1KD-FTV

00400086E

SERVICE BULLETIN FUEL INJECTION PUMP

ECD04-02E September, 2004

NEW PRODUCTS DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT : TOYOTA LAND CRUISER PRADO 1KD Common Rail system 1. Outline This bulletin describes the common rail system used in the Toyota Land Cruiser Prado 1KD. The contents of the basic system are the same as in "Common Rail System for TOYOTA HILUX / KIJYANG INNOVA / INNOVA 1KD / 2KD" (OPERATION MANUAL No.00400077). The system outline and the changed locations are explained here.

2. Applicable Vehicle Model and Pump Part Numbers Vehicle Name

Vehicle Model

Engine Model

Engine Displacement

Start of Production

LAND CRUISER PRADO

KDJ120/125

1KD-FTV

3.0L

Since September, 2004

3. PRODUCT APPLICATION LIST Vehicle Name

LAND CRUISER PRADO

DENSO Part Number

TOYOTA Part Number

Supply Pump

294000 - 0380

22100 - 30050

HP3

Injector (With gasket)

095000 - 5890

23670 - 39135

For supply

Injector (With out gasket)

095000 - 5740

23670 - 30080

Rail

Made by another manufacturer

-

• Rail Pressure Sensor

499000 - 6080

89458 - 60010

• Pressure Discharge Valve

294290 - 0051

23990 - 30020

175800 - 7251

89661 - 6A350

175800 - 7242

89661 - 6A330

EDU

101310 - 5371

89870 - 60060

Water Temperature Sensor

179700 - 0451

89422 - 33030

Crankshaft Position Sensor (NE Sensor)

029600 - 1151

90919 - 05050

Cylinder Identification Sensor (TDC Sensor)

029600 - 1160

90919 - 05052

Accelerator Pedal Module

198800 - 3020

78120 - 60350

Turbo Pressure Sensor

079800 - 7470

89421 - 71020

Part Name

Engine ECU

Remarks

SERVICE DEPARTMENT 0409-IT-342 Printed in Japan

2

4. System Configuration The configuration of the common rail system for the 1KD is shown below. Fuel Temperature Sensor Engine Speed Accelerator Opening Intake Air Pressure, Atmospheric Air Pressure Intake Air Temperature Coolant Temperature Crankshaft Angle

EDU Engine ECU

Cylinder Recognition Sensor Intake Airflow Rate

Pressure Discharge Valve

Rail

Injector

Rail Pressure Sensor

Fuel Filter

Fuel Temperature Sensor Supply Pump

Check Valve

SCV (Suction Control Valve) Fuel Tank Q000991E

5. Changed Points 5.1. Rail (1) General Description The rail used in the 1KD engine is made by another manufacturer. A pressure discharge valve and rail pressure sensor are mounted on the rail.

Rail pressure sensor

Relief passage #1 OUT

#2 OUT

IN

#3 OUT

#4 OUT

Pressure discharge valve QD2349E

3

(2) Pressure Discharge valve The pressure discharge valve controls the fuel pressure of the rail. If the fuel pressure in the rail rises above the target injection pressure, or if the ECU judges it to have risen above the target value, the solenoid coil is energized. This opens the valve passage, leaking fuel to the fuel tank and lowering the pressure to the target injection value.

Solenoid Coil

Armature

to Fuel Tank

Spring

Q000992E

5.2. DTC (DIAGNOSTIC TROUBLE CODE) CHART DTC Code

175800 -

SAE Code

DTC No.

P0045

7241 7251

Detection Item

A/T

M/T

34

With

With VN turbo (open circuit)

P0087

49

With

With Rail pressure sensor (Fixed output)

P0088

78

With

With

P0093

78

With

With Fuel leak malfunction

P0095 / P0097 / P0098

23

With

With

P0100 / P0102 / P0103

31

With

With Air flow meter (Open circuit)

P0105 / P0107 / P0108

35

With

With

Turbo pressure sensor (Open circuit inspection)

P0110 / P0112 / P0113

24

With

With

Atmospheric temperature sensor (Out-of-range)

P0115 / P0117 / P0118

22

With

With Water temperature sensor (Open circuit)

P0168

39

With

With High fuel pressure abnormality

P0180 / P0182 / P0183

39

With

With Fuel temperature sensor (Open circuit)

P0190 / P0192 / P0193

49

With

With

Pump valve malfunction (high-pressure in rail) Intake air temperature sensor (Post-turbo intake air temperature sensor)

Rail pressure sensor With back-up sensor (Open circuit)

4

DTC Code

175800 -

SAE Code

DTC No.

P0191

7241 7251

Detection Item

A/T

M/T

49

With

With

P0200

97

With

With EDU malfunction

P0234

34

With

With VN turbo (closed-side malfunction)

P0299

34

With

With VN turbo (open-side malfunction)

13

With

Crankshaft position sensor With (open circuit / phase difference, power flicker)

12

With

With Crankshaft position sensor (open circuit)

13

With

With

Crankshaft position sensor (NE power flicker)

With

With

Camshaft position sensor (open circuit, phase difference)

With

With

Camshaft position sensor (open circuit, start-up logic)

P0335

P0339

P0340

12

Rail pressure sensor with back-up sensor (out-of-range)

P0400

71

With

With EGR system malfunction

P0405 / P0406

96

With

With Lift sensor (open circuit)

P0488

15

With

With

P0500

42

With

With Vehicle speed sensor

P0504

51

With

With Brake switch (open circuit, short)

P0607

89

With

With CPU malfunction

P0627

78

With

With

Pump valve malfunction (open circuit, short)

P1229

78

With

With

Pump valve malfunction (excessive pressure)

P1251

34

With

With VN turbo (phase difference)

P1271

78

With

With Pressure limiter malfunction (EDU drive)

P1272

78

With

With

Pressure limiter malfunction (closed-side malfunction)

P1601

89

With

With

Injector multiple-point correction (EEPROM malfunction)

P1611

17

With

With

P2008

58

With

With SCV malfunction

Intake air restriction motor control system (electronic throttle malfunction)

Internal IC malfunction RUN pulse malfunction

5

DTC Code

175800 -

SAE Code

DTC No.

P2120 / P2122 / P2123 / P2125 / P2127/ P2128 / P2138

7241 7251

Detection Item

A/T

M/T

19

With

With

Accelerator position sensor (open circuit, short)

P2121

19

With

With

Accelerator position sensor (out-of-range)

P2226 / P2228 / P2229

A5

With

With

Atmospheric pressure sensor (open circuit, direct board installation)

U0001

A2

With out

With CAN communication malfunction

B2799

99

With

With Immobilizer (2-line separate type)

P0500

21

With

With Vehicle speed sensor (open circuit)

P0503

23

With

With

P0571

52

With

With Stop light switch (open circuit, short)

With

With Stop light switch input circuit malfunction

With

With Cancel circuit malfunction

With

With System circuit malfunction

P0607

54 56

Vehicle speed sensor (noise, power flicker)

6

5.3. ECU (1) External Wiring Diagram a. Wiring Diagram (1) Main Relay EFI

PCV

+B MREL

PCV + PCV –

Automatic Transmission Vehicles Only

BATT E1 E01 E02 WFSE

ECT

EDU PRD Drive Monitor DM DC Motor Driver (For Turbo)

CAN + CAN –

VNTO VNTI

DIAGNOSIS CANH CANL VCPA VCP2 VC +B

Accelerator Sensor (Main)

Airflow Sensor

Turbo Pressure Sensor

VCS

Rail Pressure Sensor (Main)

Rail Pressure Sensor (Sub)

PI

+B

RCR1 MIL

VPA

Accelerator Sensor (Sub)

Cruise Indicator Light

PIM

+B

W Glow Indicator Light

RCR2 GIND VPA2

Intake Air Temperature Sensor

THIA EGR Lift Sensor

Coolant Temperature Sensor

THW

Fuel Temperature Sensor

VG EGLS

EDU Relay IREL

+B

THF Intake Air Temperature Sensor (Built-In Airflow Meter)

E-VAV

THA Cruise Control Switch

Glow Relay

CCS E2S E2 EVG EPA2 EPA

+B

EGR

GREL MREL

Main Relay

Q000993E

7

b. Wiring Diagram (2)

Engine Speed Sensor NE + EGR Cut-Off VSV

+B

EGRC Cam Position Sensor

TACH #4

+B

G– IGSW

IGSW ST1 – STP

BATT Brake Switch

G+ NE –

Manual Transmission Vehicles Only

+B

#3 #2 #1

Meter EDU EDU EDU EDU Swirl Control Valve

+B

SCV

Clutch Switch Active Mountain VSV

CLSW ACM Throttle Full Switch THOP

EDU

P/S Oil Pressure Switch

INJF PSW

Automatic Transmission Vehicles Only

Vehicle Speed Sensor

Neutral Start Switch NSW

SPD

Manual Transmission Vehicles Only

Test Terminal

L4 Switch L4M

TC

Heater Idle-Up Switch HSW A/C Amplifier

AC1

A/C Amplifier

THWO

A/C Amplifier

ACT

Immbirazer ECU

IMI

Immbirazer ECU

IMO

Viscous Amplifier

VCH

Viscous Amplifier

VCT

Alternator

ALT

+B LU+A

LU–A LU+B

LU–B

Starter Relay

Step Motor (For Electronically Controlled Throttle)

STA Q000994E

8

(2) Connector Terminal Layout a. 175800-7241 31P

35P

35P

34P 1

7

35

41

70

75

105

111

28

34

62

69

97

104

130

135 Q000995E

b. 175800-725131P

35P

35P

34P 1

7

35

41

70

75

105

111

28

34

62

69

97

104

130

135 Q000996E

No. Code 1 E01 2 E02 3 -

Terminal Description Power Ground (Engine Ground) -

No. Code 22 #2 23 #3 24 #4

4

-

-

25 THIA

5 6

PCV+

-

26 THW 27 VC

7

PCV-

8 9

VNTI -

10 SCV 11 12 13 14 15 16 17

LU+A LU-A LU+B LU-B VNTO THOP ALT

18 NE+ 19 PCR1 20 INJF 21 #1

Pump Control Valve

28 NE-

Turbo Driver -

29 PCR2 30 PRD

Swirl Control Valve

31 THA

Step Motor (for Electronically Controlled Throttle) VN Turbo Driver Full Throttle Switch Alternator Crankshaft Position Sensor (-) Rail Pressure Sensor (Main) EDU

32 33 34 35 36 37 38

THF E2 E1 -

39 40 VCS 41 E2S 42 ACM

Terminal Description EDU Intake Air Temperature Sensor (Intake Manifold) Coolant Temperature Sensor Sensor Power Supply Crankshaft Position Sensor (-) Rail Pressure Sensor (Sub) EDU Intake Air Temperature Sensor (Airflow Meter) Fuel Temperature sensor Sensor Ground Ground (Engine Ground) Rail Pressure Sensor (Sub) Power Supply Rail Pressure Sensor (Sub) Ground Active Mount VSV

9

No. 43 44 45 46 47 48 49 50 51 52 53 54 55

Code EGRC L4M EGR -

Terminal Description EGR Cut-Off VSV L4 Switch E-VRV -

No. 77 78 79 80 81 82 83 84 85 86 87 88 89

Code STP ST1VCH CLSW CANH

56 57

VG

Airflow Meter

90 91

CANL CAN+

58

G+

59 60 61

-

Cylinder Recognition Sensor (+) (TDC Sensor) -

62

-

-

96

SPD

63 64 65

EGLS EVG

97 98 99

-

66

G-

67 68 69 70

PIM -

71

PSW

72 73

VCT PI

EGR Lift Sensor Airflow Meter (Ground) Cylinder Recognition Sensor (-) (TDC Sensor) Intake Air Pressure Sensor Power Steering Hydraulic Pressure Switch Viscous Amplifier Cruise Indicator

74 75 76

BATT HSW

Battery (+) Heater Idle-Up Switch

92

CAN-

93 94 95

ACT AC1

Terminal Description Stop Light Switch Viscous Amplifier Clutch Switch CAN1 Communication (Diagnosis) CAN2 Communication (ECT) Air Conditioning Amplifier Vehicle Speed Sensor (Meter) -

100 -

-

101 102 103 104

-

IMI IMO -

Immobilizer ECU -

105 STA

Starter Relay

106 NSW 107 -

Neutral Start Switch -

108 TACH 109 DM 110 THWO

Tachometer Multi-Display Air Conditioning Amplifier

10

No.

Code

Terminal Description

No.

Code

111

+B

Battery (+) Main Relay

124 VPA2

112

-

-

125 VPA

113 114 115 116 117 118 119 120

GREL GIND W TC IREL IGSW

Glow Relay Glow Indicator Light MIL Test Terminal EDU Relay Ignition Switch

126 127 128 129 130 131 132 133

121 MREL

Main Relay

134 VCP2

122 -

-

135 VCPA

123 -

-

-

CCS WFSE EPA2 EPA

-

Terminal Description Accelerator Position Sensor (Sub) Accelerator Position Sensor (Main) Cruise Control Switch Flash Write Tool Accelerator Position Sensor Power Supply (Sub) Accelerator Position Sensor Power Supply (Main) -