Turbocharger System
Main fault	Turbocharger sub-assembly (compressor side seal ring, turbine side seal ring, shaft, oil drain)
Symptoms	White smoke Excessive oil consumption

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 (constant lack of power)
Data List	Engine Speed of Cyl #1 to #8 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 #1 to #8 If Injection Feedback Val #1 to #8 is more than 3 mm³/st, the cylinder may have a fault.

Diesel Injection

Injector Assembly
Main fault	Blockage
Symptoms	Rough idle, lack of power, black smoke, white smoke, knocking
Data List	Injection Feedback Val #1 to #8 When an Injector Feedback Val is more than 3 mm³/st, there may be a malfunction in the corresponding cylinder. Injection Feedback Val #1 to #8 can be read after idling for 1 minute with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).

HINT:

When the sliding resistance of the internal parts of the injector assemblies (i.e. armature shaft, command piston and plunger) has increased due to internal contamination, injection quantity will increase at high common rail pressure due to a delay in injector assembly closure.

Injector Driver
Main fault	Circuit fault: The 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.

Poor Quality 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 fully
Symptoms	Rough Idle EGR valve stuck closed: A loud turbocharger sound. EGR valve stuck open: Difficult to start (does not stall), black smoke, white smoke (when engine is cold), lack of power, jerking (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. Also, when racing the engine, there will be some black smoke).
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 on (IG) (engine stopped). EGR valve opens to the halfway point at idling after the engine is warmed up. When the EGR valve does not close, MAF (Mass Air Flow) decreases when the vehicle is accelerated at full throttle. MAP also decreases in comparison to Target Booster Pressure. However, there is not a large difference. EGR Close Lrn. Val., EGR Close Lrn. Status 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.

INSPECTION PROCEDURE

NOTICE:

After replacing the ECM, the new ECM requires registration () and initialization ().

After replacing a fuel supply pump assembly, the ECM requires initialization ().

After replacing an injector assembly, the ECM requires registration ().

Explanation of Symptom

White Smoke	When the engine is misfiring, any fuel that has been injected but remains unburned is emitted as white smoke.
	Turbocharger internal oil leak () If oil leak occurs from turbine side seal, large amount of white smoke will be emitted from exhaust pipe. Internal oil leak is not visible from outside of turbocharger.

1.CONFIRM CONDITIONS PRESENT WHEN WHITE SMOKE APPEARED WITH CUSTOMER

Ask the customer about the conditions when the white smoke was emitted.

- What were the driving conditions when the white smoke was generated?

- Is the white smoke constantly emitted, or only occasionally?

- Does the white smoke occur only when the vehicle is cold, or when the vehicle is both cold and hot?

- Is the white smoke emitted just after starting the vehicle only, or does it continue while the vehicle is idling?

Determine the symptoms of the problem to narrow down the possible causes.

NEXT

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 pending DTCs.

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

GO TO DTC CHART ()

A

3.CHECK WHEN WHITE SMOKE IS EMITTED

Ecd System (W/ Dpf) - White Smoke Emitted. 1VD-FTV ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Start the engine.

Fully depress the accelerator pedal, and then release it.

Check whether white smoke is emitted or not when racing the engine.

Text in Illustration
*a	Example

NOTICE:

Be sure not to check for white smoke indoors.

HINT:

If the white smoke is emitted only just after engine start and disappears later, the smoke is not from the turbocharger.

If the turbocharger is the cause of the problem, regardless of whether the engine is cold or warmed up, there will be a large amount of white smoke to the extent that visibility is obstructed for a few meters in the area of the smoke (as shown in the illustration).

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.

When continuously traveling with the engine close to idle for 1 hour or more, such as when in heavy traffic, unburned fuel accumulates in the catalytic converter, and can produce white smoke when accelerating.

Result
Result	Proceed to
White smoke is emitted just after engine start only	A
White smoke is always and continuously emitted	B
There is oil on the exhaust pipe, etc. HINT: The oil on the exhaust pipe may be from the transmission, etc.	C

HINT:

White smoke may be emitted at a specific exhaust gas temperature. Listed are possible symptoms and causes for this case. Please use this information as reference when carrying out malfunction diagnosis.

The exhaust gas temperature may be checked using "Exhaust Temperature B1S2" and "Exhaust Temperature B1S3" in the Data List.

Symptoms	Causes
White smoke is emitted when the exhaust temperature is below 200°C (452°F) and the vehicle is traveling at low speed or when accelerating after decelerating. Related Data List - Exhaust Temperature B1S2 - Exhaust Temperature B1S3 - Exhaust Temperature B2S2 - Exhaust Temperature B2S3	When continuously traveling with the engine close to idle for 1 hour or more, such as when in heavy traffic, unburned fuel accumulates in the catalytic converter, and can produce white smoke when accelerating. : In this case the white smoke is not caused by a defect, so explain to the customer that the white smoke is caused by an accumulation of unburned fuel due to low-speed driving etc., and monitor the situation. (If the customer reports that the problem only occurs after continuous driving in heavy traffic/low speed driving, the problem may resolve itself when the catalytic converter temperature is raised through high-speed driving. However, if the catalytic converter activity is reduced, this will not resolve the problem, so the catalytic converter must be replaced. Deterioration of the catalytic converter can cause EGR malfunction and injector malfunction, so if there has not been any repair in the past, check and repair these components as well.)
White smoke is emitted when accelerating while the exhaust gas temperature is around 200 to 300°C (452 to 572°F) (in the process of rising to 500°C (932°F) for PM forced regeneration). Related Data List - DPNR/DPF Status Reju (PM) - Exhaust Temperature B1S2 - Exhaust Temperature B1S3 - Exhaust Temperature B2S2 - Exhaust Temperature B2S3	Deterioration of the exhaust gas temperature sensor may be causing the sensor to read lower than the actual temperature, so the amount of fuel added is increased and white smoke is produced. In this case the sensor will need to be replaced. If catalytic converter activity has decreased, more fuel will be added without an increase in exhaust gas temperature, possibly resulting in white smoke. In this case, the catalytic converter needs to be replaced. Deterioration of the catalytic converter can cause EGR and injector malfunction, so if there has not been any repair in the past, check these components as well and repair if necessary.

Go to step 26

Go to step 27

A

4.CHECK TEMPERATURE WHEN WHITE SMOKE IS EMITTED

Check whether the white smoke is emitted only when the engine coolant temperature is below 0°C (32°F).

HINT:

If so, the smoke is not from the turbocharger and may be the smoke of unburned fuel.

If misfiring occurs, unburned fuel is emitted.

Result
Result	Proceed to
White smoke is emitted when the temperature is below 0°C (32°F)	A
White smoke is emitted regardless of temperature	B

Go to step 6

A

5.INSPECT GLOW PLUG (RESISTANCE)

Inspect the glow plug ().

REPLACE GLOW PLUG ()

OK

6.READ VALUE USING GTS

Connect the GTS to the DLC3.

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

Start the engine

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

Take a snapshot with the GTS.

Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Common Rail Pressure) when racing the engine with the accelerator pedal fully depressed.

Result
Result	Proceed to
Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure	A
Except above	B

HINT:

"Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.

"Common Rail Pressure" is the actual fuel pressure.

Go to step 19

A

7.CHECK INJECTOR COMPENSATION CODE

Read the injector compensation codes ().

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

OK

8.READ VALUE USING GTS (INJECTION FEEDBACK VAL #1 TO #8, INJECTION VOLUME)

Check Injection Feedback Val #1 to #8 and Injection Volume in the snapshot taken after the engine is warmed up and idled for 1 minute with the A/C off.

HINT:

Engine coolant temperature is 70°C (158°F) or higher.

Result
Result	Proceed to
Injection Feedback Val #1 to #8 are 3 mm³/st or less and Injection Volume is 3 to 10 mm³/st	A
Other than above	B

Go to step 24

B

9.PERFORM PILOT QUANTITY LEARNING (DETAIL)

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

NEXT

10.CHECK WHITE SMOKE

Start the engine.

Fully depress the accelerator pedal, and then release it.

Check whether white smoke is emitted or not when racing the engine.

Text in Illustration
*a	Example

NOTICE:

Be sure not to check for white smoke indoors.

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

Go to step 11

END

11.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

12.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.

Turn the engine switch on (IG) 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.

Crank the engine.

Check the engine speed during the Active Test.

Result
Result	Proceed to
The values of Engine Speed Cyl #1 to #8 are within 10 rpm of each other	A
Other than above	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 14

B

13.CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER

HINT:

Measure the compression of the cylinder that had a high speed during the "Control the All Cylinders Fuel Cut" Active Test.

Check the cylinder compression pressure ().

CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

OK

14.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 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

15.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

16.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

Perform the injector pilot quantity learning ().

NEXT

17.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Check whether the white smoke problem has been successfully repaired by starting the engine.

Go to step 18

END

18.CHECK FUEL QUALITY

Check that only diesel fuel is being used.

Check that the fuel does not contain any impurities.

END

19.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:

A lack of fuel causes the fuel pressure to drop.

Check that the fuel filter element sub-assembly is not clogged.

Reconnect the inlet hose.

NEXT

20.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

21.CHECK AND REPLACE CLOGGED FUEL PIPE (INCLUDING FROZEN FUEL) (FUEL TANK - FUEL SUPPLY PUMP)

Check and replace the clogged fuel pipe.

NEXT

22.BLEED AIR FROM FUEL SYSTEM

HINT:

If the fuel filter element sub-assembly or fuel pipe has been replaced, be sure to remove any air in the 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.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Check whether the white smoke problem has been successfully repaired by starting the engine.

END

24.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. or EGR Close Lrn. Val. #2.

Read the values.

Standard:
3.5 to 4.5 V

REMOVE DEPOSIT (EGR VALVE ASSEMBLY)

OK

25.CHECK ENGINE ASSEMBLY

Inspect the engine to see whether white smoke is being emitted due to defects in the engine itself.

Check for oil leaking into the combustion chamber due to a faulty valve stem oil seal.

Check for oil leaking into the combustion chamber due to a faulty injector assembly nozzle sheet.

Check for low compression.

HINT:

If the engine runs too rough, Injection Feedback Val #1 to #8 cannot be corrected and the readout will (incorrectly) show that Injection Feedback Val #1 to #8 are within the normal range.

HINT:

If defects are found, perform repairs, and then check that the symptoms are no longer present.

END

26.CHECK IDLING CONDITION

Start the engine.

Check the idling condition.

Result
Result	Proceed to
Engine runs smoothly at idle, but white smoke is emitted.	A
There are problems such as rough idling or engine stall, and white smoke is emitted. HINT: If the pressure in the crank case has risen, white smoke will be produced just after the engine is started. In this case, if blow-by gas is ejected when the oil level gauge is slightly removed, it is possible that the piston is damaged. NOTICE: Do not completely remove the oil level gauge as oil may spray from the opening.	B

HINT:

It is possible to determine the faulty cylinder by carrying out the "Check the Cylinder Compression" Active Test.

REPAIR ENGINE ASSEMBLY

GO TO TURBOCHARGER OIL LEAK AND WHITE SMOKE ()

27.CHECK FOR OIL LEAKAGE

Remove any oil in the front exhaust pipe assembly.

HINT:

Oil in the exhaust pipe is producing white smoke.

If there is an oil leak, repair the leak.

END

1VD-FTV ENGINE CONTROL

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

ECD SYSTEM w/ DPF