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's age. Do not judge the vehicle to be normal even when the Data List values indicate a standard level. There are possibly some concealed factors of the malfunction.

Check that the vehicle has not been modified in any way prior to the vehicle inspection.

INSPECTION PROCEDURE

HINT:

This troubleshooting procedure checks for knocking and rattling.

Knocking is most likely to occur while the engine is idling.

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 ().

1.CHECK SOUND AREA

Find the source of the abnormal sound using a mechanic's stethoscope.

Result
Result	Proceed to
Combustion noise from engine	A
Noise from specific part	B

REPAIR OR REPLACE MALFUNCTIONING PARTS

A

2.READ OUTPUT DTCS (RELATING 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
Result	Proceed to
No DTC is output	A
Engine related DTCs are output	B

GO TO DTC CHART ()

A

3.CHECK INJECTOR COMPENSATION CODE

NOTICE:

Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head portion of each injector assembly. If an incorrect injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

Check the injector compensation code ().

OK:
Compensation codes of the installed injector assemblies are the same as the compensation codes registered in the ECM.

Go to step 18

OK

4.TAKE SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)

Connect the GTS to the DLC3.

Start the engine and turn the GTS on.

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

Take a snapshot of the Data List items.

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 list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.

NEXT

5.CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #8 AND INJECTION VOLUME)

Check Injection Feedback Val #1 to #8 and Injection Volume in the snapshot taken when the engine was idling and at 4000 rpm with no load.

Result
Result	Proceed to
Injection Feedback Val for at least one cylinder is more than +3 mm³/st	A
Injection Volume is 9 mm³/st or less at 4000 rpm	B
Except above	C

HINT:

When there is a problem with the operation of an injector assembly due to foreign matter in the inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to increase.

The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is approximately 0 mm³/st. Even if the value of Injection Feedback Val for a cylinder is less than -3.0 mm³/st (-3.0 mm³/st is the lowest normal value), as long as the value of Injection Feedback Val for each of the other cylinders is 3.0 mm³/st or less, the injector assemblies are not malfunctioning.

Go to step 14

Go to step 13

C

6.CHECK SNAPSHOT (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)

Check Common Rail Pressure and Target Common Rail Pressure in the snapshot taken when the engine was warmed up and idling.

OK:
Common Rail Pressure is within +/-5000 kPa of Target Common Rail Pressure.

Go to step 21

OK

7.PERFORM PILOT QUANTITY LEARNING (DETAIL)

Perform the injector pilot quantity learning (Detail) ().

NEXT

8.CHECK ENGINE KNOCKING OR RATTLING

Check engine knocking or rattling.

Result
Result	Proceed to
Sound disappears	A
Except above (Sound continues occurring)	B

Go to step 9

END

9.CHECK THE TEMPERATURE WHEN KNOCKING OCCURS

Check the temperature when knocking trouble occurs.

Result
Result	Proceed to
Knocking occurs only in cold engine	A
Knocking occurs both in cold and warmed up engine	B

Go to step 25

A

10.INSPECT GLOW PLUG (RESISTANCE)

Inspect the glow plug ().

REPLACE GLOW PLUG ()

OK

11.TAKE SNAPSHOT DURING IDLING (WHEN ENGINE COLD)

Make sure that the engine is cold so that the snapshot can be taken under the correct conditions.

Connect the GTS to the DLC3.

Start the engine and turn the GTS on.

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

Take a snapshot of the Data List items.

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 list below is that of a normal vehicle, but as the data varies between individual vehicles, this data should only be used for reference.

NEXT

12.CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #8)

Check Injection Feedback Val #1 to #8 in the snapshot taken when the engine was idling.

Result
Result	Proceed to
Injection Feedback Val for at least one cylinder is more than +3 mm³/st	A
Except above	B

HINT:

Go to step 16

Go to step 25

13.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.

Go to step 17

14.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
Result	Proceed to
Except below	A
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.

Go to step 16

A

15.CHECK CYLINDER COMPRESSION PRESSURE

Check the cylinder compression pressure ().

HINT:

When compression is low, there may be cracks in the piston or the injector may be installed improperly.

CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

OK

16.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

Replace the injector assembly of the malfunctioning cylinder ().

NOTICE:

When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.

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

17.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

18.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

Perform the fuel injector pilot quantity learning ().

NEXT

19.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

20.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Check whether the knocking has been successfully repaired.

END

21.REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

Replace the fuel supply pump assembly ().

HINT:

If the common rail pressure becomes too high when transitioning due to problems with SCV operation, knocking noise worsens.

NEXT

22.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

23.PERFORM FUEL SUPPLY PUMP INITIALIZATION

Perform fuel supply pump initialization ().

NEXT

24.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Check whether the knocking has been successfully repaired by starting the engine.

END

25.READ VALUE USING GTS (MAP AND ATMOSPHERE 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 / MAP and Atmosphere Pressure.

Compare MAP to Atmosphere Pressure when the engine switch is on (IG) (do not start the engine).

Standard:
Difference between MAP and Atmosphere Pressure is less than 8 kPa.

HINT:

If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of 8 kPa or more, compare the values to the atmospheric pressure for that day. The sensor whose deviation is the greatest is malfunctioning.

Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.

Result
Result	Proceed to
MAP and Atmosphere Pressure have same value	A
MAP is different from actual atmospheric pressure	B
Atmosphere Pressure is different from actual atmospheric pressure	C

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

REPLACE ECM ()

A

26.BASIC INSPECTION

Check the fuel quality.

Check the fuel for air.

Check the fuel system for blockages.

Check the air filter.

Check the engine oil.

Check the engine coolant.

Check the engine idling speed and maximum engine speed.

Check the vacuum pump.

END

1VD-FTV ENGINE CONTROL

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

ECD SYSTEM w/ DPF