05042014-Denso System CRDI Para Toyota

COMMON RAIL SYSTEM (CRS)TOYOTA 1KD/2KD ENGINE

Issued : September 2009Revised : October 2009

00400706EA

2009 DENSO CORPORATIONAll rights reserved. This material may not be reproduced or copied, in whole or in part, without the written permission of DENSO Corporation.

Revision HistoryDate Revision Contents

2009.10 Visual contents additionVisual contents are video and animation used for manual explanation. Visual con-tents can be viewed by clicking the appropriate button.

Items added to the visual contentsThe following items have been added to Microinjection Quantity Learning Controlunder FUEL INJECTION CONTROL".9 Determinations for learning conditions9 Single microinjection operation9 Detecting the change in rotational speed via injection9 Correcting the injection pulse width (TQ), and actual injection quantity (Q) char-

acteristics

Table of Contents

Table of Contents

Operation Section

1. PRODUCT APPLICATION INFORMATION1.1 OUTLINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Applicable Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2. SUPPLY PUMP2.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2.2 Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3. RAIL3.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4. INJECTOR4.1 Change Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4.2 Quick Response (QR) Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

5. FUEL INJECTION CONTROL5.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5.2 Injection Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5.3 Microinjection Quantity Learning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5.4 Wide-Range Cylinder Correction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

6. DIAGNOSTIC TROUBLE CODES (DTC)6.1 DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7. ENGINE ECU 7.1 LAND CRUISER PRADO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

7.2 DYNA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

7.3 IMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Operation Section11

1. PRODUCT APPLICATION INFORMATION

1.1 OUTLINE

z Minor changes have been made to the TOYOTA LAND CRUISER, PRADO, DYNA, and IMV. As a result, aportion of the Common Rail System (CRS) equipped with the 1KD-FTV and 2KD-FTV engines has

changed. The construction, operation, and control of main CRS components (supply pump, injectors, rail)

are identical to the components described in the previously issued "Common Rail System for TOYOTA

HILUX/KIJYANG INNOVA/INNOVA 1KD/2KD (Doc ID: 00400077)". Primary changes and additions are

listed below.

The supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type.

(refer to P1-6)

The rail pressure limiter has been replaced with a pressure discharge valve. (refer to P1-8)

The injectors have been changed from the G2 type to the G3 type. (refer to P1-9)

Microinjection quantity learning control, and wide-range cylinder correction control have been added to

injector control. (refer to P1-11)

1.2 Applicable Vehicles

1.3 Applicable Product List

LAND CRUISER PRADO

Vehicle Name Engine Type Engine Displacement Remarks

LAND CRUISER PRADO1KD-FTV 3.0 L

August 2009DYNA

IMV 1KD/2KD-FTV 3.0 L/2.5 L

Part NameDENSO

Part Number

Manufacturer

Part NumberRemarks

Supply Pump 294000-110# 22100-30140

Injector 295050-020# 23670-30400

Rail 095440-095# 23810-30100

Engine ECU

275900-045# 89661-60N10 AT, 4WD, Europe, Australia, Euro 4

275900-046# 89661-60N30 AT, 4WD, Middle East, General, Euro 3, 2

275900-047# 89661-60N50 AT, 4WD, Middle East, General, Euro 0

275900-048# 89661-60N20 MT, 4WD, Europe, Australia, Euro 4

275900-049# 89661-60N40 MT, 4WD, Middle East, General, Euro 3, 2

275900-050# 89661-60N60 MT, 4WD, Middle East, General, Euro 0

EDU 131000-155# 89871-25010

Operation Section12

DYNA

Crankshaft PositionSensor

029600-143# 90919-05066

Camshaft PositionSensor

029600-116# 90919-05052

Accelerator PedalModule

198800-742# 78110-60030

Manifold AbsolutePressure (MAP) Sensor

079800-780# 89421-20200

Coolant TemperatureSensor

179700-045# 89422-33030

Intake Air TemperatureSensor

071500-237# 89727-60010

Exhaust GasRecirculation (EGR)Valve

101397-123# 25800-30190

Part NameDENSO

Part Number

Manufacturer

Part NumberRemarks

Supply Pump 294000-070# 22100-30090 SCV: 294200-004#

Injector

295050-007# 23670-30380 Different connector, for use with cylinders 1and 2

295050-008# 23670-30390

Rail 095440-095# 23810-30100

Engine ECU

275900-053# 89661-25290MT, 2WD, Europe, Euro 4 (C/D), withcharging regulation when starting

275900-054# 89661-25300MT, 2WD, Europe, Euro 4 (C/D), withoutcharging regulation when starting

EDU101310-570# 89870-25030

101310-581# 89870-25040


029600-143# 90919-05066


029600-116# 90919-05052

Accelerator PedalModule

198300-302# 89281-35020

MAP Sensor 079800-780# 89421-20200


179700-045# 89422-33030


071500-237# 89727-60010

Part NameDENSO

Part Number

Manufacturer

Part NumberRemarks

Operation Section13

IMV

Throttle PositionSensor

192300-201# 15081-3F00B

EGR Valve101397-118# 25800-30140

101397-121# 25800-30150

Part NameDENSO

Part Number

Manufacturer

Part NumberRemarks

Supply Pump

294000-094# 22100-30120 1KD, Europe, low lubrication

294000-070# 22100-30090 1KD/2KD, Thailand

SM294000-090# 22100-0L060 1KD, Europe, Australia, Thailand

SM294000-091# 22100-0L070 1KD/2KD, Europe, Thailand, India, lowlubrication

Injector

295050-020# 23670-30400 1KD/2KD

295050-021# 23670-30410 2KD

SM295050-018# 23670-0L090 1KD/2KD

SM295050-019# 23670-0L100 2KD

Rail095440-095# 23810-30100 1KD/2KD

SM095440-095# 23810-0L030 1KD/2KD

Engine ECU

MA275900-055# 89661-0KN00 1KD, MT, PT-4WD, Europe, Euro 4

MA275900-056# 89661-0KN20 1KD, MT, 2WD, Australia, Euro 4

MA275900-057# 89661-0KN30 1KD, MT, PT-4WD, Australia, Euro 4

MA275900-058# 89661-0KN40 1KD, AT, PT-4WD, Europe, Euro 4

MA275900-059# 89661-0KN60 1KD, AT, PT-4WD PRE, Australia, Euro 4

MA275900-060# 89661-0KN80 2KD, MT, 2WD, Europe, Euro 4 Class 2

MA275900-061# 89661-0KP00 2KD, MT, 2WD, Europe, Euro 4 Class 3

MA275900-062# 89661-0KP20 2KD, MT, PT-4WD, Europe, Euro 4

MA275900-063# 89661-0KP40 2KD, MT, 2WD PRE, Thailand, Euro 3

MA275900-064# 89661-0KP50 2KD, MT, PT-4WD, Thailand, Euro 3

RB275900-065# 89661-0KN10 1KD, MT, PT-4WD, Europe, Euro 4

RB275900-066# 89661-0KN50 1KD, AT, PT-4WD, Europe, Euro 4

RB275900-067# 89661-0KN90 2KD, MT, 2WD, Europe, Euro 4 Class 2

RB275900-068# 89661-0KP10 2KD, MT, 2WD, Europe, Euro 4 Class 3

Engine ECU

RB275900-069# 89661-0KP30 2KD, MT, PT-4WD, Europe, Euro 4

HA275900-070# 89661-0KN70 1KD, MT, FT-4WD, India, Euro 4(W/OOBD)

HA275900-071# 89661-0KP60 2KD, MT, 2WD, India, Euro 4 (W/O OBD)

EDU101310-590# 89870-71070

101310-591# 89870-71080

Part NameDENSO

Part Number

Manufacturer

Part NumberRemarks

Operation Section14


029600-063# 90919-05025


029600-115# 90919-05050

MAP Sensor 079800-913# 89421-20200


179700-045# 89421-71030


170400-602# 89424-12010

EGR Valve

101397-113# 25800-30100

101397-114# 25800-30110

101397-116# 25800-30120

Part NameDENSO

Part Number

Manufacturer

Part NumberRemarks

Operation Section15

1.4 System Outline

z The CRS configuration is as per the figure below.

Q004457E

Rail

PressureDischargeValve

EGR Cooler

Variable NozzleTurbo

Injector

Fuel Tank

Supply Pump

EGR Valve

Diesel Throttle

FuelCooler

FuelFilter

EngineECU

EDU

Operation Section16

2. SUPPLY PUMP

2.1 Change Item

z The supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type. (Referto [SCV types (SV1, SV2)] on P1-7.)

2.2 Suction Control Valve (SCV)

z The supply pump is equipped with a normally closed type SCV.z When the solenoid is energized, the needle valve is pressed upon (in the compact SCV, the cylinder is

pulled upon) by the armature, completely opening the fuel passage and supplying fuel to the plunger. (Total

quantity suctioned Total quantity discharged)

z When power is removed from the solenoid, the return spring presses the needle valve back to the originalposition, closing the fuel passage.

z The solenoid is actuated by duty ratio control. Fuel is supplied in an amount corresponding to the opensurface area of the passage, which depends on the duty ratio. The fuel is then discharged by the plungers.

Q004458E

to Fuel Tank to Fuel Tank

SCV

from Fuel Tank

Fuel TemperatureSensor

Fuel TemperatureSensor

to Rail

Q004459E

Return Spring

Valve Body

Needle Valve

Solenoid

Armature

Operation Section17

Operational Concept Diagram

Operation

(1) SCV types (SV1, SV2)

The SCV is available in the SV1 type and SV2 type. The SV2 is a compact SCV, while the SV1 is a bit

larger than the SV2.

Q002505E

Feed Pump

SCV

Supply Pump

Plunger

Cylinder

Q004460E

Cylinder Cylinder

Small Valve Opening

Minimum Intake Quantity

Long Duty ONShort Duty ON

Large Valve Opening

Maximum Intake Quantity

Large OpeningSmall Opening

Q003726E

SV1 Type SCV SV2 Type SCV

Operation Section18

3. RAIL

3.1 Change Item

z Beginning from August 2006 model vehicles, a pressure discharge valve is used in place of the rail pressurelimiter. The engine ECU control and an actuation circuit (EDU) control the pressure discharge valve.

Q004461E

Rail Pressure Sensor Pressure Discharge Valve

Operation Section19

4. INJECTOR

4.1 Change Items

z The injectors used with the 1KD-FTV and 2KD-FTV engines have been changed from the G2 type to theG3 type. In comparison to the G2 type injector, the G3 type injector has the following characteristics:

The nozzle shape, and shape of the high-pressure seal service have been changed, resulting in a more

high-pressure resistant structure.

The G3 injector is more highly responsive due to changes to the nozzle and solenoid valve.

z In consideration of the mounting measurements, the overall length for the 295050-008# injector (for usewith cylinders 1 and 2 in the DYNA) has been made shorter by 5.5 mm.

Q004462E

295050-007#

295050-020#

295050-021#

SM295050-018#

SM295050-019#

295050-008#

Operation Section110

4.2 Quick Response (QR) Codes

z QR codes are used to improve the accuracy of the injector injection quantity. The code from the vehicleassembly line is read, then entered into the engine ECU. Similar to the assembly line process, when

performing service, the ID code is read by a diagnostic tool, and entered into the engine ECU.

z The injection quantity correction points contained in the injector QR code are shown in the figure below.

Q004463E

QR Codes ( 9.9 mm) QR Codes ( 9.9 mm)

ID Codes (30 Base-16 Characters)Base-16 characters noting fuel injection

quantity correction information for market

service use.

ID Codes (30 Base-16 Characters)Base-S16 characters noting fuel injection

quantity correction information for market

service use.

295050-008#295050-007#

295050-020#

295050-021#

SM295050-018#

SM295050-019#

Q004464E

140 MPa 100 MPa

64 MPa

32 MPa

Inje

ctio

n Q

ua

ntity

Q

Actuating Pulse Width TQ

Correction

12 Points

180 MPa


5. FUEL INJECTION CONTROL

5.1 Change Item

z Microinjection quantity learning control, and wide-range cylinder correction control have been added to theCRS equipped with the 1KD-FTV and 2KD-FTV engines.

5.2 Injection Pattern

z In this CRS system, injection occurs a maximum of three times. under normal operations, fuel injectioncontrol is performed with a pilot injection and a main injection. However, an additional pilot injection is added

when the engine is started at cold temperatures, as well as when the engine is operating in the low-

temperature, low-rotation speed range.

5.3 Microinjection Quantity Learning Control

(1) Outline

In microinjection quantity learning control, the actual injector injection quantity is estimated from the

change in engine rotational speed that accompanies a very small injection. The difference between the

estimated actual injection quantity, and the injection quantity command value at that time are learned by

the engine ECU. This difference is then used to correct the actual injection quantity.

(2) Goal

Microinjection quantity learning control is used to accomplish the following: 1) to minimize injection

quantity deviations due to injector deterioration over time, and 2) to prevent both engine running noise

due to misfires and exhaust smoke.

(3) Control outline

Microinjection quantity learning control is automatically performed approximately every 2000 km of

normal vehicle operation, and is completed after the vehicle has traveled approximately 500 km. Actual

learning takes place during the following processes.

Q004465E

Pilot Injection 1 Pilot Injection 2

Main Injection TDC

Note) TOYOTA terminology is used in this figure.


Determination for learning conditions9 Microinjection quantity learning control is performed when the following two engine operations are

established: 1) a reduction in vehicle speed, and 2) injection is cut off. In the determination process, the

engine ECU then judges whether or not the conditions for learning have been met. The figure below

shows the specific details for learning determinations.

Single microinjection operation9 Under the single microinjection operation process, microinjection is performed once the following items

are set: 1) the cylinder for which learning will be performed, and 2) the injection quantity. The figure

below shows the specific settings and controls for a single microinjection.

Detecting the change in rotational speed via injection9 In this process, the change in rotational speed can be detected using the set microinjection. The figure

below shows the processing for calculating changes in rotational speed.

Q002593E

TimeDetermination

Engine Rotational Speed

InjectionQuantity Q

Q = 0

Determination Content

Non-injection determination

Deceleration determination

Clutch position determination *For manual transmission vehicles

Q002594E

Injection

Quantity Q

Q = 0

Injection

Rail Pressure

Time

Settings, Control, Injection

Injection cylinder setting

Command injection quantity setting

Injection timing setting

Injection pressure (rail pressure) setting, control

Fuel injection

Q002595E

Time

Injection Quantity Q

Q = 0

Injection

Engine Rotational Speed

Processing

Rotational speed change detection

Rotational speed change processing

DetectionDetection


Correcting the injection pulse width (TQ), and actual injection quantity (Q) characteristics9 In this process, the actual injection quantity is estimated from the set microinjection, and the change in

rotational speed. The actual injection quantity is then corrected such that the value equals the target

injection quantity. The figure below shows the processing for the aforementioned corrections.

[ REFERENCE ]Learning must be performed manually when either an injector (or injectors), or the engine ECU is replaced.

As per the figure below, diagnostic tools are used to perform learning while the engine is operating.

5.4 Wide-Range Cylinder Correction Control

(1) Outline

In wide-range cylinder correction control, the combustion state for each cylinder is detected based on the

crankshaft position sensor (NE) signal. The injection quantity across all the cylinders can then be

averaged by correcting the injection quantity for each injector. Wide-range cylinder correction control

corrects the conventional FCCB control (idle speed stabilization control) performed at idle speed in all

regions of rotation.

Q002596EInjection Pulse Width

Map Value Actual InjectionQuantity

Target Q

TQ

Q

Processing

Estimation of correction quantity from eachdetected value

Reflection of correction quantity

Q002597E

Idle

No Load 3000 - 4000 rpm Non-Injection Learning

(Approximately 10 Single Injections)

Approximately 3 sec.Approximately

2 sec.1 sec. 1 sec.

Unit Cycle Approximately 7 sec.

Rail Pressure Adjusting During this Interval Injection Recovery Idle


(2) Control outline

The difference between the final injection quantity and the actual injection quantity are learned based on

the loop in the figure below. Next, the following two items are compared: 1) the results of the actual

injection quantity estimate based on the ideal state for NE input, and 2) the results of the actual injection

quantity estimate based on the actual NE input (detected value.)

Finally, the optimal emission state is found as shown in the figure below.

The correction below shows pilot injection 2 and main injection.

Q002598E

Wide-Range InjectionQuantity Learning

Command Output Actual Injection Quantity

Actual Rotational

SpeedCommandInjection Quantity

Difference Between Both Values Learned

RotationalSpeed Output

Q002599E

Optimal Emissions(Optimal Exhaust Gas)Command Output

Actual InjectionQuantity

ActualRotationalSpeed

Optimal CommandInjection Quantity

Rotational Speed Detection

Ideal RotationalSpeed

Target Value

Includes Error from Compatible Vehicle

Q004484E

Pilot Injection 1 Pilot Injection 2

Main Injection

The total deviation in injection quantity is learned via wide-range injection quantity learning.

: Reflected in the main injection quantity


6. DIAGNOSTIC TROUBLE CODES (DTC)

6.1 DTC Table

DTC

Detection ItemSAE Code

Malfunction

Indicator Lamp

(MIL)

P00AF Yes Variable Nozzle Turbo (VNT) Driver Abnormality, Position RequestSignal Abnormality

P0046 Yes VNT Nozzle Sliding Abnormality

P0047 Yes VNT Motor Circuit Open

P0048 Yes VNT Motor Circuit Short

P0069 Yes Pressure Difference Abnormality Between Boost Pressure andAtmospheric Pressure

P0087 Yes Rail Pressure Sensor Abnormality

P0088 Yes Pressure Discharge Valve Abnormality

P0093 Yes Fuel Leak

P0095 Yes Intake Air Temperature Sensor System Abnormality

P0097 Yes Intake Air Temperature Sensor Low

P0098 Yes Intake Air Temperature Sensor High

P0101 Yes Mass Air Flow (MAF) Meter Out of Range

P0102 Yes MAF Meter Low

P0103 Yes MAF Meter High

P0105 Yes Manifold Absolute Pressure (MAP) Sensor System Abnormality

P0106 Yes MAP Sensor Out of Range

P0107 Yes MAP Sensor Low

P0108 Yes MAP Sensor High

P0110 Yes Intake Air Temperature Sensor System Abnormality



P0115 Yes Coolant Temperature Sensor System Abnormality

P0116 Yes Coolant Temperature Sensor Circuit Range/Performance

P0117 Yes Coolant Temperature Sensor Low

P0118 Yes Coolant Temperature Sensor High

P0122 Yes Diesel Throttle Position Sensor Low

P0123 Yes Diesel Throttle Position Sensor High

P0168 Yes High Fuel Temperature Abnormality

P0180 Yes Fuel Temperature Sensor System Abnormality


P0182 Yes Fuel Temperature Sensor Low

P0183 Yes Fuel Temperature Sensor High

P0190 Yes Rail Pressure Sensor System Abnormality

P0191 Yes Rail Pressure Sensor Characteristics Abnormality

P0192 Yes Rail Pressure Sensor Low

P0193 Yes Rail Pressure Sensor High

P0200 Yes EDU Circuit Abnormality

P0299 Yes VNT Closed Abnormality

P0335 Yes Crankshaft Position Sensor Abnormality

P0339 No Crankshaft Position Sensor Power Flicker

P0340 Yes Camshaft Position Sensor Open Circuit

P0400 Yes Exhaust Gas Recirculation (EGR) Flow Volume Abnormality

P0405 Yes EGR Lift Sensor Low

P0406 Yes EGR Lift Sensor High

P0488 Yes EGR Throttle Motor System Abnormality

P0489 Yes EGR E-VRV Low

P0490 Yes EGR E-VRV High

P0500 Yes Vehicle Speed Sensor System Abnormality

P0503 Vehicle Speed Sensor Power Flicker Noise

P0504 No Stop Lamp Switch System Abnormality

P0516 Battery Temperature Sensor Low

P0517 Battery Temperature Sensor High

P0560 Yes Battery Abnormality

P0571 Stop Lamp Switch (Open, Short)

P0575 Cruise Cancel Circuit Abnormality

P0606 Yes Engine ECU Internal Abnormality

P0607 Yes Control Module Performance

P060A Yes Engine ECU Monitor CPU Abnormality

P060B Yes Engine ECU Peripheral Circuit Abnormality

P0617 Yes Starter Circuit High

P0627 Yes Supply Pump SCV Abnormality (Open, Shortj

P0724 Yes Stop Lamp Switch Abnormality

P1229 Yes Supply Pump Abnormality (Overfeed)

P1238 Yes Injector Injection Abnormality

P1251 Yes VNT Abnormality (Power Flicker)

P1264 Yes VNT Driver Abnormality

DTC


Malfunction

Indicator Lamp

(MIL)


P1271 Yes Pressure Discharge Valve System Abnormality

P1272 Yes Pressure Discharge Valve (Stuck Closed)



P1550 Battery Current Sensor Abnormality

P1551 Battery Current Sensor Low

P1552 Battery Current Sensor High

P1570 Laser Sensor Abnormality

P1572 Laser Sensor Optical Axis Misalignment

P1575 Warning Buzzer Abnormality

P1578 Brake System Abnormality

P1601 Yes Injector ID Code Abnormality, Unregistered

P1602 Battery Low Voltage

P1604 No Poor Start Judgment

P1605 No Unstable Idle

P1607 Yes Cruise Control CPU Abnormality

P1611 Yes Internal IC Abnormality

P1615 DSS1 ECU Communication Abnormality

P1616 Vehicle Control ECU Communication Abnormality

P1617 Vehicle Control ECU Abnormality

P1630 VSC ENG Communication Abnormality (VSC ENG)P1631 VSC ENG Communication Abnormality (ENG VSC)P2006 Yes Swirl Control Valve Stuck Fully Closed Abnormality

P2009 Yes Swirl Control Valve VSV Abnormality - Low

P2010 Yes Swirl Control Valve VSV Abnormality - High

P2120 Yes Accelerator Position Sensor No. 1 (Open)

P2121 Yes Accelerator Position Sensor (Out of Range)

P2122 Yes Accelerator Position Sensor No. 1 (Open) Low

P2123 Yes Accelerator Position Sensor No. 1 (Open) High

P2125 Yes Accelerator Position Sensor No. 2 (Open)

P2127 Yes Accelerator Position Sensor No. 2 (Open) Low

P2128 Yes Accelerator Position Sensor No. 2 (Open) High

P2138 Yes Accelerator Position Sensor No. 1/ No. 2 Open

P2226 Yes Atmospheric Pressure Sensor (Open)

P2228 Yes Atmospheric Pressure Sensor Low

P2229 Yes Atmospheric Pressure Sensor High

DTC


Malfunction

Indicator Lamp

(MIL)


P245C Yes EGR Cooler Bypass Actuation VSV Low

P245D Yes EGR Cooler Bypass Actuation VSV High

P2501 Alternator Abnormality

P2563 Yes VNT Position Sensor Characteristics Discrepancy

P2564 Yes VNT Position Sensor 1 Open

P2565 Yes VNT Position Sensor 1 Short

P2588 Yes VNT Position Sensor 2 Open

P2589 Yes VNT Position Sensor 2 Short

U0100 Vehicle Control ECU Communication Abnormality

U0101 Yes TCM ECU CAN Communication Abnormality

U0122 VSC ENG Communication Abnormality (VSC ENG)U0123 Yaw Rate Sensor Communication Abnormality

U0126 Steering Sensor Communication Abnormality

U0235 Laser Sensor Communication Abnormality (Sensor Vehicle ECU)U1102 Laser Sensor Communication Abnormality (Vehicle ECU Sensor)U1104 DSS1 ECU Communication Abnormality

DTC


Malfunction

Indicator Lamp

(MIL)


7. ENGINE ECU

7.1 LAND CRUISER PRADO

Engine ECU External Wiring Diagrams (1)Q004466E

+B

PCV+ 6

12

41

31

105

127

114

125

129

126

27

MIL

BATT

EDU Relay

Glow Plug Relay

IG2

+B

+B

+B

VSV

+B2

BATT

E1E01E02ME01

WFSE

VCPA

VPA

EPA(Main)

Engine Earth

OBDII Check

Connector

Accelerator Position Sensor

Engine Earth

140Main Relay

Fuse-EFIMREL

139

13

39

109

12V

15A

135

137

134

VCP2

VPA2

EPA2(Sub)

(Main)

(Sub)

Accelerator Position Sensor

133

136

132

65 VNVC

VNAVNT Position Sensor 83

64

44

81

45

VNE2

VCEG

EEGL

EGLSEGR Lift Sensor

MAP Sensor

Diesel Throttle Position Sensor

VCPM

PIM

EPIM

66

82

47

VCVL

VLU1

EVLU

62

80

63

51 VCS1

PCR1Rail Pressure Sensor

Rail Pressure Sensor

Fuel Temperature Sensor

Intake Air Temperature Sensor

(Intake Manifold)

(built into MAF Meter)


Coolant Temperature Sensor

53

52

50

85

68

E2S1

VCS2

E2S2

54

55

86

69

VG

E2G

THIA

ETHI

87

70

THF

ETHF

88

71

THW

ETHW

89

72

THA

ETHA

PCR2

2

143PCV (Suction Control Valve) (2.1 )

PCV-

LUSL

IREL

A/C ECU

Main Relay

Power SupplyManagement ECU

Fuel Pump

Circuit Opening

Relay

ALT

ACT

AC1

FC

MREL

#4 38

37

36

35

33

14

15

16

10

58

144

130

#3

#2

#1

PRD

NEO

SCV

SCV2

ECBV

EGR

EGRC

ACM

EDU

GREL

W

Alternator

Rotary Solenoid Driver

MAF

Meter

M

E-VRV (12 at 20

EGR Cooler Bypass VSVat 20 )(29.7

EGR Cut VSV at 20 )(36

Swirl Control Valveat 20 )(29

Swirl Control Valve 2at 20 )(29



98

100

103

21

128

110

104

34

4WD ECU

EDU

Cruise Control Switch113

124

CCS

CCHGC

an

ce

l

Se

t

Re

su

me

Ma

in

Vehic

le-to-V

ehic

le

Const

ant R

ate

C

ontrol

Crankshaft Position Sensor

Camshaft Position Sensor

Engine EarthBrake Switch

Stop Lamp Relay

BATT

GAUSE

Backup Lamp Switch (M/T)

Clutch Switch (M/T)

IG2

VNT DC Motor39

56

7

8

1140

57

120111

121

NE+Shield

Shield

Shield

VNM+

GND

ECT ECU

Power SupplyManagement ECU

ID Code

Box

Body Earth

IG

Fan Relay

Vehicle Bus

22

94

19CAN+

CAN-

CANH

95CANL

96CANP

97CANN

101IMI

102IMO

145EC

118EOM

138FANL

VNM-G+

NE-

G-

ST1-

STPIGSWIGSW

IG2

48

46

46

24

IG1

CLSW

PSW

Neutral Start Switch(AT)

PS Hydraulic Switch

L4

LGND

INJ1

SPD

NSW

STA

TC

TACHDLC3

Starter Relay

Vehicle Speed Sensor

Neutral Start Switch (AT)

D

R

Radar Sensor

With 275900-045#, -046#, -047#

With 275900-045#, -046#, -047#

With 275900-045#, -046#, -047#

With 275900-045#, -046#, -047#

With 275900-045#,

-046#, -047#

With 275900-048#, -049#, -050#

With 275900-048#, -049#, -050#


Engine ECU Connector Terminal Layout

Q002653

1 2 3 4 5

7 8 9 10 11

13 14 15 16 17

6

12

18

19 20 21

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89

90 91 92 93 94 95

98 99 100101 102103

106107108109 110 111

96 97 138 139 140

141 142 143

144 145 146

147 148 149

104105

112 113

114 115 116 117 118119

122123124125 126127

130131132133 134135

120121

128129

136137


7.2 DYNA


PCV+ 6

12

41

31

105

127

126

27

MIL

106 Glow Indicator

EDU Relay

Glow Plug Relay

IG2

+B

+B

BATT

E1

E01

E02

WFSE

VCPA

VPA

EPA

Engine Earth

OBDII Check Connector

Accelerator Position Sensor (Main)

MAP Sensor

Rail Pressure Sensor(Main)

Rail Pressure Sensor(Sub)

MAF Meter

Accelerator Position Sensor (Sub)

140Main Relay

Fuse-EFIMREL

139

13

3

109

12V

15A

135

137

134

VCP2

VPA2

EPA2

133

136

132

44 VC

PIM

EPIM

82

47

PCR153

VCS250

PCR285

E2S268

VG54

THA89


Battery Fluid Temperature Sensor

Die

se

l Th

rott

leP

ositio

n S

en

so

r

EG

R L

ift S

enso

r


Intake Air Temperature Sensor(Intake Manifold)

80 VLU1

81

86 THIA

EGLS

55 E2G

88 THW

84 THB

87 THF

45 E2

2

PCV-

LUSL

IREL

Main Relay

Meter ECU

ALT

30RLO

MREL

91OILM

GREL

W

GIND

116 LEDLOUT

Rotary Solenoid Driver

25VNTO

26VNTI VNT Driver

AlternatorWith 275900-053#

With 275900-053#

With 275900-053#

PCV (Suction Control Valve) (2.1 )

+B


Engine ECU External Wiring Diagrams (2)

Q004469E

117

103

128

110

34EDU

46 CLSW



Brake Switch

Clutch Switch

BATT

IG2

39

56

104

40

57

120

121

111

NE+

TACH

EDU

A/C Amplifier

J/C

Body Earth

35

36

Meter

33

37

38#4

#3

#2

#1

PRD

114ACT

94CANH

95CANL

145EC

118EOM

G+

+B

NE-

G-

STP

ST1-

IGSWIGSW

108

125 AC1

THWO

INJ1

SPD

STA

TC

Starter Relay

Test Connector


HSWHeat Amplifier

A/C Amplifier

A/C ECU or Meter

+B

14

16

10

58

SCV

ECBV

EGR

EGRC

Swirl Control Valveat 20 )(29

EGR Cooler Bypass VSVat 20 )(29.7

EGR Cut VSV at 20 )(36

E-VRV(12 at 20


Engine ECU Connector Terminal Layout

Q002653

1 2 3 4 5

7 8 9 10 11

13 14 15 16 17

6

12

18

19 20 21

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89

90 91 92 93 94 95

98 99 100101 102103

106107108109 110 111

96 97 138 139 140

141 142 143

144 145 146

147 148 149

104105

112 113

114 115 116 117 118119

122123124125 126127

130131132133 134135

120121

128129

136137


7.3 IMV


Main Relay

(111 )

(111 )

(194 )

12V

15A 111

121

74

35

1

2

128

E1E01

E02

WFSE

129 SIL

91 CAN+

92 CAN-

135

+B

VCPA

134 VCP2

27 VC

69 PIM

40

Rail Pressure Sensor(Main)

Rail Pressure Sensor(Sub)

MAP Sensor




Air Temperature Sensor

Cruise Control Switch

19

125

29

PCR1

VCS

VPA

PCR2

124 VPA2

25 THIA

26 THW

57 VG

68 VLU

64 EGLS

33 THF

31 THA

126 CCS

41 E2S34 E265 EVG

132 EPA2

133 EPA

Engine Earth

ECT

OBDII Check

Connector

Acce

lera

tor

Po

sitio

nS

en

so

r (M

ain

)

Acce

lera

tor

Po

sitio

nS

en

so

r (S

ub

)

Die

se

l T

hro

ttle

Po

sitio

n S

en

so

r

EG

R L

ift

Se

nso

r

+B 6PCV+

7PCV-

30PRDEDU

Multi Display

Diesel Throttle Drive IC

Cruise Indicator

MIL

Glow Indicator

109DM

38LUSL

15VNTO

8VNTI

89CANH

VSC

VNTDrive

90CANL

73PI

117W

115GIND

119IREL

52EGR

114GREL

MREL

BATT

Fuse-EFI

MAFMeter

IG2

IG2

+B

+B

EDU Relay

Glow Plug Relay

E-VRV (12 at 20

With MA275900-055#, -056#, -057#, -058#, -059#

RB275900-065#, -066#

With MA275900-055#, -056#, -057#, -058#MA275900-059#,RB275900-065#, -066#

With MA275900-058#, -059#

With MA275900-059#

RB275900 -066#

Without MA275900-060#, -061#RB275900-067#, -068#HA275900-071#

Without MA275900-059#

PCV (Suction Control Valve) (2.1 )


Engine ECU External Wiring Diagrams (2)

Q004472E



58

18

66

28

NE+

G-

NE-

G+

Brake Switch

BATT

IG2

77

78

120

STP

IG1

IG1D

CLSW

NSW

D Switch

82

82

Clutch Switch

106

HSW76

AC195

THWO110

ACT94

OILM101

IMI102

IMO103

VCH79

VCT72

STA105

Neutral Start Switch

A/C Amplifier

A/C Amplifier

A/C Amplifier

A/C Amplifier

Oil Monitor

Immobilizer

Immobilizer

Viscous Amplifier

Viscous Amplifier

ALT17Alternator

Starter Relay

ST1-

IGSWIGSW

EDU

EDU

EDU

EDU

METER

22

23

21

24

108

#4

#3

#2

#1

TACH

+B

+B

10

11

42

43

SCV

SCV2

20INJF

96SPD

118TC

113EOM

70EC

EDU


Check Connector

Body Earth

ECBV

EGR Cooler Bypass VSV

EGR Cut VSV

Swirl Control Valve

Swirl Control Valve 2

EGRC

at 20 )(29.7

at 20 )(36

at 20 )(29

at 20 )(29

With MA275900-055#, -056#, -057#, -058#, -059#

Without MA275900-058#, -059#RB275900-066#

With MA275900-058#, -059#RB275900-066#

With MA275900-058#, -059#RB275900-066#

RB275900-065#, -066#HA275900-070#


Engine ECU Connector Terminal LayoutQ004470E

1 2 3 4 5 6 7

8 9 10 11 12 13 14 16 1715

18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 33 34

35 36 70 7140 4137 38 39 72 73 74 75

42 43

54 55

44 45 46 47

56 57

48 49 50 51

58 59

52 53 76 77 78 79 80 81 82

105 106 107 108 109 110 111

83 84 85

86 87 88 89 90 91 92 93 94 95 96

97 98 99 101 102103104100 131 133132 134135130

123 124125 128129126127

116117 120121118 119112113114 115

12260 61

62 63 64 65 66 67 68 69

Service Department DENSO CORPORATION1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan

CoverOperation Section1. PRODUCT APPLICATION INFORMATION1.1 OUTLINE1.2 Applicable Vehicles1.3 Applicable Product List1.4 System Outline

2. SUPPLY PUMP2.1 Change Item2.2 Suction Control Valve (SCV)

3. RAIL3.1 Change Item

4. INJECTOR4.1 Change Items4.2 Quick Response (QR) Codes

5. FUEL INJECTION CONTROL5.1 Change Item5.2 Injection Pattern5.3 Microinjection Quantity Learning Control5.4 Wide-Range Cylinder Correction Control

6. DIAGNOSTIC TROUBLE CODES (DTC)6.1 DTC Table

7. ENGINE ECU7.1 LAND CRUISER PRADO7.2 DYNA7.3 IMV

Colophon

05042014-Denso System CRDI Para Toyota

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Transcript of 05042014-Denso System CRDI Para Toyota