Dtc P202D Reductant Leakage

DESCRIPTION

INSPECTION PROCEDURE

CHECK DTC OUTPUT

CHECK AROUND BOTTOM OF VEHICLE

PERFORM ACTIVE TEST USING GTS (CHECK UREA INJECTOR OPERATION)

PERFORM ACTIVE TEST USING GTS (CHECK INJECTION CONDITION OF UREA INJECTOR SET)

PERFORM ACTIVE TEST USING GTS (CHECK LEVEL SENSOR (UREA PUMP)

REPLACE UREA INJECTOR SET

CLEAN UREA INJECTOR SET

REPLACE UREA PUMP

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

DESCRIPTION

INSPECTION PROCEDURE

NOTICE:

Handling urea solution

1. Wear protective equipment as necessary (protective glasses and gloves).
   
2. Do not dilute urea solution.
   
3. If urea solution contacts your eyes or skin, immediately wash the contacted area with a large amount of water and consult a doctor as necessary.
   
4. If urea solution dries, it deposits a white powder. Also, if urea solution contacts metals such as copper and aluminum for a long period of time, it may promote corrosion. Therefore, if urea solution is spilled, dampen a cloth or other item and wipe it up or rinse the area with cool or warm water.
   

Handling the urea injector set

1. The urea injector set is a precision instrument. Take necessary precautions for installation and shipping. Do not use the part if it has been struck or dropped.
   
2. If the urea solution remaining inside the urea injector set dries out, it may become unable to inject urea solution. Therefore, conduct urea tube with heater assembly installation and removal quickly.
   
3. If the urea solution dries out and deposition occurs, urea may cling to the O-ring of the pipe and cause seal problems. Therefore, clean the urea tube with heater assembly and intake port of the urea injector set with water before attaching them.
   
4. Perform this procedure in an environment where urea solution will not freeze.
   

HINT:

Read freeze frame data using the GTS. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, and other data from the time the malfunction occurred.

1. Connect the GTS to the DLC3.
   

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

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

Result:

Result	Proceed to
DTC P202D is output	A
DTC P202D and other DTCs are output*	B

HINT:

*: If any other DTCs (CAN communication malfunctions or open/short circuits) are output, perform troubleshooting for those DTCs first.

1. Check around the bottom of the vehicle.
   

   HINT:

   If the urea solution dries on an object, deposition occurs and leaves behind a white powder.

   Area to check:
   
   1. Areas connecting the urea pump and urea injector set.
      
   2. Perforations in the urea tank sub-assembly.
      
   3. Connectors not connected properly
      
   4. Clogging of the cooling fins of the urea injector set
      

      HINT:

      If the cooling fins are clogged with foreign matter, remove the foreign matter and clean the cooling fins.

   Standard:

   No urea solution leaks.
   

1. Connect the GTS to the DLC3.
   

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

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Pump Check (Backward).
   

4. Perform the Active Test.
   

5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Purge.
   

6. Perform the Active Test.
   

   HINT:

   Perform the Reductant Purge to draw the urea solution back into the urea tank sub-assembly from the urea injector set.

7. After performing the Active Test, remove the urea injector set from the front exhaust pipe assembly.
   

   HINT:

   1. Do not disconnect the urea injector set from the urea tube with heater assembly.
      
   2. Use a cover, etc., to prevent foreign matter from entering the exhaust pipe.
      

8. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Injection Valve.
   

9. Perform the Active Test and check for the sound of the urea injector set operating.
   

   Standard value:

   Sound of urea injector set operation can be heard (a ticking sound).
   

1. Prepare a bucket or other receptacle for collecting urea solution from the urea injector.
   

2. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Filling (Pressure Keep).
   

3. Execute "Reductant Filling (Pressure Keep)" and prepare to inject urea.
   

   NOTICE:

   1. While "Reductant Filling (Pressure Keep)" is being executed, the pressure inside the pipe increases and the urea injector set intermittently opens, which may cause a certain amount of urea solution to leak out.
      
   2. If the urea injector set is stuck open, urea solution will leak out continuously because intermittent operation cannot be performed once this operation starts.
      

4. After "Reductant Filling (Pressure Keep)" completes, enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Injection Valve.
   

5. Execute the Active Test and check the injection condition of the urea injector set.
   

   Standard value:

   Urea solution is intermittently injected by the urea injector.
   

   HINT:

   If the urea injector set is stuck open, urea solution will leak out continuously because intermittent injection cannot be performed once this Active Test starts.

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

2. Enter the following menus: Powertrain / Engine and ECT / Data List / Reductant Level.
   

3. Check the value of "Reductant Level". If the value of the level is 1, refill the urea solution.
   

   HINT:

   Refill approximately 3 to 5 L.

4. Disconnect the urea injector set from the urea tube with heater assembly.
   

   NOTICE:

   If the urea solution remaining inside the urea injector set dries out, it may become unable to inject urea solution. Therefore, seal the urea injector set with an item such as a cover or rubber cap so that the inside does not dry out.

5. Prepare a bucket or other receptacle for collecting urea solution from the urea tube with heater assembly.
   

6. Enter the following menus: Powertrain / Engine and ECT / Active Test / Reductant Discharge / Data List / Reductant Level.
   

7. Execute the Active Test and check the urea solution level.
   

   NOTICE:

   When the Active Test is executed, urea solution will come out of the urea tube with heater assembly. Collect the urea solution with a bucket or other receptacle.

   Standard:

   Urea solution level decreases.
   

   HINT:

   When the level sensor value is stuck, the value does not decrease even when the urea solution is released.

8. Refill approximately 3 to 5 L of urea solution.
   

   Standard:

   Urea solution level increases.
   

   HINT:

   When the level sensor value is stuck, the value does not increase even when the urea solution is refilled.

9. Install the urea injector set (LandCruiser RM000005UKS000X.html).
   

1. Replace the urea injector set (LandCruiser RM000005UKV000X.html).
   

1. Wash off any matter deposited by the urea solution.
   

   NOTICE:

   1. Do not damage the urea injector set when washing it.
      
   2. Make sure to leave the connector connected when washing to prevent water from entering via the connector.
      
   3. Sufficiently wipe the area so that no urea solution remains on the flange sealing surface.
      
   4. After washing, check that 3 streams of liquid are sprayed from the urea injector set.
      

1. Replace the urea pump (LandCruiser RM000005UL0000X.html).
   

1. Connect the GTS to the DLC3.
   

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

3. Clear the DTCs (LandCruiser RM000000PDK1E5X.html).
   

4. Turn the engine switch off and wait for at least 30 seconds.
   

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

6. Start the engine and wait for 30 minutes or more.
   

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

8. Confirm that the DTC is not output again.