GSIC - Global Service Information Center

### ECD SYSTEM > Engine Difficult to Start or Stalling

## for Preparation Click here

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

   Result:

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

| B |

REPAIR OR REPLACE ENGINE CONTROL SYSTEM ACCORDING TO DTC OUTPUT

A |

2.CHECK FUEL FILTER ASSEMBLY

1. Check that the fuel filter is not clogged.

   OK:
     Fuel filter is not clogged.

| NG |

REPLACE FUEL FILTER ASSEMBLY

OK |

Go to step 2

3.CHECK ENGINE CRANKING CONDITION

1. Check the engine cranking condition.

1. Compare the cranking condition with that of a normal engine of the same model, and carefully check if there is any difference between them.

   OK:
     Engine cranking condition is normal.

| NG |

CHECK AND REPLACE BATTERY, CHARGING SYSTEM, STARTER ASSEMBLY AND STARTING SYSTEM

OK |

4.READ VALUE OF FUEL PRESSURE SENSOR

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 / Data List / Fuel Press.

1. Read the values.

   OK:

     Item | Inspection Condition | Reference Value
     Fuel Press | Cranking, and engine coolant temperature 0°C (32°F) or more | 32 MPa

| NG |

BLEED AIR FORM FUEL SYSTEM

OK |

5.CHECK IF INITIAL COMBUSTION OCCURS

1. Check if initial combustion occurs.

   Result:

     Result | Proceed To
     No initial combustion with cold engine | A
     No initial combustion with hot engine | B
     Initial combustion occurs | C

| B |

Go to step 7

| C |

Go to step 8

A |

6.CHECK GLOW INDICATOR LIGHTING TIME AND AFTER GLOW TIME

1. Check the lighting duration of glow indicator light (Click here).

   OK:
     The indicator lighting time and after glow time is normal.

| NG |

REPAIR OR REPLACE PRE-HEATING SYSTEM

OK |

7.READ VALUE OF FUEL PRESSURE SENSOR

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 / Fuel Press.

1. Check that the internal fuel pressure of the common rail is within the specification below.

   Standard:

     Engine Speed | Fuel Pressure
     Idling | Approximately 30 to 40 MPa
     3,000 rpm (No engine load) | Approximately 50 to 70 MPa

| NG |

Go to step 13

OK |

8.CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM

1. Remove the air cleaner filter.

1. Inspect the EGR valve operation.

   1. Start the engine and warm it up.

   2. When the engine is idling and the vacuum hose is disconnected from the EGR valve, check that clicking sounds are emitted from the EGR valve.

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:
        EGR valve and throttle valve operate normally.

| NG |

REPAIR OR REPLACE LOCATIONS WHERE MALFUNCTIONS EXIST

OK |

9.READ VALUE OF FUEL PRESSURE SENSOR AND INJECTOR

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 Press
   2. Injection Volume

   Standard:

     Item | Engine Speed* | Reference Value
     Fuel Press | Idling | 30 to 40 MPa
     Fuel Press | 2,000 rpm (No engine load) | 40 to 50 MPa
     Fuel Press | 3,000 rpm (No engine load) | 50 to 70 MPa
     Injection Volume | Idling | 5 to 12 mm3
     Injection Volume | 2,000 rpm (No engine load) | 5 to 12 mm3
     Injection Volume | 3,000 rpm (No engine load) | 7 to 14 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 14

OK |

10.INSPECT CYLINDER COMPRESSION PRESSURE

| NG |

CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

OK |

11.CHECK WIRE HARNESS (INJECTOR - EDU)

HINT:

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

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 |

12.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (CONTROL 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

13.CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP

1. Disconnect the inlet hose from the supply pump.

1. Operate the priming pump and check that the fuel is being supplied to the supply pump.

   OK:
     Fuel is properly supplied to the supply pump when the priming pump is operated.

| OK |

REPLACE SUPPLY PUMP ASSEMBLY

NG |

CHECK AND REPLACE FUEL PIPE CLOGGING (INCLUDING FUEL FREEZING) (FUEL TANK - SUPPLY PUMP)

14.CHECK ECM (THW VOLTAGE)

1. Start the engine.

1. Measure the voltage of the ECM connector.

     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 18

OK |

15.CHECK ECM (NE SIGNAL)

1. While idling the engine, check the waveform between the specified terminals of the E7 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 speed.

| NG |

Go to step 19

OK |

16.CHECK WIRE HARNESS (STARTER RELAY - ECM)

1. Disconnect the E5 ECM connector.

1. Remove the ST relay from the engine room R/B.

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

   Standard resistance:

     Tester Connection | Specified Condition
     R/B ST relay terminal 1 - E4-7 (STA) | Below 1 Ω
     R/B ST relay terminal 1 or E4-7 (STA) - Body ground | 10 kΩ or higher

| NG |

REPAIR OR REPLACE HARNESS AND CONNECTOR

OK |

17.CHECK ECM (PCR1 VOLTAGE)

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 | 1.8 to 2.1 V

| NG |

Go to step 20

OK |

REPLACE ECM

18.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

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 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

19.INSPECT CRANKSHAFT POSITION SENSOR

1. Disconnect the C4 sensor connector.

1. Measure the resistance between terminals 1 and 2.

   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

20.INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

1. Disconnect the F9 sensor connector.

1. Measure the resistance of the sensor.

   Standard resistance:

     Tester Connection | Specified Condition
     F8-2 (PC) - F8-1 (E2) | 3 kΩ or less
     F8-2 (PC) - F8-3 (VC) | 16.4 kΩ or less

| NG |

REPLACE COMMON RAIL ASSEMBLY

OK |

21.CHECK WIRE HARNESS (FUEL PRESSURE SENSOR - ECM)

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 (VC) | 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 |

22.REPLACE ECM

| NG |

REPLACE SUPPLY PUMP ASSEMBLY

OK |

END