Land Rover Common Rail System Crs Denso Manual
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Repair Section2–96 2.3 Non-Reoccurring Malfunctions zIn cases where the malfunction does not reoccur, perform the actions below to determine the cause of the malfunction. Action Malfunction Symptom Fully Dis- charged Bat- teryEngine will not Sta r t Idle Speed, Engine Stall, Sputtering, Poor Acceler- ation Verify that there is no DTC stored in the memory. No Yes Yes Use the questionnaire as a basis to perform a reoccurrence test in Reoccurrence mode. Use this data (engine ECU voltage value, etc.) to determine the cause of the malfunction.Ye s Ye s Ye s Assume that an electrical sys- tem wiring harness or connector is the cause of the malfunction. Shake the wiring by hand to check whether a malfunction occurs and a DTC is generated.No Yes Yes Assume that an electrical system female connector terminal is the cause of the malfunction and verify that the connection points are not defective. No Yes Yes Use a dryer to heat the acceler- ator pedal position sensor and other electronic components. Check for changes in the volt- age value (resistance value). < CAUTION > • Do not exceed 60°C (still touchable by hand) when heating. • Do not remove the component cases and add heat directly to electronic parts.No No Yes Verify whether malfunction symptoms occur under heavy engine loads (headlights, A/C, wiper, etc. switches ON.)No NoYe s If any commercial electrical products have been installed, remove such products and verify whether the malfunction symptoms occur.Ye s Ye s Ye s Q002317 Recommended Tool: KOWA Precision Handling Feeler Gauge Set (KLM-10-20) Depending on the terminal, a matching size may not be availableInsert the male terminal that matches the shape of the female terminal and check for looseness. Q002318 Q002319
Repair Section2–97 If it is likely that the malfunction occurs in rainy or high-tempera- ture weather, spray the vehicle with water and verify whether the malfunction occurs. < CAUTION > • Do not spray water directly into the engine compartment. Spray water in mist form on all surfaces of the radiator to indi- rectly change temperature and humidity. • Do not spray water directly on electrical parts.No Yes Yes Action Malfunction Symptom Fully Dis- charged Bat- teryEngine will not Sta r t Idle Speed, Engine Stall, Sputtering, Poor Acceler- ation Mist State Q002320E
Repair Section2–98 3. DTC READING (FOR TOYOTA VEHICLES) 3.1 DST-2 zThe DST-2 can check for DTCs in either normal or check mode. In comparison to the normal mode, the check mode has higher sensitivity in detecting malfunctions. Check mode is used when detection is not possible in normal mode, regardless of the assumed abnormality. 3.2 DTC Check (Code Reading via the DST-2) zConnect the DST-2 to the DLC3 connector. zOperate the DST-2 in accordance with the instructions shown on the display to view the DTC check screen. Select either the normal or check mode to verify the DTC. 3.3 DTC Memory Erasure (via the DST-2) zTo erase DTC codes, follow the instructions on the display to view the DTC and Freeze Data Erasure screen. < CAUTION > • If the DTC cannot be erased, cycle the ignition switch OFF and back ON, and then perform code erasure again. • Do not use the DST-2 to erase the DTC until the cause of the malfunction is clear. Q000916E This will erase the DTC and freeze frame data. Do you wish to proceed?DTC (ECD Erasure) NG : - OK : +
Repair Section2–99 4. TROUBLESHOOTING BY SYSTEM 4.1 Intake System Diagnosis Clogged air cleaner element 4.2 Fuel System Diagnosis Clogged air cleaner element1 Clogged air cleaner element Clean or replace the air cleaner. 2 Check the suction path for leaks. • Suction path joints • Suction pipes, hosesRepair or replace the malfunctioning compo- nent. Normal 1 Fuel system check (remaining fuel quantity, fuel properties) • Check the amount of fuel remaining in the tank. • Check the condition of the fuel. Request engine analysis from a third party as neces- sary. - Color (no color, brownish, milky) - Odor (kerosene, heavy oil, irritating odor) - Separation of materials (water, foreign objects) - Viscosity (high/low viscosity, wax consis- tency)Add fuel or replace components (clean tank.) NG OK NG OK NG OK
Repair Section2–100 2 Fuel tank interior check (modification/additions, position of fuel pipe inlet/outlet, clogging and holes) • Check the tank for modifications or additions. Consult with the user. - Fuel inlet/outlet position, tank piping - Foreign material inside the tank, water sep- aration - Tank-internal Zn cladding - Check the tank-internal fuel piping for the following. - Inlet/outlet position (below position E) - Inlet clogging, bent or deformed piping (crushed pipe) - Crushed piping connectionsRestore the fuel tank. 3 Tank-external fuel path conditions (crushed hose, clogging, air introduction at hose connec- tion) • Check the condition of the hose. - Crushing around bands, over-bending - Pinched or crushed by other parts • Air introduction through fuel system connec- tion points - Looseness - Hose deterioration (Verify by hand or visu- ally that there is no rubber hardening/split- ting.) < CAUTION > Be cautious when vacuum pressure is present, as air will be drawn into the hose.Repair or replace the hose. 4 Primary filter, sedimentor check • Check for primary filter clogging and dirt. • Check sedimentor water volume.Replace the filter, and drain water from the sedi- mentor. 5 Looseness at priming attachment point check • Check the following. - Looseness at the priming attachment point - Does the piston stick out? - Fuel leakage (oozing)Tighten or replace the priming pump. NG OK NG OK NG OK NG OK
Repair Section2–101 (1) Fuel pressure test procedure • Connect the DST-2 to the vehicle-side test connector. - With the vehicle idling, verify the rail pressure displayed on the DST-2. System selection screen: Rail a ECU Data Monitor6 Filter (supply pump inlet) clogging • Fuel filter - Check for fuel delivery from the priming pump. • Gauze filter - Visually check for clogging due to foreign material.Clean the gauze filter, fuel filter and fuel piping system, or replace the filters. 7 Oil level increase (engine internal leak) • Verify whether the oil level increases on the oil level gauge.Check the engine. 8 High-pressure piping and CRS component (injector supply pump, rail) fuel leaks (engine external leak) (Refer to (2) Fuel leak check.) • Connect the DST-2 to the diagnostic connec- tor. Activate the Fuel Leak Check Function within the active test. • Visually check and specify areas that leak fuel. < CAUTION > In the event of a large fuel leak down- stream of the flow damper, be aware that fuel flow will stop and the leak will cease due to flow damper operation.Repair leaking high-pressure piping or replace leaking parts. Normal Item Name (Abbrevi- ated)ExplanationCheck ConditionsReference ValueItems of Importance During an Abnormal- ity Rail Pressure (RP) • Displays the fuel pressure in the rail. • Display range: 0 MPa to 255 MPaFollowing engine warm-up, when the engine is rotatingFuel pressure in the rail is displayed within a range of 30 MPa to 160 MPa.PCR1, PCR2 signals (rail assembly) NG OK NG OK NG OK
Repair Section2–102 (2) Fuel leak check • Connect the DST-2 to the vehicle-side test connector. • With the vehicle idling, perform the active test by following the instructions on the DST-2 display. System selection screen: TCCS a Active Test • Verify that there are no fuel system leaks during the active test (when fuel pressure is being applied to the rail.) 4.3 Basics of Electrical/Electronic Circuit Checks (1) ECU terminal voltage and waveform measurements • When measuring the voltage and resistance of each terminal, insert the multimeter probe into the rear side of the wiring harness connector. If connectors are too small for the probe to be inserted easily, insert a fine metal wire into the rear of the connector and touch the wire to the probe. < NOTE > The number of each terminal can be seen from the rear side of the wiring harness. Item NameDescriptionControl Conditions High-Pressure Fuel System Check Raise engine speed to 2000 rpm, and then use the active test to place the fuel inside the rail under high pres- sure. < CAUTION > Engine speed cannot be raised by stepping on the accelerator pedal.• Following engine warm-up, when the engine is at idle speed • The vehicle speed sensor is operat- ing normally, and speed is 0 km/h. Q002326E Ground Ground Ground Engine ECU Side Wiring Harness Side
Repair Section2–103 (2) Open circuit check • When dealing with a wiring harness open circuit like that depicted in diagram 1, check continuity and/or voltage to determine the location of the open circuit. Continuity Check 1)Remove connectors A and C, and then measure resis- tance between the two. < NOTE > Measure resistance while gently shaking the wiring har- ness up and down, and side-to-side. 2)As shown in diagram 2, there is no continuity (open circuit) between terminal 1 of connector A and terminal 1 of con- nector C. However, there is continuity between terminal 2 of connector A and terminal 2 of connector C. Therefore, there is an open circuit between terminal 1 of connector A and terminal 1 of connector C. 3)Remove connector B and measure the connector resis- tance. 4)As shown in diagram 3, there is continuity between terminal 1 of connector A and terminal 1 of connector B1. Howev- er, there is no continuity (open circuit) between terminal 1 of connector B2 and terminal 1 of connector C. Therefore, there is an open circuit between terminal 1 of connector B2 and terminal 1 of connector C. Q002327E Diagram 1 Engine ECU SensorOpen Circuit 111 1 222 2 A B C Q002328E Diagram 2 Sensor Engine ECU 1 221 2 A B CStandard Value 1Ω or less Q002329E Diagram 3 Sensor Engine ECU 1 21 21 2 1 2 A CB2B1
Repair Section2–104 Voltage Check 1)For the circuit that applies voltage to the ECU connector ter- minals, check for an open circuit by performing a voltage check. 2)As shown in diagram 4, with all connectors connected, mea- sure the voltage for the ECU 5 V output terminal between the body ground and terminal 1 of connector A. Next mea- sure voltage for terminal 1 of connector B and terminal 1 of connector C in the same fashion. 3)The faulty circuit and measurement results are shown be- low. (3) Short circuit check • As shown in diagram 5, if there is a short in the wiring harness ground, perform a Ground Continuity Check to de- termine the cause of the short. Q002330E Diagram 4 Sensor 1 221 1 2 A B C 0 V5 V 5 V Measurement Results• Voltage between terminal 1 of con- nector A and the body ground is 5 V. • Voltage between terminal 1 of con- nector B and the body ground is 5 V. • Voltage between terminal 1 of con- nector C and the body ground is 0 V. Faulty ItemThere is an open circuit in the wiring harness between terminal 1 of connec- tor B and terminal 1 of connector C. Q002331E Diagram 5 SensorEngine ECU Short Circuit # $ %
Repair Section2–105 Ground Continuity Check 1)Remove connector A and connector C, and then mea- sure the resistance respectively between terminals 1 and 2 of connector A and ground. < NOTE > Measure resistance while gently shaking the wiring har- ness up and down, and side-to-side. 2)As shown in diagram 6, there is continuity between terminal 1 of connector A and the body ground (short circuit). How- ever, there is no continuity between terminal 2 of connector A and the body ground. Therefore, there is a short circuit between terminal 1 of connector A and terminal 1 of con- nector C. 3)Remove connector B and measure the resistance be- tween terminal 1 of connector A and the body ground, and between terminal 1 of connector B2 and the body ground. 4)The faulty circuit and measurement results are shown be- low. Q002332E Diagram 6 Sensor Engine ECU 1 221 1 2 A B C Standard Value 1Ω or less Q002333E Diagram 7 Sensor Engine ECU 1 21 21 2 1 2 A CB2B1Measurement Results• There is no continuity between termi- nal 1 of connector A and the body ground. • There is continuity between terminal 1 of connector B2 and the body ground. Faulty Item There is a short circuit between terminal 1 of connector B2 and terminal 1 of connector C.