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Lack of power
caused by abnormal
fuel injection volume
(supply pump
malfunction or
injector malfunction)
Lack of power
(b) Abnormal common rail
caused by intake air pressure
volume shortage
Supply pump
(turbocharger
malfunction, front
(c) Abnormal intake air volume
exhaust pipe or
exhaust manifold
Turbocharger
converter blocked)
Front exhaust pipe
blockage
Exhaust manifold
converter blockage
Pressure limiter
Intake air system
leakage
Intake air system
blockage
Fuel filter element is
clogged
Throttle valve
Compression pressure
Injector
compensation code
Fuel leak
Glow plug
Fuel pressure sensor
EDU (P0200/97 set
simultaneously)
Vehicle modifications
Low quality fuel
Frozen fuel
ECM
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 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.
Check that the vehicle has not been modified in any way prior to the vehicle
inspection.
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 WIRE HARNESS IN ENGINE ROOM
a. Check the wire harness and connector connections.
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OK:
Wire harnesses are connected securely.
NG
OK
NEXT
Proceed to
No DTCs
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NG
OK
Result:
Result
Proceed to
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Go to step 26
6.READ VALUE OF MANIFOLD ABSOLUTE PRESSURE SENSOR AND FUEL PRESSURE SENSOR
(MAP AND FUEL PRESS)
a. Connect the intelligent tester to the DLC3.
b. Start the engine and warm it up and turn the intelligent tester ON.
c. Enter the following menus: Powertrain / Engine / Data List.
d. Select the following menu items in order and read the values.
MAP
Fuel Press
Standard:
Item
Engine Speed*
Standard
Range
Proceed to
Description
95 to 105 kPa
(713 to 788
mmHg, 28.1
to 31 in.Hg)
113 to 133
kPa (848 to
3,000 rpm (No
998 mmHg,
engine load)
33.4 to 39.3
in.Hg)
A
(standard
range)
B (MAP
outside
standard
range)
Intake
manifold
internal
pressure
detected by
intake
pressure
sensor
25 to 35 MPa
A
(standard
range)
Common rail
C (fuel
pressure internal fuel
pressure
outside
standard
range)
HINT:
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*: The A/C switch and all accessory switches should be OFF, and the engine should be
fully warmed up.
Go to step 29
Engine Standard
Speed* Range
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
Proceed to
A
(standard
range)
B
(Injection
Feedback
Val #1 to
#4
and/or
Description
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
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Injection
Volume
Idling
3.0 to 10.0
mm3
Injection
mm3 range
Volume
outside
Fuel injection volume
standard
value controlled by
range)
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.
Go to step 16
NG
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OK
9.CLEAR BATTERY
a. Disconnect the cable from the negative (-) battery terminal for at least 2 minutes.
b. Reconnect the cable to the negative (-) battery terminal.
c. 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
NG
NEXT
OK
END
NG
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Standard resistance:
Tester Connection
Specified
Condition
Approximately
Glow plug terminal
0.95 at 20C
- Body ground
(68F)
HINT:
If any one of the glow plugs has an open
malfunction, the engine power is insufficient
only when the engine is cold.
NOTICE:
Be careful not to damage the glow plug pipes. Damaging them could
cause an open circuit, or shorten the life of the glow plugs.
Keep the glow plug free of oil and fuel while cleaning.
Wipe any oil off the terminal and Bakelite washer with a clean, dry cloth
during inspection.
Do not apply more than 11 V to the glow plug as it could cause an open
circuit.
NG
OK
13.BASIC INSPECTION
a. Check the fuel quality.
b. Check the fuel for air.
c. Check the fuel system for blockages.
d. Check the air filter.
e. Check the engine oil.
f. Check the engine coolant.
g. Check the engine idling speed and the maximum engine speed.
h. Check the vacuum pump.
OK:
Each inspection result is normal.
NG
OK
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NG
OK
NG
OK
Standard:
Item
Engine Speed*
Reference Value
Idling
Injection Volume
Idling
3.0 to 10.0mm3
HINT:
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*: 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
Between 3.0 to
More than 10.0
3
10.0 mm (Normal) mm3
Normal
C*
Proceed to
Inspection Areas
Descriptions
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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.
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).
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.
Go to step 18
Go to step 23
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MALFUNCTIONING CYLINDER)
a. Connect the intelligent tester to the DLC3.
b. Start the engine and turn the intelligent tester ON.
c. Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder#1, #2,
#3 and #4 Fuel Cut.
d. Check the four cylinders in sequence to identify any faulty cylinders by performing the
power-balance inspection.
HINT:
While the engine is idling, if the idling stability variation is small despite
cutting off the fuel injection, the cylinder is malfunctioning.
With normal cylinders, the engine idles roughly when the fuel injection is
cut off.
NEXT
NG
OK
Result:
Injector Condition
Proceed to
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Deposits
No deposits
21.CLEAN INJECTOR
NEXT
Engine Speed*
Reference Value
Idling
Injection Volume
Idling
HINT:
The A/C switch and all accessory switches should be OFF with a fully
warm engine.
When the values are outside the standard range, deposits inside the
injector may be causing the problem.
OK:
Values are within standard range.
NG
OK
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END
23.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.
a. Check the injector for any deposits.
Result:
Injector Condition
Proceed to
Deposits
No deposits
24.CLEAN INJECTOR
NEXT
Engine Speed*
Reference Value
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Idling
Injection Volume #1 to
#4
Idling
HINT:
*: The A/C switch and all accessory switches should be OFF with a fully
warm engine.
When the values are outside the standard range, deposits inside the
injector may be causing the problem.
OK:
Values are within standard range.
NG
OK
END
26.CHECK TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM)
a. Disconnect the air cleaner hose.
b. Use a mirror to visually check the turbocharger for any mechanical problems.
c. 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
OK
NG
OK
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Engine Speed*
Reference Value
MAP
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
OK
END
29.CHECK AND REPLACE FUEL FILTER ASSEMBLY
NEXT
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Standard:
Item
Engine Speed *
Reference Value
Fuel Press
Idling
25 to 35 MPa
Fuel Press
25 to 35 MPa
Fuel Press
35 to 45 MPa
Fuel Press
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
NG
OK
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3 k or less
2 (PR) - 3 (VC)
16.4 k or less
NG
OK
INSPECT COMMON RAIL ASSEMBLY (PRESSURE LIMITER)
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