Dtc P0201 Injector Circuit / Open - (Cylinder 1)

DESCRIPTION

MONITOR DESCRIPTION

WIRING DIAGRAM

INSPECTION PROCEDURE

CHECK ENGINE CRANKING CONDITION

INSPECT ECM

CHECK TERMINAL VOLTAGE INJECTOR DRIVER POWER SOURCE

CHECK HARNESS AND CONNECTOR (INJECTOR DRIVER - ECM)

REPLACE INJECTOR DRIVER

CHECK WHETHER DTC OUTPUT RECURS

INSPECT INJECTOR DRIVER

REPLACE INJECTOR ASSEMBLY (RELEVANT CYLINDER)

BLEED AIR FROM FUEL SYSTEM

REPLACE ECM

CHECK HARNESS AND CONNECTOR (INJECTOR ASSEMBLY - INJECTOR DRIVER)

REPLACE INJECTOR DRIVER

REPAIR OR REPLACE HARNESS OR CONNECTOR

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

DESCRIPTION

MONITOR DESCRIPTION

1. P0201, P0202, P0203, P0204:
   The ECM compares injection command (#1 to #4) signals and injection confirmation (INJF) signals for each cylinder. If the ECM determines that a cylinder has a malfunction, DTC P0201, P0202, P0203 or P0204 will be stored.
   

1. P062D:
   The ECM continuously monitors both injection command (IJT) signals and injection confirmation (IJF) signals. This DTC will be stored if the ECM determines that the number of IJT signals and IJF signals are inconsistent.
   The fuel injectors are grounded over a Field Effect Transistor (FET) and a serial resistor. This resistor creates a voltage drop, which is monitored by the injector driver (EDU) (injector drive circuit) in relation to the current drawn by the injector assembly. When the injector current becomes too high, the voltage drop over the resistor exceeds a specified level and no IJF signal for that cylinder is sent to the ECM.
   After the engine is started, when there is no injection confirmation (IJF) signal from the injector driver (EDU) to the ECM even though the ECM sends injection command (IJT) signals to the injector driver (EDU), DTC P062D is stored.
   If this DTC is stored, the ECM enters fail-safe mode and limits engine power or stops the engine. The fail-safe mode continues until the ignition switch is turned off.
   
   
   
   
   

WIRING DIAGRAM

INSPECTION PROCEDURE

CAUTION:

Make sure to perform work on high voltage circuits with the ignition switch off.

NOTICE:

1. Inspect the fuses of circuits related to this system before performing the following inspection procedure.
   
2. After replacing the ECM, the new ECM needs registration (HILUX_TGN26 RM0000012XK05AX.html) and initialization (HILUX_TGN26 RM000000TIN058X.html).
   

HINT:

Read freeze frame data using the GTS. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, and other data from the time the malfunction occurred.

1. Check the engine cranking condition.
   
   

   Result

   Result	Proceed to
   Engine does not start*1	A
   Engine starts, but idling is rough*2	B
   Except above	C

   HINT:

   1. *1: Once DTC P062D is cleared, it is not stored again even when the engine does not start due to a malfunction in the injector driver (EDU).
      When the engine cannot be started due to a malfunction in the injector driver (EDU), the value for "Fuel Press" is higher than the value for "Target Common Rail Pressure".
      
   2. *2: DTC P0201, P0202, P0203, P0204 and P062D are stored at this time.
      

1. Check the waveform of the ECM connectors using an oscilloscope.
   

   OK:

   Tester Connection	Condition	Specified Condition
   C166-21 (#1) - C164-6 (E1)	Cranking	Correct waveform is as shown
   C166-22 (#2) - C164-6 (E1)	Cranking	Correct waveform is as shown
   C166-23 (#3) - C164-6 (E1)	Cranking	Correct waveform is as shown
   C166-24 (#4) - C164-6 (E1)	Cranking	Correct waveform is as shown

   Text in Illustration

   *a	Component with harness connected (ECM)

1. Disconnect the injector driver connectors.
   

2. Measure the voltage according to the value(s) in the table below.
   

   Standard Voltage:

   Tester Connection	Switch Condition	Specified Condition
   C107-2 (+B) - C107-4 (GND)	Ignition switch ON	11 to 14 V

   Text in Illustration

   *a	Front view of wire harness connector (to Injector Driver)

3. Reconnect the injector driver connectors.
   

1. Disconnect the injector driver connector.
   

2. Disconnect the ECM connector.
   

3. Measure the resistance according to the value(s) in the table below.
   
   

   Standard Resistance:

   
   

   Tester Connection	Condition	Specified Condition
   C109-7 (#10) - C166-21 (#1)	Always	Below 1 Ω
   C109-3 (#20) - C166-22 (#2)	Always	Below 1 Ω
   C109-6 (#30) - C166-23 (#3)	Always	Below 1 Ω
   C109-4 (#40) - C166-24 (#4)	Always	Below 1 Ω
   C109-8 (INJF) - C166-20 (INJF)	Always	Below 1 Ω
   C109-7 (#10) or C166-21 (#1) - Body ground	Always	10 kΩ or higher
   C109-3 (#20) or C166-22 (#2) - Body ground	Always	10 kΩ or higher
   C109-6 (#30) or C166-23 (#3) - Body ground	Always	10 kΩ or higher
   C109-4 (#40) or C166-24 (#4) - Body ground	Always	10 kΩ or higher
   C109-8 (INJF) or C166-20 (INJF) - Body ground	Always	10 kΩ or higher

4. Reconnect the injector driver connector.
   

5. Reconnect the ECM connector.
   

1. Replace the injector driver (HILUX_TGN26 RM000004QZ200FX.html).
   

1. Connect the GTS to the DLC3.
   

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

3. Clear the DTCs (HILUX_TGN26 RM000000PDK12TX.html).
   

4. Turn the ignition switch off for 30 seconds.
   

5. Start the engine and idle it for 30 seconds.
   

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

7. Check the DTCs output on the GTS.
   

   HINT:

   1. The cylinder with the malfunctioning injector assembly can be determined based on the output DTCs.
      
   2. If DTC P0201 is output, check the No. 1 injector assembly circuit.
      
   3. If DTC P0202 is output, check the No. 2 injector assembly circuit.
      
   4. If DTC P0203 is output, check the No. 3 injector assembly circuit.
      
   5. If DTC P0204 is output, check the No. 4 injector assembly circuit.
      

1. Disconnect the injector assembly connectors for all cylinders.
   

   NOTICE:

   If only the injector assembly connector of the malfunctioning cylinder is disconnected, the engine will start and there will be rough idling. Therefore, disconnect all injector assembly connectors before inspecting the waveform.

2. Start the engine.
   

3. Check the waveform of the injector assembly connectors using an oscilloscope.
   

   OK:

   Tester Connection	Condition	Specified Condition
   C159-3 (#1) - C159-6 (#10)	Cranking	Voltage increases by 50 V or more
   C160-3 (#2) - C160-6 (#20)	Cranking	Voltage increases by 50 V or more
   C161-3 (#3) - C161-6 (#30)	Cranking	Voltage increases by 50 V or more
   C162-3 (#4) - C162-6 (#40)	Cranking	Voltage increases by 50 V or more

   Text in Illustration

   *a	Front view of wire harness connector (to Fuel Injector)

1. Replace the injector assembly of the cylinder relevant to the DTC (HILUX_TGN26 RM0000044TN00PX.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.
      

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

1. Replace the ECM (HILUX_TGN26 RM0000013Z001IX.html).
   

1. Disconnect the injector assembly connectors.
   

2. Disconnect the injector driver connectors.
   

3. Measure the resistance according to the value(s) in the table below.
   
   

   Standard Resistance:

   
   

   Tester Connection	Condition	Specified Condition
   C159-6 (#10) - C108-1 (IJ1+)	Always	Below 1 Ω
   C159-3 (#1) - C108-4 (IJ1-)	Always	Below 1 Ω
   C160-6 (#20) - C108-3 (IJ2+)	Always	Below 1 Ω
   C160-3 (#2) - C108-6 (IJ2-)	Always	Below 1 Ω
   C161-6 (#30) - C107-1 (IJ3+)	Always	Below 1 Ω
   C161-3 (#3) - C107-3 (IJ3-)	Always	Below 1 Ω
   C162-6 (#40) - C108-2 (IJ4+)	Always	Below 1 Ω
   C162-3 (#4) - C108-5 (IJ4-)	Always	Below 1 Ω
   C159-6 (#10) or C108-1 (IJ1+) - Body ground	Always	10 kΩ or higher
   C159-3 (#1) or C108-4 (IJ1-) - Body ground	Always	10 kΩ or higher
   C160-6 (#20) or C108-3 (IJ2+) - Body ground	Always	10 kΩ or higher
   C160-3 (#2) or C108-6 (IJ2-) - Body ground	Always	10 kΩ or higher
   C161-6 (#30) or C107-1 (IJ3+) - Body ground	Always	10 kΩ or higher
   C161-3 (#3) or C107-3 (IJ3-) - Body ground	Always	10 kΩ or higher
   C162-6 (#40) or C108-2 (IJ4+) - Body ground	Always	10 kΩ or higher
   C162-3 (#4) or C108-5 (IJ4-) - Body ground	Always	10 kΩ or higher

4. Reconnect the injector assembly connectors.
   

5. Reconnect the injector driver connectors.
   

1. Replace the injector driver (HILUX_TGN26 RM000004QZ200FX.html).
   

1. Repair or replace the harness or connector.
   

1. Connect the GTS to the DLC3.
   

2. Clear the DTCs (HILUX_TGN26 RM000000PDK12TX.html).
   

3. Turn the ignition switch off for 30 seconds or more.
   

4. Start the engine and idle it for 5 seconds.
   

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

6. Confirm that the DTC is not output again.