SERVICE BULLETIN
FUEL INJECTION PUMP
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
3. PRODUCT APPLICATION LIST
Vehicle Name Vehicle Model Engine Model Engine Displacement Start of Production
LAND CRUISER
PRADO KDJ120/125 1KD-FTV 3.0L Since September, 2004
Vehicle
Name Part Name
DENSO Part Number TOYOTA Part Number Remarks LAND CRUISER PRADO 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 Engine ECU 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
ECD04-02E September, 2004
SERVICE DEPARTMENT 0409-IT-342 Printed in Japan
4. System Configuration
The configuration of the common rail system for the 1KD is shown below.
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.
Fuel Temperature Sensor Accelerator Opening Intake Air Pressure, Atmospheric Air Pressure
Intake Airflow Rate
Rail Pressure Sensor
Rail EDU Engine ECU
Fuel Temperature Sensor
Supply Pump Fuel Tank Fuel Filter Check Valve Injector Pressure Discharge Valve SCV (Suction Control Valve) Intake Air Temperature
Coolant Temperature Crankshaft Angle Cylinder Recognition Sensor
Q000991E Engine Speed
Rail pressure
sensor Relief passage
Pressure discharge valve QD2349E #1 OUT #4 OUT #3 OUT #2 OUT IN
(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 pas-sage, leaking fuel to the fuel tank and lowering the pressure to the target injection value.
5.2. DTC (DIAGNOSTIC TROUBLE CODE) CHART
DTC Code 175800 -Detection Item SAE Code DTC No. 7241 7251 A/T M/T
P0045 34 With With VN turbo (open circuit)
P0087 49 With With Rail pressure sensor (Fixed output) P0088 78 With With Pump valve malfunction(high-pressure in rail)
P0093 78 With With Fuel leak malfunction
P0095 / P0097 / P0098 23 With With Intake air temperature sensor(Post-turbo intake air temperature sensor) 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 Rail pressure sensor With back-up sensor
(Open circuit)
Spring
Solenoid Coil to Fuel Tank
Armature
P0191 49 With With Rail pressure sensor with back-up sensor (out-of-range) P0200 97 With With EDU malfunction
P0234 34 With With VN turbo (closed-side malfunction) P0299 34 With With VN turbo (open-side malfunction)
P0335 13 With With
Crankshaft position sensor
(open circuit / phase difference, power flicker)
12 With With Crankshaft position sensor (open circuit) P0339 13 With With Crankshaft position sensor
(NE power flicker)
P0340 12
With With Camshaft position sensor (open circuit, phase difference) With With Camshaft position sensor
(open circuit, start-up logic) P0400 71 With With EGR system malfunction P0405 / P0406 96 With With Lift sensor (open circuit)
P0488 15 With With Intake air restriction motor control system (electronic throttle malfunction)
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 Internal IC malfunction RUN pulse malfunction P2008 58 With With SCV malfunction
DTC Code 175800
-Detection Item SAE Code DTC No. 7241 7251
P2120 / P2122 / P2123 / P2125 / P2127/ P2128 /
P2138
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 Vehicle speed sensor(noise, power flicker)
P0571 52 With With Stop light switch (open circuit, short)
P0607 54
With With Stop light switch input circuit malfunction With With Cancel circuit malfunction
56 With With System circuit malfunction
DTC Code 175800
-Detection Item SAE Code DTC No. 7241 7251
5.3. ECU
(1) External Wiring Diagram a. Wiring Diagram (1) +B +B +B +B +B PCV + EDU Drive Monitor
DC Motor Driver (For Turbo) PCV – PRD DM VNTO VNTI PI W GIND IREL GREL MREL EPA EPA2 E2 E2S CCS THA THF EGLS EVG EGR
Cruise Indicator Light
Cruise Control Switch Airflow
Sensor
+B
Fuel Temperature Sensor
EGR Lift Sensor
Glow Indicator Light
Glow Relay E-VAV Main Relay Q000993E EDU Relay MIL BATT E1 E01 E02 WFSE VCPA VPA VPA2 THIA THW VG VCP2 VC PIM VCS RCR1 Rail Pressure Sensor (Main) Rail Pressure Sensor (Sub)
Accelerator Sensor (Sub) Accelerator Sensor (Main)
Intake Air Temperature Sensor
Intake Air Temperature Sensor (Built-In Airflow Meter)
Coolant Temperature Sensor Turbo Pressure
Sensor
RCR2 ECT
Automatic Transmission Vehicles Only
DIAGNOSIS CAN + CAN – CANH CANL MREL Main Relay EFI PCV
b. Wiring Diagram (2) Q000994E EGRC NE + G + NE – G – TACH Cam Position Sensor
IGSW Brake Switch BATT IGSW ST1 – STP Engine Speed Sensor
Meter EDU EDU EDU EDU #4 #3 #2 #1 +B +B +B EGR Cut-Off VSV Active Mountain VSV
Throttle Full Switch Clutch Switch
P/S Oil Pressure Switch
Neutral Start Switch
Heater Idle-Up Switch
SCV THOP CLSW PSW NSW HSW L4 Switch L4M AC1 SPD TC ACT IMI IMO VCH VCT LU+A ALT STA LU–A LU+B LU–B THWO INJF EDU
Vehicle Speed Sensor
Test Terminal A/C Amplifier A/C Amplifier A/C Amplifier ACM +B Swirl Control Valve
Immbirazer ECU Immbirazer ECU Viscous Amplifier Viscous Amplifier Alternator Starter Relay +B Step Motor
(For Electronically Controlled Throttle) Automatic Transmission Vehicles Only
Manual Transmission Vehicles Only Manual Transmission Vehicles Only
(2) Connector Terminal Layout a. 175800-7241
b.
175800-7251-No. Code Terminal Description No. Code Terminal Description 1 E01 Power Ground
(Engine Ground)
22 #2
EDU
2 E02 23 #3
3 - - 24 #4
4 - - 25 THIA Intake Air Temperature
Sensor (Intake Manifold)
5 - - 26 THW Coolant Temperature Sensor
6 PCV+
Pump Control Valve
27 VC Sensor Power Supply 7 PCV- 28 NE- Crankshaft Position Sensor
(-)
8 VNTI Turbo Driver 29 PCR2 Rail Pressure Sensor (Sub)
9 - - 30 PRD EDU
10 SCV Swirl Control Valve 31 THA Intake Air Temperature Sensor (Airflow Meter) 11 LU+A
Step Motor
(for Electronically Controlled Throttle)
32 -
-12 LU-A 33 THF Fuel Temperature sensor
13 LU+B 34 E2 Sensor Ground
14 LU-B 35 E1 Ground (Engine Ground)
15 VNTO VN Turbo Driver 36 - -16 THOP Full Throttle Switch 37 -
-17 ALT Alternator 38 -
-18 NE+ Crankshaft Position Sensor
(-) 39 -
-19 PCR1 Rail Pressure Sensor (Main) 40 VCS Rail Pressure Sensor (Sub) Power Supply 20 INJF
EDU 41 E2S
Rail Pressure Sensor (Sub) Ground
21 #1 42 ACM Active Mount VSV
31P 111 135 Q000995E 130 104 97 69 62 35 7 1 34 28 105 75 70 41 35P 35P 34P 31P 111 135 Q000996E 130 104 97 69 62 35 7 1 34 28 105 75 70 41 35P 35P 34P
No. Code Terminal Description No. Code Terminal Description 43 EGRC EGR Cut-Off VSV 77 STP
Stop Light Switch
44 - - 78
ST1-45 L4M L4 Switch 79 VCH Viscous Amplifier
46 - - 80 - -47 - - 81 - -48 - - 82 CLSW Clutch Switch 49 - - 83 - -50 - - 84 - -51 - - 85 - -52 EGR E-VRV 86 - -53 - - 87 - -54 - - 88 -
-55 - - 89 CANH CAN1 Communication
(Diagnosis)
56 - - 90 CANL
57 VG Airflow Meter 91 CAN+
CAN2 Communication (ECT)
58 G+ Cylinder Recognition Sensor (+) (TDC Sensor) 92
CAN-59 - - 93 -
-60 - - 94 ACT
Air Conditioning Amplifier
61 - - 95 AC1
62 - - 96 SPD Vehicle Speed Sensor (Meter)
63 - - 97 -
-64 EGLS EGR Lift Sensor 98 - -65 EVG Airflow Meter (Ground) 99 - -66 G- Cylinder Recognition Sensor (-) (TDC Sensor) 100 -
-67 - - 101 -
-68 - - 102 IMI
Immobilizer ECU 69 PIM Intake Air Pressure Sensor 103 IMO
70 - - 104 -
-71 PSW Power Steering Hydraulic Pressure Switch 105 STA Starter Relay
72 VCT Viscous Amplifier 106 NSW Neutral Start Switch 73 PI Cruise Indicator 107 -
-74 BATT Battery (+) 108 TACH Tachometer
75 - - 109 DM Multi-Display
No. Code Terminal Description No. Code Terminal Description 111 +B Battery (+) Main Relay 124 VPA2 Accelerator Position Sensor (Sub)
112 - - 125 VPA Accelerator Position
Sensor (Main)
113 - - 126 CCS Cruise Control Switch
114 GREL Glow Relay 127 -
-115 GIND Glow Indicator Light 128 WFSE Flash Write Tool
116 - - 129 -
-117 W MIL 130 -
-118 TC Test Terminal 131 -
-119 IREL EDU Relay 132 EPA2
-120 IGSW Ignition Switch 133 EPA
-121 MREL Main Relay 134 VCP2
Accelerator Position Sensor Power Supply (Sub)
122 - - 135 VCPA
Accelerator Position Sensor Power Supply (Main)
