05–547
DIAGNOSTICS
DTC
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
05M58–02
P0200/97 INJECTOR CIRCUIT / OPEN
HINT:
S
S
For more information on the EDU, refer to the system description (see page 05–422).
If P0200/97 is present, refer to the ”Diagnostic Trouble Codes (DTCs) Table for Common Rail System”
(see page 05–547).
CIRCUIT DESCRIPTION
The EDU has been adopted to drive the injectors at high speeds. The EDU delivers high–speed driving under
highly–pressurized fuel conditions using the DC/DC converter that provides a high–voltage, and the quick–
charging system.
Soon after the EDU receives an injection command (IJT) signal from the ECM, the EDU responds to the command with an injector injection confirmation (IJF) signal when the current is applied to the injector.
EDU Wiring Diagram
EDU
COM3
From
Battery
COM2
DC/DC
Converter
Maximum 150 V
Command
Pulse
COM1
Injector
ECM
IJT#1
INJ#1
IJT#4
INJ#4
IJT#2
INJ#2
Control
Circuit
IJT#3
INJF (IJF)
INJ#3
Confirmation
Pulse
GND
EDU Connector
I5
I6
Warning: Terminals I, H, K, L, M, N are high voltage
G38712
05–548
DIAGNOSTICS
DTC No.
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
DTC Detection Condition
Trouble Area
Open or short in EDU or injector circuit
After engine is started, there is no IJF signal from EDU to
ECM, despite ECM sending IJT signal to EDU
(1 trip detection logic)
P0200/97
S Open or short in EDU circuit
S Injector
S EDU
S ECM
MONITOR DESCRIPTION
P0200/97 (Open or short in EDU or injector circuit):
The ECM continuously monitors both injection command (IJT) signals and injection confirmation (IJF) signals. This DTC will be set if the ECM judges that the number of IJT signals and IJF signals are inconsistent.
The injectors are grounded over a Field Effect Transistor (FET) and a serial resistor. This resistor creates
a voltage drop, which is monitored by the EDU (injector drive circuit), in relation to the current drawn by the
injector. When the injector current becomes too high, the voltage drop over the resistor exceeds a specified
level and no IJF signal for that cylinder is sent to the ECM.
P0200/97 refers to a malfunction in the EDU or injector circuit.
If this DTC is set, the ECM enters fail–safe mode and limits the engine power. The fail–safe mode continues
until the engine switch is turned OFF.
Malfunction Detection:
Command Signal (IJT)
ECM
Confirmation Signal (IJF)
EDU
ON
Injection
Command Signal
IJT
Injection
Confirmation Signal
IJF
OFF
Abnormal
Normal
A81495
Y
G37535
MONITOR STRATEGY
Required sensors
IJF signal from EDU
Frequency of operation
Continuous
Duration
10 seconds
MIL operation
1 driving cycle
TYPICAL ENABLING CONDITIONS
Item
Specification
Specification
Minimum
Maximum
Engine speed
Engine is running (except engine start)
–
Battery voltage
11 V
–
Ignition switch
ON
ON
TYPICAL MALFUNCTION THRESHOLDS
Threshold
The injection missing counter* for all the cylinders, or for one individual cylinder, reaches a specified number (taking approximately 1 second from
starting the engine)
*: Increments when no IJF signal is received from the EDU despite the ECM sending IJT signals
05–549
DIAGNOSTICS
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
WIRING DIAGRAM
(*1) (*2)
10 C4
IM4 IC4
B
Engine Room R/B
B
J22
J/C
B
1
E14 +B
B
C
C17
IC4
W–G
ECM
C
8
E14 MREL
W–G
2
B
EF1 Relay
D
D
J22 J23
(*1) (*2)
L
L
2
W–B
2
5
3
2
1
2
B
2
2
B
1
2
5
3
2
1
1
2
2
B
2
B
2
B
8 C8
IM4 IC4
(*1) (*2)
L
L
B
BR
J2
J/C
2 EB1
25
E17
24
E17
23
E17
22
E17
21
E17
BR
B–W
L
R–L
Y
W
I6
Injector 1
2
INJF
#1
#2
#3
#4
B
1
I9
Injector 4
3
INJ#4 E3
1 EB1
B
B
BR
B
2
INJ#2 E3
8
E3
COM2
(*3)
W–B
B
BR
EB
10
E14 IREL
B–W
7
IJF E4
6
IJT#1 E4
3
IJT#2 E4
2
IJT#3 E4
5
IJT#4 E4
4
INJ#1 E3
5
COM1 E3
(*3)
W–B
2
E15 BATT
L
EDU
EF1
L
D D
J22 J23
(*1) (*2)
A5
IC4
B–W
C/OPN or EDU Relay
J/C
Battery
EG
P
2
1
INJ#3 E3
Y
1
GND E4
W–B
8
E3 +B
*1: LHD
*2: RHD
*3: Shielded
I7
Injector 2
L
1
I8
Injector 3
2
L
2
E
W–B
E
EF
J11
J/C
G38697
05–550
DIAGNOSTICS
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
PULSE GENERATION INSPECTION
HINT:
Problem areas can be located by checking the waveform at the following terminals.
Warning: Terminals COM1, COM2, and INJ#1 to 4 are high–voltage
ECM
High–voltage Area
EDU
C IJF
INJF D
COM2
Injector
COM1
IJT#1
INJ#1
IJT#4
INJ#4
#2
IJT#2
INJ#2
#3
IJT#3
INJ#3
#1
#4
B
A
A81508
HINT:
In order to save time during the inspection, follow these instructions. When checking the ECM side first, inspect the trouble areas listed to the right of A to D (in that order).
Malfunction Point
Trouble Area
A
ECM
B (if A is normal)
Open or short in ”#1 to #4 (ECM)” – ”IJT#1 to IJT#4 (EDU)” harness or connector
C (if A and B are normal)
S Open or short in ”INJ#1 to INJ#4 (EDU)” – ”COM1 and/or COM2” (EDU) circuit
S Injector
S EDU
D (if A, B and C are normal)
Open or short in ”INJ (EDU)” – ”INJF (ECM)” circuit
(a)
Signal Waveform
#1
5 V/
Division
#3
#4
#2
20 msec./Division
A09438
Reference:
Inspection using an oscilloscope.
While idling the engine, the correct waveform is shown in
the diagram on the left.
Inspection Points
Specified Condition
A and B
Correct waveform is shown
05–551
DIAGNOSTICS
(b)
Signal Waveform
2 V/
Division
INJF
20 msec./Division
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
Reference:
Inspection using an oscilloscope.
While idling the engine, the correct waveform is shown in
the diagram on the left.
Inspection Points
Specified Condition
C and D
Correct waveform is shown
A09437
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the intelligent tester II. Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was
running or stopped, if the engine was warmed up or not, and other data from the time the malfunction occurred.
1
INSPECT INJECTOR ASSY
(a)
(b)
Injector Assy
Disconnect the I6, I7, I8 and I9 injector connectors.
Measure the resistance of the injector.
Standard:
2 1
NG
A81503
OK
Tester Connection
Specified Condition
1–2
0.85 to 1.05 Ω at 20_C (68_F)
REPLACE INJECTOR ASSY (See page 11–52)
05–552
DIAGNOSTICS
2
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
CHECK WIRE HARNESS (EDU – INJECTOR ASSY)
(a)
Wire Harness Side
I6
I7
I8
I9
Injector
1 2
Check the wire harness between the injector and EDU
(INJ terminal).
(1) Disconnect the I6, I7, I8 and I9 injector connectors.
(2) Disconnect the E3 EDU connector.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
E3
EDU
INJ#2 INJ#4
INJ#3
A80992
A84815
INJ#1
COM1
COM2
A99847
NG
OK
Tester Connection
Specified Condition
I6–2 – E3–4 (INJ#1)
Below 1 Ω
I7–2 – E3–2 (INJ#2)
Below 1 Ω
I8–2 – E3–1 (INJ#3)
Below 1 Ω
I9–2 – E3–3 (INJ#4)
Below 1 Ω
I6–1 – E3–5 (COM1)
Below 1 Ω
I7–1 – E3–6 (COM2)
Below 1 Ω
I8–1 – E3–6 (COM2)
Below 1 Ω
I9–1 – E3–5 (COM1)
Below 1 Ω
I6–2 or E3–4 (INJ#1) – Body ground
10 kΩ or higher
I7–2 or E3–2 (INJ#2) – Body ground
10 kΩ or higher
I8–2 or E3–1 (INJ#3) – Body ground
10 kΩ or higher
I9–2 or E3–3 (INJ#4) – Body ground
10 kΩ or higher
I6–1 or E3–5 (COM1) – Body ground
10 kΩ or higher
I7–1 or E3–6 (COM2) – Body ground
10 kΩ or higher
I8–1 or E3–6 (COM2) – Body ground
10 kΩ or higher
I9–1 or E3–5 (COM1) – Body ground
10 kΩ or higher
REPAIR OR
CONNECTOR
REPLACE
HARNESS
AND
05–553
DIAGNOSTICS
3
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
CHECK WIRE HARNESS (EDU – ECM)
Wire Harness Side
IJT#3
E4
EDU
IJT#2
(a)
(b)
(c)
IJF
IJT#4
Disconnect the E4 EDU connector.
Disconnect the E17 ECM connector.
Measure the resistance of the wire harness side connectors.
Standard:
IJT#1
E17
#2
INJF
#4
Tester Connection
Specified Condition
E4–6 (IJT#1) – E17–24 (#1)
Below 1 Ω
E4–3 (IJT#2) – E17–23 (#2)
Below 1 Ω
E4–2 (IJT#3) – E17–22 (#3)
Below 1 Ω
E4–5 (IJT#4) – E17–21 (#4)
Below 1 Ω
E4–7 (IJF) – E17–25 (INJF)
Below 1 Ω
E4–6 (IJT#1) or E17–24 (#1) – Body ground
10 kΩ or higher
E4–3 (IJT#2) or E17–23 (#2) – Body ground
10 kΩ or higher
E4–2 (IJT#3) or E17–22 (#3) – Body ground
10 kΩ or higher
E4–5 (IJT#4) or E17–21 (#4) – Body ground
10 kΩ or higher
E4–7 (IJF) or E17–25 (INJF) – Body ground
10 kΩ or higher
#1
A80994
A80456
#3
A99849
NG
REPAIR OR
CONNECTOR
REPLACE
HARNESS
AND
OK
4
CHECK INJECTOR DRIVER (BATTERY VOLTAGE)
Wire Harness Side
BATTERY (+)
E3
EDU
(a)
(b)
(c)
Disconnect the E3 and E4 EDU connectors.
Turn the ignition switch ON.
Measure the voltage of the wire harness side connectors.
Standard:
Tester Connection
Specified Condition
E3–8 (BATTERY) – E4–1 (GND)
9 to 14 V
GND (–)
E4
EDU
A81845
A80994
NG
A99850
OK
CHECK INJECTOR DRIVER POWER SOURCE
CIRCUIT (BATTERY – EDU)
05–554
DIAGNOSTICS
5
–
ECD SYSTEM (1KD–FTV)(From August, 2004)
CHECK ECM (INJECTOR VOLTAGE)
(a)
E17
INJF
#1
#2
#3
E16
#4
While idling the engine, check the waveform of the ECM
connectors using an oscilloscope.
Standard:
Tester Connection
Specified Condition
E17–24 (#1) – E16–7 (E1)
Correct waveform is shown
E17–23 (#2) – E16–7 (E1)
Correct waveform is shown
E17–22 (#3) – E16–7 (E1)
Correct waveform is shown
E17–21 (#4) – E16–7 (E1)
Correct waveform is shown
E17–25 (INJF) – E16–7 (E1)
Correct waveform is shown
E1
#1
5 V/
Division
#3
#4
#2
20 msec./Division
2 V/
Division
INJF
A66060
A09438
A09437
20 msec./Division
NG
A99851
REPLACE ECM (See Pub. No. RM990E, page
10–34)
NOTICE:
After replacing the ECM, allow for ECM learning start the
engine and idle it until it is fully warmed up.
OK
6
REPLACE INJECTOR DRIVER
NEXT
CHECK IF DTC OUTPUT RECURS (DTC P0200/97)
HINT:
After clearing the DTC, start the engine and let it idle for 30 seconds. Confirm that P0200/97 is not output
again.