INSPECTION AND ADJUSTMENT
EC-1047
< BASIC INSPECTION >[K9K]
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4. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
6.CHECK ENGINE CONDITION
Start engine.
Is the engine start?
YES >> GO TO 7.
NO >> GO TO 9.
7.CHECK ENGINE CONDITION
Check that the oil level is correct and that the engine coolant temperature is normal operation temperature
60°C (140°F)
Engine running at idle speed.
- Select “HIGH PRES CIRCUIT LEAK TEST” in “ACTIVE TEST” mode with CONSULT-III.
- Engine will perform 4 acceleration cycles.
- Select “DATA MONITOR” mode with CONSULT-III.
- Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
- Does “RAIL PRESSURER” follow “RAIL PRES SET” at ± 5000 kPa(50 bar, 51 kg/cm
2, 725 psi) during the
phase of the 4 acceleration cycles?
NOTE:
If the rail pressure does not reach the setpoint there is an fuel injector leak that is too great or the pressure sig-
nal is incorrect.
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 8.
8.CHECK RAIL HIGH PRESSURE CONTROL CIRCUIT
Carry out TEST 5.
>> GO TO 11.
9.CHECK ENGINE CONDITION
Check that the oil level is correct.
Select “DATA MONITOR” mode with CONSULT-III.
Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
Does “RAIL PRESSURER” follow “RAIL PRES SET” when the cranking engine.
NOTE:
If the rail pressure does not reach the setpoint there is an fuel injector leak that is too great or the pressure sig-
nal is incorrect.
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 10.
10.CHECK MAJOR LEAK IN FUEL INJECTOR/FUEL INJECTORS OPEN
Carry out TEST 6.
>> GO TO 11.
11 .INSPECTION END
High pressure supply pump (volumetric control valve) OK.
High pressure supply pump
(volumetric control valve)ECM
Continuity
Connector Terminal Connector Terminal
F54 2 F11 50 Existed
EC-1048
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement (TEST 5: Rail High Pressure Reg-
ulation Check)
INFOID:0000000001162519
NOTE:
If contaminants (swarf) can be seen in the transparent return pipe, the entire fuel injection system (fuel injec-
tors, pump, rail, high pressure pipes and all return pipes) must be replaced.
CONDITIONS PRIOR TO TEST
- Engine coolant temperature between 80 - 90°C (176 - 194°F).
- All the electrical load are switched off.
- Air conditioning is switched off.
- The tank is at least half-full.
- The pipe connections and unions have been checked.
- Check the sealing of the high pressure pipes and unions.
CAUSE
- Rail pressure variations around the setpoint.
- The rail reference pressure is not reached.
- Rough idle.
- Possibly noisy combustion.
1.CHECK AIR BUBBLES
1. Start engine
2. Are there large air bubbles in the transparent supply pipe going to the pump?
Is the inspection result normal?
YES >> Check low pressure system.
NO >> GO TO 2.
2.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-I
Disconnect high pressure supply pump (volumetric control valve) harness connector.
Does the engine stop?
YES >> GO TO 3.
NO >> Replace high pressure supply pump (the high pressure supply pump [volumetric control valve]
remains open mechanically).
3.CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE)-I
1. Reconnect high pressure supply pump (volumetric control valve) harness connector.
2. Turn ignition switch OFF and wait at least 30 seconds.
3. Start engine.
4. Disconnect high pressure supply pump (pressure control valve) harness connector.
Does the engine stop?
YES >> GO TO 4.
NO >> Replace high pressure supply pump (the high pressure supply pump [pressure control valve]
remains open mechanically).
4.CHECK FUEL INJECTOR
1. Reconnect high pressure supply pump (pressure control valve) harness connector.
2. Wait at least 30 seconds.
3. Start engine and let it idle speed.
4. Select “DATA MONITOR” mode with CONSULT-III.
5. Check that the “F/FLOW CORR CYL1”, “F/FLOW CORR CYL2”, “F/FLOW CORR CYL3”, “F/FLOW
CORR CYL4” indication.
Are the reference value 0.3 - 1.9?
YES >> GO TO 6.
NO >> GO TO 5.
5.CHECK MAJOR LEAK IN FUEL INJECTOR/FUEL INJECTORS OPEN
Carry out TEST 6.
INSPECTION AND ADJUSTMENT
EC-1049
< BASIC INSPECTION >[K9K]
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>> INSPECTION END
6.CHECK ENGINE CONDITION
Check that the oil level is correct and that the engine coolant temperature is normal operation tempera-
ture.60°C (140°F)
Engine running at idle speed.
- Select “HIGH PRES CIRCUIT LEAK TEST” in “ACTIVE TEST” mode with CONSULT-III.
- Engine will perform 4 acceleration cycles.
- Select “DATA MONITOR” mode with CONSULT-III.
- Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
- Does “RAIL PRESSURE” follow “RAIL PRES SET” at during the phase of 4 acceleration cycles?
Is the inspection result normal?
YES >> GO TO 22.
NO >> GO TO 7.
7.CHECK ENGINE COOLANT TEMPERATURE AND FUEL TEMPERATURE
1. Select “DATA MONITOR” mode with CONSULT-III.
2. Check that the “FUEL TEMP” indication when operating at idle speed is between 60 - 80°C (140 - 176°F)
3. Check that the “WATER TEMP” indication is between 80 - 90°C (176 - 194°F)
NOTE:
When the fuel temperature is above 136°C (277°F), the maximum rail pressure is reduced to protect the
plastic pipes.
When the coolant temperature is above 100°C (212°F), the maximum rail pressure is reduced to protect the
engine.
Are the
“FUEL TEMP” and “WATER TEMP” within the reference value range?
YES >> GO TO 8.
NO >> Check the fuel pump temperature sensor (Refer to EC-1137, "
Component Inspection") or engine
coolant temperature sensor (Refer to EC-1133, "
Component Inspection").
8.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) POWER SUPPLY
1. Turn ignition switch OFF.
2. Disconnect high pressure supply pump (volumetric control valve) harness connector.
3. Turn ignition switch ON.
4. Check the voltage between high pressure supply pump (volumetric control valve) harness connector and
ground.
Is the inspection result normal?
YES >> GO TO 10.
NO >> GO TO 9.
9.DETECT MALFUNCTIONING PART
Check the following.
IPDM E/R
Harness for open or short between ECM and high pressure supply pump (volumetric control valve)
Harness for open or short between IPDM E/R and high pressure supply pump (volumetric control valve)
>> Repair open circuit or short to ground or short to power in harness or connectors.
10.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) OUTPUT SIGNAL CIR-
CUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
High pressure supply pump
(volumetric control valve)
Ground Voltage
Connector Terminal
F54 1 Ground Battery voltage
EC-1054
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
- All the electrical loads are switched off.
- Air conditioning is switched off.
CAUSE
- The engine runs poorly at idle speed, possibly emits white smoke.
1.CHECK FUEL INJECTOR
Refer to EC-1141, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 2.
NO >> Replace malfunctioning fuel injector.
2.CHECK ENGINE COOLANT TEMPERATURE AND FUEL TEMPERATURE
1. Start engine let it idle speed.
2. Select “DATA MONITOR” mode with CONSULT-III.
3. Check “FUEL TEMP” indication is above 60°C (140°F)
4. Check “F/FLOW CORR CYL1“, “F/FLOW CORR CYL2”, “F/FLOW CORR CYL3”, “F/FLOW CORR CYL4”
indication.
Are the reference value 0.3 - 1.9?
YES >> GO TO 3.
NO >> GO TO 4.
3.CHECK INTERNAL FUEL TRANSFER PUMP
1. Turn ignition switch OFF.
2. Disconnect the return system connections at the fuel injectors and close off the return pipes so they are
leak-tight. While the engine is idling, check the return flow rate at the fuel injector. After 5 minutes the
return volume must be between 16 - 24 ml per fuel injector.
Is there more than 24 ml or less than 16 ml of return for each fuel injector?
Yes >> Replace malfunctioning fuel injector.
No >> INSPECTION END
4.CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-267, "
Inspection".
>> INSPECTION END
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description
INFOID:0000000001162522
When replacing ECM, this procedure must be performed.
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Re-
quirement
INFOID:0000000001162523
1.PRECONDITIONING
Connect a CONSULT-III
Connect a battery charger
Electric load switch is OFF
Wait for the engine to cool [engine coolant temperature < 60°C (140°F and air temperature < 50°C (122°F)].
NOTE:
While the ECM is being programmed the cooling fan motors are triggered automatically.
>> GO TO 2.
2.SAVE ECM DATA
Turn ignition switch ON.
Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.
ENGINE CONTROL SYSTEM
EC-1057
< FUNCTION DIAGNOSIS >[K9K]
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FUNCTION DIAGNOSIS
ENGINE CONTROL SYSTEM
System DiagramINFOID:0000000001162526
1. Mass air flow sensor 2. Intake air temperature sensor 3. Turbocharger boost sensor
4. Throttle position sensor 5. EGR volume control valve control
position sensor 6. Turbocharger boost control solenoid
valve
7. High pressure supply pump (volu-
metric control valve)8. High pressure supply pump (pres-
sure control valve)9. Fuel rail pressure sensor
10. Fuel pump temperature sensor 11. Glow plug 12. Engine coolant temperature sensor
13. Crankshaft position sensor 14. Camshaft position sensor 15. Barometric pressure sensor
16. Refrigerant pressure sensor 17. Accelerator pedal position sensor 18. ASCD clutch switch
19. Brake switch 20. CAN communication 21. Glow plug
22. Fuel tank 23. Fuel pump 24. Fuel filter
25. High pressure supply pump 26. High pressure supply pump (internal
transfer pump)27. High pressure supply pump (volu-
metric control valve)
28. High pressure supply pump (high
pressure pump)29. High pressure supply pump (pres-
sure control valve)30. Mass air flow sensor (with intake air
temperature sensor)
31. Compressor 32. Charge air cooler 33. Electric throttle control actuator
JMBIA0418ZZ
EC-1058
< FUNCTION DIAGNOSIS >[K9K]
ENGINE CONTROL SYSTEM
System Description
INFOID:0000000001162527
ECM performs various controls such as fuel injection control and furl pressure control.
Component Parts LocationINFOID:0000000001162528
34. ECM 35. EGR volume control valve 36. Fuel rail
37. Fuel injector 38. EGR cooler
1. Priming pump 2. Fuel pump 3. Glow plug
4. Fuel rail 5. Turbocharger boost control solenoid
valve6. Turbocharger boost sensor
7. Engine coolant temperature sensor 8. Crankshaft position sensor 9. Glow relay
10. ECM 11. Mass air flow sensor 12. Electric throttle control actuator
13. Camshaft position sensor 14. EGR volume control valve 15. Fuel injector
ALBIA0296ZZ
ENGINE CONTROL SYSTEM
EC-1059
< FUNCTION DIAGNOSIS >[K9K]
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1. Turbocharger boost sensor 2. Mass air flow sensor 3. EGR volume control valve
4. ECM 5. Battery 6. Engine coolant temperature sensor
7. Camshaft position sensor 8. Fuel injector 9. Crankshaft position sensor
: Vehicle front
ALBIA0297ZZ
EC-1062
< FUNCTION DIAGNOSIS >[K9K]
ENGINE CONTROL SYSTEM
Component Description
INFOID:0000000001162529
1. ASCD steering switch 2. ASCD switch 3. CANCEL switch
4. RESUME switch 5. SET - switch 6. SET + switch
7. Stop lamp switch 8. Brake pedal 9. ASCD clutch switch
10. Clutch pedal
AWBIA0056ZZ
Component Reference
Accelerator pedal position sensorEC-1191, "
Description"
ASCD steering switchEC-1174, "Description"
ASCD clutch switchEC-1208, "Description"
Cooling fan motorEC-1211, "Description"
Electric throttle control actuatorEC-1134, "Description"
Engine coolant temperature sensorEC-1132, "Description"
Fuel pump temperature sensorEC-1136, "Description"
Fuel rail pressure sensorEC-1138, "Description"
Intake air temperature sensorEC-1130, "Description"
Mass air flow sensorEC-1127, "Description"
Refrigerant pressure sensorEC-1166, "Description"
Stop lamp switchEC-1214, "Description"
Throttle control motorEC-1134, "Description"
Throttle position sensorEC-1134, "Description"
Turbocharger boost sensorEC-1147, "Description"
Vehicle speed sensorEC-1165, "Description"