00400576E

SERVICE BULLETIN
FUEL INJECTION PUMP
ECD06-07E
NEW PRODUCTS Sep, 2006
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT: TOYOTA IMV 1KD-FTV/ 2KD-FTV ENGINE COMMON RAIL SYSTEM

1.OUTLINE
This bulletin describes the common rail system used in the TOYOTA IMV 1KD-FTV/2KD-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
1KD-FTV 3.0 L Europe, Australia
IMV August, 2006
2KD-FTV 2.5 L Europe,

3. APPLICABLE PRODUCT LIST

Part Name DENSO Part Number Manufacturer Part Number Remarks
Supply Pump (HP3) 294000-036# 22100-30040
095000-676# 23670-30140 1KD-FTV
Injector (G2 type)
095000-677# 23670-30150 2KD-FTV
095440-095# 23810-30100 1KD-FTV
Rail
095440-055# 23810-30090 2KD-FTV
MA175800-873# 89661-0KC70 Australia, 1KD-FTV, MT, 2WD
MA175800-874# 89661-0KC40 Australia, 1KD-FTV, MT, 4WD
MA175800-876# 89661-0KC80 Australia, 1KD-FTV, AT, 4WD
MA175800-875# 89661-0KC50
Europe, 1KD-FTV, MT, 4WD
RB175800-892# 89661-0KC60
Engine ECU MA175800-877# 89661-0KC90
Europe, 1KD-FTV, AT, 4WD
RB175800-893# 89661-0KD00
MA175800-878# 89661-0KD30
MA175800-879# 89661-0KD10
Europe, 2KD-FTV, MT, 2WD
RB175800-894# 89661-0KD40
RB175800-895# 89661-0KD20

SERVICE DEPARTMENT
0607-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
1KD-FTV (VN turbo)
P0046 sliding abnormality (F/B Turbocharger sub-assembly ON
only
abnormality)"
• Open in DC motor cir-
cuit
1KD-FTV (VN turbo)
P0047 VN turbo (motor circuit open) • Turbo motor driver ON
only
• Turbocharger sub-
assembly (DC motor)
• Short in DC motor cir-
cuit
1KD-FTV (VN turbo)
P0048 VN turbo (motor circuit short) • Turbo motor driver ON
only
• 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 MAF
meter)
• Engine ECU
• Short in intake air
temperature sensor cir-
cuit
Intake air temperature
P0112 • Intake air temperature ON
sensor (low)
sensor (built into MAF
meter)
• Engine ECU
• Open in intake air
temperature sensor cir-
cuit
Intake air temperature
P0113 • Intake air temperature ON
sensor (high)
sensor (built into MAF
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 1KD-FTV only
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
• Open or short in glow
plug circuit
P0380 Glow plug abnormality
• Glow fuse
ON
• Glow plug relay
• Glow plug
• 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 MT only
speed sensor circuit "if cruise-speed sensor
Vehicle speed sensor
• Vehicle speed sensor abnormality is
"or cruise-speed sensor
P0500 • Combination meter ON detected, a cruise
abnormality (Refer to
• Engine ECU indicator turns on, but
Remarks)".
MIL does not turn on
(1KDFTV, AT only)".
• Wire harness and con-
nector
Vehicle speed sensor (power • Vehicle speed sensor 1KD-FTV, AT only
P0503 -
flicker, noise) • Engine ECU cruise indicator ON
• Combination meter and
gauge system
6

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• Short in stop light switch
signal circuit
P0504 Brake switch (open, short) -
• Stop light switch
• Engine ECU
• Open in back-up power
source circuit
P0560 BATT abnormality ON
• Low battery voltage
• Engine ECU
• Wire harness and con-
Stop light switch (open, nector 1KD-FTV, AT only
P0571 -
short) • Stop light switch cruise indicator ON
• Engine ECU
1KD - FTV Only
"When cruise system
related (Cruise stop
Engine ECU abnormality light switch, cruise
"or cruise system related cancel and cruise
P0607 Engine ECU ON
abnormality (Refer to system) abnormality is
Remarks)". detected, a cruise
indicator turns on, but
MIL does not turn on
(AT only)".
• 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
 7

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
< 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 1KD-FTV only
assembly
• Turbo motor driver
VN Turbo • Open or short in turbo
P1264 ON 1KD-FTV only
(driver abnormality) motor driver circuit
• Engine ECU
• Open or short in pres-
Pressure discharge valve sure discharge valve
P1271 ON 1KD-FTV only
abnormality (EDU drive) circuit
• Engine ECU
• Open or short in pres-
sure discharge valve
circuit (P1271 is set
Pressure discharge valve simultaneously)
P1272 ON 1KD-FTV only
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
8

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• 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
• 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
 9

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• 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
• 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)
• VSV for EGR cooler
bypass valve
P245C EGR cooler bypass actuation • Open or short in VSV for
ON
P245D VSV open EGR cooler bypass
valve circuit
• Engine ECU
VN Turbo (opening sensor • Nozzle vane position
P2563 ON 1KD-FTV only
characteristics discrepancy) sensor
• Nozzle vane position
VN Turbo (opening sensor
P2564 sensor ON 1KD-FTV only
characteristics 1 open)
• Turbo motor driver
• Nozzle vane position
VN Turbo (opening sensor
P2565 sensor ON 1KD-FTV only
characteristics 1 short)
• Turbo motor driver
• Nozzle vane position
VN Turbo (opening sensor
P2588 sensor ON 1KD-FTV only
characteristics 2 open)
• Turbo motor driver
• Nozzle vane position
VN Turbo (opening sensor
P2589 sensor ON 1KD-FTV only
characteristics 2 short)
• Turbo motor driver
10

DTC Code
Detection Item Trouble area MIL* Remarks
(SAE Code)
• Wire harness
B2799 Immobilizer -
• Transponder key ECU
• Wire harness and con-
nector (CANH, CANL
signal)
U0101 CAN 通信 ON 1KD-FTV, AT only
• Transmission control
computer
• Engine ECU
 11

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

91
CAN+ 1KD-FTV only
ECT 92 109
CAN- DM Multi Display
A/T only LUSL
38
Diesel throttle drive IC
135
VCPA
134
VCP2 15
27 VNTO
VC
69 VN turbo drive
+B Turbo pressure sensor PIM 8
40 VNTI
VCS
1KD-FTV only
Accelerator position

Mass airflow Rail pressure 92

PCR1
sensor sensor (main)
sensor (main)

125
VPA

Rail pressure 29
sensor (sub) PCR2
Accelerator position

1KD-FTV 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 Cruise indicator
EGLS PI +B
Fuel temperature sensor
33
THF
Intake air temperature A/T only
sensor No.2 31
THA
117 Warning light
Cruise control switch
126 W +B
CCS
115 Glow indicator
A/T only GIND
41 119
E2S IREL +B
34
E2
65 EDU relay
EVG
132 52
EPA2
133 EGR +B
EPA E-VRV
114
18 GREL
NE+ Glow plug relay
Crankshaft 58
position G+
sensor
+B
Cylinder
recognition 28
NE- 42
sensor 66 ECBV
G- EGR cooler bypass VSV
+B Ignition switch 120 43
IGSW EGRC
EGR cut VSV
78
ST1-
77
BATT STP
Brake switch

Q001847E
12

+B 108
TACH Meter
24
#4 EDU
82 CLSW/D 23
#3 EDU
D switch 22
#2 EDU
106 21
NSW #1 EDU +B
Neutral start switch
SCV
11
Swirl control valve
1KD-FTV only 10
SCV2
76 Swirl control valve 2
A/C Amplifier HSW
95 1KD-FTV only
A/C Amplifier AC1
110 EDU
A/C Amplifier THWO 20
INJF
94
A/C Amplifier ACT
101
Oil moniter OILM
102
Immobilizer IMI
103 Speed sensor
Immobilizer IMO 96
SPD
79
Viscous Amplifier VCH
72
Viscous Amplifier VCT

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

Q001848E

5.2. ENGINE ECU CONNECTOR TERMINAL LAYOUT

(1) 1KD-FTV AT (MA175800 - 876#, - 877#, RB175800 - 893#)
34P 35P 35P 31P
1 7 35 41 70 75 105 111
E01 E02 PCV+ PCV- E1 LUSL VCS E2S VCT PI BATT STA NSW TACH DM THWO +B
VNTI SCV SCV2 VNTO ALT ECBV EGRC EGR HSW STP ST1- VCH CLSW/D EOM GREL GIND W TC IREL IGSW MREL
NE+ PCR1 INJF #1 #2 #3 #4 THIA THW VC VG G+ CAN+ CAN- ACT AC1 SPD VPA2 VPA CCS WFSE SIL
NE- PCR2 PRD THA THF E2 EGLS EVG G- VLU PIM OILM IMI IMO EPA2 EPA VCP2 VCPA
28 34 62 69 97 104 130 135
Q001849E

(2) 1KD-FTV MT (MA175800 - 873#, - 874#, - 875#, RB175800 - 892#)

34P 35P 35P 31P
1 7 35 41 70 75 105 111
E01 E02 PCV+ PCV- E1 LUSL VCS E2S VCT BATT STA TACH DM THWO +B
VNTI SCV SCV2 VNTO ALT ECBV EGRC EGR HSW STP ST1- VCH EOM GREL GIND W TC IREL IGSW MREL
NE+ PCR1 INJF #1 #2 #3 #4 THIA THW VC VG G+ ACT AC1 SPD VPA2 VPA WFSE SIL
NE- PCR2 PRD THA THF E2 EGLS EVG G- VLU PIM OILM IMI IMO EPA2 EPA VCP2 VCPA
28 34 62 69 97 104 130 135
Q001850E

(3) 2KD-FTV (MA175800 - 878#, -879#, RB175800 - 894#, -895#)

34P 35P 35P 31P
1 7 35 41 70 75 105 111
E01 E02 PCV+ PCV- E1 LUSL VCT BATT STA TACH DM THWO +B
SCV ALT ECBV EGRC EGR HSW STP ST1- VCH EOM GREL GIND W TC IREL IGSW MREL
NE+ PCR1 INJF #1 #2 #3 #4 THIA THW VC VG G+ ACT AC1 SPD VPA2 VPA WFSE SIL
NE- THA THF E2 EGLS EVG G- VLU PIM OILM IMI IMO EPA2 EPA VCP2 VCPA
28 34 62 69 97 104 130 135
Q0001851E
 13

No. Pin Symbol Connections No. Pin Symbol Connections

1 E01 Power Ground 23 #3 EDU
2 E02 Power Ground 24 #4 EDU
Intake air temperature
3 - - 25 THIA
sensor
Coolant temperature
4 - - 26 THW
sensor
5 - - 27 VC Sensor (power supply)
Crankshaft position sensor
6 PCV+ Pump control valve 28 NE-
(-)
Rail pressure sensor (sub)
7 PCV- Pump control valve 29 PCR2
(1KD-FTV only)
VN turbo drive (1KD-FTV
8 VNTI 30 PRD ECD (1KD-FTV only)
only)
Intake air temperature
9 - - 31 THA
sensor No. 2
10 SCV Swirl control valve 32 - -
Swirl control valve 2 (1KD-
11 SCV2 33 THF Fuel temperature sensor
FTV only)
12 - - 34 E2 Sensor ground
13 - - 35 E1 Engine ground
14 - - 36 - -
VN turbo drive (1KD-FTV
15 VNTO 37 - -
only)
16 - - 38 LUSL Diesel throttle drive IC
17 ALT Alternator 39 - -
Rail pressure sensor (sub)
Crankshaft position sensor
18 NE+ 40 VCS power supply (1KD-FTV
(+)
only)
Rail pressure sensor Rail pressure sensor (sub)
19 PCR1 41 E2S
(main) ground (1KD-FTV only)
20 INJF EDU 42 ECBV EGR cooler bypass VSV
21 #1 EDU 43 EGRC EGR cut VSV
22 #2 EDU 44 - -
14

No. Pin Symbol Connections No. Pin Symbol Connections

45 - - 69 PIM Turbo pressure sensor
46 - - 70 - -
47 - - 71 - -
48 - - 72 VCT Viscous Amplifier
49 - - 73 PI Cruise indicator (AT only)
50 - - 74 BATT Battery ( + )
51 - - 75 - -
52 EGR E-VRV 76 HSW Heater idle up switch
53 - - 77 STP Brake switch
54 - - 78 ST1- Brake switch
55 - - 79 VCH Viscous Amplifier
56 - - 80 - -
57 VG Mass airflow meter 81 - -
Cylinder recognition
58 G+ 82 CLSW/D Shift position D (AT only)
sensor ( + )
VN turbo drive (1KD-FTV
59 VNTO 83 - -
only)
60 - - 84 - -
61 - - 85 - -
62 - - 86 - -
63 - - 87 - -
64 EGLS EGR lift sensor 88 - -
Mass airflow sensor
65 EVG 89 - -
ground
Cylinder recognition
66 G- 90 - -
sensor ( - )
CAN2 communication
67 - - 91 CAN +
(ECT) (AT only)
Diesel throttle valve CAN2 communication
68 VLU 92 CAN -
position sensor (ECT) (AT only)
 15

No. Pin Symbol Connections No. Pin Symbol Connections

93 - - 115 GIND Glow indicator
94 ACT A/C amplifier 116 - -
95 AC1 A/C amplifier 117 W Warning light
96 SPD Vehicle speed sensor 118 TC Check connector
97 - - 119 IREL EDU relay
98 - - 120 IGSW Ignition switch
99 - - 121 MREL Main relay
100 - - 122 - -
101 OILM Engine oil monitor 123 - -
Accelerator position
102 IMI immobilizer 124 VPA2
sensor (sub)
Accelerator position
103 IMO immobilizer 125 VPA
sensor (main)
Cruise control switch (AT
104 - - 126 CCS
only)
105 STA Starter Airflow 127 - -
106 NSW Clutch switch (AT only) 128 WFSE Flash programming tool
VN turbo drive (1KD-FTV
107 VNTO 129 SIL Serial communication
only)
108 TACH Meter 130 - -
109 DM Multi display 131 - -
Accelerator position
110 EHWO A/C amplifier 132 EPA2
sensor (ground)
Accelerator position
111 +B Battery (main relay) 133 EPA
sensor (ground)
Accelerator position
112 - - 134 VCP2
sensor (power supply)
Accelerator position
113 EOM Immobilizer 135 VCPA
sensor (power supply)
114 GREL Glow plug relay - - -