground	Approximately 0.95 Ω at 20°C (68°F)

   HINT:

   If any one of the glow plugs has an open malfunction, the engine power is insufficient only when the engine is cold.

   NOTICE:

   1. Be careful not to damage the glow plug pipes. Damaging them could cause an open circuit, or shorten the life of the glow plugs.
      
   2. Keep the glow plug free of oil and fuel while cleaning.
      
   3. Wipe any oil off the terminal and Bakelite washer with a clean, dry cloth during inspection.
      
   4. Do not apply more than 11 V to the glow plug as it could cause an open circuit.
      

NG	REPAIR OR REPLACE GLOW PLUG ASSEMBLY

OK

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.
   

   OK:

   Each inspection result is normal.
   

NG	REPAIR OR REPLACE MALFUNCTION PARTS

OK

1. Check for air leakage and blockage between the air cleaner and turbocharger.
   

2. Check for air leakage and blockage between the turbocharger and intake manifold.
   

   OK:

   No leakage or blockage.
   

NG	REPAIR OR REPLACE MALFUNCTION PARTS

OK

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

   Standard resistance:

   2 to 10 kΩ at 20°C (68°F)
   

   OK:

   No malfunction.
   

NG	REPLACE DIESEL THROTTLE BODY ASSEMBLY

OK

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: Perform power balance inspection and identify malfunctioning cylinder Replace malfunctioning cylinder injector	Abnormal value cylinder injector injects excessively large quantity of fuel
   B	Identify malfunctioning cylinders by conducting power balance inspection: Perform power balance inspection to identify malfunctioning cylinders Clean malfunctioning cylinder injector, then check and repair it	Abnormal value cylinder injector injects excessively small quantity of fuel: Fuel injection volume too low due to injector nozzle being blocked by deposits Abnormal value cylinder injector compression decreases 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 Pressure 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 18
C	Go to step 23

A

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 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

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 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

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

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

A

NEXT

1. Reinstall the injector to the cylinder head.
   

2. Connect the intelligent tester to the DLC3.
   

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

4. Start the engine and warm it up.
   

5. Enter the following menus: Powertrain / Engine / Data List.
   

6. 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 with a fully warm engine.
      
   2. When the values are outside the standard range, deposits inside the injector may be causing the problem.
      

   OK:

   Values are within standard range.
   

NG	REPLACE INJECTOR ASSEMBLY

OK
END

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

NEXT

1. Reinstall the injector to the cylinder head.
   

2. Connect the intelligent tester to the DLC3.
   

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

4. Start the engine and warm it up.
   

5. Enter the following menus: Powertrain / Engine / Data List.
   

6. 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 #1 to #4	Idling	3.0 to 10.0 mm3

   HINT:

   1. *: The A/C switch and all accessory switches should be OFF with a fully warm engine.
      
   2. When the values are outside the standard range, deposits inside the injector may be causing the problem.
      

   OK:

   Values are within standard range.
   

NG	REPLACE INJECTOR ASSEMBLY OF ALL CYLINDER

OK
END

1. Disconnect the air cleaner hose.
   

2. Use a mirror to visually check the turbocharger for any mechanical problems.
   

3. When the engine is cold, check that the impeller of the turbocharger rotates smoothly, and perform a contact check to confirm if it is damaged.
   

   OK:

   Impellor rotates smoothly and is not damaged.
   

NG	REPLACE TURBOCHARGER SUB-ASSEMBLY

OK

1. Inspect the actuator and waste gate valve.
   

   OK:

   The valve has no contamination and move smoothly.
   

NG	REPLACE TURBOCHARGER SUB-ASSEMBLY

OK

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up and turn the intelligent tester ON.
   

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

4. Select the following menu item and read the value.
   

   1. MAP
      
   
   

   Standard:

   
   

   Item	Engine Speed*	Reference Value
   MAP	3,500 rpm (full throttle acceleration)	Min.: 175 kPa (1,313 mmHg, 51.7 in-Hg)

   HINT:

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

   OK:

   Values are within standard value and malfunction has been successfully repaired.
   

NG	REPLACE TURBOCHARGER SUB-ASSEMBLY

OK
END

NEXT

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up, and turn the intelligent tester ON.
   

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

4. Select the following menu item and read the values.
   

   1. Fuel Press
      
   
   

   Standard:

   
   

   Item	Engine Speed *	Reference Value
   Fuel Press	Idling	25 to 35 MPa
   Fuel Press	2,000 rpm (no engine load)	25 to 35 MPa
   Fuel Press	3,000 rpm (no engine load)	35 to 45 MPa
   Fuel Press	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.

   OK:

   The values are within the standard range.
   

OK	END

NG

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

   Standard resistance:

   1.9 to 2.3 Ω at 20°C (68°F)
   

   NOTICE:

   After replacing the supply pump, the ECM needs initialization (see page ).

NG	REPLACE SUPPLY PUMP ASSEMBLY

OK

1. Disconnect the F9 sensor connector.
   

2. 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
INSPECT COMMON RAIL ASSEMBLY (PRESSURE LIMITER)