Ecd System (W/O Dpf) Lack Of Power Or Hesitation

Engine Hybrid System. Land Cruiser. Urj200, 202 Grj200 Vdj200
1Vd-Ftv Engine Control. Land Cruiser. Urj200, 202 Grj200 Vdj200

DESCRIPTION

INSPECTION PROCEDURE

READ OUTPUT DTC (RELATING TO ENGINE)

TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 2)

TAKE SNAPSHOT DURING LACK OF POWER (PROCEDURE 3)

CHECK SNAPSHOT (MAP AND MAF)

CHECK SNAPSHOT (COMMON RAIL PRESSURE, TARGET COMMON RAIL PRESSURE, MAP AND TARGET BOOSTER PRESSURE)

CHECK INTAKE SYSTEM

CLEAN FUEL FILTER CASE AND REPLACE FUEL FILTER

REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

BLEED AIR FROM FUEL SYSTEM

REGISTER INJECTOR COMPENSATION CODE

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

READ VALUE USING GTS (MAP AND ATMOSPHERIC PRESSURE)

CHECK AIR INTAKE SYSTEM

CHECK TURBOCHARGER SUB-ASSEMBLY

CHECK FOR INTERMITTENT PROBLEMS

REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

REPLACE ECM

REPAIR OR REPLACE AIR INTAKE SYSTEM

REPLACE TURBOCHARGER SUB-ASSEMBLY

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

INSPECT CLOGGED FUEL PIPE

REPLACE FUEL SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)

REPAIR OR REPLACE CLOGGED FUEL LINE

BLEED AIR FROM FUEL SYSTEM

PERFORM SUPPLY PUMP INITIALIZATION

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

CHECK AIR INTAKE SYSTEM

INSPECT EGR VALVE ASSEMBLY

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

READ VALUE USING GTS (MAF)

REMOVE DEPOSIT (EGR VALVE ASSEMBLY)

REPAIR OR REPLACE AIR INTAKE SYSTEM

REPLACE MASS AIR FLOW METER

REPLACE EGR COOLER

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

CHECK CLOGGED EXHAUST SYSTEM

INSPECT TURBOCHARGER SUB-ASSEMBLY

CHECK FOR INTERMITTENT PROBLEMS

REPLACE EGR COOLER

REPLACE CLOGGED PARTS

REPLACE TURBOCHARGER SUB-ASSEMBLY

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

COMPARE WITH SIMILAR VEHICLE WITH SAME ENGINE

EXPLAIN THE INVESTIGATION RESULT TO CUSTOMER

ECD SYSTEM (w/o DPF) - Lack of Power or Hesitation


DESCRIPTION


Malfunction Condition
Main Trouble Area
Related Trouble Area
  1. Lack of power caused by abnormal fuel injection volume (fuel supply pump assembly malfunction, injector assembly malfunction, etc.)
  2. Lack of power caused by intake air volume shortage (turbocharger malfunction, or front exhaust pipe or exhaust manifold converter blocked)
(a) Injector assembly malfunctions
  1. Injector sliding malfunction
  2. Injector stuck closed
  3. Injector stuck open
  4. Deposits in injector
  5. Injector circuit malfunction
(b) Abnormal common rail pressure
  1. Suction control valve (fuel supply pump assembly)
(c) Abnormal intake air volume
  1. Intake air system leakage or clogged
  2. Turbocharger sub-assembly
  3. Front exhaust pipe blockage
  4. Exhaust manifold converter blockage
  5. EGR valve does not close
  6. Throttle valve does not open
  1. Pressure discharge valve (common rail assembly (for bank 2)) (P1271 stored simultaneously)
  2. Intake air system blockage
  3. EGR system
  4. Fuel filter element sub-assembly is clogged
  5. Throttle valve
  6. Mass air flow meter
  7. Compression pressure
  8. Injector compensation code
  9. Fuel leak
  10. Glow plug
  11. Fuel pressure sensor (common rail assembly (for bank 1))
  12. Manifold absolute pressure sensor
  13. Vacuum hose connection for manifold absolute pressure sensor
  14. Injector driver (P062D or P062E stored simultaneously)
  15. Vehicle modifications
  16. Clutch disc wear
  17. Low quality fuel
  18. Frozen fuel
  19. 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 causing the malfunction.
  2. Check that the vehicle has not been modified in any way prior to the vehicle inspection.
  3. This troubleshooting procedure checks for the cause of an obvious lack of engine power while the vehicle is being driven (such as the maximum speed being extremely low).

Faults and Symptoms of Common Rail Diesel Components

  1. Engine Control

    Mass Air Flow Meter
    Main fault
    		Decrease in performance (foreign matter is stuck)
    Symptoms
    		Lack of power, black smoke
    Data List
    		MAF
    HINT:
    The maximum fuel injection volume is controlled according to the output from the mass air flow meter.

    Intake System
    Symptom and Corresponding Main Fault
    1. Lack of power (no black smoke) due to air filter blockage or crushed or leaking air duct
    2. Black smoke (no lack of power) due to leakage between the turbo and intake manifold
    Data List
    1. MAP
    2. Target Booster Pressure
      When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.
    3. MAF

    Turbocharger System
    Main fault
    1. Air leak in the turbocharged air passage
    2. Turbocharger sub-assembly (turbine, bearing, variable nozzle)
    Symptoms
    		Lack of power (when vehicle is starting, under heavy load)
    (Black smoke is not emitted when racing while vehicle is stopped)
    Data List
    		MAP, Target Booster Pressure
    1. When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.
    2. With the ignition switch ON or during idling, MAP = atmospheric pressure (standard atmospheric pressure = 101 kPa). When the engine speed is about 1500 rpm or more, the turbocharger starts to take effect and MAP becomes higher than atmospheric pressure.
    3. Atmospheric pressure decreases by 1 kPa each time elevation increases by 100 m, and is also affected by the current weather conditions.

    Exhaust System
    Main fault
    		Blockage
    Symptoms
    		Lack of power (high engine speed, under heavy load)
    Data List
    		MAP, Target Booster Pressure
    When the accelerator is fully depressed, if MAP is 20 kPa lower than Target Booster Pressure for more than 5 seconds, then a lack of power will be felt.

    Glow System
    Main fault
    		Glow system malfunction
    Symptoms
    		Difficult to start, rough idle, knocking, white smoke (when cold)
    Data List
    		Check the glow plug indicator light
    Diagnostic Point
    		Measure the resistance of the glow plug

    Engine - 1
    Main fault
    		Damaged, seized up
    Symptoms
    		Cannot crank, crank speed is low, strange noise

    Engine - 2
    Main fault
    		Loss of compression
    Symptoms
    		Rough idle (lack of power always)
    Data List
    		Engine Speed of Cyl#
    1. When cranking during the "Check the Cylinder Compression" Active Test, if there is a high speed cylinder, approx. 100 rpm more than the other cylinders, that cylinder may lose compression.
    Injection Feedback Val
    1. When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder.

  2. Diesel Injection

    Fuel Supply Pump Assembly
    Main fault
    		-
    Symptoms
    		Difficult to start, engine stalling, rough idle, lack of power
    Data List
    		Common Rail Pressure, Target Common Rail Pressure, Target Pump SCV Current
    1. Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).
    2. If the fuel pressure is 20000 kPa below the target common rail pressure, then a lack of power will be felt.
    3. If the fuel pressure is below 25000 kPa, then idling will be rough.
    4. If Target Pump SCV Current is 3000 mA or higher, the suction control valve may be stuck.
    HINT:
    1. The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.
    2. When Target Pump SCV Current is 3000 mA or higher, the suction control valve has a tendency to become stuck.
    Diagnostic Trouble Code
    		Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.

    Fuel Filter Element Sub-assembly
    Main fault
    		Blockage
    Symptoms
    		Difficult to start, engine stalling, rough idle, lack of power
    Data List
    		Common Rail Pressure, Target Common Rail Pressure
    1. Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).
    2. If the fuel pressure is 20000 kPa below the target pressure, then a lack of power will be felt.
    3. If the fuel pressure is below 25000 kPa, then idling will be rough.
    HINT:
    The fuel pressure changes at engine start, but is approx. 25000 kPa at engine start after the engine is warmed up.
    Diagnostic Trouble Code
    		Even if Common Rail Pressure is below Target Common Rail Pressure, a DTC will not be stored.

    Injector Assembly
    Main fault
    		Blockage
    Symptoms
    		Rough idle, lack of power, black smoke, white smoke, knocking
    Data List
    		Injection Feedback Val
    1. When an Injector Feedback Val is more than 3 mm3/st, there may be a malfunction in the corresponding cylinder. This value can be read after idling for 1 minute.

    Injector Driver
    Main fault
    		Circuit fault: The injector assembly does not open.
    Symptoms
    		Difficult to start, rough idle, lack of power, black smoke, white smoke, knocking
    Data List
    		Same as injector assembly
    Diagnostic Trouble Code
    		When the injector driver has a fault, some DTCs may be stored.

    Fuel Pressure Sensor
    Main fault
    		Open circuit, decrease in performance (foreign matter is stuck)
    Symptoms
    		Difficult to start, rough idle, engine stall, lack of power
    Data List
    		Common Rail Pressure, Target Common Rail Pressure
    1. Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure during idling with the engine warmed up (engine coolant temperature is higher than 70°C (158°F)).
    Diagnostic Code
    		When the fuel pressure sensor has a fault, some DTCs may be stored.

    Irregular Fuel
    Main fault
    		-
    Symptoms
    		Difficult to start, rough idle (especially when cold)

  3. Diesel EGR

    EGR System
    Main fault
    1. Does not move smoothly
    2. Does not close fully
    Symptoms
    1. Rough Idle
    2. EGR valve stuck closed: A loud turbocharger sound.
    3. EGR valve stuck open: Difficult to start (does not stall), black smoke, white smoke (when engine is cold), lack of power, jerking (If there is an excess in the quantity of EGR and there is a heavy load, when the vehicle starts moving, a lack of power will be felt. Also, when racing the engine, there will be some black smoke).
    Data List
    		Actual EGR Valve Pos, Actual EGR Valve Pos #2, Target EGR Valve Pos, Target EGR Valve Pos #2
    1. Generally, Actual EGR Valve Pos = Target EGR Valve Pos +/-5% (fully closed: 0%, fully open: 100%).
    2. Using the EGR valve Active Test, check whether Actual EGR Valve Pos follows Target EGR Valve Pos (the engine coolant temperature and intake air temperature should be considered when a malfunction occurs).
    3. EGR valve is fully closed when the ignition switch is ON (engine stopped).
    4. EGR valve opens to the halfway point at idling after the engine is warmed up.
    5. When the EGR valve does not close, MAF (Mass Air Flow) decreases when the vehicle is accelerated at full throttle. MAP also decreases in comparison to Target Booster Pressure. However, there is not a large difference.
    EGR Close Lrn. Val., EGR Close Lrn. Val #2
    1. When leaving the vehicle idling, the normal range of EGR Close Lrn. Val. is 3.5 to 4.5 V.
    2. In cases when EGR Close Lrn. Val. is out of the normal range (3.5 to 4.5 V), it is possible that the EGR valve cannot completely close.

  4. Diesel Throttle

    Diesel Throttle System
    Main fault
    		Stuck, does not move smoothly
    Symptoms
    1. Stuck closed: Lack of power, difficult to start, rough idle, engine stall, black smoke. These may occur when stuck almost fully closed.
    2. Stuck open: Turbocharger sound increases. When the engine is stopped, engine vibrations may occur.
    Data List
    1. Actual Throttle Position, Actual Throttle Position #2
      Fully closed: 0%
      Fully open: 100%
    2. When the ignition switch is ON (engine stopped), the diesel throttle is fully open. When idling, the diesel throttle is at the halfway point. When the ignition switch is turned from ON to off, the throttle is fully closed temporarily.

Data List Related to Lack of Power
  1. Engine Speed
  2. MAP
  3. MAF
  4. Intake Air
  5. Coolant Temp
  6. Target Common Rail Pressure
  7. Common Rail Pressure
  8. Target Pump SCV Current
  9. Injection Feedback Val #1 (to #8)
  10. Injection Volume
  11. Actual Throttle Position
  12. Actual Throttle Position #2
  13. Target EGR Valve Pos
  14. Target EGR Valve Pos #2
  15. Actual EGR Valve Pos
  16. Actual EGR Valve Pos #2

INSPECTION PROCEDURE


Explanation of Symptom

Lack of Power
The power of the diesel engine is determined by the quantity of injected fuel and the quantity of intake air.
The quantity of injected fuel is determined by the fuel pressure and the amount of time the injector assembly is open. Basically, the fuel pressure is controlled so that it reaches the target fuel pressure. The throttle valve does not restrict air flow volume, so the manifold absolute pressure is almost the same as atmospheric pressure when idling. At more than approximately 1500 rpm, the turbo starts to operate causing the manifold absolute pressure to become higher than atmospheric pressure.
The manifold absolute pressure is controlled so that it reaches the Target Booster Pressure when accelerating the vehicle at full throttle. Also, when accelerating the vehicle at full throttle, the throttle is fully open and the EGR valve is fully closed, preserving the mass air flow.
NOTICE:
  1. After replacing the ECM, the new ECM needs registration (Click here) and initialization (Click here).
  2. After replacing the fuel supply pump assembly, the ECM needs initialization (Click here).
  3. After replacing an injector assembly, the ECM needs registration (Click here).
1.READ OUTPUT DTC (RELATING TO ENGINE)

  1. Connect the GTS to the DLC3.

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

  1. Enter the following menus: Engine and ECT / Trouble Codes.

  1. Read the pending DTCs.

    Result
    Result
    		Proceed to
    No DTCs are output
    		A
    Engine related DTCs are output
    		B
    HINT:
    If only DTC P1608 is output, proceed to step 2.


B
GO TO DTC CHART (Click here)
A


2.TAKE SNAPSHOT DURING IDLING AND 4000 RPM (PROCEDURE 2)

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Engine and ECT / Data List / Lack of power.

  1. With no load after the engine is warmed up, take a snapshot when idling and at 4000 rpm.

    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.
    2. The shift lever should be in neutral and the A/C switch and all accessory switches should be off.

NEXT


3.TAKE SNAPSHOT DURING LACK OF POWER (PROCEDURE 3)

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

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

  1. Check for a lack of power during the driving test.

    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.
    2. Move the shift lever to 2nd gear and accelerate the vehicle with the accelerator pedal fully depressed (obey all laws and regulations, and pay attention to traffic conditions while driving the vehicle). Then, check the Data List with the engine warmed up and idling (the shift lever should be in neutral and the A/C switch and all accessory switches should be off).

    Result
    Result
    		Proceed to
    Apparent lack of power is present
    		A
    Apparent lack of power is not present
    		B


B
Go to step 42
A


4.CHECK SNAPSHOT (MAP AND MAF)

  1. Check MAP and MAF in the snapshot taken in procedure 2 when the engine was running at 4000 rpm with no load.

    Result
    Result
    		Proceed to
    MAP is 105 kPa or higher and MAF is 84 gm/sec or more*1
    		A
    MAP is below 90 kPa*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. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.
    *1: There may be a problem in the fuel injection system or intake system.
    *2: There may be a problem in the turbocharger system.
    *3: There may be a problem in the intake system or a problem with the EGR valve (valve stuck open or valve does not close).


B
Go to step 12

C
Go to step 27
A


5.CHECK SNAPSHOT (COMMON RAIL PRESSURE, TARGET COMMON RAIL PRESSURE, MAP AND TARGET BOOSTER PRESSURE)

  1. Check Common Rail Pressure, Target Common Rail Pressure, MAP and Target Booster Pressure in the snapshot taken in procedure 3 when the vehicle was accelerating with the accelerator pedal fully depressed in 2nd gear.

    Result
    Result
    		Proceed to
    MAP is below 190 kPa at an engine speed of 3000 rpm
    		A
    Difference between Common Rail Pressure and Target Common Rail Pressure is 20000 kPa or more
    		B
    Except above
    		C
    HINT:
    1. The above values were measured under standard atmospheric pressure. The values are influenced by elevation, weather conditions, etc.
      Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops by 1 kPa. This varies by weather.
    2. The engine speed must be 1500 rpm or less before performing the inspection in which the accelerator pedal is fully depressed and the engine is accelerated to a speed of 3000 rpm.
    3. If the turbocharger movement is not smooth, etc., the value of MAP in the snapshot taken during lack of power will not reach the target value.
      When the accelerator pedal is fully depressed and the engine speed is 3000 rpm, the MAP should be higher than 195 kPa.


B
Go to step 21

C
Go to step 27
A


6.CHECK INTAKE SYSTEM

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

    HINT:
    1. Inspect the air intake system, especially hoses and pipes between the air cleaner and turbocharger.
    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. Check for any modifications in the intake system made by the user.
    OK:
    No leakage or blockage.


NG
Go to step 18
OK


7.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


8.REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

  1. Replace the injector assemblies (Click here).

    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


9.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (Click here).

    HINT:
    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

NEXT


10.REGISTER INJECTOR COMPENSATION CODE

  1. Register the injector compensation code (Click here).


NEXT


11.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

NEXT

END

12.READ VALUE USING GTS (MAP AND ATMOSPHERIC PRESSURE)

  1. Connect the GTS to the DLC3.

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

  1. Enter the following menus: 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
Go to step 16

C
Go to step 17
A


13.CHECK AIR INTAKE SYSTEM

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

    Result
    Result
    		Proceed to
    Leaks and/or blockages exist in the intake system
    		A
    No leaks or blockages in the intake system
    		B
    HINT:
    1. Inspect the air intake system, especially hoses and pipes between the air cleaner and turbocharger.
    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. When inspecting for a clogged intake system (cause of low MAP), check the following points:
      1. Clogged air cleaner
      2. Clogged intake hose
      3. Diesel throttle valve stuck in closed position
    5. Check for any modifications in the intake system made by the user.


A
Go to step 18
B


14.CHECK TURBOCHARGER SUB-ASSEMBLY

  1. Check the turbocharger sub-assembly (for bank 1 or bank 2) (Click here).



NG
Go to step 19
OK


15.CHECK FOR INTERMITTENT PROBLEMS

  1. Check for intermittent problems (Click here).



NEXT
Go to step 20

16.REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR

  1. Replace the manifold absolute pressure sensor.



NEXT
Go to step 20

17.REPLACE ECM

  1. Replace the ECM (Click here).



NEXT
Go to step 20

18.REPAIR OR REPLACE AIR INTAKE SYSTEM

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



NEXT
Go to step 20

19.REPLACE TURBOCHARGER SUB-ASSEMBLY

  1. Replace the turbocharger sub-assembly (Click here).


NEXT


20.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

NEXT

END

21.INSPECT CLOGGED FUEL PIPE

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Engine and ECT / Data List / Diesel Injection.

  1. With no load after the engine is warmed up, take a snapshot when idling and when the vehicle is accelerating with the accelerator pedal fully depressed in 2nd gear.



  1. Check the Target Common Rail Pressure and Common Rail Pressure value.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Engine Control.Ecd System (W/ Dpf).Ecd System (W/O Dpf) Lack Of Power Or Hesitation


    Result
    Result
    		Proceed to
    While idling the vehicle, "Common Rail Pressure" deviates from the normal range and varies periodically with a period of approximately 2 seconds or more*1
    		A
    "Common Rail Pressure" is normal while idling the vehicle, but "Common Rail Pressure" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear*2
    Except above
    		B
    NOTICE:
    1. *1: The cause may be a squashed or blocked fuel pipe or hose.
    2. *2: The cause may be a clogged fuel filter.


A
Go to step 23
B


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

  1. Replace the fuel supply pump assembly (Click here).



NEXT
Go to step 24

23.REPAIR OR REPLACE CLOGGED FUEL LINE

  1. Repair or replace the clogged (including frozen fuel) fuel pipe.

  1. Replace the fuel filter element sub-assembly.

    HINT:
    If "Common Rail Pressure" does not follow "Target Common Rail Pressure" when the accelerator pedal is fully depressed in 2nd gear, replace the fuel filter element sub-assembly.

NEXT


24.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (Click here).

    HINT:
    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

NEXT


25.PERFORM SUPPLY PUMP INITIALIZATION

  1. Perform supply pump initialization (Click here).


NEXT


26.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

  1. Connect the GTS to the DLC3.

  1. Start the engine and turn the GTS on.

  1. Enter the following menus: Engine and ECT / Active Test / Test the Fuel Leak / Data List / Common Rail Pressure, Target Common Rail Pressure.

  1. Take a snapshot with the GTS during the Active Test.



  1. Measure the difference between the target fuel pressure (Target Common Rail Pressure) and the actual fuel pressure (Common Rail Pressure) when the "Test the Fuel Leak" Active Test is performed.

    HINT:
    In order to obtain an exact measurement, perform the Active Test 5 times and measure the difference once each time the Active Test is performed.

    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Engine Control.Ecd System (W/ Dpf).Ecd System (W/O Dpf) Lack Of Power Or Hesitation

    OK:
    The difference between the target fuel pressure and the actual fuel pressure 2 seconds after the Active Test starts is less than 10000 kPa.
    HINT:
    1. "Target Common Rail Pressure" is the target fuel pressure controlled by the ECM.
    2. "Common Rail Pressure" is the actual fuel pressure.

NEXT

END

27.CHECK AIR INTAKE SYSTEM

  1. Check for air leaks and blockages between the air cleaner case and turbocharger, and between the turbocharger 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.
    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 32
A


28.INSPECT EGR VALVE ASSEMBLY

  1. Connect the GTS to the DLC3.

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

  1. Enter the following menus: Engine and ECT / Active Test / Control the EGR Step Position or Control the EGR Step Position #2.

  1. While continuously changing the Active Test value to 0, 30, 60, 90, 60, 30 and 0%, check that Actual EGR Valve Pos or Actual EGR Valve Pos #2 smoothly changes to the set opening lift amount.

    OK:
    Value smoothly changes to within +/- 10% of set opening lift amount.
    HINT:
    1. EGR valve closed: 0%.
    2. EGR valve open: 95.2%.

  1. Next, after the engine is warmed up, stop the engine and wait for 15 seconds. After that, start the engine again and idle it for 30 seconds. Then stop the engine and wait for 15 seconds. After starting the engine again, read the Data List values while idling.

  1. Enter the following menus: Data List / EGR Close Lrn. Val. or EGR Close Lrn. Val. #2.

  1. Read the values.

    Standard:
    3.5 to 4.5 V


NG
Go to step 34
OK


29.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 ignition 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: 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 lift amount 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 lift amount is not 0%.

    Result
    Active Test
    		Result
    		Proceed to
    Activate the EGR Valve Close:
    Off (Open) to On (Closed)
    		MAF value does not change
    		A
    MAF value changes
    		B
    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 EGR valve assembly or mass air flow meter.

    Reference:

    EGR Valve Condition (Opening)
    		Measuring Condition
    		MAF (Reference)
    Open (55%)
    1. Atmosphere pressure: 101 kPa
    2. Engine coolant temperature: 75°C (167°F)
    		3 to 10 gm/sec
    Closed (0%)
    		12 to 21 gm/sec


B
Go to step 36
A


30.READ VALUE USING GTS (MAF)

  1. Connect the GTS to the DLC3.

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

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

  1. Read the value.

    Standard:

    GTS Display
    		Condition
    		Specified Condition
    MAF
    		Engine not running
    		Less than 0.35 gm/sec


NG
Go to step 33
OK


31.REMOVE DEPOSIT (EGR VALVE ASSEMBLY)

  1. Remove the No. 1 and No. 2 EGR valve assembly (Click here).

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

    NOTICE:
    1. When cleaning the EGR valve assembly, make sure the valve is completely closed.
    2. When cleaning the EGR valve assembly, perform initialization procedure (Click here).
    3. Do not forcibly open the valve, as it may be damaged or deformed.
    4. When cleaning the EGR 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. In this case, clean the EGR valve assembly.

  1. Reinstall the EGR valve assembly (Click here).



NEXT
Go to step 39

32.REPAIR OR REPLACE AIR INTAKE SYSTEM

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



NEXT
Go to step 35

33.REPLACE MASS AIR FLOW METER

  1. Replace the mass air flow meter (Click here).

    HINT:
    1. 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.
    2. Before replacing the mass air flow meter, perform a wire harness inspection and if there are any problems with the wire harness, repair or replace it.


NEXT
Go to step 35

34.REPLACE EGR COOLER

  1. Replace the EGR cooler (Click here).


NEXT


35.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED


NG
Go to step 36
OK

END

36.CHECK CLOGGED EXHAUST SYSTEM

  1. Remove the monolithic converter assembly RH (for bank 1 CCo catalytic converter) (Click here).

  1. Remove the monolithic converter assembly LH (for bank 2 CCo catalytic converter) (Click here).

  1. Visually check for catalyst clogging or carbon deposits adhering to the inner wall of the exhaust pipe upstream of the catalyst.

    OK:
    Less than 10% of the cells are clogged.

  1. Reinstall the monolithic converter assembly RH (for bank 1 CCo catalytic converter) (Click here).

  1. Reinstall the monolithic converter assembly LH (for bank 2 CCo catalytic converter) (Click here).



NG
Go to step 40
OK


37.INSPECT TURBOCHARGER SUB-ASSEMBLY

  1. Inspect the turbocharger sub-assembly (for bank 1 or bank 2) (Click here).



NG
Go to step 41
OK


38.CHECK FOR INTERMITTENT PROBLEMS

  1. Check for intermittent problems (Click here).



NEXT
Go to step 42

39.REPLACE EGR COOLER

  1. Replace the EGR cooler (Click here).



NEXT
Go to step 42

40.REPLACE CLOGGED PARTS

  1. Replace the monolithic converter assembly RH (for bank 1 CCo catalytic converter) (Click here).

  1. Replace the monolithic converter assembly LH (for bank 2 CCo catalytic converter) (Click here).



NEXT
Go to step 42

41.REPLACE TURBOCHARGER SUB-ASSEMBLY

  1. Replace the turbocharger sub-assembly (for bank 1) (Click here).

  1. Replace the turbocharger sub-assembly (for bank 2) (Click here).


NEXT


42.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

NEXT

END

43.COMPARE WITH SIMILAR VEHICLE WITH SAME ENGINE

  1. Confirm the situation in which the lack of power was experienced by the customer again, and compare the driving feeling under the same conditions using a similar vehicle with the same engine while collecting data with the GTS.

    HINT:
    Confirm the state of the following conditions when the lack of power was experienced.
    1. Accelerator pedal position (vehicle load)
    2. Vehicle speed
    3. Engine coolant temperature
    4. Ambient temperature
    5. Driving conditions before the lack of power occurred
    6. Climate
    7. Road and traffic conditions
    8. When (what day) the problem was noticed
    9. Whether the problem occurs suddenly or gradually
    10. How often the problem occurs
    11. Why the customer felt there is a lack of power (e.g. the customer compared their vehicle with another vehicle, somebody told the customer that their vehicle has a lack of power, etc.)
    12. Level of lack of power (slight or drastic)

    Result
    Result
    		Proceed to
    Significant difference is found
    		A
    Significant difference is not found
    		B


A
Go to step 4
B


44.EXPLAIN THE INVESTIGATION RESULT TO CUSTOMER

  1. Vehicle performance is normal.
    There is no problem at this point in time. However, if the problem reoccurs, ask the customer to explain in detail the situation in which the problem occurred.
    The best course may be to have the customer ride in another vehicle with the same specifications to understand that there is no problem with the customer's vehicle.


NEXT

END