GSIC - Global Service Information Center

### ECD SYSTEM > Rough Idling or Excessive Engine Vibrations

## for Preparation Click here

## DESCRIPTION

Malfunction Condition | Main Trouble Areas | Related Trouble Areas

1. Rough idling or juddering due to abnormal combustion
2. Juddering when vehicle starting due to clutch system malfunctions

1. Injector malfunctions

1. Injector sliding malfunction
2. Injector stuck closed
3. Injector stuck open
4. Deposit in injector
5. Injector circuit malfunction

2. Clutch system malfunctions

1. Clutch system (juddering when starting)

1. Injector compensation code
2. Fuel leak
3. Engine mounting insulator
4. Intake air system leakage
5. Intake air system blockage
6. Throttle valve system
7. Supply pump
8. Pressure limiter
9. Fuel pressure sensor
10. EDU (P0200/97 set simultaneously)
11. Low quality fuel
12. Vehicle modifications
13. Fuel filter air bleed problem
14. Accessory problem (A/C, generator, etc.)
15. ECM

HINT:

1. This troubleshooting procedure checks for rough idling and excessive engine vibrations.
2. Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result 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.
3. Check that the vehicle has not been modified in any way prior to the vehicle inspection.

## INSPECTION PROCEDURE

NOTICE:

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

1.CHECK MALFUNCTION CONDITION

1. Identify when juddering occurs.

   Result:

     Driving Condition | Proceed to
     When idling | A
     When engaging engine clutch at vehicle start | B (Clutch system judders)

| B |

REPAIR OR REPLACE CLUTCH SYSTEM

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 DTC 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 (25 mph) 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.CHECK OUTPUT DTC (RELATING TO ENGINE)

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

1. Read pending DTCs.

   Result:

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

| B |

GO TO DTC CHART

A |

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

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.

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 PARTS

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

   Result:

     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 P0105/35, P0107/35 AND P0108/35 (RELATED TO MANIFOLD ABSOLUTE PRESSURE SENSOR)

| C |

Go to step 24

A |

7.READ VALUE OF INJECTOR (INJECTION FEEDBACK 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 with a fully warm engine.

| B |

Go to step 14

A |

8.CHECK INJECTOR COMPENSATION CODE

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

HINT:

  If the injector compensation code is not correctly registered, it may cause malfunctions.

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 ENGINE MOUNTING INSULATOR

1. Visually check that the engine mounting insulator is installed correctly and is not crooked or twisted.

   OK:
     No abnormalities.

| NG |

REPAIR OR REPLACE ENGINE MOUNTING INSULATOR

OK |

12.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 |

13.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 |

14.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 |

15.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 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 |

REPLACE INJECTOR OF MALFUNCTIONING CYLINDER

16.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 |

17.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 |

18.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:

     Injector Condition | Proceed to
     Deposits | A
     No deposits | B

| B |

REPLACE INJECTOR OF MALFUNCTIONING CYLINDER

A |

19.CLEAN INJECTOR

NEXT |

20.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: Power train / 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:
     *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up. 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 OF MALFUNCTIONING CYLINDER

OK |

END

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 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.

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

OK |

END

24.INSPECT SUPPLY PUMP ASSEMBLY

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

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

| NG |

REPLACE SUPPLY PUMP ASSEMBLY

OK |

25.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
     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)