Ecd System (W/ Urea Scr System) Intake/Exhaust System


INSPECTION PROCEDURE

TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 1)

READ VALUE USING GTS (MAP AND MAF)

READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

CHECK INTAKE SYSTEM

INSPECT TURBOCHARGER SUB-ASSEMBLY

CHECK FOR INTERMITTENT PROBLEMS

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

REPLACE ECM

REPAIR OR REPLACE INTAKE SYSTEM

REPLACE TURBOCHARGER SUB-ASSEMBLY

CHECK INTAKE SYSTEM

PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)

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

REPAIR OR REPLACE INTAKE SYSTEM

READ VALUE USING GTS (MAF)

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

CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

REPLACE NO. 1 EGR COOLER

REPLACE MASS AIR FLOW METER SUB-ASSEMBLY

INSPECT INTAKE MANIFOLD (SWIRL CONTROL VALVE OPERATION)

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

ECD SYSTEM (w/ Urea SCR System) - Intake/Exhaust System


INSPECTION PROCEDURE

NOTICE:
  1. After replacing the ECM, the new ECM needs registration (LandCruiser RM0000012XK0AUX.html) and initialization (LandCruiser RM000000TIN08HX.html).
  2. After replacing an injector assembly, the ECM needs registration (LandCruiser RM0000012XK0AUX.html).
1.TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 1)

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Powertrain / Engine and ECT / Data List / Common Rail (All).

  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


2.READ VALUE USING GTS (MAP AND MAF)

  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/sec or more*2
    		B
    Except above*3
    		C
    HINT:
    The above values were measured under standard atmospheric pressure. The values 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).


B
Go to step 20

C
Go to step 11
A


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

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

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

  1. Compare MAP and Atmosphere Pressure when the engine switch on (IG) (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


B
Go to step 7

C
Go to step 8
A


4.CHECK INTAKE SYSTEM

  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 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.


B
Go to step 9
A


5.INSPECT TURBOCHARGER SUB-ASSEMBLY

  1. Inspect the turbocharger sub-assembly (LandCruiser RM000003TBT01XX.html).



NG
Go to step 10
OK


6.CHECK FOR INTERMITTENT PROBLEMS

  1. Check for intermittent problems (LandCruiser RM000000PDQ19IX.html).



NEXT
Go to step 20

7.REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

  1. Replace the manifold absolute pressure sensor (LandCruiser RM0000045B300KX.html).



NEXT
Go to step 20

8.REPLACE ECM

  1. Replace the ECM (LandCruiser RM0000013Z002DX.html).



NEXT
Go to step 20

9.REPAIR OR REPLACE INTAKE SYSTEM

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



NEXT
Go to step 20

10.REPLACE TURBOCHARGER SUB-ASSEMBLY

  1. Replace the turbocharger sub-assembly (LandCruiser RM000002S6F011X.html).



NEXT
Go to step 20

11.CHECK INTAKE SYSTEM

  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.


B
Go to step 14
A


12.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EGR VALVE CLOSE)

  1. Connect the GTS to the DLC3.

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

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

  1. Turn the GTS on.

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

  1. Read the MAF value displayed on the GTS while the engine is idling.

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

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

    HINT:
    1. 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.
    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 sub-assembly.

    Reference:

    EGR Valve Condition (Opening)
    		Measuring Condition
    		MAF (Reference)
    Open (41%)
    1. Atmosphere pressure: 101 kPa
    2. Engine coolant temperature: 75°C (167°F)
    		3 to 7 gm/sec
    Closed (0%)
    		11 to 16 gm/sec


B
Go to step 15
A


13.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

  1. Connect the GTS to the DLC3.

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

  1. Turn the engine switch off and wait for 30 seconds.

  1. Start the engine and turn the GTS on.

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

  1. Read the MAF value displayed on the GTS while the engine is idling.

  1. 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.

  1. 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:
    1. 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.
    2. When operating "Activate the VSV for EGR Cooler Bypass", check that "Cooler" and "Bypass" can be switched between and the EGR cooler by-pass valve regulating link operates. If the link does not operate, the inspection cannot be performed correctly. Therefore, inspect and repair the following parts, perform the Active Test and read the changes in the MAF value.
      1. No. 2 EGR valve assembly (LandCruiser RM000005UDV000X_01_0007.html).
      2. Vacuum hose connection (LandCruiser RM000005UDV000X_01_0004.html).
      3. No. 1 vacuum switching valve assembly (for EGR bypass valve) (LandCruiser RM000005UJX000X.html).

    Result
    GTS 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 No. 1 EGR cooler is clogged, the mass air flow changes.


A
Go to step 20

B
Go to step 18

14.REPAIR OR REPLACE INTAKE SYSTEM

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



NEXT
Go to step 20

15.READ VALUE USING GTS (MAF)

  1. Connect the GTS to the DLC3.

  1. Turn the engine switch on (IG) and turn the GTS on.

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

  1. Start the engine and read the value when 30 seconds has elapsed.

    Standard:

    GTS Display
    		Switch Condition
    		Standard
    MAF
    		Idling
    1. 3.0 to 15.0 gm/sec (EGR on)
    2. 10.0 to 21.0 gm/sec (EGR off)
    Running without load (3000 rpm):
    1. 45.0 to 89.0 gm/sec (EGR on)
    2. 72.0 to 94.0 gm/sec (EGR off)


NG
Go to step 19
OK


16.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE VSV FOR EGR COOLER BYPASS)

  1. Connect the GTS to the DLC3.

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

  1. Turn the engine switch off and wait for 30 seconds.

  1. Start the engine and turn the GTS on.

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

  1. Read the MAF value displayed on the GTS while the engine is idling.

  1. 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.

  1. 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:
    1. 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.
    2. When operating "Activate the VSV for EGR Cooler Bypass", check that "Cooler" and "Bypass" can be switched between and the EGR cooler by-pass valve regulating link operates. If the link does not operate, the inspection cannot be performed correctly. Therefore, inspect and repair the following parts, perform the Active Test and read the changes in the MAF value.
      1. No. 2 EGR valve assembly (LandCruiser RM000005UDV000X_01_0007.html).
      2. Vacuum hose connection (LandCruiser RM000005UDV000X_01_0004.html).
      3. No. 1 vacuum switching valve assembly (for EGR bypass valve) (LandCruiser RM000005UJX000X.html).

    Result
    GTS 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 No. 1 EGR cooler is clogged, the mass air flow changes.


B
Go to step 18
A


17.CHECK FOR DEPOSIT (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

  1. Remove the electric EGR control valve assembly (LandCruiser RM000005UJR000X.html).

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

    NOTICE:
    1. When cleaning the electric EGR control valve assembly, make sure the valve is completely closed.
    2. When cleaning the electric EGR control valve assembly, perform initialization procedure (LandCruiser RM000000TIN08HX.html).
    3. Do not forcibly open the valve, as it may be damaged or deformed.
    4. When cleaning the electric EGR control valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying the solvent directly onto these parts or soaking the parts in the solvent may damage the parts.
    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.

  1. Reinstall the electric EGR control valve assembly (LandCruiser RM000005UJO000X.html).


NEXT


18.REPLACE NO. 1 EGR COOLER

  1. Replace the No. 1 EGR cooler (LandCruiser RM000005UJV000X.html).



NEXT
Go to step 20

19.REPLACE MASS AIR FLOW METER SUB-ASSEMBLY

  1. Replace the mass air flow meter sub-assembly (LandCruiser RM000000VHD05PX.html).

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

NEXT


20.INSPECT INTAKE MANIFOLD (SWIRL CONTROL VALVE OPERATION)

  1. Connect the GTS to the DLC3.

  1. Turn the GTS on.

  1. Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.

  1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for Swirl Control Valve.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Perform the Active Test.

    Standard:
    Swirl control valve rod moves smoothly in the direction indicated by the arrow in the illustration.

NEXT


21.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

NEXT

END