Ecd System (For Dpf) Intake/Exhaust System

INSPECTION PROCEDURE

TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 1)

READ VALUE USING INTELLIGENT TESTER (MAP AND MAF)

READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE)

CHECK AIR INTAKE SYSTEM

INSPECT TURBOCHARGER SUB-ASSEMBLY

CHECK FOR INTERMITTENT PROBLEMS

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

REPLACE ECM

REPAIR OR REPLACE AIR INTAKE SYSTEM

REPLACE TURBOCHARGER SUB-ASSEMBLY

CHECK AIR INTAKE SYSTEM

PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE EGR VALVE CLOSE)

PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

REPAIR OR REPLACE AIR INTAKE SYSTEM

READ VALUE USING INTELLIGENT TESTER (MAF)

PERFORM ACTIVE TEST USING INTELLIGENT TESTER (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

REPLACE EGR COOLER

REPLACE MASS AIR FLOW METER

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

INSPECTION PROCEDURE

NOTICE:

1. After replacing the ECM, the new ECM needs registration (HILUX_TGN26 RM0000012XK070X.html) and initialization (HILUX_TGN26 RM000000TIN057X.html).
   
2. After replacing the fuel supply pump assembly, the ECM needs initialization (HILUX_TGN26 RM000000TIN057X.html).
   
3. After replacing an injector assembly, the ECM needs registration (HILUX_TGN26 RM0000012XK070X.html).
   

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 / All Data.
   

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

   Text in Illustration

   *1	Snapshot Button
   *a	Reference

   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. Graphs like the ones shown below can be displayed by transferring the stored snapshot data from the tester to a PC (Personal Computer). Intelligent Viewer must be installed on the PC.
      
   3. Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.
      

1. Check MAP and MAF in the snapshot taken in procedure 1 when the engine was running at 4000 rpm with no load.
   
   

   Result

   Result	Proceed to
   MAP is below 90 kPa*1	A
   MAP is 105 kPa or more and MAF is 84 gm/s or more*2	B
   Except above*3	C

   HINT:

   The above values were measured under standard atmospheric pressure. The value are influenced by elevation, weather conditions, etc.

   Standard atmospheric pressure is 101 kPa (1.0 kgf/cm², 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm², 0.1 psi). This varies by weather.

   *1: There may be a problem in the turbocharger system.

   *2: There may be a problem in the fuel system or intake system.

   *3: There may be a problem in intake system or a problem with the EGR valve (valve stuck open or valve does not close).

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 / MAP and Atmosphere Pressure.
   

4. Compare MAP and Atmosphere Pressure when the ignition switch 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 10 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 (1.0 kgf/cm², 15 psi). For every 100 m (328 ft.) increase in elevation, pressure drops by 1 kPa (0.01 kgf/cm², 0.1 psi). 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

1. Check for air leaks and blockages between the air cleaner case and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.
   
   

   Result

   Result	Proceed to
   No leaks or blockages in the intake system	A
   Leaks and/or blockages exist in the intake system	B

   HINT:

   1. Inspect the air intake system, especially hoses and pipes between the air cleaner and turbocharger sub-assembly.
      
   2. Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.
      
   3. Using your hand, check whether the pipes and hoses in the intake system are securely connected.
      
   4. By applying soapy water and revving up the engine, air leaks from the intake system can be checked by checking for bubbles.
      
   5. Make sure that the hose between the manifold absolute pressure sensor and intake manifold is not loose or disconnected.
      
   6. Check for any modifications in the intake system made by the user.
      

1. Inspect the turbocharger sub-assembly (HILUX_TGN26 RM000003TBT010X.html).
   

1. Check for intermittent problems (HILUX_TGN26 RM000000PDQ0Y1X.html).
   

1. Replace the manifold absolute pressure sensor.
   

1. Replace the ECM (HILUX_TGN26 RM0000013Z001HX.html).
   

1. Repair or replace the malfunctioning part in the air intake system.
   

1. Replace the turbocharger sub-assembly (HILUX_TGN26 RM000002S6F00OX.html).
   

1. Check for air leaks and blockages between the air cleaner case and turbocharger sub-assembly, and between the turbocharger sub-assembly and intake manifold.
   
   

   Result

   Result	Proceed to
   No leaks or blockages in the intake system	A
   Leaks and/or blockages exist in the intake system	B

   HINT:

   1. Inspect the air intake system, especially hoses and pipes between the air cleaner and turbocharger sub-assembly.
      
   2. Check for abnormal disconnections, pipe and hose squashing, and any damage in the intake system.
      
   3. Using your hand, check whether the pipes and hoses in the intake system are securely connected.
      
   4. By applying soapy water and revving up the engine, air leaks from the intake system can be checked by checking for bubbles.
      
   5. Make sure that the hose between the manifold absolute pressure sensor and intake manifold is not loose or disconnected.
      
   6. Check for any modifications in the intake system made by the user.
      

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
   

3. Turn the ignition switch off. Wait for 30 seconds, and then restart the engine.
   

4. Turn the tester on.
   

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

6. Read the MAF value displayed on the tester while the engine is idling.
   

7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the EGR Valve Close.
   

8. Read the MAF value when the EGR valve is closed using the Active Test function.
   

   HINT:

   1. If idling continues for 15 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.
      
   2. Before performing the diagnosis, confirm that the EGR valve target opening angle is not 0%.
      
   
   

   Result

   Active Test	Result	Proceed to
   Activate the EGR Valve Close: Off (Open) to On (Closed)	MAF value does not change	B
   	MAF value changes	A

   NOTICE:

   As the measured values may differ from those shown below due to factors such as differences in measuring environments and changes in vehicle condition due to aging, do not use these values to determine whether the vehicle is malfunctioning or not.

   HINT:

   The problem may be a temporary one, due to the entry of deposits or foreign matter. Check that there are no deposits or foreign matter in the electric EGR control valve assembly or mass air flow meter.

   
   

   Reference

   EGR Valve Condition (Opening)	Measuring Condition	MAF (Reference)
   Open (55%)	Atmosphere pressure: 101 kPa Intake air temperature: 30°C (86°F) Engine coolant temperature: 88°C (190°F)	3 to 10 gm/s
   Closed (0%)		12 to 21 gm/s

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
   

3. Turn the ignition switch off and wait for 30 seconds.
   

4. Start the engine and turn the tester on.
   

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

6. Read the MAF value displayed on the tester while the engine is idling.
   

7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EGR Cooler Bypass / Data List / EGR Cooler Bypass Position.
   

   HINT:

   Whether the EGR is passing through the bypass side or cooler side during the Active Test can be confirmed by checking EGR Cooler Bypass Position.

8. Using the Active Test function, switch the EGR valve bypass switching valve between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".
   

   HINT:

   If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

   
   

   Result

   Tester Display	Result	Proceed to
   Activate the VSV for EGR Cooler Bypass: Cooler to Bypass	MAF value does not change	A
   	MAF value changes	B

   HINT:

   If the EGR cooler is clogged, the mass air flow changes.

1. Repair or replace the malfunctioning part in the air intake system.
   

1. Connect the intelligent tester to the DLC3.
   

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

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

4. With the ignition switch ON and engine stopped, read the value when 30 seconds has elapsed.
   
   

   Standard:

   
   

   Tester Display	Switch Condition	Standard
   MAF	Ignition switch ON (do not start engine)	Less than 0.35 gm/s

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine and warm it up, and make sure the A/C switch and all accessory switches are off.
   

3. Turn the ignition switch off and wait for 30 seconds.
   

4. Start the engine and turn the tester on.
   

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

6. Read the MAF value displayed on the tester while the engine is idling.
   

7. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EGR Cooler Bypass / Data List / EGR Cooler Bypass Position.
   

   HINT:

   Whether the EGR is passing through the bypass side or cooler side during the Active Test can be confirmed by checking EGR Cooler Bypass Position.

8. Using the Active Test function, switch the EGR valve bypass switching valve between "Cooler" and "Bypass" a few times, and then check whether the MAF value changes after switching the valve from "Cooler" to "Bypass".
   

   HINT:

   If idling continues for 20 minutes or more, the EGR valve target opening angle becomes 0% (EGR valve fully closed). As this makes diagnosis impossible, it becomes necessary to drive the vehicle or restart the engine.

   
   

   Result

   Tester Display	Result	Proceed to
   Activate the VSV for EGR Cooler Bypass: Cooler to Bypass	MAF value does not change	A
   	MAF value changes	B

   HINT:

   If the EGR cooler is clogged, the mass air flow changes.

1. Remove the electric EGR control valve assembly (HILUX_TGN26 RM000004QWK00GX.html).
   

2. Visually check the electric EGR control valve assembly for deposits.
   If there are deposits, clean the electric EGR control valve assembly.
   

   HINT:

   1. If the EGR valve does not open properly or is stuck closed, the amount of intake air increases and combustion sounds and engine vibration may increase.
      
   2. If the EGR valve does not close properly or is stuck open, EGR becomes excessive and combustion becomes unstable. Also, there may be a lack of power.
      

3. Reinstall the electric EGR control valve assembly (HILUX_TGN26 RM000004QWH00GX.html).
   

1. Replace the EGR cooler (HILUX_TGN26 RM000004QWO00GX.html).
   

1. Replace the mass air flow meter (HILUX_TGN26 RM000000VHD04DX.html).
   

   HINT:

   If foreign matter is stuck inside the mass air flow meter, the output characteristics of the mass air flow meter may change, resulting in a malfunction.