Troble Shoting Comainril

1
Inspection Procedure for
2KD-FTV Engines
Inspection Procedure 2
3 inspection procedures for problem of the common-rail
diesel engine when no DTC is present
•Rough idling
•Excessive engine vibrations
•Engine knocking
Click!
•Engine rattling
•Lack of engine power

•Engine 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
•Injector piston • Intake air system leakage
• Rough 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
• Juddering when •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
Inspection Procedure
Before troubleshooting, check the following items (Basic

Inspections)
•Fuel quality
•Fuel for air OK
•Fuel system for blockages
•Air filter
•Engine oil
•Engine coolant
•Engine idling speed and the max. engine speed
•Vacuum pump
Check wire harness and connector

in engine room
OK [MT only] When idling •Sensors OK
Check •Supply Pump
malfunction •Common-rail
condition •Injectors
•EDU
•Turbocharger System
When engaging •Intake and Exhaust System
engine clutch at
vehicle start Repair or
replace clutch NG
system
Repair or
replace
[DTC check for pressure discharge valve]
Perform following procedure for 2 times

OK No DTCs
Engine Engine
Start Stop
Wait 10 sec. or more
Some DTCs
Repair or
replace
[DTC check for fuel system and intake system]
1. Transfer to CHECK MODE

2. Warm-up Engine
3. Idle for 5 min. or more
(to set DTCs relating to rough idling)
4. Drive the vehicle more than 40 km/h for 30 sec. or No DTCs
No DTC more
5. Stop the vehicle (don’t stop the engine)
6. Perform Step (4) ~ (5) 4 times or more
7. Stop the engine and wait 10 sec.
8. Perform Step (4) ~ (7) again (to set DTCs relating
to EGR system and intake shutter)
9. Drive the vehicle more than 70 km/h for 1 min. or
more (to set DTCs relating to supply pump)
Some DTCs
Repair or
replace
Check fuel leak No

No DTC Leakage
• Fuel leak test (Active Test)
• Visually check for supply pump, injector and fuel
line between the supply pump and injector
Leakage
Repair or
replace
Common-rail Check
pressure is outside common-
of standard rail system
(Click !)
No Check the following values of DATA Standard

Leakage LIST on IT II range
•PIM
•MAF
•Common-rail Pressure
MAF is outside
PIM is of standard
PIM and MAF
outside of
are outside Inspection of
standard
of standard DTC
(related to mass
Check intake Inspection of DTC air flow meter)
system (related to
(Click !) manifold absolute
sensor)
Standard
Check the following values of
range OK OK
DATA LIST on IT II Check injector
•Revised injection volume compensation
(#1 - #4) code
•Injection volume
NG
Either item
is outside of
standard
Register injector
compensation
Check
code
injection
volume
(Click !)
1. Disconnect battery negative

OK terminal for 2 min. or more NG OK
2. Reconnect the terminal Check engine
3. Check the malfunction is mounting insulator
successfully repaired by
driving test NG
Repaired
successfully
Repair or
replace
Check for
intermittent
problems
PIM and MAF
are outside
of standard
Check air
OK OK OK Check intake OK
leakage and any Check EGR valve
shutter
blockages in (refer to each
(refer to each
intake and repair manual)
repair manual)
exhaust system
NG
NG
NG
Repair or
Repair or
Repair or replace
replace
replace
Power-balance Inspection
Check cylinder
OK OK
compression
To identity the
pressure of
malfunctioning cylinder,
malfunction
perform Active Test (Injector
cylinder
Cut #1, #2, #3 and #4)
NG
Malfunction cylinder:
When the injector is cut off, idling
stability variation is small Repair or
replace
Normal cylinder:
When the injector is cut off, engine
idles roughly
OK Deposits
Check malfunction
Clean injector and
cylinder injector for
then reinstall it
deposit
No
Deposits
Replace the injector

of malfunction
cylinder

DATA LIST on IT II OK
•Revised injection volume
(#1 - #4)
END
•Injection volume
Either item
is outside of
standard
Deposits inside the
Replace the injector injector may be
causing the
of malfunction
problem
cylinder
Click to reference
Result of DATA LIST 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 power- Check all

balance injectors
(Click !) (Click !)
A Replace the
END
To identity the injector of
malfunctioning cylinder, malfunction
perform Active Test (Injector cylinder
Cut #1, #2, #3 and #4)
When the injector is cut off, idling
stability variation is small
Normal cylinder:
When the injector is cut off, engine
idles roughly
Deposits
Check all cylinder Clean injectors and
C
injectors for deposit then reinstall it
No
Deposits
Replace the injectors

of all cylinder

(#1 - #4)
END
•Injection volume
Either item
is outside of
standard
Deposits inside the
Replace the injector may be
causing the
injector of all
problem
cylinder
Common-rail Inspect fuel OK Inspect supply OK

pressure is pressure sensor pump assy
outside of (refer to each (refer to each
standard repair manual) repair manual)
NG NG
Replace Replace
pressure supply
sensor pump assy
OK Check and replace common-rail
END
assy (discharge valve or
pressure limiter)
(refer to each repair manual)
23
Engine Knocking
or
Rattling
Engine Knocking or Rattling 24
General
Malfunction
Condition
1.Injector malfunctions
•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

Inspections)
•Fuel quality
•Fuel for air OK
•Air filter
•Engine oil
•Engine coolant
•Vacuum pump
Check wire harness and

Supply pump connector in engine room
or
OK Check abnormal knocking •Sensors
OK
sound area using •Supply Pump
mechanic’s •Common-rail
stethoscope •Injectors
•EDU
Parts other •Turbocharger System
than supply •Intake and Exhaust System
pump
NG
Replace
pressure
sensor Repair or
replace
[DTC check for pressure discharge valve]
Perform following procedure for 2 times

OK No DTCs
Engine Engine
Start Stop
Wait 10 sec. or more
Some DTCs
Repair or
replace

2. Warm-up Engine
No DTC 4. Drive the vehicle more than 40 km/h for 30 sec. or No DTCs
more
8. Perform Step (4) ~ (7) again (to set DTCs
relating to EGR system and intake shutter)
Some DTCs
Repair or
replace
Check fuel leak No

No DTC Leakage
• Visually check for supply pump, injector and fuel
line between the supply pump and injector
Leakage
Repair or
replace
Common-rail Check
(Click !)
No Check the following values of DATA Standard

Leakage LIST on IT II range
•PIM
•MAF
•Common-rail Pressure
MAF is outside
PIM is of standard
PIM and MAF
are outside outside of Inspection of
of standard standard DTC
(related to mass
system (related to
sensor)
Standard
range OK OK
(#1 - #4) code
•Injection volume
NG
Either item is
outside of
standard
Register injector
compensation
Check injection code
volume
(Click !)
PIM and MAF

are outside
of standard

OK terminal for 2 min. or more Check air leakage OK
2. Reconnect the terminal NG
and any blockages
3. Check the malfunction is in intake and
successfully repaired by exhaust system
driving test
NG
Repaired
successfully
Repair or
Check for replace
intermittent
problems
OK OK OK
Check EGR valve Check intake shutter
(refer to each repair (refer to each repair
manual) manual)
NG NG
Repair or Repair or
replace replace
OK Knocking
Check
combustion
sound
Sound from
supply pump
Bleed air from Check the knocking is

fuel system by
priming pump
successfully repaired
by driving test
END
Knocking Check cylinder OK
To identity the compression
malfunctioning cylinder, pressure of
perform Active Test (Injector malfunction
Cut #1, #2, #3 and #4) cylinder
NG
When the injector is cut off,
idling stability variation is small Repair or
replace
Normal cylinder:
engine idles roughly
OK Deposits
Check malfunction
Clean injector and
then reinstall it
deposit
No
Deposits

of malfunction
cylinder

(#1 - #4)
END
•Injection volume
Either item
is outside of
standard
Deposits inside the
causing the
of malfunction
problem
cylinder
Click to reference
Injection
Volume
Less More
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

balance injectors
(Click !) (Click !)
A Replace the
END
Cut #1, #2, #3 and #4)
idling stability variation is small
Normal cylinder:
Deposits
Check all cylinder Clean injectors and
C
injectors for deposit then reinstall it
No
Deposits
Replace the
injectors of all
cylinder

(#1 - #4)
END
•Injection volume
Either item
is outside of
standard
Deposits inside the
causing the
injector of all
problem
cylinder
Common-rail Inspect fuel OK Inspect supply OK

pressure is pressure sensor pump assy
outside of (refer to each (refer to each
standard repair manual) repair manual)
NG NG
Replace Replace
pressure supply
sensor pump assy
OK Check and replace common-rail
END
assy (discharge valve or
pressure limiter)
44
Lack of Power
or
Hesitation
Lack of Power or Hesitation 45
General
Malfunction
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
• Lackof power
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

Inspections)
•Fuel quality
•Fuel for air OK
•Air filter
•Engine oil
•Engine coolant
•Vacuum pump
[DTC check for pressure

Check wire harness and discharge valve]
connector in engine room
Perform following
•Sensors procedure for 2 times No DTCs
OK •Supply Pump OK
•Common-rail
•Injectors Engine Engine
•EDU Start Stop
•Turbocharger System
•Intake and Exhaust
System Wait 10 sec. or more
NG
Some DTCs
Repair or
Repair or
replace
replace

2. Warm-up Engine
4. Drive the vehicle more than 40 km/h for 30 sec. or No DTC
No DTC
more
8. Perform Step (4) ~ (7) again (to set DTCs relating
to EGR system and intake shutter)
Some DTCs
Repair or
replace
Check white smoke

Check fuel leak
No No • Check white smoke by rev
DTC Leakage up the engine idling  OK
• Visually check for supply 3000rpm several times
pump, injector and fuel • Check the intake system
line between the supply pipes and hoses are not
pump and injector excessively contaminated
with oil
White smoke
Leakage or
contaminated
Repair or with oil
replace
Check intake
system
(Click !)
Common-rail Check
(Click !)
Check the following values of DATA Standard

OK LIST on IT II range
•PIM
•MAF
•Common-rail Pressure MAF is outside
of standard
PIM and MAF PIM is
are outside outside of Inspection of
of standard standard DTC
(related to mass
system (related to
sensor)
Standard
range OK OK
(#1 - #4) code
•Injection volume
NG
Either item
is outside of
standard
Register injector
Check injection compensation
volume code
(Click !)

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

intermittent
problems
Lack of
power Inspect glow plug
OK Check air leakage OK
circuit and glow
END
and any blockages
plug assy
in intake and
(refer to each
exhaust system
repair manual)
NG
NG
Repair or Repair or
replace replace
Click to reference
Injection
Volume
Less More
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

balance injectors
(Click !) (Click !)
A Replace the
END
Cut #1, #2, #3 and #4)
Normal cylinder:
Check cylinder OK
To identity the compression
B
malfunctioning cylinder, pressure of
perform Active Test (Injector malfunction
Cut #1, #2, #3 and #4) cylinder
NG
Repair or
Normal cylinder: replace
OK Deposits
Check malfunction
Clean injector and
then reinstall it
deposit
No
Deposits

of malfunction
cylinder

(#1 - #4)
END
•Injection volume
Either item
is outside of
standard
Deposits inside the
causing the
of malfunction
problem
cylinder
Deposits
Check all cylinder Clean injectors
C injectors for and then
deposit reinstall it
No
Deposits
Replace the injectors

of all cylinder

(#1 - #4)
END
•Injection volume
Either item
is outside of
standard
Deposits inside the
causing the
injector of all
problem
cylinder
Common-rail Check and NG

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

OK
sensor Inspect supply pump assy
(refer to each repair (refer to each repair manual)
manual)
NG
NG
Replace supply
Replace pump assy
pressure
sensor
OK Check and replace common-
END
rail assy (discharge valve or
pressure limiter)
OK OK
PIM and MAF Check EGR valve Check intake shutter
are outside (refer to each (refer to each repair
of standard repair manual) manual)
NG NG
Repair or Repair or
replace replace
White smoke
or
contaminated with oil
Check turbocharger
OK Check air leakage OK 1.Disconnect the air cleaner hose OK

and any blockages 2.Visually check the turbocharger for
in intake and any mechanical problems
exhaust system 3.When the engine is cold, check that
the impellor rotates smoothly, and
NG confirm whether there is any
damage to it
NG
Repair or
replace
Repair or
replace
Check vacuum type VN turbocharger
• Check vacuum hose (for VRV)

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

hose NG NG
NG
Replace or replace Replace Replace

vacuum hose VRV turbocharger
Check the following

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

of DATA LIST on IT II range
•PIM
•MAF
END
NG
Replace
turbocharger

Troble Shoting Comainril

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Troble Shoting Comainril

Загружено:

Авторское право:

Доступные форматы

1

Inspection Procedure for

•Lack of engine power

to abnormal •Injector stuck closed • EGR system

Before troubleshooting, check the following items (Basic

Check wire harness and connector

[DTC check for pressure discharge valve]

Perform following procedure for 2 times

Wait 10 sec. or more

[DTC check for fuel system and intake system]

1. Transfer to CHECK MODE

Check fuel leak No

No Check the following values of DATA Standard

1. Disconnect battery negative

Replace the injector

Check the following values of

Result of DATA LIST reading

Check power- Check all

Replace the injectors

Check the following values of

Common-rail Inspect fuel OK Inspect supply OK

OK Check and replace common-rail

Before troubleshooting, check the following items (Basic

Check wire harness and

[DTC check for pressure discharge valve]

Perform following procedure for 2 times

Wait 10 sec. or more

[DTC check for fuel system and intake system]

1. Transfer to CHECK MODE

Check fuel leak No

No Check the following values of DATA Standard

PIM and MAF

1. Disconnect battery negative

Bleed air from Check the knocking is

Replace the injector

Check the following values of

Result of DATA LIST reading

Check power- Check all

Check the following values of

Common-rail Inspect fuel OK Inspect supply OK

OK Check and replace common-rail

• Pressure discharge valve

Before troubleshooting, check the following items (Basic

[DTC check for pressure

[DTC check for fuel system and intake system]

1. Transfer to CHECK MODE

Check white smoke

Check the following values of DATA Standard

1. Disconnect battery negative

Check for END

Result of DATA LIST reading

Check power- Check all

Replace the injector

Check the following values of

Replace the injectors

Check the following values of

Common-rail Check and NG

NG Inspect fuel pressure OK

OK Check and replace common-

OK Check air leakage OK 1.Disconnect the air cleaner hose OK

Check vacuum type VN turbocharger

• Check vacuum hose (for VRV)