Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
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1GD-FTV ENGINE CONTROL ECD SYSTEM Engine Knocking or Rattling
DESCRIPTION
Malfunction Condition Main Trouble Area Related Trouble Area
· Injector compensation
codes
(a) Injector assembly malfunctions
· Fuel leakage
· Injector sliding malfunction · Intake system leakage
· Injector stuck closed · Intake system blockage
· Injector stuck open · EGR system
· Deposits in injector · Throttle valve system
· Knocking and abnormal · Injector circuit malfunction · Fuel pressure sensor
sound due to extremely
· Manifold absolute pressure
rich combustion (b) Abnormal common rail sensor
· Abnormal sound due to pressure · Mass air flow meter sub-
friction between parts
· Pre-stroke control valve assembly
· Fuel pulsation sound · Atmospheric pressure
· Air in fuel sensor (built into ECM)
· Vehicle modifications
(c) Friction between parts · Low quality fuel
(d) Compression pressure · Lack of fuel
· ECM
HINT:
· Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data
List values may occur depending on the measuring conditions or the vehicle's age. Do not judge the
vehicle to be normal even when the Data List values indicate a standard level. There are possibly some
concealed factors of the malfunction.
· Check that the vehicle has not been modified in any way prior to the vehicle inspection.
CAUTION / NOTICE / HINT
HINT:
· This troubleshooting procedure checks for knocking and rattling.
· Knocking is most likely to occur while the engine is idling.
NOTICE:
· After replacing the ECM, the new ECM needs registration (Click here Engine / Hybrid System>1GD-FTV
ENGINE CONTROL>ECD SYSTEM>REGISTRATION) and initialization (Click here Engine / Hybrid
System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>INITIALIZATION).
· After replacing an injector assembly, the ECM needs registration (Click here Engine / Hybrid
System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION).
PROCEDURE
[Link] SOUND AREA
a. Find the source of the abnormal sound using a mechanic's sound scope.
Result:
Result Proceed to
Combustion noise from engine A
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
Noise from specific part B
[Link] OUTPUT DTCS (RELATING TO ENGINE)
REPAIR OR REPLACE MALFUNCTIONING PARTS
[Link] OUTPUT DTCS (RELATING TO ENGINE)
a. Connect the GTS to the DLC3.
b. Turn the ignition switch to ON and turn the GTS on.
c. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
d. Read the DTCs.
Powertrain > Engine and ECT > Trouble Codes
Execute
Result:
Result Proceed to
No DTC is output A
Engine related DTCs are output B
[Link] INJECTOR COMPENSATION CODE
GO TO DTC CHART
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>DIAGNOSTIC
TROUBLE CODE CHART
[Link] INJECTOR COMPENSATION CODE
NOTICE:
Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head portion of each
injector assembly. If an incorrect injector compensation code is input into the ECM, the engine may rattle or
engine idling may become rough. In addition, engine failure may occur and the life of the engine may be
shortened.
a. Check the injector compensation code.
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION
Powertrain > Engine and ECT > Utility
Tester Display
Injector Compensation
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
Execute
OK:
Compensation codes of the installed injector assemblies are the same as the compensation
codes registered in the ECM.
Result:
Proceed to
OK
NG
OK
[Link] SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)
NG
[Link] INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY
LEARNING
[Link] SNAPSHOT DURING IDLING AND 4000 RPM (AFTER ENGINE WARMED UP)
a. Connect the GTS to the DLC3.
b. Start the engine and turn the GTS on.
c. Enter the following menus: Powertrain / Engine and ECT / Data List / Diesel Knocking.
d. Take a snapshot of the following Data List items.
HINT:
· A snapshot can be used to compare vehicle data from the time of the malfunction to normal data
and is very useful for troubleshooting. The data in the list below is that of a normal vehicle, but as
the data varies between individual vehicles, this data should only be used for reference.
· Check the Data List at idling and at 4000 rpm with no load after the engine is warmed up.
Result:
Proceed to
NEXT
NEXT
[Link] SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION
VOLUME)
[Link] SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4 AND INJECTION VOLUME)
a. Check Injection Feedback Val #1 to #4 and Injection Volume in the snapshot taken when the engine was
idling and at 4000 rpm with no load.
Result:
Result Proceed to
Injection Feedback Val for at least one cylinder is more than +3
3
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
mm3/st A
Injection Volume is less than 10 mm3/st at 4000 rpm B
Except above C
HINT:
· When there is a problem with the operation of an injector assembly due to foreign matter in the
inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM
gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to
increase.
· The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is
approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than
-3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback
Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not
malfunctioning.
[Link] ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)
[Link] INJECTOR ASSEMBLIES OF ALL CYLINDERS
[Link] SNAPSHOT (COMMON RAIL PRESSURE AND TARGET COMMON RAIL
PRESSURE)
[Link] ACTIVE TEST USING GTS (CHECK THE CYLINDER COMPRESSION)
HINT:
Use this Active Test to help determine whether a cylinder has compression loss or not.
a. Connect the GTS to the DLC3.
b. Start the engine and turn the GTS on.
c. Enter the following menus: Powertrain / Engine and ECT / Active Test / Check the Cylinder Compression /
Data List / Compression / Engine Speed of Cyl #1 to #4.
d. Check the engine speed during the Active Test.
Powertrain > Engine and ECT > Active Test
Active Test Display
Check the Cylinder Compression
Data List Display
Engine Speed of Cyl #1
Engine Speed of Cyl #2
Engine Speed of Cyl #3
Engine Speed of Cyl #4
Execute
Result:
Result Proceed to
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
Except below A
The values of Engine Speed Cyl #1 to #4 are within 10 rpm of each
B
other
HINT:
When cranking, if the speed of a cylinder is approximately 100 rpm more than the other cylinders, there
is probably a complete loss of compression in that cylinder.
[Link] CYLINDER COMPRESSION PRESSURE
[Link] INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
[Link] CYLINDER COMPRESSION PRESSURE
a. Check the cylinder compression pressure.
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE>ON-VEHICLE INSPECTION
HINT:
When compression is low, there may be cracks in the piston or the injector may be installed improperly.
Result:
Proceed to
OK
NG
OK
[Link] INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
NG
CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION
[Link] INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
a. Replace the injector assembly of the malfunctioning cylinder.
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL
NOTICE:
· When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection
pipe sub-assembly and a new No. 2 injection pipe sub-assembly.
· Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-
assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, and then
correctly position the injector assemblies. After that, tighten parts according to the torque
specifications.
· If the installation procedure is not performed correctly, injector assemblies may become out of
position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
· If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough
idle, etc. may occur.
· If an injector assembly becomes out of position, it is possible that the seal between the injector
assembly and injection pipe sub-assembly may become incomplete, resulting in a fuel leak.
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
Result:
Proceed to
NEXT
NEXT
[Link] FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY
[Link] FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY
a. Clean the fuel filter case and replace the fuel filter element assembly.
HINT:
Be sure to clean the inside of the fuel filter case as the injector assemblies may not operate properly if
the fuel filter element assembly is installed with foreign matter remaining inside the fuel filter case.
Result:
Proceed to
NEXT
NEXT
[Link] INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY
LEARNING
[Link] INJECTOR COMPENSATION CODE AND PERFORM PILOT QUANTITY LEARNING
a. Register the injector compensation codes.
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION
Powertrain > Engine and ECT > Utility
Tester Display
Injector Compensation
Execute
b. Perform the fuel injector pilot quantity learning.
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION
Powertrain > Engine and ECT > Utility
Tester Display
Pilot Quantity Learning
Execute
Result:
Proceed to
NEXT
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
NEXT
[Link] AIR FROM FUEL SYSTEM
[Link] AIR FROM FUEL SYSTEM
a. Bleed the air from the fuel system.
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
Result:
Proceed to
NEXT
NEXT
[Link] WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
[Link] WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
a. Check whether the knocking has been successfully repaired.
Result:
Proceed to
NEXT
NEXT
END
[Link] INJECTOR ASSEMBLIES OF ALL CYLINDERS
a. Replace the injector assemblies.
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL
NOTICE:
· When replacing the injector assembly for a cylinder, always be sure to use a new No. 1 injection
pipe sub-assembly and a new No. 2 injection pipe sub-assembly.
· Follow the procedure in the repair manual and temporarily install the No. 1 injection pipe sub-
assembly, No. 2 injection pipe sub-assembly and No. 1 nozzle leakage pipe assembly, and then
correctly position the injector assemblies. After that, tighten parts according to the torque
specifications.
· If the installation procedure is not performed correctly, injector assemblies may become out of
position, which may cause the injector assemblies to deteriorate, resulting in malfunctions.
· If an injector assembly deteriorates and malfunctions, other problems such as knocking, rough
idle, etc. may occur.
· If an injector assembly becomes out of position, it is possible that the seal between the injector
assembly and injection pipe sub-assembly may become incomplete, resulting in a fuel leak.
Result:
Proceed to
NEXT
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
NEXT
[Link] FUEL FILTER CASE AND REPLACE FUEL FILTER ELEMENT ASSEMBLY
[Link] SNAPSHOT (COMMON RAIL PRESSURE AND TARGET COMMON RAIL PRESSURE)
a. Check Common Rail Pressure and Target Common Rail Pressure in the snapshot taken when the engine was
warmed up and idling.
OK:
Common Rail Pressure is within 5000 kPa of Target Common Rail Pressure.
Result:
Proceed to
OK
NG
OK
[Link] PILOT QUANTITY LEARNING (DETAIL)
NG
[Link] FUEL SUPPLY PUMP ASSEMBLY (PRE-STROKE CONTROL VALVE)
[Link] PILOT QUANTITY LEARNING (DETAIL)
a. Perform the pilot quantity learning (detail).
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION
Result:
Proceed to
NEXT
NEXT
[Link] ENGINE KNOCKING OR RATTLING
[Link] ENGINE KNOCKING OR RATTLING
a. Check engine knocking or rattling.
Result:
Result Proceed to
Sound disappears A
Except above (Sound continues occurring) B
END
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
[Link] THE TEMPERATURE WHEN KNOCKING OCCURS
[Link] THE TEMPERATURE WHEN KNOCKING OCCURS
a. Check the temperature when knocking trouble occurs.
Result:
Result Proceed to
Knocking occurs only in cold engine A
Knocking occurs both in cold and warmed up engine B
[Link] GLOW PLUG (RESISTANCE)
[Link] VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)
[Link] GLOW PLUG (RESISTANCE)
a. Inspect the glow plug.
Click hereEngine / Hybrid System>1GD-FTV STARTING>GLOW PLUG>ON-VEHICLE INSPECTION
Result:
Proceed to
OK
NG
OK
[Link] SNAPSHOT DURING IDLING (WHEN ENGINE COLD)
NG
REPLACE GLOW PLUG
Click hereEngine / Hybrid System>1GD-FTV STARTING>GLOW PLUG>REMOVAL
[Link] SNAPSHOT DURING IDLING (WHEN ENGINE COLD)
a. Make sure that the engine is cold so that the snapshot can be taken under the correct conditions.
b. Connect the GTS to the DLC3.
c. Start the engine and turn the GTS on.
d. Enter the following menus: Powertrain / Engine and ECT / Data List / Diesel Knocking.
e. Take a snapshot of the following Data List items.
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
HINT:
A snapshot can be used to compare vehicle data from the time of the malfunction to normal data and is
very useful for troubleshooting. The data in the list below is that of a normal vehicle, but as the data
varies between individual vehicles, this data should only be used for reference.
Result:
Proceed to
NEXT
NEXT
[Link] SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4)
[Link] SNAPSHOT (INJECTION FEEDBACK VAL #1 TO #4)
a. Check Injection Feedback Val #1 to #4 in the snapshot taken when the engine was idling.
Result:
Result Proceed to
Injection Feedback Val for at least one cylinder is more than +3
A
mm3/st
Except above B
HINT:
· When there is a problem with the operation of an injector assembly due to foreign matter in the
inside of the injector assembly, etc., the fuel injection volume decreases. As a result, the ECM
gives instructions to increase the fuel injection volume, which causes Injection Feedback Val to
increase.
· The ECM controls the system so that the sum of Injection Feedback Val for all of the cylinders is
approximately 0 mm3/st. Even if the value of Injection Feedback Val for a cylinder is less than
-3.0 mm3/st (-3.0 mm3/st is the lowest normal value), as long as the value of Injection Feedback
Val for each of the other cylinders is 3.0 mm3/st or less, the injector assemblies are not
malfunctioning.
[Link] INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
[Link] VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)
[Link] FUEL SUPPLY PUMP ASSEMBLY (PRE-STROKE CONTROL VALVE)
a. Replace the fuel supply pump assembly.
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SUPPLY PUMP>REMOVAL
HINT:
If the common rail pressure becomes too high when transitioning due to problems with pre-stroke control
valve operation, knocking noise worsens.
When the common rail pressure becomes excessively high as a result of a pre-stroke control valve
malfunction, knocking sounds worsen.
Result:
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
Proceed to
NEXT
NEXT
[Link] AIR FROM FUEL SYSTEM
[Link] AIR FROM FUEL SYSTEM
a. Bleed the air from the fuel system.
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
Result:
Proceed to
NEXT
NEXT
[Link] WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
[Link] WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
a. Check whether the knocking has been successfully repaired by starting the engine.
Result:
Proceed to
NEXT
NEXT
END
[Link] VALUE USING GTS (MAP AND ATMOSPHERE PRESSURE)
a. Connect the GTS to the DLC3.
b. Turn the ignition switch to ON and turn the GTS on.
c. Enter the following menus: Powertrain / Engine and ECT / Data List / MAP and Atmosphere Pressure.
Powertrain > Engine and ECT > Data List
Tester Display
Atmosphere Pressure
MAP
Execute
d. Compare MAP to Atmosphere Pressure when the ignition switch is ON (do not start the engine).
Standard:
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
Difference between MAP and Atmosphere Pressure is less than 8 kPa.
HINT:
· If MAP and Atmosphere Pressure have the same value, both are normal. If there is a difference of
8 kPa or more, compare the values to the atmospheric pressure for that day. The sensor whose
deviation is the greatest is malfunctioning.
· Standard atmospheric pressure is 101 kPa. For every 100 m increase in elevation, pressure drops
by 1 kPa. This varies by weather.
Result:
Result Proceed to
MAP and Atmosphere Pressure have same value A
MAP is different from actual atmospheric pressure B
Atmosphere Pressure is different from actual atmospheric pressure C
[Link] INSPECTION
REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>MANIFOLD ABSOLUTE
PRESSURE SENSOR>REMOVAL
REPLACE ECM
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECM>REMOVAL
[Link] INSPECTION
a. Check the fuel quality.
b. Check the fuel for air.
c. Check the fuel system for blockages.
d. Check the air cleaner filter element sub-assembly.
e. Check the engine oil.
f. Check the engine coolant.
g. Check the engine idling speed and maximum engine speed.
h. Check the vacuum pump.
Result:
Proceed to
NEXT
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Inspection Procedure - Toyota Service Information 11/3/17, 4(23 pm
NEXT
END
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