Ecd System Black Smoke Emitted

INSPECTION PROCEDURE

CHECK OUTPUT DTC (RELATED TO ENGINE)

READ VALUE OF INJECTOR ASSEMBLY (INJECTION VOLUME AND INJECTION FEED BACK VAL #1 TO #4)

PERFORM ENGINE RPM ACCELERATION

CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM

CHECK EGR VALVE ASSEMBLY

CHECK TURBOCHARGING PRESSURE

PERFORM ACTIVE TEST BY FUEL PRESSURE SENSOR AND INJECTOR ASSEMBLY

CHECK CYLINDER COMPRESSION PRESSURE

CHECK WIRE HARNESS (INJECTOR - EDU)

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (CONTROL THE CYLINDER FUEL CUT)

READ VALUE USING INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE)

READ VALUE OF MANIFOLD ABSOLUTE PRESSURE SENSOR

READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

READ VALUE USING INTELLIGENT TESTER (ACCEL POSITION 1 AND 2)

READ VALUE USING INTELLIGENT TESTER (INTAKE AIR TEMPERATURE)

READ VALUE USING INTELLIGENT TESTER (FUEL PRESSURE)

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

CHECK WIRE HARNESS (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)

INSPECT CRANKSHAFT POSITION SENSOR

CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM)

INSPECT INTAKE AIR TEMPERATURE SENSOR

INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

CHECK WIRE HARNESS (FUEL PRESSURE SENSOR - ECM)

REPLACE ECM

INSPECTION PROCEDURE

ПРИМЕЧАНИЕ:

1. After replacing the ECM, the new ECM needs registration (see page RAV4_ACA30 RM000000TJ400AX.html) and initialization (see page RAV4_ACA30 RM000000TIN009X.html).
   
2. After replacing a supply pump, the ECM needs initialization (see page RAV4_ACA30 RM000000TIN009X.html).
   
3. After replacing a injector, the ECM needs registration (see page RAV4_ACA30 RM000000TJ400AX.html).
   

УКАЗАНИЕ:

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 assume the vehicle to be normal when the Data List outputs standard values. There may be concealed factors of the malfunction.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

3. Enter the following menus: Powertrain / Engine and ECT / DTC.
   

4. Read the DTCs.
   

   Result:

   Display (DTC Output)	Proceed to
   No output	A
   DTCs related to the engine	B

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and turn the tester ON.
   

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

4. Select the following menu items in order and read the values.
   

   1. Injection Volume
      
   2. Injection Feedback Val #1, #2, #3, and #4
      
   
   

   Standard value:

   
   

   Item	Engine Speed*	Reference Value
   Injection Volume	Idling (No engine load)	4.5 to 9.0 mm3
   Injection Feedback Val #1	Idling (No engine load)	-3.5 to 3.5 mm3
   Injection Feedback Val #2	Idling (No engine load)	-3.5 to 3.5 mm3
   Injection Feedback Val #3	Idling (No engine load)	-3.5 to 3.5 mm3
   Injection Feedback Val #4	Idling (No engine load)	-3.5 to 3.5 mm3

   УКАЗАНИЕ:

   *: If no idling conditions are specified, the shift lever should be in the neutral position, and the A/C switch and all accessory switches should be OFF.

УКАЗАНИЕ:

If the exhaust gas contains excessive black smoke, perform the following operations:

1. Accelerate the engine speed to the maximum rpm with no load 20 times.
   

2. Check the volume of black smoke in the exhaust gas.
   

   Result:

   Result	Proceed to
   Black smoke is not present	OK
   Black smoke remains in the exhaust gas	NG

   УКАЗАНИЕ:

   Soot deposits in the exhaust system may cause excessive black smoke.

1. Inspect the engine condition (see page RAV4_ACA30 RM000001877005X_02_0002.html).
   

1. Check the EGR valve assembly (see page RAV4_ACA30 RM0000015C4002X.html).
   

1. Check the turbocharger pressure (see page RAV4_ACA30 RM0000022TO000X.html).
   

   Standard pressure:

   58.5 to 78.9 kPa (0.60 to 0.80 kgf/cm², 8.5 to 11.4 psi)
   

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and turn the tester ON.
   

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

4. Select the following menu items in order and read the values.
   

   1. Fuel Pressure
      
   2. Injection Volume
      
   3. Main Injection
      
   4. Pilot 2 Injection
      
   5. Injection Feedback Val #1, #2, #3, and #4
      
   
   

   Reference:

   
   

   Item	Engine Speed*	Reference Value
   Fuel Pressure	Idling	35 to 40 MPa
   Fuel Pressure	2,000 rpm (no engine load)	65 to 78 MPa
   Fuel Pressure	3,000 rpm (no engine load)	78 to 88 MPa
   Injection Volume	Idling	4.5 to 9.0 mm3
   Injection Volume	2,000 rpm (no engine load)	5.0 to 9.5 mm3
   Injection Volume	3,000 rpm (no engine load)	6.6 to 11.1 mm3
   Main Injection	Idling	460 to 610 μs
   Pilot 2 Injection	Idling	410 to 510 μs
   Injection Feedback Val #1	Idling	-3.5 to 3.5 mm3
   Injection Feedback Val #2	Idling	-3.5 to 3.5 mm3
   Injection Feedback Val #3	Idling	-3.5 to 3.5 mm3
   Injection Feedback Val #4	Idling	-3.5 to 3.5 mm3

   УКАЗАНИЕ:

   If no idling conditions are specified, the shift lever should be in the neutral position, and the A/C switch and all accessory switches should be OFF.

   
   

   Result:

   
   

   Result	Proceed to
   Within reference value	A
   One of Injection Feedback Val #1 to #4 is not within reference value	B
   Other result	C

1. Check the cylinder compression pressure (see page RAV4_ACA30 RM000000RPP005X_01_0008.html).
   

   Standard pressure:

   2,700 kPa (27.5 kgf/cm², 392 psi)
   

   Minimum pressure:

   2,200 kPa (22.4 kgf/cm², 319 psi)
   

   Difference between each cylinder:

   500 kPa (5.1 kgf/cm², 73 psi)
   

1. Disconnect the B36, B37, B38, and B39 injector connectors.
   

2. Disconnect the B64 EDU connector.
   

3. Measure the resistance of the wire harness side connectors.
   

   Standard resistance:

   Tester Connection	Specified Condition
   B36-1 - B64-4 (INJ1)	Below 1 Ω
   B37-1 - B64-2 (INJ2)	Below 1 Ω
   B38-1 - B64-1 (INJ3)	Below 1 Ω
   B39-1 - B64-3 (INJ4)	Below 1 Ω
   B36-2 - B64-5 (COM1)	Below 1 Ω
   B37-2 - B64-6 (COM2)	Below 1 Ω
   B38-2 - B64-6 (COM2)	Below 1 Ω
   B39-2 - B64-5 (COM1)	Below 1 Ω
   B36-1 or B64-4 (INJ1) - Body ground	10 kΩ or higher
   B37-1 or B64-2 (INJ2) - Body ground	10 kΩ or higher
   B38-1 or B64-1 (INJ3) - Body ground	10 kΩ or higher
   B39-1 or B64-3 (INJ4) - Body ground	10 kΩ or higher
   B36-2 or B64-5 (COM1) - Body ground	10 kΩ or higher
   B37-2 or B64-6 (COM2) - Body ground	10 kΩ or higher
   B38-2 or B64-6 (COM2) - Body ground	10 kΩ or higher
   B39-2 or B64-5 (COM1) - Body ground	10 kΩ or higher

4. Reconnect the injector connectors.
   

5. Reconnect the EDU connector.
   

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and turn the tester ON.
   

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Cylinder #1, #2, #3, and #4 Fuel Cut.
   

4. Check the engine idling condition while the fuel injection of each cylinder is cut using the tester.
   

   Result:

   Engine Idling Condition	Proceed to
   Becomes unstable	A
   Does not change	B

   УКАЗАНИЕ:

   Replace the injector mounted on the cylinder that causes no significant idle speed change.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

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

4. Read the value.
   

   Standard value:

   Between 75 and 95°C (167 and 203°F) with warm engine.
   

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

3. Enter the following menus: Powertrain / Engine and ECT / Data List / MAP and Atmosphere Pressure.
   

4. Read the value.
   

   Standard value:

   Condition	MAP Value
   No pressure applied	Same as atmospheric pressure
   Vacuum applied	Becomes vacuum
   Pressure applied	Becomes pressurized

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

3. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.
   

4. Read the value.
   

   Standard value:

   Between 750 to 1,000 rpm with warm engine (A/C switch OFF).
   

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

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

4. Read the value.
   

   Standard voltage:

   Accelerator Pedal	Accelerator Pedal Condition	Specified Condition
   Accel Position 1	Released	0.6 to 1.0 V
   Accel Position 1	Depressed	3.4 to 3.8 V
   Accel Position 2	Released	1.4 to 1.8 V
   Accel Position 2	Depressed	4.2 to 4.6 V

   УКАЗАНИЕ:

   In the chart above, "Idling" means that the engine should be idled under the following conditions:

   1. Idle the engine, turn the A/C switch OFF and move the shift lever to N.
      
   2. After the engine is warmed up, the engine should have no load.
      

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

3. Enter the following menus: Powertrain / Engine and ECT / Data List / Inlet Air.
   

4. Read the value.
   

   OK:

   Same as air temperature near to intake manifold.
   

   УКАЗАНИЕ:

   In the chart above, "Idling" means that the engine should be idled under the following conditions:

   1. Idle the engine, turn the A/C switch OFF and move the shift lever to N.
      
   2. After the engine is warmed up, the engine should have no load.
      

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG) and turn the tester ON.
   

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

4. Read the value.
   

   Standard value:

   35 to 45 MPa engine idling.
   

1. Disconnect the engine coolant temperature sensor.
   

2. Measure the resistance of the sensor.
   

   Standard resistance:

   Connection	Specified Condition
   20°C (68°F)	2.32 to 2.59 kΩ
   80°C (176°F)	0.310 to 0.326 kΩ

   ПРИМЕЧАНИЕ:

   When checking the ECT sensor in water, keep the terminals dry. After the check, wipe the sensor dry.

   УКАЗАНИЕ:

   Alternative procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values against the resistance/ temperature graph. Change the engine temperature (warm up or cool down) and repeat the test.

3. Reconnect the engine coolant temperature sensor.
   

1. Disconnect the B45 manifold absolute pressure sensor connector.
   

2. Disconnect the B32 ECM connector.
   

3. Measure the resistance of the wire harness side connectors.
   

   Standard resistance:

   Tester Connection	Specified Condition
   B45-2 (PIM) - B32-117 (PIM)	Below 1 Ω
   B45-3 (VC) - B32-71 (VCPM)	Below 1 Ω
   B45-1 (E) - B32-94 (EPIM)	Below 1 Ω
   B45-2 (PIM) or B32-117 (PIM) - Body ground	10 kΩ or higher
   B45-3 (VC) or B32-71 (VCPM) - Body ground	10 kΩ or higher
   B45-1 (E) or B32-94 (EPIM) - Body ground	10 kΩ or higher

4. Reconnect the manifold absolute pressure sensor connector.
   

5. Reconnect the ECM connector.
   

1. Disconnect the B42 crankshaft position sensor connector.
   

2. Measure the resistance of the sensor.
   

   Standard resistance:

   Tester Connection	Condition	Specified Condition
   B42-1 (NE) - B42-2 (NE-)	Cold	835 to 1,400 Ω
   B42-1 (NE) - B42-2 (NE-)	Hot	1,060 to 1,645 Ω

   УКАЗАНИЕ:

   In the table above, the terms "Cold" and "Hot" refer to the temperature of the coils in the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F).

3. Reconnect the crankshaft position sensor connector.
   

1. Disconnect the A6 sensor connector.
   

2. Disconnect the A12 ECM connector.
   

3. Measure the resistance of the wire harness side connectors.
   

   Standard resistance:

   Tester Connection	Specified Condition
   A6-1 (VCP2) - A12-56 (VCP2)	Below 1 Ω
   A6-2 (EPA2) - A12-58 (EPA2)	Below 1 Ω
   A6-3 (VPA2) - A12-54 (VPA2)	Below 1 Ω
   A6-4 (VCPA) - A12-55 (VCPA)	Below 1 Ω
   A6-5 (EPA) - A12-57 (EPA)	Below 1 Ω
   A6-6 (VPA) - A12-53 (VPA)	Below 1 Ω
   A6-1 (VCP2) or A12-56 (VCP2) - Body ground	10 kΩ or higher
   A6-2 (EPA2) or A12-58 (EPA2) - Body ground	10 kΩ or higher
   A6-3 (VPA2) or A12-54 (VPA2) - Body ground	10 kΩ or higher
   A6-4 (VCPA) or A12-55 (VCPA) - Body ground	10 kΩ or higher
   A6-5 (EPA) or A12-57 (EPA) - Body ground	10 kΩ or higher
   A6-6 (VPA) or A12-53 (VPA) - Body ground	10 kΩ or higher

4. Reconnect the sensor connector.
   

5. Reconnect the ECM connector.
   

1. Remove the intake air temperature sensor.
   

2. Measure the resistance of the sensor.
   

   Standard resistance:

   Tester Connection	Condition	Specified Condition
   1 - 2	20°C (68°F)	2.21 to 2.69 kΩ

   ПРИМЕЧАНИЕ:

   When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry.

3. Reconnect the intake air temperature sensor.
   

1. Disconnect the B60 fuel pressure sensor connector.
   

2. Measure the resistance of each terminal of the fuel pressure sensor.
   

   Standard resistance:

   Tester Connection	Specified Condition
   B60-2 (PR) - B60-1 (E2)	16.4 kΩ or less
   B60-2 (PR) - B60-3 (VC)	3 kΩ or less

3. Reconnect the fuel pressure sensor connector.
   

1. Disconnect the B60 fuel pressure sensor connector.
   

2. Disconnect the B32 ECM connector.
   

3. Measure the resistance of the wire harness side connectors.
   

   Standard resistance:

   Tester Connection	Specified Condition
   B60-2 (PR) - B32-67 (PCR1)	Below 1 Ω
   B60-3 (VC) - B32-69 (VCM)	Below 1 Ω
   B60-1 (E2) - B32-91 (E2M)	Below 1 Ω
   B60-2 (PR) or B32-67 (PCR1) - Body ground	10 kΩ or higher
   B60-3 (VC) or B32-69 (VCM) - Body ground	10 kΩ or higher
   B60-1 (E2) or B32-91 (E2M) - Body ground	10 kΩ or higher

4. Reconnect the fuel pressure sensor connector.
   

5. Reconnect the ECM connector.
   

1. Replace the ECM.
   

   ПРИМЕЧАНИЕ:

   After replacing the ECM, the new ECM needs registration (see page RAV4_ACA30 RM000000TJ400AX.html) and initialization (see page RAV4_ACA30 RM000000TIN009X.html).

2. Check the volume of black smoke in the exhaust gas.
   

   OK:

   Black smoke is not present.