05042014-Denso System CRDI Para Toyota

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  • 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

    Crankshaft PositionSensor

    029600-143# 90919-05066

    Camshaft PositionSensor

    029600-116# 90919-05052

    Accelerator PedalModule

    198300-302# 89281-35020

    MAP Sensor 079800-780# 89421-20200

    Coolant TemperatureSensor

    179700-045# 89422-33030

    Intake Air TemperatureSensor

    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

    Crankshaft PositionSensor

    029600-063# 90919-05025

    Camshaft PositionSensor

    029600-115# 90919-05050

    MAP Sensor 079800-913# 89421-20200

    Coolant TemperatureSensor

    179700-045# 89421-71030

    Intake Air TemperatureSensor

    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

  • Operation Section111

    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.

  • Operation Section112

    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

  • Operation Section113

    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

  • Operation Section114

    (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

  • Operation Section115

    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

    P0112 Yes Intake Air Temperature Sensor Low

    P0113 Yes Intake Air Temperature Sensor High

    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

  • Operation Section116

    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

    Detection ItemSAE Code

    Malfunction

    Indicator Lamp

    (MIL)

  • Operation Section117

    P1271 Yes Pressure Discharge Valve System Abnormality

    P1272 Yes Pressure Discharge Valve (Stuck Closed)

    P1496 Yes Intake Air Temperature Sensor Low

    P1497 Yes Intake Air Temperature Sensor High

    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

    Detection ItemSAE Code

    Malfunction

    Indicator Lamp

    (MIL)

  • Operation Section118

    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

    Detection ItemSAE Code

    Malfunction

    Indicator Lamp

    (MIL)

  • Operation Section119

    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)

    Intake Air Temperature Sensor

    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

  • Operation Section120

    Engine ECU External Wiring Diagrams (2)Q004467E

    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#

  • Operation Section121

    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

  • Operation Section122

    7.2 DYNA

    Engine ECU External Wiring Diagrams (1)Q004468E

    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

    Fuel Temperature Sensor

    Battery Fluid Temperature Sensor

    Die

    se

    l Th

    rott

    leP

    ositio

    n S

    en

    so

    r

    EG

    R L

    ift S

    enso

    r

    Coolant Temperature Sensor

    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

  • Operation Section123

    Engine ECU External Wiring Diagrams (2)

    Q004469E

    117

    103

    128

    110

    34EDU

    46 CLSW

    Crankshaft PositionSensor

    Camshaft PositionSensor

    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

    Vehicle Speed Sensor

    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

  • Operation Section124

    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

  • Operation Section125

    7.3 IMV

    Engine ECU External Wiring Diagrams (1)Q004471E

    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

    Intake Air Temperature Sensor

    Coolant Temperature Sensor

    Fuel Temperature 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 )

  • Operation Section126

    Engine ECU External Wiring Diagrams (2)

    Q004472E

    Crankshaft PositionSensor

    Camshaft PositionSensor

    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

    Vehicle Speed Sensor

    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#

  • Operation Section127

    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

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