00400579E

SERVICE BULLETIN
FUEL INJECTION PUMP
ECD06-10E
NEW PRODUCTS Sep, 2006
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT: TOYOTA DYNA 1KD-FTV ENGINE COMMON RAIL SYSTEM

1.OUTLINE
This bulletin describes the common rail system used in the TOYOTA DYNA 1KD-FTV
engine.The basic construction and operation are the same as in the previous SERVICE MAN-
UAL "Common Rail System for TOYOTA HILUX / KIJYANG INNOVA / INNOVA 1KD/2KD"
(No.00400077) in July, 2004.Additions and changes are explained in this manual.
1.1. ADD AND CHANGE ITEMS
• Main component (supply pump, injector) part numbers
• Engine ECU wiring diagram and connector pin position
• Diagnostic trouble codes (DTCs)

2. APPLICABLE VEHICLE MODEL

Vehicle Name Engine Model Displacement Destination Start of production
DYNA 1KD-FTV 3.0L Europe, Australia August, 2006

3. APPLICABLE PRODUCT LIST

DENSO Part Manufacturer
Part Name Remarks
Number Part Number
Supply Pump (HP3) 294000-036# 22100-30040
095000-678# 23209-30050 Set Part Number
Injector (G2 type) 095000-671# 23670-30120 2 pieces
095000-672# 23670-30130 2 pieces
Rail 095440-096# 23810-30110
175800-887# 89661-25170
Engine ECU MT, 2WD
175800-888# 89661-25160

SERVICE DEPARTMENT
0610-IT-001 Printed in Japan
2

4. DTC (DIAGNOSTIC TROUBLE CODE) CHART

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
VN turbo "nozzle function
P0046 sliding abnormality (F/B Turbocharger sub-assembly ON
abnormality)"
• Open in DC motor cir-
cuit
P0047 VN turbo (motor circuit open) • Turbo motor driver ON
• Turbocharger sub-
assembly (DC motor)
• Short in DC motor cir-
cuit
P0048 VN turbo (motor circuit short) • Turbo motor driver ON
• Turbocharger sub-
assembly (DC motor)
Pressure difference
P0069 abnormality (boost pressure Engine ECU ON
- atmospheric pressure)
• Open or short in Rail
Rail pressure sensor (Fixed pressure sensor circuit
P0087 ON
Output) • Rail pressure sensor
• Engine ECU
• Supply pump (suction
control valve)
Rail high pressure
P0088 • Pressure limiter ON
abnormality
• Short in supply pump
(suction control valve)
• Fuel line between sup-
ply pump and rail
• Fuel line between rail
and each injector
• Supply pump
• Rail
P0093 Fuel leak abnormality ON
• Injectors
• Pressure limiter
• Open or short in EDU
circuit (P0200 set simul-
taneously)
• Engine ECU
• Open or short in intake
Intake air temperature air temperature sensor
P0095
sensor No. 2 (Post-Turbo No. 2 circuit
P0097 ON
P0098
Intake Air Temperature • Intake air temperature
Sensor) sensor No. 2
• Engine ECU
• Open or short in mass
P0100
air flow meter circuit
P0102 Mass airflow meter (open) ON
P0103
• Mass airflow meter
• Engine ECU
*: Malfunction Indicator Light
 3

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
Mass airflow meter (out-of-
P0101 Mass airflow meter ON
range)
• Open or short in boost
pressure sensor circuit
P0105
Boost Pressure Sensor • Boost pressure sensor
P0107 ON
P0108
(open) • Turbocharger assembly
• EGR valve assembly
• Engine ECU
Boost Pressure Sensor (out-
P0106 Boost pressure sensor ON
of-range)
• Open or short in intake
air temperature sensor
circuit
Intake air temperature
P0110 • Intake air temperature ON
sensor (open、out-of-range)
sensor (built into mass
airflow meter)
• Engine ECU
• Short in intake air
temperature sensor cir-
cuit
Intake air temperature
P0112 • Intake air temperature ON
sensor (low)
sensor (built into mass
airflow meter)
• Engine ECU
• Open in intake air
temperature sensor cir-
cuit
Intake air temperature
P0113 • Intake air temperature ON
sensor (high)
sensor (built into mass
airflow meter)
• Engine ECU
• Open or short in coolant
temperature sensor cir-
P0115
Coolant temperature sensor cuit
P0117 ON
P0118
(open) • Coolant temperature sen-
sor
• Engine ECU
Coolant temperature sensor
P0116 Coolant temperature sensor ON
(high out-of-range)
• Diesel throttle position
sensor
P0122 Diesel throttle position • Open or short in VLU
ON
P0123 sensor (open) circuit
• Open in VC circuit
• Engine ECU
Abnormally High Fuel
P0168 Fuel temperature sensor ON
Temperature
4

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• Open or short in fuel
temperature sensor cir-
P0180
Fuel temperature sensor　 cuit
P0182 ON
P0183
(open) • Fuel temperature sen-
sor
• Engine ECU
• Open or short in fuel
P0190
pressure sensor circuit
P0192 Rail pressure sensor (open) ON
P0193
• Fuel pressure sensor
• Engine ECU
Rail pressure sensor (out-of- • Fuel pressure sensor
P0191 ON
range)
• Open or short in EDU
circuit
P0200 EDU abnormality • Injector ON
• EDU
• Engine ECU
• Open or short in crank-
shaft position sensor
circuit
Crankshaft position sensor
• Crankshaft position sen-
P0335 (NE sensor) (open/phase ON
difference/power flicker)
sor
• No.1 crankshaft position
sensor plate
• Engine ECU
• Open or short in crank-
shaft position sensor
circuit
Crankshaft position sensor • Crankshaft position sen-
P0339 -
(NE sensor) (power flicker) sor
• No.1 crankshaft position
sensor plate
• Engine ECU
• Open or short in cylinder
recognition sensor circuit
Cylinder Recognition Sensor
• Cylinder recognition sen-
P0340 (TDC Sensor) (open/ phase ON
difference/ Start-up logic)
sor
• Pump drive shaft pulley
• Engine ECU
• Glow plug relay
P0380 Glow plug abnormality • Glow plug ON
• Engine ECU
 5

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• EGR valve stuck
• EGR valve does not
move smoothly
• Open or short in E-VRV
for EGR cut circuit
• E-VRV for EGR
• Open or short in VSV for
EGR cut circuit
• VSV for EGR cut
P0400 EGR, EGR-V abnormality ON
• Open or short in EGR
valve position sensor
circuit
• EGR valve position sen-
sor
• Vacuum pump
• Vacuum hose connec-
tion loose
• Engine ECU
• Open or short in EGR
valve position sensor
P0405 circuit
Lift sensor (open) ON
P0406 • EGR valve position sen-
sor
• Engine ECU
• Throttle valve stuck
• Throttle valve does not
move smoothly
• Open or short in throttle
valve circuit
Intake air throttle motor
• Open or short in throttle
P0488 control system (diesel ON
throttle valve abnormality)
valve position sensor
circuit
• Throttle position sensor
(built in diesel throttle
body assembly)
• Engine ECU
• Open or short in vehicle
speed sensor circuit
P0500 Vehicle speed sensor • Vehicle speed sensor ON
• Combination meter
• Engine ECU
• Short in stop light switch
signal circuit
P0504 Brake switch (open, short) -
• Stop light switch
• Engine ECU
6

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• Wire harness and con-
nector
P0516 Battery fluid temperature
• Battery thermal meter ON 175800-888# only
P0517 sensor (open circuit)
sensor
･ Engine ECU
• Open in back-up power
source circuit
P0560 BATT abnormality ON
• Low battery voltage
• Engine ECU
P0607 Engine ECU abnormality Engine ECU ON
• Starter relay circuit
P0617 Starter signal abnormality • Ignition switch ON
• Engine ECU
• Open in alternator cir-
cuit
Alternator duty Signal
P0622 • Alternator ON
abnormality
• Drive belt
• Engine ECU
• Open or short in suction
Supply pump abnormality control valve circuit
P0627 ON
(Open, Short) • suction control valve
• Engine ECU
• Short in supply pump
(suction valve) circuit
Supply pump abnormality
P1229 • Supply pump (suction ON
(excessive pumping)
control valve)
• Engine ECU
< Main Trouble Area >
• injector
• EDU (P0200 is set
simultaneously)
• Open or short in engine
wire harness (P0200 is
set simultaneously)
P1238 Injector injection abnormality • Connector connection ON
(P0200 is set simulta-
neously)
• Compression pressure
• Valve clearance
< Related Trouble Area >
• Valve timing
• Engine ECU
• Turbocharger sub-
P1251 VN Turbo (power flicker) ON
assembly
• Turbo motor driver
VN Turbo • Open or short in turbo
P1264 ON
(driver abnormality) motor driver circuit
• Engine ECU
 7

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• Open or short in pres-
Pressure discharge valve sure discharge valve
P1271 ON
abnormality (EDU drive) circuit
• Engine ECU
• Open or short in pres-
sure discharge valve
circuit (P1271 is set
Pressure discharge valve simultaneously)
P1272 ON
abnormality (seized closed)) • Pressure discharge
valve
• Supply pump
• Engine ECU
Multiple-point injector • Injector compensation
P1601 correction (EEPROM code ON
abnormality) • Engine ECU
Engine ECU internal IC
P1611 abnormality, RUN plus Engine ECU ON
abnormality
• VSV for swirl control
valve
P2009
Swirl control VSV • Open or short in VSV for ON
P2010
swirl control valve circuit
• Engine ECU
• VSV for swirl control
valve
• Open or short in VSV for
swirl control valve circuit
SCV (swirl control valve)
P2006 • Intake manifold (swirl ON
abnormality
control valve)
• EGR valve assembly
• Mass airflow meter
• Engine ECU
• Accelerator position
sensor
Accelerator position sensor • Accelerator pedal
P2120 ON
(open、short) • Accelerator pedal rod
(arm) deformed
• Engine ECU
• Accelerator position
Accelerator position sensor
P2121 (APP) sensor ON
(out-of-range)
• Engine ECU
8

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• Accelerator position
sensor
• Open in VCP1 circuit
• VPA1 circuit open or
Accelerator position sensor
P2122 ground short ON
(open、short)
• Accelerator pedal
• Accelerator pedal rod
(arm) deformed
• Engine ECU
• Accelerator position
sensor
• Open in EP1 circuit
• VPA1 circuit open or
Accelerator position sensor
P2123 ground short ON
(open、short)
• Accelerator pedal
• Accelerator pedal rod
(arm) deformed
• Engine ECU
• Accelerator position
sensor
Accelerator position sensor • Accelerator pedal
P2125 ON
(open、short) • Accelerator pedal rod
(arm) deformed
• Engine ECU
• Accelerator position
sensor
• Open in VCP2 circuit
• VPA2 circuit open or
Accelerator position sensor
P2127 ground short ON
(open、short)
• Accelerator pedal
• Accelerator pedal rod
(arm) deformed
• Engine ECU
• Accelerator position
sensor
• Open in EP2 circuit
• VPA2 circuit open or
Accelerator position sensor
P2128 ground short ON
(open、short)
• Accelerator pedal
• Accelerator pedal rod
(arm) deformed
• Engine ECU
 9

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• VPA1 and VPA2 circuit
are short circuited
• Accelerator position
Accelerator position sensor sensor
P2138 ON
(open、short) • Accelerator pedal
• Accelerator pedal rod
(arm) deformed
• Engine ECU
P2226 Atmospheric pressure
P2228 sensor (open, direct board Engine ECU ON
P2229 installation)
VN Turbo (opening sensor • Nozzle vane position
P2563 ON
characteristics discrepancy) sensor
• Nozzle vane position
VN Turbo (opening sensor
P2564 sensor ON
characteristics 1 open)
• Turbo motor driver
• Nozzle vane position
VN Turbo (opening sensor
P2565 sensor ON
characteristics 1 short)
• Turbo motor driver
• Nozzle vane position
VN Turbo (opening sensor
P2588 sensor ON
characteristics 2 open)
• Turbo motor driver
• Nozzle vane position
VN Turbo (opening sensor
P2589 sensor ON
characteristics 2 short)
• Turbo motor driver
• Wire harness
B2799 Engine Immobilizer System -
• Transponder key ECU
10

5. EXTERNAL WIRING DIAGRAM

5.1. ENGINE ECU EXTERNAL WIRING DIAGRAM

Main relay
111
+B
Fuse-EFI 121
MREL

12V 74
BATT
35
E1
1
E01
6 PCV
2 PCV+
E02
7
PCV-
Engine ground
128
WFSE
OBD-II check connector 129 30
SIL PRD EDU

89
CANH
DTC 90 109
CANL DM Multi Display
38
LUSL Diesel throttle drive IC
135
VCPA
134
VCP2
27
VC
+B 69
Turbo pressure sensor PIM
40 15
VCS VNTO
Accelerator position

Mass airflow Rail pressure 92

sensor sensor (main)
PCR1 VN turbo drive
8
VNTI
sensor (main)

125
VPA
+B
Rail pressure 29
sensor (sub) PCR2 13
Accelerator position

RLO
Regulator

175800- 888# only

sensor (sub)

124
VPA2
Intake air temperature
sensor 25
THIA

Coolant temperature sensor

26
position sensor
Diesel throttle

THW
57
VG
68
VLU
EGR lift sensor

64 73 Charge light
EGLS LOUT +B
Fuel temperature sensor
33
THF
Intake air temperature 175800- 888# only
sensor No. 2 31
THA

Battery fluid 117 Warning light

W +B
temperature sensor 127
THB
115 Glow indicator
175800- 888# only GIND
41 119
E2S IREL +B
34
E2
65 EDU relay
EVG
132 52
EPA2 EGR +B
133 E-VRV
EPA
114
18 GREL
NE+ Glow plug relay
Crankshaft 58
position G+ 121
MREL
sensor Main relay
Cylinder
recognition 28
NE-
sensor 66
G-
+B Ignition switch 120
IGSW +B
78
ST1- 43
77 EGRC
BATT STP EGR cut VSV
Brake switch

Q001856E
 11

108
TACH Meter
24
#4 EDU
#3 23
EDU
22
#2 EDU
#1
21 +B
EDU

10
SCV
Swirl control valve 2

76
Heater Amplifier HSW
EDU
20
95 INJF
A/C Amplifier AC1

110
A/C Amplifier THWO

94 Speed sensor
A/C Amplifier ACT
96
SPD
101
Oil moniter OILM

118
TC
17 Check connector
Alternator ALT
Stater relay 105 113
EOM
STA

Q001857E
12

5.2. ENGINE ECU CONNECTOR TERMINAL LAYOUT

(1) 175800 - 887#
34P 35P 35P 31P
1 7 35 41 70 75 105 111
E01 E02 PCV+ PCV- E1 LUSL VCS E2S EC BATT STA TACH THWO +B
VNTI SCV VNTO ALT EGRC EGR HSW STP ST1- EOM GREL GIND W TC IREL IGSW MREL
NE+ PCR1 INJF #1 #2 #3 #4 THIA THW VC VG G+ CANH CANL ACT AC1 SPD VPA2 VPA WFSE
NE- PCR2 PRD THA THF E2 EGLS EVG G- VLU PIM OILM EPA2 EPA VCP2 VCPA
28 34 62 69 97 104 130 135
Q001972E

(2) 175800 - 888#

34P 35P 35P 31P
1 7 35 41 70 75 105 111
E01 E02 PCV+ PCV- E1 LUSL VCS E2S EC LOUT BATT STA TACH THWO +B
VNTI SCV RLO VNTO ALT EGRC EGR HSW STP ST1- EOM GREL GIND W TC IREL IGSW MREL
NE+ PCR1 INJF #1 #2 #3 #4 THIA THW VC VG G+ CANH CANL ACT AC1 SPD VPA2 VPA THB WFSE
NE- PCR2 PRD THA THF E2 EGLS EVG G- VLU PIM OILM EPA2 EPA VCP2 VCPA
28 34 62 69 97 104 130 135
Q001858E

No. Pin Symbol Connections No. Pin Symbol Connections

1 E01 Power Ground 16 - -
2 E02 Power Ground 17 ALT Alternator
Crankshaft position sensor
3 - - 18 NE+
(+)
Rail pressure sensor
4 - - 19 PCR1
(main)
5 - - 20 INJF EDU
6 PCV+ Pump control valve 21 #1 EDU
7 PCV- Pump control valve 22 #2 EDU
8 VNTI VN turbo drive 23 #3 EDU
9 - - 24 #4 EDU
Intake air temperature
10 SCV Swirl control valve 25 THIA
sensor
Coolant temperature
11 26 THW
sensor
12 - - 27 VC Sensor (power supply)
Regulator Crankshaft position sensor
13 RLO 28 NE-
(175800-888# only) (-)
14 - - 29 PCR2 Rail pressure sensor (sub)
15 VNTO VN turbo drive 30 PRD ECD
 13

No. Pin Symbol Connections No. Pin Symbol Connections

Intake air temperature Cylinder recognition
31 THA 58 G+
sensor No. 2 sensor ( + )
32 - - 59 - -
33 THF Fuel temperature sensor 60 - -
34 E2 Sensor ground 61 - -
35 E1 Engine ground 62 - -
36 - - 63 - -
37 - - 64 EGLS EGR lift sensor
38 LUSL Diesel throttle drive IC 65 EVG Airflow sensor earth
Cylinder recognition
39 - - 66 G-
sensor ( - )
Rail pressure sensor (sub)
40 VCS 67 - -
power supply
Rail pressure sensor (sub) Diesel throttle valve
41 E2S 68 VLU
earth position sensor
42 - - 69 PIM Turbo pressure sensor
43 EGRC EGR cut VSV 70 EC Body ground
44 - - 71 - -
45 - - 72 - -
Charge light
46 - - 73 LOUT
(175800 - 888# only)
47 - - 74 BATT Battery ( + )
48 - - 75 - -
49 - - 76 HSW Heater idle up switch
50 - - 77 STP Brake switch
51 - - 78 ST1- Brake switch
52 EGR E-VRV 79 - -
53 - - 80 - -
54 - - 81 - -
55 - - 82 - -
56 - - 83 - -
57 VG Mass airflow meter 84 - -
14

No. Pin Symbol Connections No. Pin Symbol Connections

85 - - 111 +B Battery (main relay)
86 - - 112 - -
87 - - 113 EOM Immobilizer
88 - - 114 GREL Glow plug relay
CAN1 Communication
89 CANH 115 GIND Glow indicator
(DTC)
CAN1 Communication
90 CANL 116 - -
(DTC)
91 - - 117 W Warning light
92 - - 118 TC Check connector
93 - - 119 IREL EDU relay
94 ACT A/C amplifier 120 IGSW Ignition switch
95 AC1 A/C amplifier 121 MREL Main relay
96 SPD Vehicle speed sensor 122 - -
97 - - 123 - -
Accelerator position
98 - - 124 VPA2
sensor (sub)
Accelerator position
99 - - 125 VPA
sensor (main)
100 - - 126 - -
Battery fluid temperature
101 OILM Engine oil monitor 127 THB sensor (175800 - 888#
only)
102 - - 128 WFSE Flash programming tool
103 - - 129 - -
104 - - 130 - -
105 STA Starter Airflow 131 - -
Accelerator position
106 - - 132 EPA2
sensor (ground)
Accelerator position
107 - - 133 EPA
sensor (ground)
Accelerator position
108 TACH Meter 134 VCP2
sensor (power supply)
Accelerator position
109 DM Multi display 135 VCPA
sensor (power supply)
110 THWO A/C amplifier