Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1VD-FTV ENGINE CONTROL

DESCRIPTION

INSPECTION PROCEDURE

CHECK ENGINE CRANKING CONDITION

READ ALL OUTPUT DTCS

TAKE SNAPSHOT DURING STARTING AND IDLING (PROCEDURE 3)

CHECK SNAPSHOT (COMMON RAIL PRESSURE)

CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY

CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

BLEED AIR FROM FUEL SYSTEM

PERFORM SUPPLY PUMP INITIALIZATION

READ VALUE USING GTS (COMMON RAIL PRESSURE)

INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)

CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)

BLEED AIR FROM FUEL SYSTEM

READ VALUE USING GTS (COMMON RAIL PRESSURE)

REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

PERFORM SUPPLY PUMP INITIALIZATION

REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)

CHECK DATA LIST

REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER

BLEED AIR FROM FUEL SYSTEM

REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

INSPECT INJECTOR DRIVER

INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)

CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS

READ VALUE USING ENGINE COOLANT TEMPERATURE SENSOR (COOLANT TEMP)

INSPECT GLOW PLUG (RESISTANCE)

CHECK FUEL QUALITY

READ OUTPUT DTC (RELATED TO ENGINE)

CHECK COMMUNICATION BETWEEN GTS AND ECM

READ VALUE USING GTS (STARTER SIGNAL AND NEUTRAL POSITION SW SIGNAL)

CHECK STARTING SYSTEM

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

ECD SYSTEM (w/ DPF) - Engine Difficult to Start or Stalling

DESCRIPTION

Faults and Symptoms of Common Rail Diesel Components

Engine Control

Mass Air Flow Meter
Main faultDecrease in performance (foreign matter is stuck)
SymptomsLack of power, black smoke
Data ListMAF
  • HINT:
  • The maximum fuel injection volume is controlled according to the output from the mass air flow meter.
Intake System
Symptom and Corresponding Main Fault
Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct
Black smoke (no lack of power) due to leakage between the turbo and intake manifold
Data ListMAP
Turbocharger System
Main fault
Air leak in the turbocharged air passage
ECM not operating well
Turbocharger sub-assembly (turbine, bearing)
SymptomsLack of power (when vehicle is starting, under heavy load)
(Black smoke is not emitted when racing while vehicle is stopped)
Data ListMAP
With the engine switch on (IG) or during idling, MAP = atmospheric pressure (standard atmospheric pressure = 101 kPa). When the engine speed is about 1500 rpm or more, the turbocharger starts to take effect and MAP becomes higher than atmospheric pressure.
Atmospheric pressure decreases by 1 kPa each time elevation increases by 100 m, and is also affected by the current weather conditions.
Exhaust System
Main faultBlockage
SymptomsLack of power (high engine speed, under heavy load)
Glow System
Main faultGlow system malfunction
SymptomsDifficult to start, rough idle, knocking, white smoke (when cold)
Data ListCheck the glow plug indicator light
Diagnostic PointMeasure the resistance of the glow plug
Battery
Main faultBattery is depleted
SymptomsDifficult to start (cannot crank, crank speed is low), horn is quiet
Data ListBattery Voltage
When cranking, battery voltage is below 5 V.
Engine - 1
Main faultDamaged, seized up
SymptomsCannot crank, crank speed is low, strange noise
Engine - 2
Main faultLoss of compression
SymptomsRough idle (lack of power always)
Data ListEngine Speed of Cyl
When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.
Injection Feedback Val
When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.
Start System
Main faultStarter system malfunction
SymptomsDifficult to start
Data ListStarter Signal
Engine switch (STA) output:
Open: Starter is operating
Close: Starter is not operating

Diesel Injection

Fuel Supply Pump Assembly
Main fault-
SymptomsDifficult to start, engine stalling, rough idle, lack of power
Data ListCommon Rail Pressure, Target Common Rail Pressure, Target Pump SCV Current
Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).
If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.
If the fuel pressure is below 25000 kPa, then idling will be rough.
  • HINT:
The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.
When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.
Diagnostic Trouble CodeEven if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.
Fuel Filter
Main faultBlockage
SymptomsDifficult to start, engine stalling, rough idle, lack of power
Data ListCommon Rail Pressure, Target Common Rail Pressure
Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).
If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.
If the fuel pressure is below 25000 kPa, then idling will be rough.
  • HINT:
  • The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.
Diagnostic Trouble CodeEven if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.
Injector Assembly
Main faultBlockage
SymptomsRough idle, lack of power, black smoke, white smoke, knocking
Data ListInjection Feedback Val
When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.
Pressure Discharge Valve
Main faultDoes not completely close
SymptomsDifficult to start, engine stall, rough idle, lack of power
Injector Driver
Main faultCircuit fault: The injector assembly does not open.
SymptomsDifficult to start, rough idle, lack of power, black smoke, white smoke, knocking
Data ListSame as injector assembly
Diagnostic Trouble CodeWhen the injector driver has a fault, some DTCs may be stored.
Fuel Pressure Sensor
Main faultOpen circuit, decrease in performance (foreign matter is stuck)
SymptomsDifficult to start, rough idle, engine stall, lack of power
Data ListCommon Rail Pressure, Target Common Rail Pressure
Slowly raise the engine speed from idling to 3000 rpm with the vehicle stopped and check that Common Rail Pressure follow Target Common Rail Pressure. If the fuel pressure sensor malfunctions, the actual fuel pressure may deviate from the target fuel pressure (either Common Rail Pressure decreases to a value less than Target Common Rail Pressure).
Diagnostic Trouble CodeWhen the fuel pressure sensor has a fault, some DTCs may be stored.
Irregular Fuel
Main fault-
SymptomsDifficult to start, rough idle (especially when cold)

Diesel EGR

EGR System
Main fault
Does not move smoothly
Does not close completely
Symptoms
Rough idle
EGR valve stuck closed: A loud turbocharger sound.
EGR valve stuck open: Difficult to start (does not stall), black smoke, lack of power (if there is an excess in the quantity of EGR and there is a heavy load, when the vehicle starts moving, a lack of power will be felt).
Data ListActual EGR Valve Pos, Actual EGR Valve Pos #2, Target EGR Valve Pos, Target EGR Valve Pos #2
Generally, Actual EGR Valve Pos = Target EGR Valve Pos +/-5% (fully closed: 0%, fully open: 100%).
Using the EGR valve Active Test, check whether Actual EGR Valve Pos follows Target EGR Valve Pos (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).
EGR valve is fully closed when the engine switch is turned to on (IG) (engine stopped).
EGR valve opens to the halfway point at idling after the engine is warmed up.
EGR Close Lrn. Val., EGR Close Lrn. Val. #2
When leaving the vehicle idling, the normal range of EGR Close Lrn. Val. is 3.5 to 4.5 V.
In cases when EGR Close Lrn. Val. is out of the normal range (3.5 to 4.5 V), it is possible that the EGR valve cannot completely close.

Diesel Throttle

Diesel Throttle System
Main faultStuck, does not move smoothly
Symptoms
Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.
Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.
Data List
Actual Throttle Position, Actual Throttle Position #2
100%: Fully open
0%: Fully closed
When the engine switch is on (IG) (the engine is stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the engine switch is turned from on (IG) to off, the throttle is fully closed temporarily.
Data List Related to Starting Trouble
MAP
MAF
Intake Air
Coolant Temp
Battery Voltage
Starter Signal
Engine Speed of Cyl #1 (to #8)
Target Common Rail Pressure
Common Rail Pressure
Target Pump SCV Current
Injection Feedback Val #1 (to #8)
Injection Volume
Actual Throttle Position
Actual Throttle Position #2
Target EGR Valve Pos.
Target EGR Valve Pos #2
Actual EGR Valve Pos
Actual EGR Valve Pos #2
EGR Close Lrn. Val.
EGR Close Lrn. Val #2

INSPECTION PROCEDURE

Explanation of Symptom
Starting TroubleFor good starting it is essential to have:
Sufficient cranking speed.
Properly operating engine preheating system.
Good quality fuel.
The fuel is ignited by the heat which is generated by compression pressure.
With problems such as a depleted battery, the crankshaft speed can become low, or if the engine compression is poor due to leakage, the compression pressure will not rise and there will be difficulty starting.
When the engine is cold, even if there is compression heat, it will escape from the combustion chamber. For this reason, when the engine is started when it is cold, the glow plugs heat the compressed air.
Also, after starting the engine, by charging the glow plugs for a fixed time set according to the engine coolant temperature, diesel knocking and white smoke are prevented. The quantity of fuel injected is determined by the fuel pressure and also the amount of time the injector assembly is open.
Trouble Area Chart According to Problem Cause

Ecd System (W/ Dpf) - Engine Difficult To Start Or Stalling. 1VD-FTV ENGINE CONTROL. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Ecd System (W/ Dpf) - Engine Difficult To Start Or Stalling. 1VD-FTV ENGINE CONTROL. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

  • NOTICE:
After replacing the ECM, the new ECM needs registration () and initialization ().
After replacing the fuel supply pump assembly, the ECM needs initialization ().
After replacing an injector assembly, the ECM needs registration ().
  • 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 age. Do not assume the vehicle is normal when the Data List outputs standard values. There may be concealed factors of the malfunction.
1.CHECK ENGINE CRANKING CONDITION

Check the engine cranking condition.

Result
ResultProceed to
Cranking is OK.A
Low cranking speed.
  • HINT:
  • When cranking speed is low, especially when the temperature is low, check if the engine oil grade matches the recommendation.
B
Does not crank at all.C
B
CHECK BATTERY CONDITION ()
C
Go to step 34
A
2.READ ALL OUTPUT DTCS

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Utility / All Codes.

Result
ResultProceed to
No DTC is outputA
Engine related DTCs are outputB
  • HINT:
  • If only DTC P1604 is output, proceed to step 3.
B
GO TO RELATED DTC ()
A
3.TAKE SNAPSHOT DURING STARTING AND IDLING (PROCEDURE 3)

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Engine and ECT / Data List / All Data.

Take a snapshot when idling with no load after the engine is warmed up and when starting trouble is occurring.

  • HINT:
A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is very useful for troubleshooting. The data in the illustration below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.
When there is trouble starting with a cold engine, take the snapshot when the engine is cold. Then warm up the engine (engine coolant temperature is 70°C (158°F) or higher) and after idling the vehicle for 1 minute (A/C off, electrical load off), take a snapshot of the data for 15 seconds while idling.
Take a snapshot when the problem is occurring, such as when the engine is cold. However, if the problem does not reoccur, it is acceptable to only take a snapshot after the engine is warmed up and when the engine is started.
NEXT
4.CHECK SNAPSHOT (COMMON RAIL PRESSURE)

Check Common Rail Pressure in the snapshot taken in procedure 3 when the engine was started.

Ecd System (W/ Dpf) - Engine Difficult To Start Or Stalling. 1VD-FTV ENGINE CONTROL. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Result
ResultProceed to
At the point in the illustration labeled "a", Common Rail Pressure is less than 10000 kPa from the value of Common Rail Pressure when cranking startsA
At the point in the illustration labeled "c", Common Rail Pressure is below Target Common Rail Pressure by 15000 kPa or moreB
Common Rail Pressure increases to a value that is higher than Target Common Rail Pressure immediately after cranking, and, at the point in the illustration labeled "d", Common Rail Pressure is higher than Target Common Rail PressureC
Except aboveD
  • HINT:
Even if Common Rail Pressure is temporarily higher than Target Common Rail Pressure, as shown at the point in the illustration labeled "b", the fuel supply pump assembly is normal.
Common Rail Pressure is about 25000 to 35000 kPa when the engine is cranking and the engine coolant temperature is 0°C (32°F) or higher.
Common Rail Pressure increases rapidly during cranking.
B
Go to step 14
C
Go to step 28
D
Go to step 18
A
5.CHECK IF FUEL IS BEING SUPPLIED TO FUEL SUPPLY PUMP ASSEMBLY

Disconnect the inlet hose from the fuel supply pump assembly.

Operate the priming pump and check that fuel is being supplied to the fuel supply pump assembly.

  • OK:
  • Fuel is properly supplied to the fuel supply pump assembly when the priming pump is operated.
  • HINT:
When there is a lack of fuel, fuel pressure drops.
Inspect for fuel filter clogging (check that the fuel filter is not clogged).

Reconnect the inlet hose.

NG
Go to step 12
OK
6.CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

Disconnect the suction control valve connector.

Disconnect the ECM connector.

Measure the resistance according to the value(s) in the table below.

  • Standard Resistance:
  • for LHD
    Tester ConnectionConditionSpecified Condition
    z64-1 (+B) - C45- 104 (PCV+)AlwaysBelow 1 Ω
    z64-2 (PCV) - C45-105 (PCV-)AlwaysBelow 1 Ω
    z64-1 (+B) or C45- 104 (PCV+) - Body groundAlways10 kΩ or higher
    z64-2 (PCV) or C45-105 (PCV-) - Body groundAlways10 kΩ or higher
  • Standard Resistance:
  • for RHD
    Tester ConnectionConditionSpecified Condition
    z64-1 (+B) - C46- 104 (PCV+)AlwaysBelow 1 Ω
    z64-2 (PCV) - C46-105 (PCV-)AlwaysBelow 1 Ω
    z64-1 (+B) or C46- 104 (PCV+) - Body groundAlways10 kΩ or higher
    z64-2 (PCV) or C46-105 (PCV-) - Body groundAlways10 kΩ or higher

Reconnect the suction control valve connector.

Reconnect the ECM connector.

NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
7.REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

Replace the supply pump assembly ().

NEXT
8.BLEED AIR FROM FUEL SYSTEM

Bleed the air from the fuel system ().

Perform PM forced regeneration ().

  • HINT:
  • When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.
NEXT
9.PERFORM SUPPLY PUMP INITIALIZATION

Perform supply pump initialization ().

NEXT
10.READ VALUE USING GTS (COMMON RAIL PRESSURE)

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Engine and ECT / Data List / Common Rail Pressure.

Start the engine.

Read the Fuel Press values while cranking and idling the engine.

Result
ResultProceed to
The engine cannot be started or the engine can be started but Common Rail Pressure is below 20000 kPa 2 seconds after the starter signal changes from OFF to ONB
Except aboveA
B
Go to step 11
A
END
11.INSPECT INJECTOR ASSEMBLY (INSPECTION FOR VALVE CLOSING PROBLEM)

Remove the glow plug assembly for all the cylinders ().

Visually check if there is fuel on the glow plugs.

  • HINT:
If there is fuel on a glow plug, fuel may be leaking from an injector assembly.
After replacing an injector assembly, make sure that the common rail pressure is within 5000 kPa of the target fuel pressure while cranking the engine.
If there is fuel on a glow plug, fuel may have mixed with the engine oil. Check the engine oil amount and whether the engine oil smells of diesel fuel. If the oil level is above the full line or the engine oil smells of diesel fuel, replace the engine oil.

Install the glow plug assembly ().

NEXT
Go to step 23
12.CHECK AND REPAIR OR REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)

Check and repair or replace the clogged fuel pipe.

NEXT
13.BLEED AIR FROM FUEL SYSTEM

Bleed the air from the fuel system ().

Perform PM forced regeneration ().

  • HINT:
  • When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.
NEXT
Go to step 27
14.READ VALUE USING GTS (COMMON RAIL PRESSURE)

Check Common Rail Pressure in the snapshot taken in procedure 3 when the engine was warmed up.

Result
ResultProceed to
Difference between Common Rail Pressure and Target Common Rail Pressure is 5000 kPa (51.0 kgf/cm2, 725 psi) or moreA
Except aboveB
B
Go to step 17
A
15.REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

Replace the fuel supply pump assembly ().

NEXT
16.PERFORM SUPPLY PUMP INITIALIZATION

Perform supply pump initialization ().

NEXT
17.REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

Replace the injector assemblies ().

  • NOTICE:
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
NEXT
Go to step 24
18.INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)

When the engine does not start, perform the following procedure.


Stop the engine and leave the vehicle for 4 hours or more.

  • HINT:
  • It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

Check that the engine starts.

  • OK:
  • The engine starts.

When the engine starts, perform the following procedure.


Bleed the air from the fuel system ().

Check that the engine starts.

  • OK:
  • The engine starts.
NG
Go to step 19
OK
END
19.CHECK DATA LIST

Check Injection Feedback Val # in the snapshot taken in procedure 3 when the engine was idling.

Result
ResultProceed to
Injection Feedback Val #1 to #8 are 3 mm3/st or less.
Injection Volume is more than 13 mm3/st.
A*
Injection Feedback Val for at least one cylinder is more than +3 mm3/st
  • HINT:
  • There may be a malfunction in the corresponding cylinder.
B
Except aboveC
  • HINT:
*: When this case occurs, usually symptoms may be noticeable, such as difficulty starting or lack of power.
The shift lever should be in neutral and the A/C switch and all accessory switches should be off.
B
Go to step 21
C
Go to step 30
A
20.REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

Replace the injector assemblies ().

  • NOTICE:
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
NEXT
Go to step 24
21.PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)
  • HINT:
  • Use this Active Test to help determine whether a cylinder has compression loss or not.

Connect the GTS to the DLC3.

Start the engine and turn the GTS on.

Enter the following menus: Engine and ECT / Active Test / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #8.

Check the engine speed during the Active Test.

Result
ResultProceed to
Except belowA
The values of Engine Speed Cyl #1 to #8 are within +/-10 rpm of each other.B
  • HINT:
  • When cranking, if the speed of a cylinder is approximately 100 rpm more than the other cylinders, there is probably a complete loss of compression in that cylinder.
B
Go to step 23
A
22.CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER
  • HINT:
  • Measure the compression of the cylinder that had a high speed during the "Check the Cylinder Compression" Active Test.

Check the cylinder compression pressure ().

NG
CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION
OK
23.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
  • HINT:
  • It can be determined that the injector assembly is faulty as the corresponding cylinder is malfunctioning, but has no compression loss.

Replace the injector assembly ().

  • NOTICE:
When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
Follow the procedure in the repair manual and temporarily install the injection pipes and nozzle leakage pipe, and then correctly position the injector assemblies. After that, tighten parts according to the torque specifications.
If the installation procedure is not performed correctly, injector assemblies may become out of position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
If an injector assembly becomes out of position, it is possible that the seal between the injector assembly and injection pipe may become incomplete, resulting in a fuel leak.
NEXT
24.CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER

Clean the fuel filter case and replace the fuel filter.

  • HINT:
  • Be sure to clean the inside of the fuel filter case as the fuel injectors may not operate properly if the fuel filter is installed with foreign matter remaining inside the fuel filter case.
NEXT
25.BLEED AIR FROM FUEL SYSTEM

Bleed the air from the fuel system ().

Perform PM forced regeneration ().

  • HINT:
  • When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.
NEXT
26.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

Register the injector compensation codes ().

Perform the injector pilot quantity learning ().

NEXT
27.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
NEXT
END
28.INSPECT INJECTOR DRIVER

Even in cases where DTC P062D and P062E are not stored even though the engine cannot be started, perform the DTC P062D troubleshooting procedure ().

  • HINT:
When the engine cannot be started due to a malfunction in the injector driver system, once the DTCs are cleared, the system cannot store DTC P062D and P062E even if it is confirmed that the engine cannot be started when trying to reproduce the problem symptoms.
As DTC P062D and P062E cannot be stored when starting the engine, fuel injection signals are output by the ECM, but fuel is not actually injected. Therefore, an excessive amount of fuel is supplied to the common rail by the fuel supply pump assembly, and as a result, the fuel pressure is higher than the target common rail pressure in the data recorded at the time the engine was having trouble starting.
If the problem cannot be determined even after performing the DTC P062D and P062E troubleshooting procedure and the fuel pressure is higher than the target common rail pressure when attempting to start the engine, proceed to the next step.
Result
ResultProceed to
Injector driver (EDU) circuit is normalA
Injector driver (EDU) circuit is abnormalB
B
REPAIR OR REPLACE MALFUNCTIONING PARTS
A
29.INSPECT INJECTOR ASSEMBLY (CHECKING FOR PRESENCE OF AIR)

When the engine does not start, perform the following procedure.


Stop the engine and leave the vehicle for 4 hours or more.

  • HINT:
  • It is necessary to leave the vehicle for 4 hours or more to wait for air in the injector assembly to come out.

Confirm the engine starts.

When the engine starts, perform the following procedure.


Bleed the air from the fuel system ().

Confirm the engine starts.

NEXT
Go to step 38
30.CHECK TEMPERATURE WHEN STARTING TROUBLE OCCURS

Check the temperature when starting trouble occurs.

Result
ResultProceed to
Difficult to start only for cold engine.A
Difficult to start both for cold and warmed up engine.B
B
Go to step 33
A
31.READ VALUE USING ENGINE COOLANT TEMPERATURE SENSOR (COOLANT TEMP)

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Engine and ECT / Data List / All Data / Coolant Temp.

Read the value displayed on the GTS.

  • OK:
  • Coolant Temp is not high when the engine is cold, and not low after the engine is warmed up
NG
INSPECT ENGINE COOLANT TEMPERATURE SENSOR ()
OK
32.INSPECT GLOW PLUG (RESISTANCE)

Inspect the glow plug ().

NG
REPLACE GLOW PLUG ()
OK
33.CHECK FUEL QUALITY

Check that only diesel fuel is being used.

Check that the fuel does not contain any impurities.

NEXT
Go to step 38
34.READ OUTPUT DTC (RELATED TO ENGINE)

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Engine and ECT / Trouble Codes.

Read the DTCs.

Result
ResultProceed to
No DTC is outputA
Engine related DTCs are outputB
B
GO TO RELATED DTC ()
A
35.CHECK COMMUNICATION BETWEEN GTS AND ECM

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Check if the normal starting screen appears (check whether communication with the ECM is possible).

  • HINT:
  • Use a GTS that is able to communicate with other vehicles.
  • OK:
  • Communication is possible (vehicle can be recognized).
NG
CHECK VC OUTPUT CIRCUIT ()
OK
36.READ VALUE USING GTS (STARTER SIGNAL AND NEUTRAL POSITION SW SIGNAL)

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Enter the following menus: Engine and ECT / Data List / All Data / Starter Signal and Neutral Position SW Signal.

Read the value displayed on the GTS.

  • OK:
  • GTS DisplayConditionSpecified Condition
    Starter SignalCrankingOpen
    Neutral Position SW SignalShift lever in neutralON
NG
INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
OK
37.CHECK STARTING SYSTEM

Inspect the starting system.

  • HINT:
  • Be sure to inspect the following areas:
Starter relay
Starter assembly
Immobiliser system
NEXT
38.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
NEXT
END