Juke F15 (2012 year). Service Repair Manual — part 166
DIAGNOSIS AND REPAIR WORKFLOW
EC-865
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There are present DTCs and stored DTCs (which appeared in a certain context and have since disappeared
or which are still present but have not had trouble diagnosis performed on them in the current context).
The “present” or “stored” status of DTCs must be considered when activating the diagnostic tool after power is
supplied to the ECM (without activating the system components).
Deal with present DTCs according to the procedure specified in the corresponding DTC trouble diagnosis.
For stored DTCs, note the DTCs displayed and follow the instructions in the Notes section.
If the DTC is confirmed when the instructions in the Notes section are applied, the malfunction is present. Deal
with the DTC.
If the DTC is not confirmed, check:
• Electrical lines which correspond to the malfunction
• Connectors for these lines (for oxidation, bent pins, etc.)
• Resistance of the malfunction component
• Condition of the wires (melted or cut insulation, wear)
Conformity Check
The conformity check is designed to check the states and data monitor items which do not display any DTCs
on the diagnostic tool when inconsistent. This phase therefore allows:
• Diagnoses malfunctions that do not have a DTC display, and which may correspond to a customer com-
plaint.
• Checks that the system is operating correctly and that there is no risk of a DTC reappearing after repairs.
This section gives the trouble diagnosis procedures for states and parameters and the conditions for checking
them.
If a state is not operating normally or a data monitor value is outside permitted tolerance values, you should
consult the corresponding trouble diagnosis page.
Customer Complaints - Trouble Diagnosis
If the test with the CONSULT-III is OK, but the customer complaint still present, the malfunction should be
treated by customer complaints.
SAFETY ADVICE
• The safety instructions must be followed at all times when working on components, to avoid damage or
injury:
- make sure that the battery is properly charged to avoid damaging the computers with a low load,
- use the appropriate tools,
- do not touch the xenon bulbs.
Diagnostic Work Sheet
INFOID:0000000006496533
DESCRIPTION
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make trou-
bleshooting faster and more accurate.
In general, each customer feels differently about a incident. It is
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink and
DTC to be detected. Examples:
• Vehicle ran out of fuel, which caused the engine to misfire.
• Fuel filler cap was left off or incorrectly screwed on, allowing fuel to
evaporate into the atmosphere.
A synopsis of the general procedure to follow is pro-
vided on the previous page in the form of a flow
chart.
SEF907L
EC-866
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DIAGNOSIS AND REPAIR WORKFLOW
WORKSHEET SAMPLE
MTBL0017
BASIC INSPECTION
EC-867
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BASIC INSPECTION
Description
INFOID:0000000006496534
NOTE:
Only consult the tests after following the diagnostic procedure chart.
Some specific checks are grouped under the “tests” heading and are used as required in different diagnostic
charts.
Work Procedure (TEST 1: Low Pressure Fuel Supply System Check)
INFOID:0000000006496535
NOTE:
• CAUSE
- No fuel can be seen in the transparent supply pipe leading to the pump or large air bubbles can be seen
(small air bubbles are permitted).
- engine does not start.
1.
CHECK CONFORMITY
Check the conformity and presence of the fuel (gasoline instead of diesel, contaminated fuel).
Is the inspection result normal?
Yes
>> GO TO 2.
No
>> Bleed the fuel supply system with the manual priming pump.
2.
CHECK FUEL CIRCUIT
Does the fuel circulate correctly when pumped manually?
Yes or No
Yes
>> GO TO 5.
No
>> GO TO 3.
3.
CHECK FOR LEAK
Look for leaks on the unions.
Are there leaks in the hoses and unions?
Yes
>> Carry out the required repairs.
Basic test
Trouble diagnosis
Reference page
Low pressure fuel supply system check
TEST 1
Internal fuel transfer pump check
TEST 2
High pressure supply pump (Pressure control valve) check
TEST 3
High pressure supply pump (Volumetric control valve) check
TEST 4
[TEST 4: High Pressure Sup-
ply Pump (Volumetric Control
Rail high pressure regulation check
TEST 5
Major leak in fuel injectors/fuel injectors open
TEST 6
Incorrect fuel injection quantity
TEST 7
EC-868
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BASIC INSPECTION
No
>> GO TO 4.
4.
CHECK FUEL FILTER
Check the correctness of the fuel filter.
Is the fuel filter correct?
Yes
>> GO TO 5.
No
>> Replace the fuel filter with a genuine part.
5.
INSPECTION END
Low pressure circuit OK.
>> INSPECTION END
Work Procedure (TEST 2: Internal Fuel Transfer Pump Check)
INFOID:0000000006496536
NOTE:
• CONDITIONS PRIOR TO TEST
- Test 1 Low pressure fuel supply system check has been carried out previously and results are satisfactory.
• CAUSE
- Fuel can be seen in the transparent supply pipe leading to the pump.
- However, fuel does not move during starting.
1.
CHECK INTERNAL FUEL TRANSFER PUMP
1.
Disconnect high pressure supply pump (volumetric control valve) harness connector.
2.
Remove fuel return pipe from the pump and block it so that it is sealed. Connect a pipe to the pump to
measure the flow of diesel.
3.
To authorise a 15 second cranking engine and carry out this test it is essential to carry out the following
procedure: measure the flow of diesel.
-
Turn ignition switch ON.
-
Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.
-
Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
-
Cranking engine for at least 15 seconds (starting speed 250 rpm).
-
Check the flow rate of the fuel being collected in a graduated measuring cylinder (500 ml minimum).The
minimum flow rate must be 25 ml every 15 sec.
-
Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
Does the flow measure less than 25ml?
Yes
>> Replace high pressure supply pump.
No
>> GO TO 2.
2.
INSPECTION END
Low pressure system OK.
>> INSPECTION END
Work Procedure [TEST 3: High Pressure Supply Pump (Pressure Control Valve)
Check]
INFOID:0000000006496537
NOTE:
• CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
• CAUSE
- Rail pressure approximately 5000 kPa (50 bar, 51 kg/cm
2
, 725 psi) during starting.
1.
CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE) POWER SUPPLY
1.
Turn ignition switch OFF.
2.
Disconnect high pressure supply pump (pressure control valve) harness connector.
3.
Turn ignition switch ON.
BASIC INSPECTION
EC-869
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4.
Check the voltage between high pressure supply pump (pressure control valve) harness connector and
ground.
Is the inspection result normal?
YES
>> GO TO 3.
NO
>> GO TO 2.
2.
DETECT MALFUNCTIONING PART
Check the following.
• IPDM E/R
• Harness for open or short between IPDM E/R and high pressure supply pump (pressure control valve)
• Harness for open or short between ECM and high pressure supply pump (pressure control valve)
>> Repair open circuit or short to ground or short to power in harness or connectors.
3.
CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE) OUTPUT SIGNAL CIRCUIT
FOR OPEN AND SHORT
1.
Turn ignition switch OFF.
2.
Disconnect ECM harness connector.
3.
Check the continuity between high pressure supply pump (pressure control valve) harness connector and
ECM harness connector.
4.
Also check harness for short to ground and short to power.
Is the inspection result normal?
YES
>> GO TO 4.
NO
>> Repair open circuit or short to ground or short to power in harness or connectors.
4.
HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE) CHECK
EC-900, "Component Inspection"
Is the inspection result normal?
Yes
>> INSPECTION END
No
>> Replace high pressure supply pump.
Work Procedure [TEST 4: High Pressure Supply Pump (Volumetric Control Valve)
Check]
INFOID:0000000006496538
NOTE:
• CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
• CAUSE
- Not enough or no rail pressure during starting.
- Rail reference pressure during starting, minimum 15,000 kPa (150 bar, 153 kg/cm
2
, 2,175 psi).
1.
CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-I
EC-889, "Component Inspection"
Is the inspection result normal?
YES
>> GO TO 2
High pressure supply pump
(Pressure control valve)
Ground
Voltage
Connector
Terminal
F60
3
Ground
Battery voltage
High pressure supply pump
(Pressure control valve)
ECM
Continuity
Connector
Terminal
Connector
Terminal
F60
4
F57
100
Existed
EC-870
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[K9K]
BASIC INSPECTION
NO
>> Replace high pressure supply pump.
2.
CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-II
• Reconnect all harness connectors disconnected.
• Turn ignition switch ON.
• Select “DATA MONITOR” mode with CONSULT-III.
• Check that the “FUEL FLOW S/V CU” indication when the cranking engine.
Is the excitation current between 0.6 - 1.0A?
YES
>> GO TO 6.
NO
>> GO TO 3.
3.
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 5.
NO
>> GO TO 4.
4.
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.
5.
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.
3.
Check the continuity between high pressure supply pump (volumetric control valve) harness connector
and ECM harness connector.
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.
High pressure supply pump
(volumetric control valve)
Ground
Voltage
Connector
Terminal
F61
1
Ground
Battery voltage
High pressure supply pump
(volumetric control valve)
ECM
Continuity
Connector
Terminal
Connector
Terminal
F61
2
F57
65
Existed
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EC-871
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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
±
5,000 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 set point there is an fuel injector leak that is too great or the pressure
signal 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 set point there is an fuel injector leak that is too great or the pressure
signal 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.
>> INSPECTION END
Work Procedure (TEST 5: Rail High Pressure Regulation Check)
INFOID:0000000006496539
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 set point.
EC-872
< BASIC INSPECTION >
[K9K]
BASIC INSPECTION
- 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 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
BASIC INSPECTION
EC-873
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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 temperature sensor (Refer to
EC-916, "Component Inspection"
) or engine coolant
temperature sensor (Refer to
EC-908, "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.
3.
Check the continuity between high pressure supply pump (volumetric control valve) harness connector
and ECM harness connector.
4.
Also check harness for short to ground and short to power.
Is the inspection result normal?
YES
>> GO TO 11.
NO
>> Repair open circuit or short to ground or short to power in harness or connectors.
11.
CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-II
EC-889, "Component Inspection"
Is the inspection result normal?
YES
>> GO TO 12.
High pressure supply pump
(volumetric control valve)
Ground
Voltage
Connector
Terminal
F61
1
Ground
Battery voltage
High pressure supply pump
(volumetric control valve)
ECM
Continuity
Connector
Terminal
Connector
Terminal
F61
2
F57
65
Existed
EC-874
< BASIC INSPECTION >
[K9K]
BASIC INSPECTION
NO
>> Replace high pressure supply pump.
12.
CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE) POWER SUPPLY
1.
Turn ignition switch OFF.
2.
Disconnect high pressure supply pump (pressure control valve) harness connector.
3.
Turn ignition switch ON.
4.
Check the voltage between high pressure supply pump (pressure control valve) harness connector and
ground.
Is the inspection result normal?
YES
>> GO TO 14.
NO
>> GO TO 13.
13.
DETECT MALFUNCTIONING PART
Check the following.
• IPDM E/R
• Harness for open or short between IPDM E/R and high pressure supply pump (pressure control valve)
• Harness for open or short between ECM and high pressure supply pump (pressure control valve)
>> Repair open circuit or short to ground or short to power in harness or connectors.
14.
CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE) OUTPUT SIGNAL CIR-
CUIT FOR OPEN AND SHORT
1.
Turn ignition switch OFF.
2.
Disconnect ECM harness connector.
3.
Check the continuity between high pressure supply pump (pressure control valve) harness connector and
ECM harness connector.
4.
Also check harness for short to ground and short to power.
Is the inspection result normal?
YES
>> GO TO 15.
NO
>> Repair open circuit or short to ground or short to power in harness or connectors.
15.
CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE)-II
EC-900, "Component Inspection"
Is the inspection result normal?
YES
>> GO TO 16.
NO
>> Replace high pressure supply pump.
16.
CHECK FUEL RAIL PRESSURE SENSOR POWER SUUPLY CIRCUIT
1.
Turn ignition switch OFF.
2.
Disconnect fuel rail pressure sensor harness connector.
3.
Turn ignition switch ON.
4.
Check the voltage between fuel rail pressure sensor harness connector and ground.
High pressure supply pump
(Pressure control valve)
Ground
Voltage
Connector
Terminal
F60
3
Ground
Battery voltage
High pressure supply pump
(Pressure control valve)
ECM
Continuity
Connector
Terminal
Connector
Terminal
F60
4
F57
100
Existed
BASIC INSPECTION
EC-875
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Is the inspection result normal?
YES
>> GO TO 17.
NO
>> Repair open circuit or short to ground or short to power in harness or connectors.
17.
CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
Turn ignition switch OFF.
2.
Disconnect ECM harness connector.
3.
Check the continuity between fuel rail pressure sensor harness connector and ECM harness connector.
4.
Also check harness for short to ground and short to power.
Is the inspection result normal?
YES
>> GO TO 18.
NO
>> Repair open circuit or short to ground or short to power in harness or connectors.
18.
CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check the continuity between fuel rail pressure sensor harness connector and ECM harness connector.
2.
Also check harness for short to ground and short to power.
Is the inspection result normal?
YES
>> GO TO 19.
NO
>> Repair open circuit or short to ground or short to power in harness or connectors.
19.
CHECK FUEL RAIL PRESSURE SENSOR
EC-918, "Component Inspection"
Is the inspection result normal?
YES
>> GO TO 20.
NO
>> Replace fuel rail.
20.
CHECK FUEL RAIL PRESSURE-I
1.
Reconnect all harness connectors disconnected.
2.
Start engine and let it idle speed.
3.
Select “DATA MONITOR” mode with CONSULT-III.
4.
Check that the “RAIL PRESSURE” indication under the following conditions.
NOTE:
An unusual combustion noise may be heard.
Is the inspection result normal?
Fuel rail pressure sensor
Ground
Voltage (V)
Connector
Terminal
F72
3
Ground
Approx. 5
Fuel rail pressure sensor
ECM
Continuity
Connector
Terminal
Connector
Terminal
F72
2
F58
27
Existed
Fuel rail pressure sensor
ECM
Continuity
Connector
Terminal
Connector
Terminal
F72
1
F58
54
Existed
CONDITION (ENGINE SPEED)
INDICATION
At idle speed
190 - 210 bar
2,000 rpm
400 - 500 bar
3,000 rpm
500 - 700 bar
4,000 rpm
700 - 900 bar
EC-876
< BASIC INSPECTION >
[K9K]
BASIC INSPECTION
YES
>> GO TO 22.
NO
>> GO TO 21.
21.
CHECK FUEL RAIL PRESSURE-II
1.
Turn ignition switch OFF.
2.
Replace fuel rail. Refer to
EM-294, "Removal and Installation"
.
3.
Start engine and let it idle speed.
4.
Select “DATA MONITOR” mode with CONSULT-III.
5.
Check that the “RAIL PRESSURE” indication under the following conditions.
NOTE:
An unusual combustion noise may be heard.
Is the inspection result normal?
YES
>> GO TO 22.
NO
>> Replace high pressure supply pump.
22.
INSPECTION END
High pressure supply pump (volumetric control valve) OK.
>> INSPECTION END
Work Procedure (TEST 6: Fuel Injectors Leak Check)
INFOID:0000000006496540
NOTE:
• CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
- Test 3 High pressure supply pump (pressure control valve) check is OK
- Test 4 High pressure supply pump (volumetric control valve) check is OK
- Test 5 Rail high pressure regulation circuit check is OK.
• CAUSE
- Not enough or no rail pressure during starting.
- The engine does not start.
1.
CHECK FUEL INJECTOR-I
EC-920, "Component Inspection"
Is the inspection result normal?
YES
>> GO TO 2.
NO
>> Replace malfunctioning fuel injector.
2.
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.
3.
To authorise a 15 second cranking engine and carry out this test it is essential to carry out the following
procedure:
-
Disconnect high pressure supply pump (volumetric control valve) harness connector
-
Turn ignition switch ON.
-
Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.
-
Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
-
Cranking engine for at least 15 seconds (starting speed 250 rpm)
-
Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
Is the return volume at the fuel injectors more than 20 ml per fuel injector for the starting phase?
CONDITION (ENGINE SPEED)
INDICATION
At idle speed
190 - 210 bar
2,000 rpm
400 - 500 bar
3,000 rpm
500 - 700 bar
4,000 rpm
700 - 900 bar
BASIC INSPECTION
EC-877
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NOTE:
•
Do not repeat this procedure more than 3 times and wait 30 seconds between each 15 second cranking
engine.
•
Then wait 30 minutes before cranking the engine for 315 second cycles.
•
Follow this instruction so that the starter does not get damaged.
Does the flow measure more than 20 ml?
Yes
>> Replace malfunctioning fuel injector.
No
>> GO TO 3.
3.
CHECK FUEL INJECTOR-II
1.
Turn ignition switch OFF.
2.
Reconnect return pipes.
3.
Start Engine.
4.
Select “DATA MONITOR” mode with CONSULT-III.
5.
Check “RAIL PRESSURE” and “RAIL PRES SET” indication.
6.
Does “RAIL PRESSURE” follow “RAIL PRES SET” during the 3 second cranking engine?
Is the inspection result normal?
YES
>> GO TO 5.
NO
>> GO TO 4.
4.
CHECK GLOW PLUG
1.
Turn ignition switch OFF.
2.
Remove the glow plugs and check for moisture.
3.
If the glow plugs are wet with fuel, it is possible that the fuel injector is leaking.
Are the glow plugs wet with fuel?
Yes
>> Replace malfunction fuel injector.
No
>> Replace high pressure supply pump.
5.
INSPECTION END
Fuel injector system OK.
>> INSPECTION END
Work Procedure (TEST 7: Fuel Injection Quantity Check)
INFOID:0000000006496541
NOTE:
• CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
- Test 3 High pressure supply pump (pressure control valve) check is OK
- Test 4 High pressure supply pump (volumetric control valve) check is OK
- Test 5 Rail high pressure regulation circuit check is OK.
- 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
EC-920, "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.
EC-878
< BASIC INSPECTION >
[K9K]
BASIC INSPECTION
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.
>> INSPECTION END
ADDITIONAL SERVICE WHEN REPLACING ECM
EC-879
< BASIC INSPECTION >
[K9K]
C
D
E
F
G
H
I
J
K
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A
EC
N
P
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ADDITIONAL SERVICE WHEN REPLACING ECM
Description
INFOID:0000000006496542
When replacing ECM, this procedure must be performed.
Work Procedure
INFOID:0000000006496543
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.
>> GO TO 3.
3.
REPLACE ECM
Replace ECM.
>> GO TO 4.
4.
WRITE ECM DATA
1.
Wait at least 30 seconds to turn ON the ignition switch.
2.
Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
3.
Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
4.
Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to
SEC-50, "ECM : Work Procedure"
(With intelligent key system),
(Without intelligent key system).
5.
Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
6.
Select “DATA MONITOR” mode in ECM with CONSULT-III.
7.
Check that the “CODE PROGRAM” indication.
Which is displayed on CONSULT-III?
YES
>> GO TO 6.
NO
>> GO TO 5.
5.
WRITE ECM DATA
1.
Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to
SEC-50, "ECM : Work Procedure"
(With intelligent key system),
(Without intelligent key system).
2.
Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
3.
Select “DATA MONITOR” mode in ECM with CONSULT-III.
4.
Check that the “CODE PROGRAM” indication.
Which is displayed on CONSULT-III?
YES
>> GO TO 6.
NO
>> Repeat above steps.
6.
PERFORM VIN REGISTRATION
1.
Start engine and warm it up to normal operating temperature.
NOTE:
The start-up phase may last up to 30 seconds.
EC-880
< BASIC INSPECTION >
[K9K]
ADDITIONAL SERVICE WHEN REPLACING ECM
2.
Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
3.
Perform “VIN REGISTRATION” in WORK SUPPORT mode with CONSULT-III.
4.
Follow the instruction of CONSULT-III display.
NOTE:
After replace ECM, stored DTC may appear on other control unit. Clear the malfunction memory of these
control unit.
>> END
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