Inspection Procedure 5: Starting impossible (Starter operative but no initial combustion)

PROBABLE CAUSES

Failed battery
Improper fuel used
Fuel contaminated with foreign matter
Injector leaking or clogged
Failed injector
Fuel injection learning failure
Fuel filter clogged
Fuel line leaking or clogged
Failed fuel pressure limiter valve
Failed fuel pressure sensor
Failed supply pump (suction control valve)
Failed glow system
Timing chain torn
Failed engine-ECU
Air cleaner clogged
Compression pressure low

DIAGNOSIS PROCEDURE

STEP 1. Check battery voltage.

Measure battery voltage at cranking.

OK: 8 V or more

Q. Is the check result normal?

	Go to Step 2.

	Check battery (Refer to GROUP 54A - Battery - On-vehicle Service - Battery test ).

STEP 2. M.U.T.-III diagnosis code.

Q. Is the diagnosis code set?

	Inspection chart for diagnosis code (Refer to ).

	Go to Step 3.

STEP 3. Check injector identification code.

Check injector identification code (Refer to GROUP 00 - Precautions Before Service - Injector Identification code Registration Procedure ).

Q. Is the check result normal?

	Go to Step 4.

	Register the injector ID.

STEP 4. M.U.T.-III data list.

Item 40: Starter switch

OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)

Q. Is the check result normal?

	Go to Step 5.

	Check for starting impossible to operate (Refer to Inspection Procedure 4 <M/T>, <A/T>).

STEP 5. Check for torn timing chain.

Q. Is the check result normal?

	Go to Step 6.

	Replace the timing chain.

STEP 6. Confirm the using fuel.

Q. Is the specified fuel being used?

	Go to Step 7.

	Replace the fuel.

STEP 7. Check glow system.

Check glow system (Refer to Inspection Procedure 27 ).

Q. Is the check result normal?

	Go to Step 8.

	Repair or replace the failed item.

STEP 8. Check fuel supply line.

Check for fuel leakage and clogging
Check fuel filter for clogging

Q. Is the check result normal?

	Go to Step 9.

	Repair or replace the failed item.

STEP 9. Priming (air bleeding)

Bleed air

Q. Does trouble symptom persist?

	Go to Step 10.

	The procedure is complete.

STEP 10. M.U.T.-III actuator test.

Refer to Actuator Test Reference Table .

Item 19: Suction control valve.

Q. Is the check result normal?

	Go to Step 11.

	Replace the supply pump. After replacing the supply pump, learn the supply pump (Refer to GROUP 00 - Precautions Before Service - What The Common Rail Engine Learns ).

STEP 11. Check suction control valve itself.

Check suction control valve itself (Refer to ).

Q. Is the check result normal?

	Go to Step 12.

	Replace the supply pump. After replacing the supply pump, learn the supply pump (Refer to GROUP 00 - Precautions Before Service - What The Common Rail Engine Learns ).

STEP 12. M.U.T.-III data list.

Refer to Data List Reference Table .

Item 63: Rail pressure sensor
Item 64: Rail pressure target

Q. Are the check results normal?

	Go to Step 14.

	Go to Step 13.

STEP 13. Replace the fuel pressure sensor.

Replace the common-rail assembly.

Q. Does trouble symptom persist?

	Go to Step 18.

	The procedure is complete.

STEP 14. Check the waveforms of crank angle sensor and camshaft position sensor.

Check the waveforms during cranking.

Q. Are waveforms being output?

	Go to Step 15.

	Proceed to the diagnostic code procedure for the sensor that does not output waveforms (Refer to Inspection Chart for Diagnosis Code ).

STEP 15. Check compression pressure.

Check compression pressure (Refer to GROUP 11G - On-vehicle Service - Compression Pressure Check ).

Q. Is the check result normal?

	Go to Step 16.

	Check and repair the engine itself.

STEP 16. Check injector itself.

Check injector itself (Refer to ).

Q. Is the check result normal?

	Go to Step 17.

	Replace the injector at the failed cylinder. After replacing the Injector, register the injector identification code and learn fuel injection (Refer to GROUP 00 - Precautions Before Service - What The Common Rail Engine Learns ).

STEP 17. M.U.T.-III data list.

Refer to Data List Reference Table .

Item 05: Barometric pressure sensor
Item 07: Engine coolant temperature sensor
Item 08: No. 2 intake air temperature sensor
Item 21: Fuel temperature sensor
Item 43: No. 1 intake air temperature sensor

Q. Are the check results normal?

	Go to Step 18.

	Perform the diagnosis code classified check procedure for the sensor that has shown an abnormal data value (Refer to Inspection Chart for Diagnosis Code ).

STEP 18. Check the trouble symptoms.

Q. Does trouble symptom persist?

	Replace the engine-ECU. When the engine-ECU is replaced, write the chassis number (Refer to GROUP 00 - Precautions Before Service - How to Perform Chassis Number Writing ). After replacing the engine-ECU, register the injector identification code and learn fuel injection (Refer to GROUP 00 - Precautions Before Service - What The Common Rail Engine Learns ).

	Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunction ).