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ECD SYSTEM > Lack of Power or Hesitation

for Preparation Click here
DESCRIPTION
Malfunction Condition

Main Trouble Areas

Related Trouble Areas

(a) Injector malfunctions

Injector sliding
malfunction
Injector stuck closed
Injector stuck open
Deposits in injector
Injector circuit
malfunction

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

REPAIR OR REPLACE HARNESS AND

CONNECTOR

OK

2.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 DTCs are set, problem areas can be identified.
a. Enter CHECK MODE (Click here).
b. Fully warm up the engine.
c. Allow the engine to idle for 5 minutes or more.
d. Drive the vehicle at more than 40 km/h (25 mph) for several tens of seconds.
e. Decelerate and stop the vehicle.
f. Repeat steps (d) and (e) 4 times or more.
g. Stop the engine and wait for at least 10 seconds.
h. Repeat steps (d) and (g) described above (to set DTCs relating to the throttle valve).
i. 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

3.READ OUTPUT DTC (RELATING TO ENGINE)

a. Enter the following menus: Powertrain / Engine / DTC.
b. Read pending DTCs.
Result:
Display (DTC Output)

Proceed to

No DTCs

Engine related DTCs (Click here)

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REPAIR OR REPLACE ENGINE CONTROL

SYSTEM ACCORDING TO DTC OUTPUT

4.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TEST THE FUEL LEAK)

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.
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 / Test the Fuel Leak.
d. 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

5.CHECK WHITE SMOKE

a. Rev up the engine from idling to 3,000 rpm several times to check whether white smoke is
emitted from the exhaust pipe.
b. Check that the intake system pipes and hoses are not excessively contaminated with oil.
If white smoke is emitted from the intake system, its pipes and hoses are excessively contaminated
with oil. If the presence of white smoke in the exhaust gas is confirmed, there is a high possibility of
mechanical problems in the turbocharger or engine.

Result:
Result

Proceed to

No problems described above

White smoke emitted, or intake system pipes and hoses

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excessively contaminated with oil

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

Ignition switch Same as

ON (engine
atmospheric
stopped)
pressure
Idling
MAP

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

3,500 rpm (full Min.: 175 kPa

throttle
(1,313 mmHg,
acceleration) 51.7 in.Hg)
Idling

25 to 35 MPa

2,000 rpm (No

25 to 35 MPa
engine load)
Fuel Press

3,000 rpm (No

35 to 45 MPa
engine load)
3,500 rpm (full
throttle
Min.: 121 MPa
acceleration)

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 DTC P0105/35, P0107/35 AND

P0108/35 (RELATED TO MANIFOLD
ABSOLUTE PRESSURE SENSOR)

Go to step 29

7.READ VALUE OF INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

a. Select the following menu items in order and read the values.
Injection Feedback Val #1, #2, #3 and #4
Injection Volume
Standard:
Item

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

8.CHECK INJECTOR COMPENSATION CODE

a. Read the injector compensation code (Click here).
HINT:
If the injector compensation code is not correctly registered, it may cause malfunctions (Click
here).
b. Check the injector compensation code (Click here).
OK:
Compensation code of installed injector is same as registered in ECM.

NG

REGISTER INJECTOR COMPENSATION

CODE

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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

CHECK FOR INTERMITTENT PROBLEMS

NG

10.BLEED AIR FROM FUEL SYSTEM

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

NEXT

11.CONFIRM WHETHER LACK OF POWER HAS BEEN SUCCESSFULLY REPAIRED

a. 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

12.INSPECT GLOW PLUG ASSEMBLY

a. Disconnect the glow plug wire.

b. Measure the resistance of the glow plug.
c. Check other glow plugs in the same way.
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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

REPAIR OR REPLACE GLOW PLUG

ASSEMBLY

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

REPAIR OR REPLACE MALFUNCTION

PARTS

OK
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14.CHECK INTAKE AND EXHAUST SYSTEM

a. Check for air leakage and blockage between the air cleaner and turbocharger.
b. Check for air leakage and blockage between the turbocharger and intake manifold.
OK:
No leakage or blockage.

NG

REPAIR OR REPLACE MALFUNCTION

PARTS

OK

15.INSPECT DIESEL THROTTLE BODY ASSEMBLY

a. Measure the resistance between terminal 1 of the diesel throttle body and body ground.
Standard resistance:
2 to 10 k at 20C (68F)
OK:
No malfunction.

NG

REPLACE DIESEL THROTTLE BODY

ASSEMBLY

OK

16.IDENTIFY MALFUNCTIONING CYLINDER INJECTOR

a. 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:
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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

Less than 3.0

mm3

Between 3.0 to
More than 10.0
3
10.0 mm (Normal) mm3

3.0 mm3 or more, -3.0

A
mm3 or less

Between -3.0 to 3.0

mm3

Normal

C*

Proceed to

Inspection Areas

Descriptions

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

Abnormal value cylinder

injector injects
excessively small quantity
Identify malfunctioning
of fuel:
cylinders by conducting
Fuel injection
power balance
volume too low
inspection:
due to injector
Perform power
nozzle being
balance
blocked by
inspection to
deposits
identify
Abnormal value
malfunctioning
cylinder
cylinders
injector
Clean
compression
malfunctioning
decreases
cylinder
Abnormal value
injector, then
cylinder
check and
injector injects
repair it
excessively
large quantity
of fuel
Inspect and repair all
cylinder injectors:

All cylinder injectors

inject excessively small
quantity of fuel:

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Clean all cylinder

injectors, and then
inspect and repair them

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.
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

17.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTOR CUT FOR IDENTIFYING

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
REPLACE INJECTOR ASSEMBLY
18.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTOR CUT FOR IDENTIFYING
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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

19.CHECK CYLINDER COMPRESSION PRESSURE

a. 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

20.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.
a. Check the injector for any deposits.

Result:
Injector Condition

Proceed to

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Deposits

No deposits

REPLACE INJECTOR ASSEMBLY

21.CLEAN INJECTOR
NEXT

22.READ VALUE OF INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

a. Reinstall the injector to the cylinder head.
b. Connect the intelligent tester to the DLC3.
c. Turn the ignition switch ON and turn the intelligent tester ON.
d. Start the engine and warm it up.
e. Enter the following menus: Powertrain / Engine / Data List.
f. Select the following menu items in order and read the values.
Injection Feedback Val #1, #2, #3 and #4
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 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

REPLACE INJECTOR ASSEMBLY

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

REPLACE INJECTOR ASSEMBLY OF ALL

CYLINDER

24.CLEAN INJECTOR
NEXT

25.READ VALUE OF INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

a. Reinstall the injector to the cylinder head.
b. Connect the intelligent tester to the DLC3.
c. Turn the ignition switch ON and turn the intelligent tester ON.
d. Start the engine and warm it up.
e. Enter the following menus: Powertrain / Engine / Data List.
f. Select the following menu items in order and read the values.
Injection Feedback Val #1, #2, #3 and #4
Injection Volume
Standard:
Item

Engine Speed*

Reference Value

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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:
*: 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

REPLACE INJECTOR ASSEMBLY OF ALL

CYLINDER

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

REPLACE TURBOCHARGER SUBASSEMBLY

OK

27.INSPECT TURBOCHARGER ACTUATOR

a. Inspect the actuator and waste gate valve.
OK:
The valve has no contamination and move smoothly.

NG

REPLACE TURBOCHARGER SUBASSEMBLY

OK
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28.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

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 item and read the value.
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 SUBASSEMBLY

OK
END
29.CHECK AND REPLACE FUEL FILTER ASSEMBLY
NEXT

30.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

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 item and read the values.
Fuel Press

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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

31.INSPECT SUPPLY PUMP ASSEMBLY

a. Measure the resistance of the suction control valve terminals.
Standard resistance:
1.9 to 2.3 at 20C (68F)
NOTICE:
After replacing the supply pump, the ECM needs initialization (see page ).

NG

REPLACE SUPPLY PUMP ASSEMBLY

OK

32.INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

a. Disconnect the F9 sensor connector.

b. Measure the resistance of the sensor.
Standard resistance:
Specified
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Tester Connection Condition

1 (E2) - 2 (PR)

3 k or less

2 (PR) - 3 (VC)

16.4 k or less

NG

REPLACE COMMON RAIL ASSEMBLY

OK
INSPECT COMMON RAIL ASSEMBLY (PRESSURE LIMITER)

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