1

Inspection Procedure for

1CD-FTV, 1KD-FTV and

2KD-FTV Engines

Model: CDE1#0, CDT220, CDT250 (without D-CAT),

CLM20, CLR30, CLA2#, KDY2##, KLH1#, 2#,
KDN151, KDN166, KDJ90, KDJ12#
Inspection Procedure 2
3 inspection procedures for problem of the common-rail
diesel engine when no DTC is present

•Rough
•Rough idling
idling
•Excessive
•Excessive engine
engine vibrations
vibrations

•Engine
•Engine knocking
knocking
Click!
•Engine
•Engine ratting
ratting

•Lack
•Lack of
of engine
engine power
power
•Engine
•Engine hesitation
hesitation
 3

Rough Idling
or
Excessive Engine Vibrations
Rough Idling or Excessive Engine Vibrations 4
General

Malfunction
Main Trouble Areas Related Trouble Areas
Condition
• Injector compensation code
• Fuel leakage
1.Injector malfunctions • Engine mounting insulator

• Rough
• Injector piston • Intake air system leakage
idling or
juddering due movement malfunction • Intake air system blockage

to abnormal • Injector stuck closed • EGR system

combustion • Injector stuck open • Intake shutter system
• Deposit in injector • Mass air flow meter
• Judderingwhen • injector circuit • Supply pump
vehicle starting malfunction • Pressure discharge valve
due to clutch • Fuel pressure sensor
system 2.Clutch system malfunction • EDU (if P0200 set
malfunctions • Clutch system (juddering simultaneously)
when vehicle starting) • Low quality fuel
• Vehicle modifications
• ECM
Rough Idling or Excessive Engine Vibrations 5
Inspection Procedure

Before
Before troubleshooting,
troubleshooting, check
check the
the following
following items
items (Basic
(Basic
Inspections)
Inspections)
•Fuel
•Fuel quality
quality
•Fuel
•Fuel for
for air
air OK
•Fuel
•Fuel system
system for
for blockages
blockages
•Air
•Air filter
filter
•Engine
•Engine oiloil
•Engine
•Engine coolant
coolant
•Engine
•Engine idling
idling speed
speed and
and the
the max.
max. engine
engine speed
speed
•Vacuum
•Vacuum pump pump
Rough Idling or Excessive Engine Vibrations 6
Inspection Procedure

Check
Check wire
wire harness
harness and
and connector
connector
in
in engine
engine room
room
OK [MT
[MT only]
only] When idling •Sensors
•Sensors OK
Check
Check •Supply
•Supply Pump
Pump
malfunction
malfunction •Common-rail
•Common-rail
condition
condition •Injectors
•Injectors
•EDU
•EDU
•Turbocharger
•Turbocharger System
System
•Intake
•Intake and
and Exhaust
Exhaust System
System
When engaging
engine clutch at
vehicle start Repair
Repair or
or
replace
replace clutch
clutch NG
system
system Repair
Repair or
or
replace
replace
Rough Idling or Excessive Engine Vibrations 7
Inspection Procedure

[DTC
[DTC check
check for
for pressure
pressure discharge
discharge valve]
valve]

Perform
Perform following
following procedure
procedure for
for 22 times
times
OK No DTCs
Engine
Engine Engine
Engine
Start
Start Stop
Stop

Wait 10 sec. or more

Some DTCs

Repair
Repair or
or
replace
replace
Rough Idling or Excessive Engine Vibrations 8
Inspection Procedure

[DTC
[DTC check
check for
for fuel
fuel system
system and
and intake
intake system]
system]

1.
1. Transfer
Transfer to to CHECK
CHECK MODE
MODE
2.
2. Warm-up
Warm-up EngineEngine
3.
3. Idle
Idle for
for 55 min.
min. or
or more
more
(to
(to set DTCs relating to
set DTCs relating to rough
rough idling)
idling)
4.
4. Drive
Drive the
the vehicle
vehicle more
more than
than 4040 km/h
km/h for
for 30
30 sec.
sec. or
or
No DTC No DTCs
more
more
5.
5. Stop
Stop the
the vehicle
vehicle (don’t
(don’t stop
stop the
the engine)
engine)
6.
6. Perform
Perform StepStep (4)
(4) ~
~ (5)
(5) 44 times
times or
or more
more
7. Stop the engine and wait
7. Stop the engine and wait 10 sec. 10 sec.
8.
8. Perform
Perform StepStep (4)
(4) ~
~ (7)
(7) again
again (to
(to set
set DTCs
DTCs relating
relating
to
to EGR
EGR system
system andand intake
intake shutter)
shutter)
9.
9. Drive
Drive the
the vehicle
vehicle more
more than
than 7070 km/h
km/h for
for 11 min.
min. or
or
more (to set DTCs relating to supply
more (to set DTCs relating to supply pump) pump)

Some DTCs

Repair
Repair or
or
replace
replace
Rough Idling or Excessive Engine Vibrations 9
Inspection Procedure

Check No Leakage
No DTC Check fuel
fuel leak
leak

•• Fuel
Fuel leak
leak test
test (Active
(Active Test)
Test)
•• Visually
Visually check
check forfor supply
supply pump,
pump, injector
injector and
and fuel
fuel
line
line between
between thethe supply
supply pump
pump and
and injector
injector

Leakage

Repair
Repair or
or
replace
replace
Rough Idling or Excessive Engine Vibrations 10
Inspection Procedure

Common-rail Check
Check
pressure is outside common-
common-
of standard rail
rail system
system
(Click
(Click !)!)

No Check
Check the
the following
following values
values of
of DATA
DATA Standard
Leakage LIST
LIST on
on IT
IT II
II range
•PIM
•PIM
•MAF
•MAF
•Common-rail
•Common-rail Pressure
Pressure
MAF is outside
PIM is of standard
PIM and MAF
outside of
are outside Inspection
Inspection ofof
standard
of standard DTC
DTC
(related
(related toto mass
mass
Check
Check intake
intake Inspection
Inspection of
of DTC
DTC air
air flow
flow meter)
meter)
system
system (related
(related to
to
(Click
(Click !)
!) manifold
manifold absolute
absolute
sensor)
sensor)
Rough Idling or Excessive Engine Vibrations 11
Inspection Procedure

Standard
Check
Check the
the following
following values
values of
of
range OK OK
DATA LIST on IT
DATA LIST on IT II II Check
Check injector
injector
•Revised
•Revised injection
injection volume
volume compensation
compensation
(#1 - #4)
(#1 - #4) code
code
•Injection
•Injection volume
volume
NG
Either item
is outside of
standard
Register
Register injector
injector
compensation
compensation
Check
Check code
code
injection
injection
volume
volume
(Click
(Click !)
!)
Rough Idling or Excessive Engine Vibrations 12
Inspection Procedure

1.
1. Disconnect
Disconnect battery
battery negative
negative
OK terminal
terminal for
for 22 min.
min. or
or more
more NG OK
2.
2. Reconnect
Reconnect thethe terminal
terminal Check
Check engine
engine
3.
3. Check the malfunction is
Check the malfunction is mounting
mounting insulator
insulator
successfully
successfully repaired
repaired by
by
driving
driving test
test NG

Repaired
successfully
Repair
Repair or
or
replace
replace
Check
Check for
for
intermittent
intermittent
problems
problems
Rough Idling or Excessive Engine Vibrations 13
Inspection Procedure
PIM and MAF
are outside
of standard

Check
Check air
air
OK OK OK Check
Check intake
intake OK
leakage
leakage and
and any
any Check
Check EGR
EGR valve
valve shutter
shutter
blockages
blockages in in (refer to each
(refer to each (refer
(refer to
to each
each
intake
intake and
and repair
repair manual)
manual) repair manual)
repair manual)
exhaust
exhaust system
system
NG
NG
NG

Repair
Repair or
or Repair
Repair or
or
Repair
Repair or
or replace
replace replace
replace
replace
replace
Rough Idling or Excessive Engine Vibrations 14
Inspection Procedure

Power-balance
Power-balance Inspection
Inspection Check
Check cylinder
cylinder
OK OK
compression
compression
To
To identity
identity the
the pressure
pressure ofof
malfunctioning
malfunctioning cylinder,
cylinder, malfunction
malfunction
perform
perform Active Test (Injector
Active Test (Injector cylinder
cylinder
Cut
Cut #1,
#1, #2,
#2, #3
#3 and
and #4)
#4)
NG

Malfunction cylinder:
When the injector is cut off, idling
stability variation is small Repair
Repair or
or
replace
replace
Normal cylinder:
When the injector is cut off, engine
idles roughly
Rough Idling or Excessive Engine Vibrations 15
Inspection Procedure

OK Deposits
Check
Check malfunction
malfunction Clean
Clean injector
injector and
and
cylinder
cylinder injector
injector for
for then
then reinstall
reinstall itit
deposit
deposit

No
Deposits

Replace
Replace the
the injector
injector
of
of malfunction
malfunction
cylinder
cylinder
Rough Idling or Excessive Engine Vibrations 16
Inspection Procedure

Check
Check the
the following
following values
values of
of
DATA LIST on IT
DATA LIST on IT II II OK
•Revised
•Revised injection
(#1 - #4)
(#1 - #4)
injection volume
volume END
•Injection
•Injection volume
volume

Either item
is outside of
standard
Deposits inside the
Replace injector may be
Replace the
the injector
injector causing the
of malfunction
of malfunction problem
cylinder
cylinder
Rough Idling or Excessive Engine Vibrations 17
Inspection Procedure
Click to reference

Result
Result of
of DATA
DATA LIST
LIST reading
reading
Injection
Volume
Less More
Revised injection than STD than
Revised A
volume STD STD
Injection
or Volume #1 - #4
Injection volume
3.0 mm3 or more, -3.0
is outside of A B B
mm3 or less
standard range
Between 3.0 mm3 and
- Normal C
-3.0 mm3

B C

Check
Check power-
power- Check
Check all
all
balance
balance injectors
injectors
(Click
(Click !)
!) (Click
(Click !)
!)
Rough Idling or Excessive Engine Vibrations 18
Inspection Procedure

Power-balance
Power-balance Inspection
Inspection
A Replace
Replace thethe

END
To
To identity
identity the
the injector
injector of
of
malfunctioning
malfunctioning cylinder,
cylinder, malfunction
malfunction
perform
perform Active Test (Injector
Active Test (Injector cylinder
cylinder
Cut
Cut #1,
#1, #2,
#2, #3
#3 and
and #4)
#4)

Malfunction cylinder:
When the injector is cut off, idling
stability variation is small

Normal cylinder:
When the injector is cut off, engine
idles roughly
Rough Idling or Excessive Engine Vibrations 19
Inspection Procedure

Deposits
Check
Check all
all cylinder
cylinder Clean
Clean injectors
injectors and
and
C
injectors
injectors for
for deposit
deposit then
then reinstall
reinstall itit

No
Deposits

Replace
Replace thethe injectors
injectors
of
of all
all cylinder
cylinder
Rough Idling or Excessive Engine Vibrations 20
Inspection Procedure

Check
Check the
the following
following values
values of
of
DATA LIST on IT
DATA LIST on IT II II OK
•Revised
•Revised injection
(#1 - #4)
(#1 - #4)
injection volume
volume END
•Injection
•Injection volume
volume

Either item
is outside of
standard
Deposits inside the
Replace injector may be
Replace the
the causing the
injector
injector of
of all
all problem
cylinder
cylinder
Rough Idling or Excessive Engine Vibrations 21
Inspection Procedure

Common-rail Inspect
Inspect fuel
fuel OK Inspect
Inspect supply
supply OK
pressure is pressure
pressure sensor
sensor pump
pump assy
assy
outside of (refer
(refer to
to each
each (refer
(refer to
to each
each
standard repair
repair manual)
manual) repair
repair manual)
manual)
NG NG

Replace
Replace Replace
Replace
pressure
pressure supply
supply
sensor
sensor pump
pump assy
assy
Rough Idling or Excessive Engine Vibrations 22
Inspection Procedure

OK Check
Check and
and replace
replace common-rail
common-rail

END
assy
assy (discharge
(discharge valve
valve or
or
pressure
pressure limiter)
limiter)
(refer
(refer to
to each
each repair
repair manual)
manual)
 23

Engine Knocking
or
Rattling
Engine Knocking or Rattling 24
General
Malfunction
Main Trouble Areas Related Trouble Areas
Condition
1.Injector malfunctions
• Injector compensation code
• Injector piston
• Fuel leakage
movement malfunction
• Intake air system leakage
• Injector stuck closed
• Intake air system blockage
• Knocking and • Injector stuck open
• EGR system
abnormal • Deposit in injector
sound due to • Intake shutter system
• Injector circuit
extremely rich • Fuel pressure sensor
malfunction
combustion • Manifold absolute pressure
2.Abnormal common-rail sensor
• Abnormal pressure • Mass air flow meter
sound due to • Supply pump • Atmosphere air pressure
friction • Fuel pulsation sound sensor (in ECM)
between parts • Air in fuel • Vehicle modifications
• Low quality fuel
3.Friction between parts • Lack of fuel
• ECM
4.Compression pressure
Engine Knocking or Rattling 25
Inspection Procedure

Before
Before troubleshooting,
troubleshooting, check
check the
the following
following items
items (Basic
(Basic
Inspections)
Inspections)
•Fuel
•Fuel quality
quality
•Fuel
•Fuel for
for air
air OK
•Fuel
•Fuel system for
system for blockages
blockages
•Air
•Air filter
filter
•Engine
•Engine oiloil
•Engine
•Engine coolant
coolant
•Engine
•Engine idling
idling speed
speed and
and the
the max.
max. engine
engine speed
speed
•Vacuum
•Vacuum pump pump
Engine Knocking or Rattling 26
Inspection Procedure

Check
Check wire
wire harness
harness and
and
Supply pump connector
or connector in
in engine
engine room
room
OK Check knocking •Sensors
•Sensors
Check abnormal
abnormal OK
sound •Supply
•Supply Pump
Pump
sound area
area using
using
mechanic’s •Common-rail
•Common-rail
mechanic’s
stethoscope •Injectors
•Injectors
stethoscope
•EDU
•EDU
Parts other •Turbocharger
•Turbocharger System
System
than supply •Intake
•Intake and
and Exhaust
Exhaust System
System
pump

NG
Replace
Replace
pressure
pressure
sensor Repair
Repair or
or
sensor replace
replace
Engine Knocking or Rattling 27
Inspection Procedure

[DTC
[DTC check
check for
for pressure
pressure discharge
discharge valve]
valve]

Perform
Perform following
following procedure
procedure for
for 22 times
times
OK No DTCs
Engine
Engine Engine
Engine
Start
Start Stop
Stop

Wait 10 sec. or more

Some DTCs

Repair
Repair or
or
replace
replace
Engine Knocking or Rattling 28
Inspection Procedure

[DTC
[DTC check
check for
for fuel
fuel system
system and
and intake
intake system]
system]

1.
1. Transfer
Transfer to to CHECK
CHECK MODE
MODE
2.
2. Warm-up Engine
Warm-up Engine
3.
3. Idle
Idle for
for 55 min.
min. oror more
more
(to
(to set
set DTCs
DTCs relating
relating to to rough
rough idling)
idling)
No DTC 4.
4. Drive
Drive the
the vehicle
vehicle more
more than
than 4040 km/h
km/h for
for 30
30 sec.
sec. or
or No DTCs
more
more
5.
5. Stop
Stop the
the vehicle
vehicle (don’t
(don’t stop
stop the
the engine)
engine)
6.
6. Perform
Perform StepStep (4)
(4) ~~ (5)
(5) 44 times
times oror more
more
7.
7. Stop
Stop the
the engine
engine and
and wait
wait 1010 sec.
sec.
8.
8. Perform
Perform StepStep (4)
(4) ~~ (7)
(7) again
again (to
(to set
set DTCs
DTCs
relating
relating to EGR system and intake shutter)
to EGR system and intake shutter)
9.
9. Drive
Drive the
the vehicle
vehicle more
more than
than 7070 km/h
km/h for
for 11 min.
min. or
or
more
more (to(to set
set DTCs
DTCs relating
relating to to supply
supply pump)
pump)

Some DTCs

Repair
Repair or
or
replace
replace
Engine Knocking or Rattling 29
Inspection Procedure

Check No Leakage
No DTC Check fuel
fuel leak
leak

•• Fuel
Fuel leak
leak test
test (Active
(Active Test)
Test)
•• Visually
Visually check
check forfor supply
supply pump,
pump, injector
injector and
and fuel
fuel
line
line between
between thethe supply
supply pump
pump and
and injector
injector

Leakage

Repair
Repair or
or
replace
replace
Engine Knocking or Rattling 30
Inspection Procedure

Common-rail Check
Check
pressure is outside common-
common-
of standard rail
rail system
system
(Click
(Click !)!)

No Check
Check the
the following
following values
values of
of DATA
DATA Standard
Leakage LIST
LIST on
on IT
IT II
II range
•PIM
•PIM
•MAF
•MAF
•Common-rail
•Common-rail Pressure
Pressure
MAF is outside
PIM is of standard
PIM and MAF
are outside outside of Inspection
Inspection ofof
of standard standard DTC
DTC
(related
(related toto mass
mass
Check
Check intake
intake Inspection
Inspection of
of DTC
DTC air
air flow
flow meter)
meter)
system
system (related
(related to
to
(Click
(Click !)
!) manifold
manifold absolute
absolute
sensor)
sensor)
Engine Knocking or Rattling 31
Inspection Procedure

Standard
Check
Check the
the following
following values
values of
of
range OK OK
DATA LIST on IT
DATA LIST on IT II II Check
Check injector
injector
•Revised
•Revised injection
injection volume
volume compensation
compensation
(#1 - #4)
(#1 - #4) code
code
•Injection
•Injection volume
volume
NG
Either item is
outside of
standard
Register
Register injector
injector
compensation
compensation
Check
Check injection
injection code
code
volume
volume
(Click
(Click !)
!)
Engine Knocking or Rattling 32
Inspection Procedure

PIM and MAF

are outside
of standard

1.
1. Disconnect
Disconnect battery
battery negative
negative
OK terminal
terminal for
for 22 min.
min. or
or more
more Check
Check airair leakage
leakage OK
2. NG
2. Reconnect
Reconnect thethe terminal
terminal and
and any
any blockages
blockages
3.
3. Check the malfunction is
Check the malfunction is in
in intake
intake and
and
successfully
successfully repaired
repaired by
by exhaust
exhaust system
system
driving
driving test
test
NG
Repaired
successfully

Repair
Repair or
or
Check
Check for
for replace
replace
intermittent
intermittent
problems
problems
Engine Knocking or Rattling 33
Inspection Procedure

OK OK OK
Check
Check EGR
EGR valve
valve Check
Check intake
intake shutter
shutter
(refer
(refer to each repair
to each repair (refer
(refer to each repair
to each repair
manual)
manual) manual)
manual)
NG NG

Repair
Repair or
or Repair
Repair or
or
replace
replace replace
replace
Engine Knocking or Rattling 34
Inspection Procedure

OK Knocking
Check
Check
combustion
combustion
sound
sound

Sound from
supply pump

Bleed
Bleed air
air from
from Check
Check the
the knocking
knocking is
is
fuel
fuel system
system by
priming pump
priming pump
by successfully
by
by driving
repaired
successfully repaired
driving test
test
END
Engine Knocking or Rattling 35
Inspection Procedure

Power-balance
Power-balance Inspection
Inspection
Knocking Check
Check cylinder
cylinder OK
To
To identity
identity the
the compression
compression
malfunctioning
malfunctioning cylinder,
cylinder, pressure
pressure ofof
perform
perform Active
Active Test
Test (Injector
(Injector malfunction
malfunction
Cut
Cut #1, #2, #3 and #4)
#1, #2, #3 and #4) cylinder
cylinder
NG

Malfunction cylinder:
When the injector is cut off,
idling stability variation is small Repair
Repair or
or
Normal cylinder:
replace
replace
When the injector is cut off,
engine idles roughly
Engine Knocking or Rattling 36
Inspection Procedure

OK Deposits
Check
Check malfunction
malfunction Clean
Clean injector
injector and
and
cylinder
cylinder injector
injector for
for then
then reinstall
reinstall itit
deposit
deposit

No
Deposits

Replace
Replace the
the injector
injector
of
of malfunction
malfunction
cylinder
cylinder
Engine Knocking or Rattling 37
Inspection Procedure

Check
Check the
the following
following values
values of
of
DATA
DATA LIST
LIST onon IT
IT II
II OK
•Revised
•Revised injection
(#1
injection volume
(#1 -- #4)
#4)
volume END
•Injection
•Injection volume
volume
Either item
is outside of
standard
Deposits inside the
Replace injector may be
Replace the
the injector
injector causing the
of malfunction
of malfunction problem
cylinder
cylinder
Engine Knocking or Rattling 38
Inspection Procedure
Click to reference

Result
Result of
of DATA
DATA LIST
LIST reading
reading
Injection
Volume
Less More
Revised injection than STD than
Revised A
volume STD STD
Injection
or Volume #1 - #4
Injection volume
3.0 mm3 or more, -3.0
is outside of A B B
mm3 or less
standard
Between 3.0 mm3 and
- Normal C
-3.0 mm3

B C

Check
Check power-
power- Check
Check all
all
balance
balance injectors
injectors
(Click
(Click !)
!) (Click
(Click !)
!)
Engine Knocking or Rattling 39
Inspection Procedure

Power-balance
Power-balance Inspection
Inspection
A Replace
Replace thethe

END
To
To identity
identity the
the injector
injector of
of
malfunctioning
malfunctioning cylinder,
cylinder, malfunction
malfunction
perform
perform Active
Active Test
Test (Injector
(Injector cylinder
cylinder
Cut
Cut #1, #2, #3 and #4)
#1, #2, #3 and #4)

Malfunction cylinder:
When the injector is cut off,
idling stability variation is small

Normal cylinder:
When the injector is cut off,
engine idles roughly
Engine Knocking or Rattling 40
Inspection Procedure

Deposits
Check
Check all
all cylinder
cylinder Clean
Clean injectors
injectors and
and
C
injectors
injectors for
for deposit
deposit then
then reinstall
reinstall itit
No
Deposits

Replace
Replace the
the
injectors
injectors of
of all
all
cylinder
cylinder
Engine Knocking or Rattling 41
Inspection Procedure

Check
Check the
the following
following values
values of
of
DATA
DATA LIST
LIST onon IT
IT II
II OK
•Revised
•Revised injection
(#1
injection volume
(#1 -- #4)
#4)
volume END
•Injection
•Injection volume
volume
Either item
is outside of
standard
Deposits inside the
Replace injector may be
Replace the
the causing the
injector
injector of all
of all problem
cylinder
cylinder
Engine Knocking or Rattling 42
Inspection Procedure

Common-rail Inspect
Inspect fuel
fuel OK Inspect
Inspect supply
supply OK
pressure is pressure
pressure sensor
sensor pump
pump assy
assy
outside of (refer
(refer to
to each
each (refer
(refer to
to each
each
standard repair
repair manual)
manual) repair
repair manual)
manual)
NG NG

Replace
Replace Replace
Replace
pressure
pressure supply
supply
sensor
sensor pump
pump assy
assy
Engine Knocking or Rattling 43
Inspection Procedure

OK Check
Check and
and replace
replace common-rail
common-rail

END
assy
assy (discharge
(discharge valve
valve or
or
pressure
pressure limiter)
limiter)
(refer
(refer to
to each
each repair
repair manual)
manual)
 44

Lack of Power
or
Hesitation
Lack of Power or Hesitation 45
General
Malfunction
Main Trouble Areas Related Trouble Areas
Condition

• Pressure discharge valve

(P1271 set simultaneously)
1.Injector malfunctions • Mass air flow meter
• Lack of power • Injector piston movement • Intake air system leakage
caused by abnormal malfunction • Intake air system blockage
fuel injection • Injector stuck closed • EGR system
volume (supply • Injector stuck open • Fuel filter element is clogged
pump malfunction) • Deposit in injector • Intake shutter system
• Injector circuit malfunction • Compression pressure
• Lack of power
• Injector compensation code
caused by intake air 2.Abnormal common-rail pressure
• Fuel leakage
volume shortage • Supply pump
• Glow plug
(turbocharger
malfunction, front 3.Abnormal intake air volume • Fuel pressure sensor
exhaust pipe or • Turbocharger • EDU (if P0200 set
exhaust manifold • Front exhaust pipe blockage simultaneously)
converter blocked) • Exhaust manifold converter • Vehicle modifications

blockage • Low quality fuel

• Frozen of fuel
• ECM
Lack of Power or Hesitation 46
Inspection Procedure

Before
Before troubleshooting,
troubleshooting, check
check the
the following
following items
items (Basic
(Basic
Inspections)
Inspections)
•Fuel
•Fuel quality
quality
•Fuel
•Fuel for air
for air OK
•Fuel
•Fuel system
system for
for blockages
blockages
•Air
•Air filter
filter
•Engine
•Engine oiloil
•Engine coolant
•Engine coolant
•Engine
•Engine idling
idling speed
speed and
and the
the max.
max. engine
engine speed
speed
•Vacuum
•Vacuum pump pump
Lack of Power or Hesitation 47
Inspection Procedure

[DTC
[DTC check
check for
for pressure
pressure
Check discharge
discharge valve]
Check wire
wire harness
harness and
and valve]
connector
connector in
in engine
engine room
room
Perform
Perform following
following
•Sensors
•Sensors procedure
procedure for
for 22 times
times No DTCs
OK •Supply
•Supply Pump
Pump OK
•Common-rail
•Common-rail
•Injectors Engine
Engine Engine
Engine
•Injectors
•EDU Start
Start Stop
Stop
•EDU
•Turbocharger
•Turbocharger System
System
•Intake
•Intake and
and Exhaust
Exhaust
System
System Wait 10 sec. or more

NG
Some DTCs

Repair
Repair or
or Repair
Repair or
or
replace
replace replace
replace
Lack of Power or Hesitation 48
Inspection Procedure

[DTC
[DTC check
check for
for fuel
fuel system
system and
and intake
intake system]
system]

1.
1. Transfer
Transfer to to CHECK
CHECK MODE
MODE
2. Warm-up
2. Warm-up EngineEngine
3.
3. Idle
Idle for
for 55 min.
min. oror more
more
(to
(to set
set DTCs
DTCs relating
relating to to rough
rough idling)
idling)
4.
4. Drive
Drive the
the vehicle
vehicle more
more than
than 4040 km/h
km/h for
for 30
30 sec.
sec. or
or No DTC
No DTC
more
more
5.
5. Stop
Stop the
the vehicle
vehicle (don’t
(don’t stop
stop the
the engine)
engine)
6.
6. Perform
Perform StepStep (4)
(4) ~~ (5)
(5) 44 times
times or
or more
more
7.
7. Stop
Stop the
the engine
engine and
and wait
wait 1010 sec.
sec.
8.
8. Perform
Perform StepStep (4)
(4) ~~ (7)
(7) again
again (to
(to set
set DTCs
DTCs relating
relating
to EGR system and intake
to EGR system and intake shutter) shutter)
9.
9. Drive
Drive the
the vehicle
vehicle more
more than
than 7070 km/h
km/h for
for 11 min.
min. or
or
more
more (to(to set
set DTCs
DTCs relating
relating to to supply
supply pump)
pump)

Some DTCs

Repair
Repair or
or
replace
replace
Lack of Power or Hesitation 49
Inspection Procedure

Check
Check white
white smoke
smoke
Check
Check fuel
fuel leak
leak
No No Leakage •• Check
Check white
white smoke
smoke by by rev
rev
DTC up OK
•• Fuel
Fuel leak
leak test
test (Active
(Active Test)
Test) up the
the engine
engine idling
idling 

•• Visually 3000rpm
3000rpm several
several times
times
Visually check
check for
for supply
supply
pump, • Check the intake system
• Check the intake system
pump, injector
injector and
and fuel
fuel
line pipes
pipes and
and hoses
hoses are
are not
not
line between
between thethe supply
supply
pump excessively
excessively contaminated
contaminated
pump andand injector
injector
with
with oil
oil
White smoke
Leakage or
contaminated
Repair
Repair or
or with oil
replace
replace
Check
Check intake
intake
system
system
(Click
(Click !)
!)
Lack of Power or Hesitation 50
Inspection Procedure

Common-rail Check
Check
pressure is outside common-
common-
of standard rail
rail system
system
(Click
(Click !)!)

Check
Check the
the following
following values
values of
of DATA
DATA Standard
OK LIST on IT II
LIST on IT II range
•PIM
•PIM
•MAF
•MAF
•Common-rail
•Common-rail Pressure
Pressure MAF is outside
of standard
PIM and MAF PIM is
are outside outside of Inspection
Inspection ofof
of standard standard DTC
DTC
(related
(related toto mass
mass
Check
Check intake
intake Inspection
Inspection of
of DTC
DTC air
air flow
flow meter)
meter)
system
system (related
(related to
to
(Click
(Click !)
!) manifold
manifold absolute
absolute
sensor)
sensor)
Lack of Power or Hesitation 51
Inspection Procedure

Standard
Check
Check the
the following
following values
values of
of
range OK OK
DATA LIST on IT
DATA LIST on IT II II Check
Check injector
injector
•Revised
•Revised injection
injection volume
volume compensation
compensation
(#1 - #4)
(#1 - #4) code
code
•Injection
•Injection volume
volume
NG
Either item
is outside of
standard
Register
Register injector
injector
Check compensation
compensation
Check injection
injection
volume code
code
volume
(Click
(Click !)
!)
Lack of Power or Hesitation 52
Inspection Procedure

1.
1. Disconnect
Disconnect battery
battery negative
negative Lack of
OK terminal
terminal for
for 22 min.
min. or
or more
more NG Bleed
Bleed air
air from
from fuel
fuel power
2.
2. Reconnect
Reconnect thethe terminal
terminal
3. system
system by
by priming
priming
3. Check the malfunction is
Check the malfunction is
successfully pump
pump
successfully repaired
repaired by
by
driving
driving test
test
Lack of power
Repaired has been
successfully repaired
successfully

Check
Check for
for
END
intermittent
intermittent
problems
problems
Lack of Power or Hesitation 53
Inspection Procedure

Lack of
power Inspect
Inspect glow
glow plug
plug OK Check
Check airair leakage
leakage OK
circuit
circuit and
and glow
glow
END
and
and any
any blockages
blockages
plug
plug assy
assy in
in intake
intake and
and
(refer
(refer to
to each
each exhaust
exhaust system
system
repair
repair manual)
manual)
NG
NG

Repair Repair
Repair or
or
Repair or
or
replace replace
replace
replace
Lack of Power or Hesitation 54
Inspection Procedure
Click to reference

Result
Result of
of DATA
DATA LIST
LIST reading
reading
Injection
Volume
Less More
Revised injection than STD than
Revised A
volume STD STD
Injection
or Volume #1 - #4
Injection volume
3.0 mm3 or more, -3.0
is outside of A B B
mm3 or less
standard
Between 3.0 mm3 and
- Normal C
-3.0 mm3

B C

Check
Check power-
power- Check
Check all
all
balance
balance injectors
injectors
(Click
(Click !)
!) (Click
(Click !)
!)
Lack of Power or Hesitation 55
Inspection Procedure

Power-balance
Power-balance Inspection
Inspection
A Replace
Replace thethe

END
To
To identity
identity the
the injector
injector of
of
malfunctioning
malfunctioning cylinder,
cylinder, malfunction
malfunction
perform
perform Active
Active Test
Test (Injector
(Injector cylinder
cylinder
Cut
Cut #1, #2, #3 and #4)
#1, #2, #3 and #4)

Malfunction cylinder:
When the injector is cut off,
idling stability variation is small

Normal cylinder:
When the injector is cut off,
engine idles roughly
Lack of Power or Hesitation 56
Inspection Procedure

Power-balance
Power-balance Inspection
Inspection
Check
Check cylinder
cylinder OK
To
To identity
identity the
the compression
compression
B
malfunctioning
malfunctioning cylinder,
cylinder, pressure
pressure ofof
perform
perform Active
Active Test
Test (Injector
(Injector malfunction
malfunction
Cut
Cut #1, #2, #3 and #4)
#1, #2, #3 and #4) cylinder
cylinder

NG
Malfunction cylinder:
When the injector is cut off,
idling stability variation is small
Repair
Repair or
or
Normal cylinder: replace
replace
When the injector is cut off,
engine idles roughly
Lack of Power or Hesitation 57
Inspection Procedure

OK Deposits
Check
Check malfunction
malfunction Clean
Clean injector
injector and
and
cylinder
cylinder injector
injector for
for then
then reinstall
reinstall itit
deposit
deposit

No
Deposits

Replace
Replace the
the injector
injector
of
of malfunction
malfunction
cylinder
cylinder
Lack of Power or Hesitation 58
Inspection Procedure

Check
Check the
the following
following values
values of
of
DATA LIST on IT
DATA LIST on IT II II OK
•Revised
•Revised injection
(#1 - #4)
(#1 - #4)
injection volume
volume END
•Injection
•Injection volume
volume

Either item
is outside of
standard
Deposits inside the
Replace injector may be
Replace the
the injector
injector causing the
of
of malfunction
malfunction problem
cylinder
cylinder
Lack of Power or Hesitation 59
Inspection Procedure

Deposits
Check
Check all
all cylinder
cylinder Clean
Clean injectors
injectors
C injectors
injectors for
for and
and then
then
deposit
deposit reinstall
reinstall itit

No
Deposits

Replace
Replace thethe injectors
injectors
of
of all
all cylinder
cylinder
Lack of Power or Hesitation 60
Inspection Procedure

Check
Check the
the following
following values
values of
of
DATA
DATA LIST
LIST onon IT
IT II
II OK
•Revised
•Revised injection
(#1
injection volume
(#1 -- #4)
#4)
volume END
•Injection
•Injection volume
volume

Either item
is outside of
standard
Deposits inside the
Replace injector may be
Replace the
the causing the
injector
injector of all
of all problem
cylinder
cylinder
Lack of Power or Hesitation 61
Inspection Procedure

Common-rail Check NG
Check and
and Check
Check the
the following
following values
values
pressure is replace
replace fuel
fuel of
of DATA
DATA LIST
LIST onon IT
IT II
II
outside of filter
filter element
element
standard assy •Common-rail
•Common-rail Pressure
Pressure
assy
Standard
range

END
Lack of Power or Hesitation 62
Inspection Procedure

NG Inspect
Inspect fuel
fuel pressure
pressure OK
OK
sensor
sensor Inspect
Inspect supply
supply pump
pump assy
assy
(refer
(refer to
to each
each repair
repair (refer
(refer to
to each
each repair
repair manual)
manual)
manual)
manual)
NG
NG

Replace
Replace supply
supply
Replace
Replace pump
pump assy
assy
pressure
pressure
sensor
sensor
Lack of Power or Hesitation 63
Inspection Procedure

OK Check
Check andand replace
replace common-
common-

END
rail
rail assy
assy (discharge
(discharge valve
valve or
or
pressure
pressure limiter)
limiter)
(refer
(refer to
to each
each repair
repair manual)
manual)
Lack of Power or Hesitation 64
Inspection Procedure

OK OK
PIM and MAF Check
Check EGR
EGR valve
valve Check
Check intake
intake shutter
shutter
are outside (refer
(refer to
to each
each (refer
(refer to each repair
to each repair
of standard repair
repair manual)
manual) manual)
manual)

NG NG

Repair
Repair or
or Repair
Repair or
or
replace
replace replace
replace
Lack of Power or Hesitation 65
Inspection Procedure
White smoke
or
contaminated with oil

Check
Check turbocharger
turbocharger

OK Check OK 1.Disconnect
1.Disconnect the the air
air cleaner
cleaner hose
hose OK
Check airair leakage
leakage
and 2.Visually
2.Visually check
check the the turbocharger
turbocharger for for
and any
any blockages
blockages
in any
any mechanical
mechanical problems
problems
in intake
intake and
and
exhaust 3.When
3.When the engine is
the engine is cold,
cold, check
check that
that
exhaust system
system
the
the impellor
impellor rotates
rotates smoothly,
smoothly, and
and
NG confirm
confirm whether
whether therethere is is any
any
damage
damage to to itit
NG
Repair
Repair or
or
replace
replace
Repair
Repair or
or
replace
replace
Lack of Power or Hesitation 66
Inspection Procedure

Check
Check vacuum
vacuum type
type VN
VN turbocharger
turbocharger

•• Check
Check vacuum
vacuum hose
hose (for
(for VRV)
VRV)
 Installed correctly
 Installed correctly
No
No cracks,
cracks, damage,
damage, air
air leaks
leaks and
and blockage
blockage
•• Check
Check VRV
VRV
OK OK
Using
Using vacuum
vacuum gauge,
gauge, confirm
confirm that
that the
the vacuum
vacuum applied
applied to
to actuator
actuator
decreased
decreased according
according to
to raised
raised engine
engine speeds
speeds
•• Inspect
Inspect actuator
actuator
1.Apply
1.Apply aa negative
negative pressure
pressure (minimum:
(minimum: -60-60 kPa)
kPa) to
to actuator
actuator using
using
vacuum
vacuum pump
pump
2.Allow
2.Allow the
the negative
negative pressure
pressure in
in the
the actuator
actuator toto decreases
decreases gradually
gradually
3.Check
3.Check the
the actuator
actuator rod
rod stroke
stroke from
from initial
initial position
position

Vacuum VRV Actuator

hose NG NG
NG

Replace
Replace or
or replace
replace Replace
Replace Replace
Replace
vacuum hose
vacuum hose VRV
VRV turbocharger
turbocharger
Lack of Power or Hesitation 67
Inspection Procedure

Check
Check the
the following
following
OK values of DATA NG
Replace
Replace front
front values of DATA Replace
Replace exhaust
exhaust
exhaust
exhaust pipe
pipe LIST
LIST on
on IT
IT II
II manifold
manifold
assy
assy •PIM converter
converter assy
assy
•PIM
•MAF
•MAF

Standard
range

END
Lack of Power or Hesitation 68
Inspection Procedure

Check
Check the
the following
following values
values Standard
of DATA LIST on IT
of DATA LIST on IT II II range
•PIM
•PIM
•MAF
•MAF
END
NG

Replace
Replace
turbocharger
turbocharger