Ecd System (W/ Egr Cooler) 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)

CHECK INJECTOR COMPENSATION CODE

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 FUEL INJECTORS OF ALL CYLINDERS

PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CHECK THE CYLINDER COMPRESSION)

CHECK CYLINDER COMPRESSION PRESSURE

REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER

REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

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 FUEL SUPPLY PUMP INITIALIZATION

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE)

BASIC INSPECTION

ECD SYSTEM (w/ EGR Cooler) - 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 (fuel supply pump assembly)
    2. Fuel pulsation sound
    3. Air in fuel
  1. (c) Friction between parts
  1. (d) Compression pressure
  1. Injector compensation codes
  2. Fuel leakage
  3. Intake air system leakage
  4. Intake air system blockage
  5. EGR system
  6. Throttle valve system
  7. Fuel pressure sensor (common rail assembly)
  8. Manifold absolute pressure sensor
  9. Mass air flow meter
  10. Atmospheric pressure sensor (built into ECM)
  11. Vehicle modifications
  12. Low quality fuel
  13. Lack of fuel
  14. 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 RM0000012XK040X.html) and initialization (HILUX_TGN26 RM000000TIN04CX.html).
  2. After replacing the fuel supply pump, the ECM needs initialization (HILUX_TGN26 RM000000TIN04CX.html).
  3. After replacing an injector assembly, the ECM needs registration (HILUX_TGN26 RM0000012XK040X.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 intelligent tester to the DLC3.

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

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

  1. Read the DTCs.

    Result
    Result
    		Proceed to
    No output
    		A
    Engine related DTCs
    		B



B
GO TO DTC CHART (HILUX_TGN26 RM0000031HW01ZX.html)
A


3.CHECK INJECTOR COMPENSATION CODE
NOTICE:
Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head portion of each injector assembly. If an incorrect injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

  1. Check the injector compensation code (HILUX_TGN26 RM0000012XK040X_02_0006.html).

    OK:
    Compensation codes of the installed injector assemblies are the same as the compensation codes registered in the ECM.


NG
Go to step 16
OK


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

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / 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. Graphs like the ones shown below can be displayed by transferring the stored snapshot data from the tester to a PC. 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.

NEXT


5.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 12

B
Go to step 11
C


6.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 19
OK


7.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 23
A


8.INSPECT GLOW PLUG (RESISTANCE)

  1. Inspect the glow plug (HILUX_TGN26 RM0000013XN017X_01_0001.html).



NG
REPLACE GLOW PLUG (HILUX_TGN26 RM0000013XP01BX.html)
OK


9.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 intelligent tester to the DLC3.

  1. Start the engine and turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / 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. Graphs like the ones shown below can be displayed by transferring the stored snapshot data from the tester to a PC. Intelligent Viewer must be installed on the PC.

NEXT


10.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 14

B
Go to step 23

11.REPLACE FUEL INJECTORS OF ALL CYLINDERS

  1. Replace the fuel injectors (HILUX_TGN26 RM000002SY101RX.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

12.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CHECK THE CYLINDER COMPRESSION)
HINT:
Use this Active Test to help determine whether a cylinder has compression loss or not.

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / 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 14
A


13.CHECK CYLINDER COMPRESSION PRESSURE

  1. Check the cylinder compression pressure (HILUX_TGN26 RM000001473018X_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


14.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

  1. Replace the injector assembly of the malfunctioning cylinder (HILUX_TGN26 RM000002SY101RX.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.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

  1. Register the injector compensation codes (HILUX_TGN26 RM0000012XK040X_02_0003.html).

  1. Perform the fuel injector pilot quantity learning (HILUX_TGN26 RM0000012XK040X_02_0009.html).


NEXT


17.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (HILUX_TGN26 RM000002SY8025X_01_0002.html).


NEXT


18.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

  1. Check whether the knocking has been successfully repaired.


NEXT

END

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

  1. Replace the fuel supply pump assembly (HILUX_TGN26 RM0000014FO01BX.html).

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

NEXT


20.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (HILUX_TGN26 RM000002SY8025X_01_0002.html).


NEXT


21.PERFORM FUEL SUPPLY PUMP INITIALIZATION

  1. Perform fuel supply pump initialization (HILUX_TGN26 RM000000TIN04CX.html).


NEXT


22.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

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


NEXT

END

23.READ VALUE USING INTELLIGENT TESTER (MAP AND ATMOSPHERE PRESSURE)

  1. Connect the intelligent tester to the DLC3.

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

  1. Enter the following menus: Powertrain / Engine and ECT / 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 RM000004Q2F008X.html)

C
REPLACE ECM (HILUX_TGN26 RM0000013Z0019X.html)
A


24.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