05–318 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA

MADE FOR ARGENTINA)) 05M5T–05

LACK OF POWER OR HESITATION (2KD–FTV)

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

HINT:
S 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 assume
the vehicle to be normal when the Data List outputs standard values. There may be concealed factors
of the malfunction.
S Check that the vehicle has not been modified in any way prior to the vehicle inspection.
INSPECTION PROCEDURE
1 CHECK WIRE HARNESS IN ENGINE ROOM

(a) Check the wire harness connections.

OK: Wire harnesses are connected securely.
NG REPAIR OR REPLACE HARNESS AND
CONNECTOR

OK

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 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA 05–319
MADE FOR ARGENTINA))

2 CHECK DTC OUTPUT (RELATING TO FUEL SYSTEM AND INTAKE SYSTEM)

HINT:
Drive the vehicle according to the driving pattern below to allow the ECM to set DTCs relating to malfunctions
of the fuel system, EGR system and throttle valve. If DTCs are set, problem areas can be identified.
(a) Switch the ECM from normal mode to check mode using the intelligent tester II (see page 05–52).
(b) Fully warm up the engine.
(c) Allow the engine to idle for 5 minutes or more.
(d) Drive the vehicle at more than 40 km/h (25 mph) for several tens of seconds.
(e) Decelerate and stop the vehicle.
(f) Repeat steps (d) and (e) 4 times or more.
(g) Stop the engine and wait for at least 10 seconds.
(h) Repeat steps (d) and (g) described above to set DTCs relating to the EGR system and throttle valve.
(i) Drive the vehicle at more than 70 km/h (43 mph) for at least 1 minute to set DTCs relating to the supply
pump.
NEXT

3 READ OUTPUT DTC (RELATING TO ENGINE)

(a) Enter the following menus: Auto / Pick Up / Engine / DTC.

(b) Read pending DTCs.
Result:
Display (DTC Output) Proceed to
No DTCs A
Engine related DTCs (see page 05–50) B

B REPAIR OR REPLACE ENGINE CONTROL

SYSTEM ACCORDING TO DTC OUTPUT
(See page 05–50)

4 PERFORM ACTIVE TEST (TEST THE FUEL LEAK)

HINT:
By performing this Active Test, engine speed is maintained at 2,000 rpm and the common rail internal fuel
pressure is raised to the maximum operating pressure. As a result, a fuel leak check can be conducted while
retaining the high common rail pressure condition.
(a) Connect the intelligent tester II to the DLC3.
(b) Start the engine and turn the intelligent tester II ON.
(c) Enter the following menus: Auto / Pick Up / Engine / Active Test / Test the Fuel Leak.
(d) Visually check the supply pump, injector and fuel line located between the supply pump and common
rail for fuel leaks and fuel pressure leaks. Also, perform the same check on the fuel line between the
common rail and the injector (see page 11–4).
HINT:
There may be fuel leaks inside components, such as the supply pump.
OK: No leakage.
NG REPAIR OR REPLACE

OK
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MADE FOR ARGENTINA))

5 CHECK FOR WHITE SMOKE

(a) Rev up the engine from idling to 3,000 rpm several times to check whether white smoke is emitted from
the exhaust pipe.
(b) Check that the intake system pipes and hoses are not excessively contaminated with oil.
If white smoke is emitted from the intake system, its pipes and hoses are excessively contaminated with oil.
If the presence of white smoke in the exhaust gas is confirmed, there is a high possibility of mechanical prob-
lems in the turbocharger or engine.
Result:
Result Proceed to
No problems described above A
White smoke emitted, or intake system pipes and hoses excessively contam-
B
inated with oil

B Go to step 27

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 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA 05–321
MADE FOR ARGENTINA))

6 READ DATA LIST (MAP, FUEL PRESS)

(a) Connect the intelligent tester II to the DLC3.

(b) Start the engine and warm it up, and turn the intelligent tester II ON.
(c) Enter the following menus: Auto / Pick Up / Engine / Data List.
(d) Select the following menu items in order and read the values.
S MAP
S Fuel Press
Standard:
Item Engine Speed* Standard Range Proceed to Description
Ignition switch ON (engine Same as atmospheric
stopped) pressure
95 to 105 kPa (713 to 788
Idling S A (standard range) Intake manifold internal
mmHg, 28.1 to 31 in.Hg)
MAP S B (MAP outside standard pressure detected by in-
in
113 to 133 kPa (848 to 998
3,000 rpm (No engine load) range) take pressure sensor
mmHg, 33.4 to 39.3 in.Hg)
3,500 rpm (full throttle ac- Min.: 175 kPa (1,313
celeration) mmHg, 51.7 in.Hg)
Idling 25 to 35 MPa
2,000 rpm (No engine load) 25 to 35 MPa S A (standard range)
Common rail internal fuel
Fuel Press 3,000 rpm (No engine load) 35 to 45 MPa S C (fuel pressure outside
pressure
standard range))
3,500 rpm (full throttle ac-
Min.: 121 MPa
celeration)

HINT:
*: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
B GO TO DTC P0105/31, P0107/31 AND P0108/31
(RELATED TO MANIFOLD ABSOLUTE PRES-
SURE SENSOR) (See page 05–101)

C Go to step 30

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MADE FOR ARGENTINA))

7 READ DATA LIST (INJECTION FEEDBACK VAL #1 TO #4, INJECTION VOLUME)

(a) Select the following menu items in order and read the values.
S Injection Feedback Val #1, #2, #3 and #4
S Injection Volume
Standard:
Item Engine Speed* Standard Range Proceed to Description
Value of injector fuel injec-
Injection Feedback Val #1 Idling –3.0 to 3.0 mm3 tion volume compensates
for differences in combus-
tion condition of cylinders
S Positive values indicate
Injection Feedback Val #2 Idling –3.0 to 3.0 mm3 control which corrects
combustiondegradation
S Negative values indicate
control which corrects ex-
Injection Feedback Val #3 Idling –3.0 to 3.0 mm3 cessive combustion pres-
sure
S A (standard range) S If problems
bl exist,
i t Injection
I j ti
S B (Injection Feedback Val Feedback Val may devi-
Injection Feedback Val #4 Idling –3.0 to 3.0 mm3 #1 to #4 and/or Injection ate from –3.0 and 3.0 mm
Volume outside standard range
range) Fuel injection volume value
controlled by ECU
S Controls NE signal, fuel
temperature, engine cool-
ant temperature, intake
air temperature, boost
Injection Volume Idling 3.0 to 10.0 mm3
pressure, atmospheric
pressure and EGR vol-
ume
S If problems exist, injection
volume may be outside
standard range

HINT:
*: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
B Go to step 17

8 CHECK INJECTOR COMPENSATION CODE (See page 05–27)

HINT:
If the injector compensation code is not correctly registered, it may cause malfunctions (see page 05–27).
OK: Compensation code of installed injector is same as code registered in ECM.
NG REGISTER INJECTOR COMPENSATION CODE
(See page 05–32)

OK

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 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA 05–323
MADE FOR ARGENTINA))

9 CHECK BATTERY

(a) Disconnect the cable from the negative (–) battery terminal for at least 2 minutes.
(b) Reconnect the cable to the negative (–) battery terminal.
(c) Perform a driving test.
(d) Check whether the malfunction has been successfully repaired by comparing the driving test data and
the freeze frame data recorded at the time the malfunction occurred.
OK: Malfunction has been repaired successfully.
OK CHECK FOR INTERMITTENT PROBLEMS
(See page 05–24)

NG

10 BLEED AIR FROM FUEL SYSTEM (See page 11–7)

(a) To bleed air from the priming pump, pump the priming pump until it becomes hard and cannot be
pumped any more.
NEXT

11 CONFIRM WHETHER LACK OF POWER HAS BEEN SUCCESSFULLY REPAIRED

(a) Perform a driving test.

(b) Check whether the malfunction has been successfully repaired by comparing the driving test data and
the freeze frame data recorded at the time the malfunction occurred.
OK: Malfunction has been repaired successfully.
OK END

NG

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05–324 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA
MADE FOR ARGENTINA))

12 INSPECT GLOW PLUG ASSY

Ohmmeter (a) Disconnect the glow plug wire.

(b) Measure the resistance of the glow plug.
(c) Check other glow plugs in the same way.
Standard:
Tester Connection Condition Specified Condition
Glow plug terminal – Body ground 20_C (68_F) Approximately 0.95 Ω
HINT:
If any one of the glow plugs has an open malfunction, the en-
A99235 gine power is insufficient only when the engine is cold.
NOTICE:
S Be careful not to damage the glow plug pipes. Damag-
ing them could cause an open circuit, or shorten the
life of the glow plugs.
S Keep the glow plug free of oil and fuel while cleaning.
S Wipe any oil off the terminal and Bakelite washer with
a clean, dry cloth during inspection.
S Do not apply more than 11 V to the glow plug as it
could cause an open circuit.
NG REPAIR OR REPLACE (See page 19–21)

OK

13 BASIC INSPECTION (See page 05–25)

(a) Check the fuel quality.

(b) Check the fuel for air.
(c) Check the fuel system for blockages.
(d) Check the air filter.
(e) Check the engine oil.
(f) Check the engine coolant.
(g) Check the engine idling speed and the maximum engine speed.
(h) Check the vacuum pump.
OK: Each inspection result is normal.
NG REPAIR OR REPLACE

OK

14 CHECK INTAKE AND EXHAUST SYSTEM

(a) Check for air leakage and blockage between the air cleaner and turbocharger.
(b) Check for air leakage and blockage between the turbocharger and intake manifold.
OK: No leakage or blockage.
NG REPAIR OR REPLACE

OK

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 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA 05–325
MADE FOR ARGENTINA))

15 CHECK ECM (EGLS VOLTAGE)

HINT:
The lifting amount of the EGR valve can be checked using the output of the EGR position sensor.
(a) Turn the ignition switch ON.
E8 E7 (b) Measure the voltage of the ECM connector.
ECM ECM Standard:
Tester Connection Specified Condition
E7–33 (EGLS) – E8–28 (E2) A (0.3 to 1.3 V)
(c) Turn the ignition switch ON.
(d) Start the engine and warm it up.
E2 (–) EGLS (+)
(e) Measure the voltage of the ECM connector.
A66060 Standard:
Tester Connection Condition Specified Condition
E7–33 (EGLS) – E8–28 (E2) Idling: 750 rpm A + (1.91 to 2.70 V)

HINT:
In the chart above, ”Idling” means that the engine should be
idled under the following conditions:
S Idle the engine, turn the A/C switch OFF and move the
shift lever to N.
S After the engine warms up, the engine should have no
load.
NG REPLACE EGR VALVE ASSY
(See page 12–11)

OK

16 INSPECT DIESEL THROTTLE BODY ASSY (See page 12–8)

OK: No malfunction.
NG REPAIR OR REPLACE (See page 10–11)

OK

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05–326 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA
MADE FOR ARGENTINA))

17 IDENTIFY MALFUNCTIONING CYLINDER INJECTOR

(a) Follow the instructions in the table below according to the check result of the intelligent tester II.
HINT:
This operation is based on the premise that the common rail pressure is normal.
Standard:
Item Engine Speed* Reference Value
Injection Feedback Val #1 to #4 Idling –3.0 to 3.0 mm3
Injection Volume Idling 3.0 to 10.0 mm3

HINT:
*: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
Result:
Injection Volume
Between 3.0 to 10.0 mm3 More than 10.0 mm3
Less than 3.0 mm3
(Normal)
Injection Feedback Val #1 to #4

3.0 mm3 or more, –3.0 mm3 or less A B B

Between –3.0 to 3.0 mm3 –– Normal C*

Proceed to Inspection Area Description

Inspect and repair cylinder injector with revised
injection volume of less than –3.0 mm3:
Abnormal value cylinder injector injects exces-
A S Perform power balance inspection and identify
sively large quantity of fuel
malfunctioning cylinder
S Replace malfunctioning cylinder injector
Abnormal value cylinder injector injects exces-
Identify malfunctioning cylinders by conducting sively small quantity of fuel:
power balance inspection: S Fuel injection volume too low due to injector
S Perform power balance inspection to identify nozzle being blocked by deposits
B
malfunctioning cylinders S Abnormal value cylinder injector compression
S Clean malfunctioning cylinder injector, then decreases
check and repair it S Abnormal value cylinder injector injects exces-
sively large quantity of fuel
All cylinder injectors inject excessively small
Inspect and repair all cylinder injectors:
quantity of fuel:
C Clean all cylinder injectors, and then inspect and
Fuel injection volume too low due to all cylinder
repair them
injector nozzles being blocked by deposits

HINT:
*: When the Injection Volume displayed on the intelligent tester II is large despite Fuel Press and Injection
Feedback Val #1 to #4 values in the Data List being normal, the injector may be clogged. In this case, there
may be deposits inside or outside the injector.
S Despite the injector functioning normally, the indicated Injection Feedback Val #1 to #4 values may be
outside the normal operating range due to compensation for other problems (such as low compres-
sion).
S The Injection Feedback Val #1 to #4 values are used to correct the fuel injection volumes of each cylin-
der in order to optimize (compensate for the unevenness between) all the cylinder combustion condi-
tions. If any of the cylinders malfunction, the fuel injection volumes for the normal cylinders are cor-
rected simultaneously. As a result, the Injection Feedback Val #1 to #4 values may deviate from the
standard range.
B Go to step 19

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MADE FOR ARGENTINA))

C Go to step 24

18 PERFORM ACTIVE TEST (FUEL CUT FOR IDENTIFYING MALFUNCTIONING

CYLINDER)

(a) Connect the intelligent tester II to the DLC3.

(b) Start the engine and turn the intelligent tester II ON.
(c) Enter the following menus: Auto / Pick Up / Engine / Active Test / Control the Cylinder#1 Fuel Cut, #2,
#3 and #4.
(d) Check the 4 cylinders in sequence to identify any faulty cylinders by performing the power balance
inspection.
HINT:
S While the engine is idling, if the idling stability variation is small despite cutting off the fuel injection,
the cylinder is malfunctioning.
S With normal cylinders, the engine idles roughly when the fuel injection is cut off.
NEXT

REPLACE INJECTOR OF MALFUNCTIONING CYLINDER (See page 11–14)

19 PERFORM ACTIVE TEST (FUEL CUT FOR IDENTIFYING MALFUNCTION

CYLINDER)

(a) Connect the intelligent tester II to the DLC3.

(b) Start the engine and turn the intelligent tester II ON.
(c) Enter the following menus: Auto / Pick Up / Engine / Active Test / Control the Cylinder#1 Fuel Cut, #2,
#3 and #4.
(d) Check the 4 cylinders in sequence to identify any faulty cylinders by performing the power balance
inspection.
HINT:
S While the engine is idling, if the idling stability variation is small despite cutting off the fuel injection,
the cylinder is malfunctioning.
S With normal cylinders, the engine idles roughly when the fuel injection is cut off.
NEXT

20 CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTION CYLINDER

(See page 14–1)

OK: Cylinder compression pressure is normal.

NG REPAIR OR REPLACE

OK

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05–328 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA
MADE FOR ARGENTINA))

21 CHECK MALFUNCTIONING CYLINDER INJECTOR FOR DEPOSIT

HINT:
If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This
may cause malfunctions.
(a) Check the injectors for any deposits.
Result:
Injector Condition Proceed to
Deposits A
No deposits B

B REPLACE INJECTOR OF MALFUNCTIONING

CYLINDER (See page 11–14)

22 CLEAN INJECTOR

NEXT

23 READ DATA LIST (INJECTION FEEDBACK VAL #1 TO #4, INJECTION VOLUME)

(a) Reinstall the injector to the cylinder head.

(b) Connect the intelligent tester II to the DLC3.
(c) Turn the ignition switch ON and turn the intelligent tester II ON.
(d) Start the engine and warm it up.
(e) Enter the following menus: Auto / Pick Up / Engine / Data List.
(f) Select the following menu items in order and read the values.
S Injection Feedback Val #1, #2, #3 and #4
S Injection Volume
Standard:
Item Engine Speed* Reference Value
Injection Feedback Val #1 to #4 Idling –3.0 to 3.0 mm3
Injection Volume Idling 3.0 to 10.0mm3
HINT:
S *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed
up.
S When the values are outside the standard range, deposits inside the injector may be causing the prob-
lem.
OK: Values are within standard range.
NG REPLACE INJECTOR OF MALFUNCTIONING
CYLINDER (See page 11–14)

OK

END

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 DIAGNOSTICS – ECD SYSTEM (HILUX/1KD–FTV, 2KD–FTV (TASA 05–329
MADE FOR ARGENTINA))

24 CHECK ALL CYLINDER INJECTORS FOR DEPOSIT

HINT:
If an injector is contaminated with deposits, the fuel injection volume deviates from the standard range. This
may cause malfunctions.
(a) Check the injector for any deposits.
Result:
Injector Condition Proceed to
Deposits A
No deposits B

B REPLACE ALL CYLINDER INJECTORS

(See page 11–14)

25 CLEAN INJECTOR

NEXT

26 READ DATA LIST (INJECTION FEEDBACK VAL #1 TO #4, INJECTION VOLUME)

(a) Reinstall the injector to the cylinder head.

(b) Connect the intelligent tester II to the DLC3.
(c) Turn the ignition switch ON and turn the intelligent tester II ON.
(d) Start the engine and warm it up.
(e) Enter the following menus: Auto / Pick Up / Engine / Data List.
(f) Select the following menu items in order and read the values.
S Injection Feedback Val #1, #2, #3 and #4
S Injection Volume
Standard:
Item Engine Speed* Reference Value
Injection Feedback Val #1 to #4 Idling –3.0 to 3.0 mm3
Injection Volume Idling 3.0 to 10.0 mm3
HINT:
S *: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed
up.
S When the values are outside the standard range, deposits inside the injector may be causing the prob-
lem.
OK: Values are within standard range.
NG REPLACE ALL CYLINDER INJECTORS
(See page 11–14)

OK

END

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MADE FOR ARGENTINA))

27 CHECK TURBOCHARGER SUB–ASSY (MECHANICAL PROBLEM)

(See page 13–24)

(a) Disconnect the air cleaner hose.

(b) Use a mirror to visually check the turbocharger for any mechanical problems.
(c) 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.
NG REPAIR OR REPLACE

OK

28 INSPECT TURBOCHARGER ACTUATOR (See page 13–24)

NG REPLACE TURBOCHARGER SUB–ASSY

(See page 13–37)

OK

29 CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

(a) Connect the intelligent tester II to the DLC3.

(b) Start the engine and warm it up, and turn the intelligent tester II ON.
(c) Enter the following menus: Auto / Pick Up / Engine / Data List.
(d) Select the following menu item and read the value.
S MAP
Standard:
Item Engine Speed* Reference Value
MAP 3,500 rpm (full throttle acceleration) Min.: 175 kPa (1,313 mmHg, 51.7 in.Hg)

HINT:
*: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
OK: Value is within standard range and malfunction has been successfully repaired.
NG REPLACE TURBOCHARGER SUB–ASSY
(See page 13–37)

OK

END

30 CHECK AND REPLACE FUEL FILTER ELEMENT

NEXT

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MADE FOR ARGENTINA))

31 CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED

(a) Connect the intelligent tester II to the DLC3.

(b) Start the engine and warm it up, and turn the intelligent tester II ON.
(c) Select the following menus: Auto / Pick Up / Engine / Data List.
(d) Select the following menu item and read the values.
S Fuel Press
Standard:
Item Engine Speed* Reference Value
Fuel Press Idling 25 to 35 MPa
Fuel Press 2,000 rpm (no engine load) 25 to 35 MPa
Fuel Press 3,000 rpm (no engine load) 35 to 45 MPa
Fuel Press 3,500 rpm (full throttle acceleration) Min.: 121 MPa
HINT:
*: The A/C switch and all accessory switches should be OFF, and the engine should be fully warmed up.
OK: The values are within the standard range.
OK END

NG

32 INSPECT SUPPLY PUMP ASSY (See page 11–5)

NG REPLACE SUPPLY PUMP ASSY

(See page 11–24)

NOTICE:
After replacing the supply pump, the ECM needs initializa-
tion (see page 05–38).
OK

33 INSPECT COMMON RAIL ASSY (FUEL PRESSURE SENSOR)

(a) Disconnect the F9 sensor connector.

Fuel Pressure Sensor (b) Measure the resistance of the sensor.
Standard:
Tester Connection Specified Condition
1 (E2) – 2 (PR) 3 kΩ or less
2 (PR) – 3 (VC) 16.4 kΩ or less

VC E2
PR A62213
NG REPLACE COMMON RAIL ASSY
(See page 11–30)

OK

INSPECT COMMON RAIL ASSY (PRESSURE LIMITER) (See page 11–5)

HILUX REPAIR MANUAL (Argentina) (DR201E)