Practical Worksheet

CRS
System Diagnosis

TOYOTA HIACE

< 2KD-FTV Engine>

Company Name:

Name: DENSO Singapore Training Center

DENSO Corporation
Installed Locations
of Component Parts

Parts Chk Parts Chk Parts Chk Parts Chk Parts Chk
Crankshaft Common-rail Turbo charger Injector DLC3 connector
Position
Sensor(NE)

Cylinder Common-rail ECU EDU Acceleration

Identification Pressure sensor
Sensor(G) Sensor

Supply pump Pressure EGR Valve Electronic -------

Limiter Throttle

SCV(Supply Water TDCL Airflow -------

Pump) Temperature Connector meter
Sensor

Fuel Intake E-VRV(EGR) Intake --------

Temperature Temperature Pressure
Sensor Sensor Sensor

1
1)Check the fuel flow along the fuel pipe routing.
Fuel Fuel Feed Supply Commo
Injector
Tank Filter Pump Pump n Rail
(inside supply pump) Pressure Limiter

Overflow

2) Complete the fuel pipe routing by connecting the

components shown below.

3.Intake system inspection

1)Verify the intake air passages and related
components.
Air Turbo Electronic EGR Intake
Cleaner Charger Throttle Valve Port

Intake
Airflow VN Turbo Temperature Intake
Meter Motor Pressure
Sensor
Sensor

2
 4. Parts Unit Characteristics Check
1) Using an engine bench, measure the resistance of the following parts, and inscribe the results.

Measurement Location Measurement Result

A. Measure the resistance of the ①Measurement terminals:

cylinder identification sensor(G) G1+G1-(cylinder identification)
(cam position sensor).
Standard Approx. 2 to 2.4kΩ
value (at 20)
B. Measure the resistance of Measured
the crankshaft position value
KΩ
sensor(NE).
Speed Sensor System (Magnetic Pickup)

②Measurement terminals:
NE+⇔NE-(crank position)
Standard Approx.2 to 2.4kΩ
value (at 20)
Measured
value KΩ

[Wiring Diagram]

C. Measure the resistance of SCV

Standard Approx. 1.2 to 2.0Ω
Value
Measured SCV Ω
value
Supply Pump

SCV
amperage 12V / Ω= A

d. How many amperes of current

flows to the SCV?

3
 Measurement Location Measurement Result
E. Measure the resistance of the
water temperature sensor.

Water temperature
Temperature Sensor System (Thermistor Type)

kΩ
sensor measured
value Approx. 0
C
※Estimate the temperature from the
conversion table indicated below.
F⑤ Measure the resistance of
the fuel temperature sensor.

Fuel temperature kΩ
sensor measured
value Approx. 0
C

G⑥ Measure the resistance of the

intake temperature sensor and the
air temperature sensor.

Intake temperature
sensor(THA) kΩ
measured value Approx. 0
C

Air temperature
sensor(THAF) kΩ
measured value Approx. 0
C

[Resistance⇔Temperature Conversion Table] [Writing Diagram]

Resistance Temperature

Approx. 25KΩ 200 C

Approx. 17KΩ 300 C

Approx. 1.1KΩ 400 C

Standard
value Approx. 820Ω 500 C

Approx. 600Ω 600 C

Approx. 430Ω 700 C

Approx. 300Ω 800 C

4
 Measurement Location Measurement Result
H ⑦ Measure the resistance of the *Measure the fourth cylinder on the
injector(TWV). engine bench.
Measurement terminals: TWV terminals
Standard Approx. 2.2 to 3.2 Ω
value
Measured Ω
value
Injector

Correction
resistor Ω/№

The No. will be indicated by the

instructor.

I⑧ Measure the resistance between Measurement terminals:

the terminals of the acceleration VA(VPA2)⇔(EP2)
sensor.
Pedal Standard Measured
*Disconnect the ECU and measure Position value value
the resistance at the switch box
Release Approx. 1.3Ω Ω
terminals.
Acceleration Sensor

Depressed Approx. 3Ω Ω

[Wiring Diagram]

VPA1

VPA2

5
5.Input/Output Voltage Measurement
1)Measure the voltage between the following terminals under the respective
conditions.
(Unit: V)
Key On 1,500rpm
Measurement Part (terminal name) (E/G stop) Idling
Power source voltage +B & E1 (v)
Sensor power source(VC) VC& E １
Crankshaft Position Sensor NE+ &NE-
(NE)
Cylinder Identification G+ & G1-
Sensor(G)
Water Temperature Sensor THW & E2 THW open
circuit
Fuel Temperature Sensor THF & E2
Intake Temperature Sensor THA & E2
Acceleration Sensor VPA2&EP2
Common-Rail Pressure PCR & E2
Sensor
Intake Pressure Sensor PIM & E2
(turbo pressure)
Injector Correction Sensor RINJ1 &E2
(No.1 Cylinder)
Airflow Meter VG & EVG
Throttle Full Open Switch THOP & E1

6
 6.Input/Output Signal Measurement
1)Observe the input/output signal waveforms of the following parts.

Practical Lesson Item Measurement Result

A. Measure the crankshaft position NE+  NE-

sensor (NE) signal during idling.

Affix
(A1) Read the following voltage.
NE signal: Vp-p ( )V

2mS 1:SIG1 2V AUTO 1:SIG1

RUN 2:SIG2 2V LEVEL +01.40V

B Measure the cylinder G1+  G1-

NE Sensor/G Sensor

identification sensor (G) signal

during idling.

(1)Measure the following

Affix
voltage.
G signal: Vp-p ( )V

2mS 1:SIG1 2V AUTO 1:SIG1

RUN 2:SIG2 2V LEVEL +01.40V

C Measure the crankshaft position NE+  NE-

sensor(NE) signal and the G1+  G-
cylinder identification sensor (G)
signal during idling at two
symptoms.
(1)Verify the positional relationship between

Affix
the NE missing wave and the G surplus
wave during one revolution of the engine.

20mS 1:SIG1 5V AUTO 2:SIG2

RUN 2:SIG2 2V LEVEL +01.40V

D Measure the signals of PCV

SCV Actuation Signal

PCV+ ⇔PCV-
during idling.

2ms 1:SIG1 5V AUTO ↑2 ： SIG2

RUN 2 ： SIG2 2V LEVEL +01.40V

7
 Practical Lesson Item Measurement Result
#1  E01
E Observe the relationship between
the #1 & # 2 signal waveforms,and #2  E02
confirm the pilot & main injection.

Affix
Injection Timing and Failure Signal

5mS 1:SIG1 2V SIGNAL  2:SIG2

RUN 2:SIG2 2V LEVEL 00.78V

F Observe the relationship between IJT  E01

the #1(IJT #1) INJF (IJF) signal INJF  E02
waveforms, which pertain to
injector actuation, at two
symptoms.

Affix
(F1)Verify the timing when the respective
signals are generated and their voltage.
Read the voltage of #1 (IJT #1).
( ) v to ( ) v
Read the voltage of INJF (IJF). 500US 1:SIG1 2V SIGNAL 1:SIG1
( ) v to ( )v RUN 2:SIG2 2V LEVEL +01.71V
G Measure the actuation INJ#1  E01
waveforms of INJ1 (injector) INJT#1  E2
during idling.

*Measure at the EDU output terminals.

Injector Actuation

Affix
(1)Verify the relationship between the pilot
injection and the main injection, as well as
Current
Waveforms

the state of the current control. control

Pilot Main
injection injection
[The upper end of the peak voltage will be
cut because the maximum value that 20mS 1:SIG1 2V SIGNAL 1:SIG2
appears on the display is 70V.] RUN 2:SIG2 2V LEVEL +02.00V

8
 Practical Lesson Item Measurement Result
H Observe the “acceleration sensor [Common-Rail Pressure Sensor]
VPA1  EP1
signal” and the following signals at
two symptoms. PCR  E2
Acceleration Signal and Sensor Outputs

(H1)Acceleration signal and common-rail

pressure sensor signal

(H2)Acceleration signal and intake pressure

Affix
sensor signal
(H3)Acceleration signal and airflow ( intake air
volume ) signal
500mS 1:SIG1 1V AUTO 2:SIG2
・ Verify the output voltage of the sensors that RUN 2:SIG2 2V LEVEL +00.00V
change along with the acceleration
opening(engine speed).
VPA1  EP1 [Intake Pressure Sensor] VPA1  EP1 [Airflow Signal]
PIM  E2 VG  EVG
Affix

Affix
500mS 1:SIG1 1V AUTO ↑2:SIG2 500mS 1:SIG1 1V AUTO 2:SIG2
RUN 2:SIG2 500mV LEVEL RUN 2:SIG2 1V LEVEL +00.00V
+00.00V
9 Observe the actuation waveforms
Throttle Motor Actuation Signal

LU+  E01
of the electric throttle motor LU-  E02
( D throttle)

(1)Measure the D throttle actuation

Affix
waveforms at the instant the engine is
stopped ( as the throttle becomes actuated
in the fully closed direction).

500mS 1:SIG1 10V AUTO 2:SIG2

RUN 2:SIG2 10V LEVEL +00.00V

9
7.ECU DATA MONITOR

E/G 2KD-FTV
2001

E/G Stop Idling 1500rpm

Key SW On
E/G Coolant Temperature (THW) C
0

I- M Absolute Pressure (MAP) kPa

E/G Speed (ESPD) rpm
Vehicle Speed(SPD1) km/h
Intake Air Temperature (THA) C
0

Air Flow Meter (MAF) g/sec

Injection QTY.(QFIN) Q
Injection Timing (AACT) CA
Fuel Temperature (THF) C
0

Accelerator Pendal(APA) C
0

Throttle Step(ETSM) step

Common Rail Pressure(CRP) MPa
Final Target Amp.(PVA) mA
Pilot 1 Injection Duration(PLFM) μsec
Pilot 2 Injection Duration(PLFO) μsec
Main Injection Duration(PLFS) μsec
Post Turbo Intake Temp.(THAF) C
0

Cyl Injection Revision Q

(#1)(QCY1)
Cyl Injection Revision Q
(#2)(QCY2)
Cyl Injection Revision Q
(#3)(QCY3)
Cyl Injection Revision Q
(#4)(QCY4)

10
 8.Failure Verification Experiment
1) Examine the ECD data when open and short circuits are occurring at the following
sensors.
[Create open and short circuits by operating the switch box.]

Sensor Name(terminal name) Open Circuit Short Circuit Significant changes in engine
Data Data condition

Water Temperature Sensor THW

Intake Temperature Sensor THIA

Fuel Temperature Sensor THF

Common-Rail Pressure PCR

Sensor

2) Verify the changes in the engine when an open circuit occurs at the following
terminals.
[Create an open circuit by operating the switch box.]
*To revert to normal after an open circuit, stop the engine for 5 seconds or longer; then, perform the following
experiment.( It will not revert to normal if the main relay is ON.)

Open Circuit Operation Engine Condition DTC Code

Terminal Part Name Engine stalling, stability, vibration, etc. Acceleration

Name rpm
Open circuit
before start
NE+ Crankshaft Position
Sensor Open circuit
after start

G+ Cylinder Identification Open circuit

Sensor before start

Open circuit
after start

#1( IJT# 1) No.1 cylinder injection Open circuit aft

signal er start

#1( IJT#1) No.1 and 2 cylinder Open circuit aft

injection signals er start
#2( IJT#2)

LU+A Electronic Throttle Open circuit aft

Motor er start
LU-A

VPA1 Acceleration Sensor Open circuit aft

er start
VPA2

PCR Common-Rail Pressure Open circuit aft

Sensor er start

PCV Intake Regulation Open circuit aft

Valve er start

INJF Injection Fail Signal Open circuit aft

er start

11
3) Verify that the engine sound changes while raising the engine speed slowly
( idle to approx. 2,500 rpm).

1) Pilot injection occurs → pilot injection stops

Speed when engine sound changes [approx. rpm]

12