Ecd System (For I-Art) Engine Knocking Or Rattling

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Kd-Ftv Engine Control. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

DESCRIPTION

INSPECTION PROCEDURE

CHECK SOUND AREA

READ OUTPUT DTCS (RELATING TO ENGINE)

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

CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)

CHECK SNAPSHOT (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)

CHECK THE TEMPERATURE WHEN KNOCKING OCCURS

INSPECT GLOW PLUG (RESISTANCE)

TAKE SNAPSHOT DURING IDLING (WHEN ENGINE COLD)

CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4)

REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

CHECK CYLINDER COMPRESSION PRESSURE

CHECK SNAPSHOT (INJECTOR LEAKING COUNT #1 TO #4, I-ART LEARNING STATUS HISTORY #1 TO #4)

REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER

BLEED AIR FROM FUEL SYSTEM

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

BLEED AIR FROM FUEL SYSTEM

PERFORM SUPPLY PUMP INITIALIZATION

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

CHECK SNAPSHOT (INJECTOR LEAKING COUNT #1 TO #4, I-ART LEARNING STATUS HISTORY #1 TO #4)

REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

BASIC INSPECTION

ECD SYSTEM (for i-ART) - Engine Knocking or Rattling


DESCRIPTION


Malfunction Condition
Main Trouble Area
Related Trouble Area
  1. Knocking and abnormal sound due to extremely rich combustion
  2. Abnormal sound due to friction between parts
  1. (a) Injector assembly malfunctions
    1. Injector sliding malfunction
    2. Injector stuck closed
    3. Injector stuck open
    4. Deposits in injector
    1. Injector circuit malfunction
  1. (b) Abnormal common rail pressure
    1. Suction control valve
    2. Fuel pulsation sound
    3. Air in fuel
  1. (c) Friction between parts
  1. (d) Compression pressure
  1. Fuel leakage
  2. Intake air system leakage
  3. Intake air system blockage
  4. EGR system
  5. Throttle valve system
  6. Fuel pressure sensor (built into injector assembly)
  7. Manifold absolute pressure sensor
  8. Mass air flow meter
  9. Atmospheric pressure sensor (built into ECM)
  10. Vehicle modifications
  11. Low quality fuel
  12. Lack of fuel
  13. ECM
HINT:
  1. 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.
  2. Check that the vehicle has not been modified in any way prior to the vehicle inspection.

INSPECTION PROCEDURE

HINT:
  1. This troubleshooting procedure checks for knocking and rattling.
  2. Knocking is most likely to occur while the engine is idling.
NOTICE:
  1. After replacing the ECM, the new ECM needs registration (HILUX_TGN26 RM0000012XK05AX.html) and initialization (HILUX_TGN26 RM000000TIN058X.html).
  2. After replacing the fuel supply pump, the ECM needs initialization (HILUX_TGN26 RM000000TIN058X.html).
1.CHECK SOUND AREA

  1. 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



B
REPAIR OR REPLACE MALFUNCTIONING PARTS
A


2.READ OUTPUT DTCS (RELATING TO ENGINE)

  1. Connect the GTS to the DLC3.

  1. Turn the ignition switch to ON and turn the GTS on.

  1. Enter the following menus: Powertrain / Engine / Trouble Codes.

  1. Read the DTCs.

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



B
GO TO DTC CHART (HILUX_TGN26 RM0000031HW032X.html)
A


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

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Powertrain / Engine / Data List / All Data.

  1. Take a snapshot of the following Data List items.

    HINT:
    1. 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.
    2. Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.

NEXT


4.CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)

  1. Check Injection Feedback Val #1 to #4 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 10 mm3/st or less at 4000 rpm
    		B
    Except above
    		C

    HINT:
    1. 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.
    2. 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.


A
Go to step 11

B
Go to step 10
C


5.CHECK SNAPSHOT (FUEL PRESS AND TARGET COMMON RAIL PRESSURE)

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

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


NG
Go to step 18
OK


6.CHECK THE TEMPERATURE WHEN KNOCKING OCCURS

  1. 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



B
Go to step 22
A


7.INSPECT GLOW PLUG (RESISTANCE)

  1. Inspect the glow plug (HILUX_TGN26 RM0000044ZK009X_01_0001.html).



NG
REPLACE GLOW PLUG (HILUX_TGN26 RM000000JIT00JX.html)
OK


8.TAKE SNAPSHOT DURING IDLING (WHEN ENGINE COLD)

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

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Powertrain / Engine / Data List / All Data.

  1. Take a snapshot of the following 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


9.CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4)

  1. Check Injection Feedback Val #1 to #4 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:
    1. 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.
    2. 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.


A
Go to step 13

B
Go to step 22

10.REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

  1. Replace the injector assemblies (HILUX_TGN26 RM0000044TN00FX.html).

    NOTICE:
    1. When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
    2. 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.
    3. 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.
    4. If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
    5. 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
Go to step 15

11.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.

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Powertrain / Engine / Active Test / Check the Cylinder Compression / Data List / Compression / Engine Speed of Cyl #1 to #4.

  1. Check the engine speed during the Active Test.

    Result
    Result
    		Proceed to
    Except below
    		A
    The values of Engine Speed Cyl #1 to #4 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.


B
Go to step 13
A


12.CHECK CYLINDER COMPRESSION PRESSURE

  1. Check the cylinder compression pressure (HILUX_TGN26 RM00000147301IX_01_0002.html).

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


NG
CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION
OK


13.CHECK SNAPSHOT (INJECTOR LEAKING COUNT #1 TO #4, I-ART LEARNING STATUS HISTORY #1 TO #4)

  1. Check Injector Leaking Count #1 to #4 and i-ART Learning Status History #1 to #4 in the snapshot taken in procedure 3 when the engine was idling and at 4000 rpm.

  1. Record the value displayed for Injector Leaking Count #1 to #4 and i-ART Learning Status History #1 to #4.


NEXT


14.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
NOTICE:
  1. Replace the injector assembly of the cylinder which displays a value of 3.0 mm3/st or higher for Injection Feedback Val #1 to #4 in step 4 or 9.
  2. Only replace the injector assembly for the cylinder which displays an Injector Leaking Count #1 to #4 value of 1 or more, or i-ART Learning Status History #1 to #4 value of 1 Trip or more.
  3. If Injector Leaking Count #1 to #4 and i-ART Learning Status History #1 to #4 both display 0, only replace the injector assembly for the cylinder which was determined to be malfunctioning using Injection Feedback Val #1 to #4.

  1. Replace the injector assembly of the malfunctioning cylinder (HILUX_TGN26 RM0000044TN00FX.html).

    NOTICE:
    1. When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
    2. 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.
    3. 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.
    4. If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
    5. 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.CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER

  1. 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


16.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (HILUX_TGN26 RM000002SY802GX_01_0002.html).


NEXT


17.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

  1. Check whether the knocking has been successfully repaired.


NEXT

END

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

  1. Replace the fuel supply pump assembly (HILUX_TGN26 RM0000014FO01OX.html).

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

NEXT


19.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (HILUX_TGN26 RM000002SY802GX_01_0002.html).


NEXT


20.PERFORM SUPPLY PUMP INITIALIZATION

  1. Perform supply pump initialization (HILUX_TGN26 RM000000TIN058X.html).


NEXT


21.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

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


NEXT

END

22.CHECK SNAPSHOT (INJECTOR LEAKING COUNT #1 TO #4, I-ART LEARNING STATUS HISTORY #1 TO #4)

  1. Check Injector Leaking Count #1 to #4 and i-ART Learning Status History #1 to #4 in the snapshot taken in procedure 3 when the engine was idling and at 4000 rpm.

    Result
    Result
    		Proceed to
    The value for Injector Leaking Count #1 to #4 does not change from 0
    The value for i-ART Learning Status History #1 to #4 does not change from 0 Trip
    		A
    The value for Injector Leaking Count #1 to #4 displays 1 or more
    The value for i-ART Learning Status History #1 to #4 displays 1 Trip or more
    		B



A
Go to step 24
B


23.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
NOTICE:
Only replace the injector assembly for the cylinder which displays an Injector Leaking Count #1 to #4 value of 1 or more, or i-ART Learning Status History #1 to #4 value of 1 Trip or more.

  1. Replace the injector assembly of the malfunctioning cylinder (HILUX_TGN26 RM0000044TN00FX.html).

NOTICE:
  1. When replacing the injector assembly for a cylinder, always be sure to use a new injection pipe.
  2. 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.
  3. 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.
  4. If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough idle, etc. may occur.
  5. 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
Go to step 15

24.READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

  1. Connect the GTS to the DLC3.

  1. Turn the ignition switch to ON and turn the GTS on.

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

  1. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).

    Standard:
    Difference between MAP and Atmosphere Pressure is less than 8 kPa.
    HINT:
    1. 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.
    2. 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


B
REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR (HILUX_TGN26 RM000004Q2F00CX.html)

C
REPLACE ECM (HILUX_TGN26 RM0000013Z001IX.html)
A


25.BASIC INSPECTION

  1. Check the fuel quality.

  1. Check the fuel for air.

  1. Check the fuel system for blockages.

  1. Check the air filter.

  1. Check the engine oil.

  1. Check the engine coolant.

  1. Check the engine idling speed and maximum engine speed.

  1. Check the vacuum pump.


NEXT

END