Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1VD-FTV ENGINE CONTROL
CHECK HARNESS AND CONNECTOR IN ENGINE COMPARTMENT
PERFORM CONFIRMATION DRIVING PATTERN
READ OUTPUT DTC (RELATING TO ENGINE)
READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)
CHECK FUEL INJECTOR COMPENSATION CODE
CHECK EGR VALVE ASSEMBLY (No. 1 or No. 2)
READ VALUE USING INTELLIGENT TESTER (ACTUAL THROTTLE POSITION)
PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTION)
CHECK CYLINDER COMPRESSION PRESSURE
CHECK MALFUNCTIONING CYLINDER FUEL INJECTOR FOR DEPOSITS
READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)
IDENTIFY MALFUNCTIONING CYLINDER FUEL INJECTOR
PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)
CHECK FUEL INJECTORS FOR DEPOSITS
READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
ECD SYSTEM (w/o DPF) - Engine Knocking or Rattling
DESCRIPTION
Malfunction Condition | Main Trouble Area | Related Trouble Area |
Knocking and abnormal sound due to extremely rich combustion Abnormal sound due to friction between parts | Fuel injector malfunctions Fuel injector sliding malfunction Fuel injector stuck closed Fuel injector stuck open Deposits in fuel injector Fuel injector circuit malfunction Abnormal common rail pressure Fuel supply pump Fuel pulsation sound Air in fuel Friction between parts Compression pressure | Fuel injector compensation codes Fuel leakage Intake air system leakage Intake air system blockage EGR system Throttle valve system Fuel pressure sensor Manifold absolute pressure sensor Atmospheric pressure sensor (built into ECM) Vehicle modifications Low quality fuel Lack of fuel ECM |
- HINT:
INSPECTION PROCEDURE
- NOTICE:
- HINT:
1.CHECK SOUND AREA |
Find the source of the abnormal sound using a mechanic's stethoscope.
Result | Proceed to |
Sound from fuel supply pump | A |
Sound from parts other than fuel supply pump | B |
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A | |
2.CHECK HARNESS AND CONNECTOR IN ENGINE COMPARTMENT |
Check the wire harness connections.
- OK:
- Wire harnesses are connected securely.
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OK | |
3.PERFORM CONFIRMATION DRIVING PATTERN |
- HINT:
- Drive the vehicle according to the driving pattern below to allow the ECM to store DTCs relating to malfunctions of the fuel system, EGR system and throttle valve. If DTCs are stored, problem areas can be identified.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter Check Mode ().
Fully warm up the engine.
Allow the engine to idle for 5 minutes or more.
Drive the vehicle at more than 40 km/h (25 mph) for 1 minute or more (procedure "A").
Decelerate and stop the vehicle (procedure "B").
Repeat procedure "A" and procedure "B" 4 times or more.
Stop the engine and wait for at least 10 seconds (procedure "C").
Repeat procedure "A" and procedure "C" described above to store DTCs relating to the EGR system and throttle valve.
Drive the vehicle at more than 70 km/h (43 mph) for at least 1 minute (to store DTCs relating to the fuel supply pump).
NEXT | |
4.READ OUTPUT DTC (RELATING TO ENGINE) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / DTC.
Read pending DTCs.
Result | Proceed to |
No DTCs are output | A |
Engine related DTCs are output | B |
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A | |
5.READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME) |
Connect the intelligent tester to the DLC3.
Start the engine, warm it up, and turn the tester on.
Select the following menu items in order and read the values.
- Standard Value:
Item Engine Speed* Standard Range Description Injection Feedback Val #1 to #8 Idling -3.0 to 3.0 mm3/st Value of fuel injector injection volume compensates for differences in combustion condition of cylinders Positive values indicate control which corrects combustion degradationNegative values indicate control which corrects excessive combustion pressureIf problems exist, Injection Feedback Val may deviate from the -3.0 to 3.0 mm3/st rangeInjection Volume Idling 3.0 to 10 mm3/st Fuel injection volume value controlled by ECU Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure, EGR volume, and MAFIf problems exist, Injection Volume may be outside standard range
Result | Proceed to |
Standard range | A |
Injection Feedback Val #1 to #8 and/or Injection Volume outside standard range | B |
- HINT:
- *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.
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A | |
6.CHECK FUEL INJECTOR COMPENSATION CODE |
Read the fuel injector compensation code ().
- HINT:
- If the fuel injector compensation code is not correctly registered, it may cause malfunctions ().
Check the fuel injector compensation code.
- OK:
- Compensation code of the installed fuel injector is the same as the code registered in the ECM.
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OK | |
7.RESET ECM |
Disconnect the cable from the negative (-) battery terminal for at least 2 minutes.
Reconnect the cable to the negative (-) battery terminal.
Check whether the malfunction has been successfully repaired by performing a driving test using the freeze frame data recorded at the time the malfunction occurred.
- OK:
- Malfunction has been repaired successfully.
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OK | ||
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8.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 the maximum engine speed.
Check the vacuum pump.
- OK:
- Each inspection result is normal.
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OK | |
9.CHECK INTAKE SYSTEM |
Check for air leakage and blockage between the air cleaner and turbocharger, and between the turbocharger and intake manifold.
- OK:
- No air leakage or blockage.
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OK | |
10.CHECK EGR VALVE ASSEMBLY (No. 1 or No. 2) |
- HINT:
- For vehicles without EGR valve, perform troubleshooting from the next step.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / Active Test / Control the EGR Step Position or Control the EGR Step Position #2 / Data List / Actual EGR Valve Pos. or Actual EGR Valve Pos. #2.
When changing the Active Test value from 0 to 100%, check that Actual EGR Valve Pos. or Actual EGR Valve Pos. #2 smoothly changes to the set opening angle.
- OK:
- Value smoothly changes to within +/-10% of set opening angle.
- HINT:
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OK | |
11.READ VALUE USING INTELLIGENT TESTER (ACTUAL THROTTLE POSITION) |
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Enter the following menus: Powertrain / Engine / Actual Throttle Position and Actual Throttle Position #2.
Read the value.
- OK:
- Ignition switch ON:
- -5 to 5%
- Idling (Warmed up engine):
- 0 to 90%
- Accelerator pedal fully depressed:
- -5 to 5%
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OK | |
12.CHECK COMBUSTION SOUND |
Confirm type of sound emitted.
Result | Proceed to |
Knocking | A |
Mechanical sound other than knocking | B |
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A | |
13.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTION) |
Connect the intelligent tester to the DLC3.
Start the engine and turn the tester on.
Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3, #4, #5, #6, #7 and #8 Fuel Cut.
Check the 8 cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.
- HINT:
NEXT | |
14.CHECK CYLINDER COMPRESSION PRESSURE |
Check the cylinder compression pressure ().
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OK | |
15.CHECK MALFUNCTIONING CYLINDER FUEL INJECTOR FOR DEPOSITS |
- HINT:
- If a fuel injector is contaminated with deposits, the injection volume deviates from the standard range. This may cause malfunctions.
Check the fuel injector for any deposits.
Result | Proceed to |
Deposits | A |
No deposits | B |
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A | |
16.CLEAN FUEL INJECTOR |
Wipe away deposits from the tips of the fuel injectors.
- HINT:
- Solvent or carbon removal agents help remove the deposits easily.
- NOTICE:
- Exercise extreme care not to damage the fuel injectors while wiping off the deposits.
NEXT | |
17.READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME) |
Reinstall the fuel injector to the cylinder head.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Start the engine and warm it up.
Enter the following menus: Powertrain / Engine / Data List.
Select the following menu items in order and read the values.
- Standard Value:
Item Engine Speed* Reference Value Injection Feedback Val #1 to #8 Idling -3.0 to 3.0 mm3/st Injection Volume Idling 3.0 to 10 mm3/st
- HINT:
- OK:
- Values are within the standard range.
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OK | ||
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18.IDENTIFY MALFUNCTIONING CYLINDER FUEL INJECTOR |
Follow the instructions in the table below according to the check result of the intelligent tester.
- HINT:
- This operation is based on the premise that the common rail pressure is normal.
- Standard Value:
Item Engine Speed* Reference Value Injection Feedback Val #1 to #8 Idling -3.0 to 3.0 mm3/st Injection Volume Idling 3.0 to 10 mm3/st
- HINT:
- *: The A/C switch and all accessory switches should be off, and the engine should be fully warmed up.
Injection Feedback Val #1 to #8 | Injection Volume | Proceed to |
3.0 mm3/st or more, -3.0 mm3/st or less | Less than 3.0 mm3/st | A |
Between 3.0 and 10 mm3/st (Normal) | B | |
More than 10 mm3/st | B | |
Between -3.0 and 3.0 mm3/st | Less than 3.0 mm3/st | - |
Between 3.0 and 10 mm3/st (Normal) | Normal | |
More than 10 mm3/st | C* |
- HINT:
- *: When the Injection Volume displayed on the tester is large despite the Fuel Press and Injection Feedback Val #1 to #8 in the Data List being normal, the fuel injector may be clogged. In this case, there may be deposits inside or outside the tip of the fuel injector.
Proceed to | Inspection Area | Description |
A | Inspect and repair cylinder fuel injector with revised injection volume of less than 3.0 mm3: Perform power balance inspection and identify malfunctioning cylinder Replace malfunctioning cylinder fuel injector |
Fuel injector of cylinder with abnormal value injects excessively large quantity of fuel |
B | Identify malfunctioning cylinders by conducting power balance inspection: Perform power balance inspection to identify malfunctioning cylinders Clean malfunctioning cylinder fuel injector, then check and repair it |
Fuel injector of cylinder with abnormal value injects excessively large quantity of fuel Injection volume too low due to fuel injector nozzle being blocked by deposits Compression of cylinder with abnormal value decreases Fuel injector of cylinder with abnormal value injects excessively large quantity of fuel |
C | Inspect and repair all cylinder fuel injectors: Clean all cylinder fuel injectors, and then inspect and repair them |
All cylinder fuel injectors inject excessively small quantity of fuel: Injection volume too low due to all cylinder fuel injector nozzles being blocked by deposits |
- HINT:
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A | |
19.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (FUEL CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER) |
Connect the intelligent tester to the DLC3.
Start the engine and turn the tester on.
Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3, #4, #5, #6, #7 and #8 Fuel Cut.
Check the 8 cylinders in sequence to identify any faulty cylinders by performing the power balance inspection.
- HINT:
NEXT | ||
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20.CHECK FUEL INJECTORS FOR DEPOSITS |
- HINT:
- If a fuel injector is contaminated with deposits, the injection volume deviates from the standard range. This may cause malfunctions.
Check the fuel injector for any deposits.
Result | Proceed to |
Deposits | A |
No Deposits | B |
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A | |
21.CLEAN FUEL INJECTOR |
Wipe away deposits from the tips of the fuel injectors.
- HINT:
- Solvent or carbon removal agents help remove the deposits easily.
- NOTICE:
- Exercise extreme care not to damage the fuel injectors while wiping off the deposits.
NEXT | |
22.READ VALUE USING INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME) |
Reinstall the fuel injector to the cylinder head.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the tester on.
Start the engine and warm it up.
Enter the following menus: Powertrain / Engine / Data List.
Select the following menu items in order and read the values displayed on the tester respectively.
- Standard Value:
Item Engine Speed* Reference Value Injection Feedback Val #1 to #8 Idling -3.0 to 3.0 mm3/st Injection Volume Idling 3.0 to 10 mm3/st
- HINT:
- OK:
- Values are within the standard range.
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OK | ||
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23.CHECK SOUND AREA |
Find the source of the abnormal sound using a mechanic's stethoscope.
Result | Proceed to |
Sound from fuel supply pump | A |
Sound from parts other than fuel supply pump | B |
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A | |
24.BLEED AIR FROM FUEL SYSTEM |
To bleed air from the priming pump, pump the priming pump until it becomes hard and cannot be pumped any more.
NEXT | |
25.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED |
Check whether the knocking has been successfully repaired by performing a driving test.
- OK:
- Malfunction has been repaired successfully.
NEXT | ||
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