Malfunction Condition	Main Trouble Area	Related Trouble Area
Rough idling or juddering due to abnormal combustion Juddering when vehicle is starting due to clutch system malfunctions	Injector assembly malfunctions Injector sliding malfunction Injector stuck closed Injector stuck open Deposits in injector Injector circuit malfunction	Injector compensation code Fuel leak Engine mounting insulator Intake air system leakage Intake air system blockage EGR system Throttle valve system Mass air flow meter Suction control valve (fuel supply pump assembly) Fuel pressure sensor (common rail assembly (for bank 1)) No. 1 or No. 2 injector driver (P062D, P062E stored simultaneously) Low quality fuel Vehicle modifications Fuel filter air bleed problem Accessory problem (A/C, generator, etc.) ECM

HINT:

This troubleshooting procedure checks for the cause of rough idling and excessive engine vibrations.

Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data List result 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 causing the malfunction.

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

Faults and Symptoms of Common Rail Diesel Components

Engine Control

Mass Air Flow Meter
Main fault	Decrease in performance (foreign matter is stuck)
Symptoms	Lack of power, black smoke
Data List	MAF
HINT: The maximum fuel injection volume is controlled according to the output from the mass air flow meter.

Glow System
Main fault	Glow system malfunction
Symptoms	Difficult to start, rough idle, knocking, white smoke (when cold)
Data List	Check the glow plug indicator light
Diagnostic Point	Measure the resistance of the glow plug

Engine
Main fault	Loss of compression
Symptoms	Rough idle (lack of power always)
Data List	Engine 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.

Diesel Injection

Fuel Supply Pump Assembly
Main fault	-
Symptoms	Difficult to start, engine stalling, rough idle, lack of power
Data List	Common 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 common rail 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 Code	Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.

Fuel filter
Main fault	Blockage
Symptoms	Difficult to start, engine stalling, rough idle, lack of power
Data List	Common 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 common rail 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 Code	Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.

Injector Assembly
Main fault	Blockage
Symptoms	Rough idle, lack of power, black smoke, white smoke, knocking
Data List	Injection 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.

Injector Driver
Main fault	Circuit fault: The fuel injector assembly does not open.
Symptoms	Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
Data List	Same as injector assembly
Diagnostic Trouble Code	When the injector driver has a fault, some DTCs may be stored.

Fuel Pressure Sensor
Main fault	Open circuit, decrease in performance (foreign matter is stuck)
Symptoms	Difficult to start, rough idle, engine stall, lack of power
Data List	Common 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 Code	When the fuel pressure sensor has a fault, some DTCs may be stored.

Irregular Fuel
Main fault	-
Symptoms	Difficult 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 List	Actual 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 fault	Stuck, 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 turned to 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 Rough Idling

Engine Speed

MAF

Intake Air

Coolant Temp

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. #2

EGR Close Lrn. Val.

INSPECTION PROCEDURE

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 WIRE HARNESS AND CONNECTION IN ENGINE COMPARTMENT

Check the wire harness and connector connections of common rail system components.

OK:
The wire harnesses and connectors are connected securely.

HINT:

The engine may have problems when there is an intermittent disconnection in a circuit related to the fuel pressure sensor, crankshaft position sensor, engine coolant temperature sensor, etc.

Go to step 13

OK

2.READ OUTPUT DTC (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 pending DTCs.

Result
Result	Proceed to
No DTCs are output	A
Engine related DTCs are output	B

HINT:

If only DTC P1605 is output, proceed to step 4.

GO TO DTC CHART ()

A

3.TAKE SNAPSHOT DURING IDLING (PROCEDURE 3)

Connect the GTS to the DLC3.

Start the engine and turn the GTS on.

Warm up the engine (engine coolant temperature is 70°C (158°F) or higher).

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 the problem 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 shift lever should be in neutral and the A/C switch and all accessory switches should be off.

If rough idling occurs when the A/C switch is on, take another snapshot with the A/C switch on.

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.

NEXT

4.CHECK WHITE SMOKE

Start the engine.

Fully depress the accelerator pedal, and then release it.

Check whether white smoke is emitted when racing the engine.

NOTICE:

Be sure not to check for white smoke indoors.

HINT:

Depending on whether there is oil mixed with the fuel, or whether there is unburned fuel present, the smell of the exhaust gas differs. When oil is mixed in, the exhaust gas smells like burning oil.

Result
Result	Proceed to
White smoke is not emitted	A
White smoke is emitted	B

Go to step 14

A

5.CHECK DATA LIST (ENGINE SPEED)

Check engine speed in the snapshot taken in procedure 3 when the engine was idling.

Result
Result	Proceed to
Change in engine speed coincides with air conditioning system operation	B
Except above	A

Go to step 15

A

6.CHECK DATA LIST (INJECTION FEEDBACK VAL #1 TO #8 AND INJECTION VOLUME)

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

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

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, 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 16

A

7.INSPECT INJECTOR COMPENSATION CODE

Read the injector compensation code ().

OK:
Compensation codes stored in the ECM match compensation codes of the installed injector assemblies.

Go to step 12

OK

8.PERFORM ACTIVE TEST USING GTS (CONTROL THE SELECT CYLINDER FUEL CUT)

HINT:

Use this Active Test to determine the malfunctioning cylinder.

Connect the GTS to the DLC3.

Start the engine and turn the GTS on.

Enter the following menus: Engine and ECT / Active Test / Control the Select Cylinder Fuel Cut / #1 to #8.

Check the 8 cylinders in sequence to identify any faulty cylinders by performing the power-balance inspection.

HINT:

If the engine idle speed does not change when an injector assembly is disabled, the cylinder being tested is malfunctioning.

If the cylinder being tested is normal, there will be a significant change in idle speed when the fuel injection is stopped for that cylinder.

NEXT

9.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.

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

10.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

11.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

12.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

Perform the injector pilot quantity learning ().

Go to step 28

13.REPAIR OR REPLACE HARNESS AND CONNECTOR

Repair or replace the harness or connector.

Go to step 28

14.CHECK AND REPAIR ENGINE ASSEMBLY

Check the following items and repair the malfunctioning part if necessary.

Check the cylinder compression pressure ().

Go to step 28

15.CHECK AIR CONDITIONING SYSTEM

Check the air conditioning system.

HINT:

Be sure to check the air conditioning hoses and pipes.

Check the refrigerant pressure ().

Go to step 28

16.CHECK DATA LIST (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)

Check the engine speed in the snapshot taken in procedure 3 when the engine was idling after having been warmed up.

Result
Result	Proceed to
Difference between Common Rail Pressure and Target Common Rail Pressure is 5000 kPa (51.0 kgf/cm², 725 psi) or more	A
Except above	B

Go to step 23

A

17.INSPECT CLOGGED FUEL PIPE

Connect the GTS to the DLC3.

Start the engine and turn the GTS on.

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

With no load after the engine is warmed up, take a snapshot when idling and when the vehicle is accelerating with the accelerator pedal fully depressed in 2nd gear.

Check the Target Common Rail Pressure and Common Rail Pressure value.

Ecd System (W/ Dpf) - Rough Idling Or Excessive Engine Vibrations. 1VD-FTV ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Result
Result	Proceed to
While idling the vehicle, "Common Rail Pressure" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1	A
"Common Rail Pressure" is normal while idling the vehicle, but "Fuel Press" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear*2	A
Except above	B

NOTICE:

*1: The cause may be a squashed or blocked fuel pipe or hose.

*2: The cause may be a clogged fuel filter.

Go to step 21

B

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

Replace the fuel supply pump assembly ().

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.PERFORM FUEL SUPPLY PUMP INITIALIZATION

Perform fuel supply pump initialization ().

Go to step 28

21.REPAIR OR REPLACE CLOGGED FUEL LINE

Repair or replace the clogged (including frozen fuel) fuel pipe.

Replace the fuel filter element sub-assembly.

HINT:

If "Common Rail Pressure" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element sub-assembly.

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.

Go to step 28

23.INSPECT EGR VALVE ASSEMBLY

Connect the GTS to the DLC3.

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

Enter the following menus: Engine and ECT / Active Test / Control the EGR Step Position or Control the EGR Step Position #2.

While continuously changing the Active Test value to 0, 30, 60, 90, 60, 30 and 0%, check that Actual EGR Valve Pos or Actual EGR Valve Pos #2 smoothly changes to the set opening lift amount.

OK:
Value smoothly changes to within +/- 10% of set opening lift amount.

HINT:

EGR valve closed: 0%.

EGR valve open: 95.2%.

Next, after the engine is warmed up, stop the engine and wait for 15 seconds. After that, start the engine again and idle it for 30 seconds. Then stop the engine and wait for 15 seconds. After starting the engine again, read the Data List values while idling.

Enter the following menus: Data List / EGR Close Lrn. Val. and EGR Close Lrn. Val. #2.

Read the values.

Standard:
3.5 to 4.5 V

Go to step 25

Go to step 24

24.REMOVE DEPOSIT (EGR VALVE ASSEMBLY)

Remove the No. 1 and No. 2 EGR valve assembly ().

Visually check the EGR valve assembly for deposits.

If there are deposits, clean the EGR valve assembly.

NOTICE:

When cleaning the EGR valve assembly, make sure the valve is completely closed.

When cleaning the EGR valve assembly, perform initialization procedure ().

Do not forcibly open the valve, as it may be damaged or deformed.

When cleaning the EGR valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.

HINT:

If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.

If the EGR valve does not close properly or is stuck open, EGR becomes excessive and combustion becomes unstable. Also, there may be a lack of power. In this case, clean the EGR valve assembly.

Reinstall the EGR valve assembly ().

Go to step 28

25.PERFORM PILOT QUANTITY LEARNING (DETAIL)

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

NEXT

26.CHECK ROUGH IDLING OR EXCESSIVE ENGINE VIBRATIONS

Check rough idling or excessive engine vibrations.

Result
Result	Proceed to
Rough idling or excessive engine vibrations do not occur	A
Except above	B

END

B

27.CHECK AND REPLACE ENGINE MOUNTING INSULATOR

Check the following items and repair or replace the malfunctioning part if necessary.

Check that the engine mounting insulators are installed correctly.

Check that the engine mounting insulators are not twisted.

Check that deformation of an engine mounting insulator is not causing the engine to contact the vehicle body.

NEXT

28.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

END

1VD-FTV ENGINE CONTROL

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

ECD SYSTEM w/ DPF