Malfunction Condition	Main Trouble Areas	Related Trouble Areas
Lack of power caused by abnormal fuel injection volume (supply pump malfunction or injector malfunction) Lack of power caused by intake air volume shortage (turbocharger malfunction, front exhaust pipe or exhaust manifold converter blocked)	Injector malfunctions Injector sliding malfunction Injector stuck closed Injector stuck open Deposits in injector Injector circuit malfunction Abnormal common rail pressure Supply pump Abnormal intake air volume Turbocharger Front exhaust pipe blockage Exhaust manifold converter blockage	Pressure limiter Intake air system leakage Intake air system blockage EGR system Fuel filter element is clogged Throttle valve Compression pressure Injector compensation code Fuel leak Glow plug Fuel pressure sensor EDU (P0200/97 set simultaneously) Vehicle modifications Low quality fuel Frozen fuel ECM

HINT:

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.

Check that the vehicle has not been modified in any way prior to the vehicle inspection.

This troubleshooting procedure checks for the cause of an obvious lack of engine power (the vehicle speed does not reach the target speed in the high speed range) while the vehicle is being driven.

INSPECTION PROCEDURE

NOTICE:

After replacing the supply pump, the ECM needs initialization .

After replacing the injector, the ECM needs registration .

HINT:

Before troubleshooting, conduct the following:

Check the fuel quality.

Check the fuel for air.

Check the fuel system for blockages.

Check the air filter.

Check the engine oil.

Check the engine coolant.

Check the engine idling speed and the maximum engine speed.

Check the vacuum pump.

1.CHECK HARNESS AND CONNECTOR (IN ENGINE COMPARTMENT)

Check the wire harness and connector connections of common rail system components.

HINT:

Check the following components and system:

Sensors

Supply pump

Common rail

Injectors

EDU

Turbocharger system

Intake and exhaust system

OK:
The wire harnesses and connectors are connected securely.

Go to step 27

A

6.READ VALUE OF INTELLIGENT TESTER (MAP, MAF AND FUEL PRESSURE)

Connect the intelligent tester to the DLC3.

Start the engine and warm it up and turn the intelligent tester ON.

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

Select the following menu items in order and read the values.

MAP

MAF

Fuel Press

Standard:

Item	Engine Speed *1	Standard Range	Description
MAP *2	Engine switch ON (IG) (engine stopped)	Same as atmospheric pressure	Intake manifold internal pressure detected by manifold absolute pressure sensor
	Idling	85 to 93 kPa
	3,000 rpm (no engine load)	120 to 140 kPa
	3,000 rpm (driving with full throttle acceleration) *5	239 to 259 kPa
	3600 rpm (driving with full throttle acceleration) *5	245 to 265 kPa
MAF 2, 4	Engine switch ON (IG) (engine stopped)	0 g/s	Intake air volume detected by mass air flow meter
	Idling	2.5 to 5.52 g/s
	3,000 rpm (no engine load)	49 to 57 g/s
	3,000 rpm (driving with full throttle acceleration) *5	124 to 136 g/s
	3,600 rpm (driving with full throttle acceleration) *5	151 to 163 g/s
Common Rail Pressure *3	Idling	37 to 43 MPa	Common rail internal fuel pressure
	2,000 rpm (no engine load)	47 to 53 MPa
	3,000 rpm (no engine load)	60 to 66 MPa
	3,000 rpm (driving with full throttle acceleration) *5	150 to 156 MPa
	3,600 rpm (driving with full throttle acceleration) *5	177 to 183 MPa

HINT:

*1: The A/C switch and all accessory switches should be OFF with a fully warm engine.

*2: This value is indicated when the ambient temperature is 25°C (77°F) and the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and the stable boost pressure is maintained for approximately 10 seconds.

*3: This value is indicated when the ambient temperature is 25°C (77°F) and the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and the vehicle is accelerated for approximately 10 seconds.

*4: When the mass air flow meter malfunctions, the MAF output may deviate from the standard (referential) range when the engine idles and is accelerated from 3,000 to 4,000 rpm with full throttle acceleration.

*5: Fully depress the accelerator pedal with the vehicle creeping at idle speed in 2nd gear.

Result:
Item Result Proceed to
MAP, MAF, and Fuel press Standard range A
MAP and MAF Outside standard range B
Only MAP Outside standard range C
Only MAF Outside standard range D
Only Fuel Press Outside standard range E

Go to step 24

Go to step 34

A

7.READ VALUE OF INTELLIGENT TESTER (INJECTION FEED BACK VAL AND INJECTION VOLUME)

Select the following menu items in order and read the values.

Injection Feedback Val #1, #2, #3, and #4

Injection Volume

Standard:

Item	Engine Speed*	Standard Range	Description
Injection Feedback Val #1	Idling	-3.0 to 3.0 mm³	Value of injector fuel injection volume compensates for differences in combustion condition of cylinders Positive values indicate control which corrects combustion degradation Negative values indicate control which corrects excessive combustion pressure If problems exist, "Injection Feedback Val" may deviate from the -3.0 and 3.0 mm range
Injection Feedback Val #2	Idling	-3.0 to 3.0 mm³
Injection Feedback Val #3	Idling	-3.0 to 3.0 mm³
Injection Feedback Val #4	Idling	-3.0 to 3.0 mm³
Injection Volume	Idling	3.9 to 7.0 mm³	Fuel injection volume value controlled by ECU Controls NE signal, fuel temperature, engine coolant temperature, intake air temperature, boost pressure, atmospheric pressure, and EGR volume. If problems exist, "Injection Volume" may be outside the standard range

Result:
Result Proceed to
Standard range A
Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range B

HINT:

*: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.

Go to step 14

A

8.CHECK INJECTOR COMPENSATION CODE

Read the injector compensation code.

HINT:

If the injector compensation code is not correctly registered, it may cause malfunctions .

Check the injector compensation code.

OK:
Compensation code of the installed injector is the same as the one registered in the ECM.

Go to step 16

Go to step 23

A

15.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTOR CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)

Connect the intelligent tester to the DLC3.

Start the engine and turn the intelligent tester ON.

Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3, and #4 Fuel Cut.

Check the four cylinders in sequence to identify any faulty cylinders by performing the power-balance inspection.

HINT:

If the engine idle does not change when an injector is disabled, the cylinder being tested is malfunctioning.

If the cylinder being tested is normal, there will be a significant change of idle speed when the fuel injection is stopped for that cylinder.

REPLACE INJECTORASSEMBLY OF MALFUNCTIONING CYLINDER

16.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTOR CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER)

Connect the intelligent tester to the DLC3.

Start the engine and turn the intelligent tester ON.

Enter the following menus: Powertrain / Engine / Active Test / Control the Cylinder #1, #2, #3, and #4 Fuel Cut.

Check the four cylinders in sequence to identify any faulty cylinders by performing the power-balance inspection.

HINT:

If the engine idle does not change when an injector is disabled, the cylinder being tested is malfunctioning.

If the cylinder being tested is normal, there will be a significant change of idle speed when the fuel injection is stopped for that cylinder.

NEXT

17.CHECK CYLINDER COMPRESSION PRESSURE

Check the cylinder compression pressure .

Standard:
2,700 kPa (27.5 kgf/cm², 392 psi)

Minimum pressure:
2,200 kPa (22.4 kgf/cm², 319 psi)

Difference between each cylinder:
500 kPa (5.1 kgf/cm², 73 psi)

CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION

OK

18.CHECK MALFUNCTIONING CYLINDER'S INJECTOR FOR DEPOSITS

HINT:

If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This may cause malfunctions.

Check the injector for any deposits.

Result:
Injector Condition Proceed to
Deposits A
No deposits B

REPLACE INJECTORASSEMBLY OF MALFUNCTIONING CYLINDER

A

19.CLEAN INJECTOR

Wipe away deposits from the tips of the injectors.

HINT:

Solvent or carbon removal agents help remove the deposits easily.

Exercise extreme care not to damage the injectors while wiping off the deposits.

NEXT

20.READ VALUE OF INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

Reinstall the injector to the cylinder head.

Connect the intelligent tester to the DLC3.

Turn the engine switch ON (IG) and turn the intelligent tester ON.

Start the engine and warm it up.

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

Select the following menu items in order and read the values.

Injection Feedback Val #1, #2, #3, and #4

Injection Volume

Standard:
Item Engine Speed* Reference Value
Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm³
Injection Volume Idling 3.9 to 7.0 mm³

HINT:

*: The A/C switch and all accessory switches should be OFF with a fully warm engine.

When the values are outside the standard range, deposits inside the injector may be causing the problem.

OK:
Values are within the standard range.

REPLACE INJECTORASSEMBLY OF MALFUNCTIONING CYLINDER

END

21.CHECK INJECTORS FOR DEPOSITS (EXCEPT FUEL ADDITION INJECTOR)

HINT:

If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This may cause malfunctions.

Check the injector for any deposits.

Result:
Injector Condition Proceed to
Deposits A
No deposits B

REPLACE INJECTORS

A

22.CLEAN INJECTOR

Wipe away deposits from the tips of the injectors.

HINT:

Solvent or carbon removal agents help remove the deposits easily.

Exercise extreme care not to damage the injectors while wiping off the deposits.

NEXT

23.READ VALUE OF INTELLIGENT TESTER (INJECTION FEEDBACK VAL AND INJECTION VOLUME)

Reinstall the injector to the cylinder head.

Connect the intelligent tester to the DLC3.

Turn the engine switch ON (IG) and turn the intelligent tester ON.

Start the engine and warm it up.

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

Select the following menu items in order and read the values.

Injection Feedback Val #1, #2, #3, and #4

Injection Volume

Standard:
Item Engine Speed* Reference Value
Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm³
Injection Volume #1 to #4 Idling 3.9 to 7.0 mm³

HINT:

*: The A/C switch and all accessory switches should be OFF with a fully warm engine.

When the values are outside the standard range, deposits inside the injector may be causing the problem.

OK:
Values are within the standard range.

REPLACE INJECTORS

END

24.CHECK EGR VALVE ASSEMBLY

Check the EGR valve assembly .

REPLACE EGR VALVE ASSEMBLY

OK

25.INSPECT DIESEL THROTTLE BODY ASSEMBLY

Connect the intelligent tester to the DLC3.

Turn the engine switch ON (IG) and tester ON.

Enter the following menus: Powertrain / Engine / Diesel Throttle Angle.

Read the value.

Standard:
Engine switch ON (IG):
0%
Idling (Warmed up engine):
95%
Accelerator pedal fully depressed:
0%

REPLACE DIESEL THROTTLE BODY ASSEMBLY

OK

26.CHECK INTAKE SYSTEM

Check for air leakage and blockage between the air cleaner and turbocharger.

Check for air leakage and blockage between the turbocharger and intake manifold.

OK:
No leakage or blockage.

REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

OK

27.CHECK TURBOCHARGER SUB-ASSEMBLY (MECHANICAL PROBLEM)

Disconnect the air cleaner hose.

Use a mirror to visually check the turbocharger for any mechanical problems.

When the engine is cold, check that the impeller of the turbocharger rotates smoothly, and perform a contact check to confirm if it is damaged.

OK:
Impeller rotates smoothly and is not damaged.

REPLACE TURBOCHARGER SUB-ASSEMBLY

OK

28.CHECK VACUUM HOSE (TURBOCHARGER - E-VRV, E-VRV - VACUUM PUMP)

Check that the vacuum hoses are installed correctly.

Check the vacuum hoses for any cracks and damage.

Check the vacuum hoses for air leaks and any blockage.

OK:
The vacuum hoses are correctly connected.

REPAIR OR REPLACE VACUUM HOSE

OK

29.CHECK E-VRV FOR TURBOCHARGER CONTROL

Check the E-VRV .

REPLACE E-VRV FOR TURBOCHARGER CONTROL

OK

30.INSPECT TURBOCHARGER ACTUATOR

Inspect the actuator.

OK:
The valve has no contamination and it moves smoothly.

REPLACE TURBOCHARGER SUB-ASSEMBLY

OK

31.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Connect the intelligent tester to the DLC3.

Start the engine, warm it up, and turn the intelligent tester ON.

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

Select the following menu items in order and read the values.

MAP

MAF

Fuel Press

Standard:

Item	Engine Speed *1	Standard Range	Description
MAP *2	Engine switch ON (IG) (engine stopped)	Same as atmospheric pressure	Intake manifold internal pressure detected by manifold absolute pressure sensor
	Idling	85 to 93 kPa
	3,000 rpm (no engine load)	120 to 140 kPa
	3,000 rpm (driving with full throttle acceleration) *4	239 to 259 kPa
	3600 rpm (driving with full throttle acceleration) *4	245 to 265 kPa
MAF 2, 3	Engine switch ON (IG) (engine stopped)	0 g/s	Intake air volume detected by mass air flow meter
	Idling	2.5 to 5.52 g/s
	3,000 rpm (no engine load)	49 to 57 g/s
	3,000 rpm (driving with full throttle acceleration) *4	124 to 136 g/s
	3,600 rpm (driving with full throttle acceleration) *4	151 to 163 g/s

HINT:

*1: The A/C switch and all accessory switches should be OFF with a fully warm engine.

*2: This value is indicated when the ambient temperature is 25°C (77°F) and the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and the stable boost pressure is maintained for approximately 10 seconds.

*3: When the mass air flow meter malfunctions, the MAF output may deviate from the standard (referential) range when the engine idles and is accelerated from 3,000 to 4,000 rpm with full throttle acceleration.

*4: Fully depress the accelerator pedal with the vehicle creeping at idle speed in 2nd gear.

OK:
The values are within the standard range.

END

NG

32.REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

NEXT

33.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Connect the intelligent tester to the DLC3.

Start the engine, warm it up, and turn the intelligent tester ON.

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

Select the following menu items in order and read the values.

MAP

MAF

Fuel Press

Standard:

Item	Engine Speed *1	Standard Range	Description
MAP *2	Engine switch ON (IG) (engine stopped)	Same as atmospheric pressure	Intake manifold internal pressure detected by manifold absolute pressure sensor
	Idling	85 to 93 kPa
	3,000 rpm (no engine load)	120 to 140 kPa
	3,000 rpm (driving with full throttle acceleration) *4	239 to 259 kPa
	3600 rpm (driving with full throttle acceleration) *4	245 to 265 kPa
MAF 2, 3	Engine switch ON (IG) (engine stopped)	0 g/s	Intake air volume detected by mass air flow meter
	Idling	2.5 to 5.52 g/s
	3,000 rpm (no engine load)	49 to 57 g/s
	3,000 rpm (driving with full throttle acceleration) *4	124 to 136 g/s
	3,600 rpm (driving with full throttle acceleration) *4	151 to 163 g/s

HINT:

*1: The A/C switch and all accessory switches should be OFF with a fully warm engine.

*2: This value is indicated when the ambient temperature is 25°C (77°F) and the atmospheric pressure is 101 kPa (758 mmHg, 29.83 in.Hg), and the stable boost pressure is maintained for approximately 10 seconds.

*3: When the mass air flow meter malfunctions, the MAF output may deviate from the standard (referential) range when the engine idles and is accelerated from 3,000 to 4,000 rpm with full throttle acceleration.

*4: Fully depress the accelerator pedal with the vehicle creeping at idle speed in 2nd gear.

OK:
The values are within the standard range

REPLACE TURBOCHARGER SUB-ASSEMBLY

END

34.CHECK AND REPLACE FUEL FILTER ASSEMBLY

NEXT

35.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

Connect the intelligent tester to the DLC3.

Start the engine and warm it up, and turn the intelligent tester ON.

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

Select the following menu item and read the values.

Fuel Press

Standard:

Item	Engine Speed *1	Reference Value
Fuel Press	Idling	37 to 43 MPa
Fuel Press	2,000 rpm (no engine load)	47 to 53 MPa
Fuel Press	3,000 rpm (no engine load)	60 to 66 MPa
Fuel Press	3,600 rpm (driving with full throttle acceleration) *2	177 to 183 MPa

HINT:

*1: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.

*2: Fully depress the accelerator pedal with the vehicle creeping at idle speed in 2nd gear.

OK:
The values are within the standard range.

END

NG

36.INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

Ecd System - Lack Of Power Or Hesitation. 2AD-FHV ENGINE CONTROL SYSTEM. Lexus IS250 IS220d GSE20 ALE20

Disconnect the E65 fuel sensor connector.

Measure the resistance between each terminal of the fuel pressure sensor connector.

Standard resistance:
Tester Connection Specified Condition
PR (E65-5) - E2 (E65-4) 16.4 kΩ or less
PR2 (E65-2) - E2S (E65-3) 16.4 kΩ or less
PR (E65-5) - VC (E65-6) 3 kΩ or less
PR2 (E65-2) - VCS (E65-1) 3 kΩ or less

Reconnect the fuel pressure sensor connector.

REPLACE COMMON RAIL ASSEMBLY

OK

37.INSPECT SUPPLY PUMP ASSEMBLY

Measure the resistance of the suction control valve terminals.

Standard resistance:
Condition Specified Condition
20°C (68°F) 1.9 to 2.3 Ω

REPLACE SUPPLY PUMP ASSEMBLY

CHECK AND REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)

LEXUS IS250, IS220d / GSE20 ALE20

2AD-FHV ENGINE CONTROL SYSTEM

Lexus IS250 IS220d GSE20 ALE20

ECD SYSTEM