Ecd System (W/ Urea Scr System) Engine Knocking Or Rattling


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 (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)

PERFORM PILOT QUANTITY LEARNING (DETAIL)

CHECK ENGINE KNOCKING OR RATTLING

CHECK THE TEMPERATURE WHEN KNOCKING OCCURS

INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)

TAKE SNAPSHOT DURING IDLING (WHEN ENGINE COLD)

CHECK SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4)

REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

PERFORM ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)

CHECK CYLINDER COMPRESSION PRESSURE

REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

REPLACE FUEL FILTER ELEMENT ASSEMBLY

BLEED AIR FROM FUEL SYSTEM

REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

REPLACE FUEL SUPPLY PUMP ASSEMBLY (PRE-STROKE CONTROL VALVE)

BLEED AIR FROM FUEL SYSTEM

CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

READ VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)

BASIC INSPECTION

ECD SYSTEM (w/ Urea SCR System) - 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. Pre-stroke control valve
    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
  8. Manifold absolute pressure sensor
  9. Mass air flow meter sub-assembly
  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 (LandCruiser RM0000012XK0AUX.html) and initialization (LandCruiser RM000000TIN08HX.html).
  2. After replacing an injector assembly, the ECM needs registration (LandCruiser RM0000012XK0AUX.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 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 / Trouble Codes.

  1. Read the DTCs.

    Result
    Result
    		Proceed to
    No DTC is output
    		A
    Engine related DTCs are output
    		B



B
GO TO DTC CHART (LandCruiser RM0000031HW07OX.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 (LandCruiser RM0000012XK0AUX_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 19
OK


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

  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 / Diesel Knocking.

  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


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 14

B
Go to step 13
C


6.CHECK SNAPSHOT (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)

  1. Check Common Rail Pressure and Target Common Rail Pressure in the snapshot taken when the engine was warmed up and idling.

    OK:
    Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure.


NG
Go to step 21
OK


7.PERFORM PILOT QUANTITY LEARNING (DETAIL)

  1. Perform the pilot quantity learning (detail) (LandCruiser RM0000012XK0AUX_02_0010.html).


NEXT


8.CHECK ENGINE KNOCKING OR RATTLING

  1. Check engine knocking or rattling.

    Result:
    Result
    		Proceed to
    Sound disappears
    		A
    Except above (Sound continues occurring)
    		B



A
END
B


9.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 24
A


10.INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)

  1. Inspect the glow plug assembly (LandCruiser RM0000044ZK00TX_01_0001.html).



NG
REPLACE GLOW PLUG ASSEMBLY (LandCruiser RM000000JIT01FX.html)
OK


11.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 GTS to the DLC3.

  1. Start the engine and turn the GTS on.

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

  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.

NEXT


12.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 16

B
Go to step 24

13.REPLACE INJECTOR ASSEMBLIES OF ALL CYLINDERS

  1. Replace the injector assemblies of all cylinder (LandCruiser RM000005UHS000X.html).

    NOTICE:
    1. When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection pipe sub-assembly and a new No. 2 injection pipe sub-assembly.
    2. Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, 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 sub-assembly may become incomplete, resulting in a fuel leak.


NEXT
Go to step 17

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

  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 / 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 16
A


15.CHECK CYLINDER COMPRESSION PRESSURE

  1. Check the cylinder compression pressure (LandCruiser RM000005UTQ000X_02_0009.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


16.REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

  1. Replace the injector assembly of the malfunctioning cylinder (LandCruiser RM000005UHS000X.html).

    NOTICE:
    1. When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection pipe sub-assembly and a new No. 2 injection pipe sub-assembly.
    2. Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, 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 sub-assembly may become incomplete, resulting in a fuel leak.

NEXT


17.REPLACE FUEL FILTER ELEMENT ASSEMBLY

  1. Replace the fuel filter element assembly (LandCruiser RM0000045HW008X.html).


NEXT


18.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (LandCruiser RM000002SY803FX_01_0002.html).


NEXT


19.REGISTER INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING

  1. Register the injector compensation codes (LandCruiser RM0000012XK0AUX_02_0003.html).

  1. Perform the fuel injector pilot quantity learning (LandCruiser RM0000012XK0AUX_02_0009.html).


NEXT


20.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

  1. Check whether the knocking has been successfully repaired.


NEXT

END

21.REPLACE FUEL SUPPLY PUMP ASSEMBLY (PRE-STROKE CONTROL VALVE)

  1. Replace the fuel supply pump assembly (LandCruiser RM000005UHX000X.html).

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

NEXT


22.BLEED AIR FROM FUEL SYSTEM

  1. Bleed the air from the fuel system (LandCruiser RM000002SY803FX_01_0002.html).


NEXT


23.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

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


NEXT

END

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

  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 / MAP and Atmosphere Pressure.

  1. Compare MAP to 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 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 (LandCruiser RM0000045B300KX.html)

C
REPLACE ECM (LandCruiser RM0000013Z002DX.html)
A


25.BASIC INSPECTION

  1. Check the fuel quality.

  1. Check the fuel for air.

  1. Check the fuel system for blockages.

  1. Check the air cleaner filter element subassembly.

  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