00400086E

SERVICE BULLETIN
FUEL INJECTION PUMP
ECD04-02E
NEW PRODUCTS September, 2004
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT : TOYOTA LAND CRUISER PRADO 1KD Common Rail system

1. Outline
This bulletin describes the common rail system used in the Toyota Land Cruiser Prado 1KD.
The contents of the basic system are the same as in "Common Rail System for TOYOTA
HILUX / KIJYANG INNOVA / INNOVA 1KD / 2KD" (OPERATION MANUAL No.00400077).
The system outline and the changed locations are explained here.

2. Applicable Vehicle Model and Pump Part Numbers

Vehicle Engine
Vehicle Name Engine Displacement Start of Production
Model Model
LAND CRUISER Since September,
KDJ120/125 1KD-FTV 3.0L
PRADO 2004

3. PRODUCT APPLICATION LIST

Vehicle DENSO Part TOYOTA Part
Part Name Remarks
Name Number Number
Supply Pump 294000 - 0380 22100 - 30050 HP3
Injector (With gasket) 095000 - 5890 23670 - 39135 For supply
Injector (With out gasket) 095000 - 5740 23670 - 30080
Made by
Rail another -
manufacturer
• Rail Pressure Sensor 499000 - 6080 89458 - 60010
• Pressure Discharge Valve 294290 - 0051 23990 - 30020
LAND 175800 - 7251 89661 - 6A350
CRUISER Engine ECU
PRADO 175800 - 7242 89661 - 6A330
EDU 101310 - 5371 89870 - 60060
Water Temperature Sensor 179700 - 0451 89422 - 33030
Crankshaft Position Sensor
029600 - 1151 90919 - 05050
(NE Sensor)
Cylinder Identification
029600 - 1160 90919 - 05052
Sensor (TDC Sensor)
Accelerator Pedal Module 198800 - 3020 78120 - 60350
Turbo Pressure Sensor 079800 - 7470 89421 - 71020

SERVICE DEPARTMENT
0409-IT-342 Printed in Japan
2

4. System Configuration
The configuration of the common rail system for the 1KD is shown below.
Fuel Temperature Sensor
Engine Speed
Accelerator Opening EDU
Intake Air Pressure,
Atmospheric Air Pressure Engine ECU
Intake Air Temperature
Coolant Temperature
Crankshaft Angle
Cylinder Recognition Sensor
Intake Airflow Rate
Pressure
Rail Discharge
Valve Injector
Rail Pressure
Sensor
Check
Valve
Fuel Filter

Fuel Temperature Sensor SCV

Supply Pump (Suction
Control Valve) Fuel Tank
Q000991E

5. Changed Points
5.1. Rail
(1) General Description
The rail used in the 1KD engine is made by another manufacturer.
A pressure discharge valve and rail pressure sensor are mounted on the rail.

Rail pressure Relief passage

sensor

#1 #2 #3 #4
OUT OUT IN OUT OUT

Pressure discharge
valve

QD2349E
 3

(2) Pressure Discharge valve

The pressure discharge valve controls the fuel pressure of the rail.
If the fuel pressure in the rail rises above the target injection pressure, or if the ECU judges it to
have risen above the target value, the solenoid coil is energized. This opens the valve pas-
sage, leaking fuel to the fuel tank and lowering the pressure to the target injection value.

Solenoid Coil to Fuel Tank

Armature Spring

Q000992E

5.2. DTC (DIAGNOSTIC TROUBLE CODE) CHART

DTC Code 175800 -
DTC 7241 7251 Detection Item
SAE Code
No. A/T M/T
P0045 34 With With VN turbo (open circuit)
P0087 49 With With Rail pressure sensor (Fixed output)
Pump valve malfunction
P0088 78 With With
(high-pressure in rail)
P0093 78 With With Fuel leak malfunction
Intake air temperature sensor
P0095 / P0097 / P0098 23 With With
(Post-turbo intake air temperature sensor)
P0100 / P0102 / P0103 31 With With Air flow meter (Open circuit)
Turbo pressure sensor
P0105 / P0107 / P0108 35 With With
(Open circuit inspection)
Atmospheric temperature sensor
P0110 / P0112 / P0113 24 With With
(Out-of-range)
P0115 / P0117 / P0118 22 With With Water temperature sensor (Open circuit)
P0168 39 With With High fuel pressure abnormality
P0180 / P0182 / P0183 39 With With Fuel temperature sensor (Open circuit)
Rail pressure sensor With back-up sensor
P0190 / P0192 / P0193 49 With With
(Open circuit)
4

DTC Code 175800 -

DTC 7241 7251 Detection Item
SAE Code
No. A/T M/T
Rail pressure sensor with back-up sensor
P0191 49 With With
(out-of-range)
P0200 97 With With EDU malfunction
P0234 34 With With VN turbo (closed-side malfunction)
P0299 34 With With VN turbo (open-side malfunction)
Crankshaft position sensor
13 With With (open circuit / phase difference, power
P0335 flicker)
12 With With Crankshaft position sensor (open circuit)
Crankshaft position sensor
P0339 13 With With
(NE power flicker)
Camshaft position sensor
With With
(open circuit, phase difference)
P0340 12
Camshaft position sensor
With With
(open circuit, start-up logic)
P0400 71 With With EGR system malfunction
P0405 / P0406 96 With With Lift sensor (open circuit)
Intake air restriction motor control system
P0488 15 With With
(electronic throttle malfunction)
P0500 42 With With Vehicle speed sensor
P0504 51 With With Brake switch (open circuit, short)
P0607 89 With With CPU malfunction
Pump valve malfunction
P0627 78 With With
(open circuit, short)
Pump valve malfunction
P1229 78 With With
(excessive pressure)
P1251 34 With With VN turbo (phase difference)
P1271 78 With With Pressure limiter malfunction (EDU drive)
Pressure limiter malfunction
P1272 78 With With
(closed-side malfunction)
Injector multiple-point correction
P1601 89 With With
(EEPROM malfunction)
Internal IC malfunction
P1611 17 With With
RUN pulse malfunction
P2008 58 With With SCV malfunction
 5

DTC Code 175800 -

DTC 7241 7251 Detection Item
SAE Code
No. A/T M/T
P2120 / P2122 / P2123 /
Accelerator position sensor
P2125 / P2127/ P2128 / 19 With With
(open circuit, short)
P2138
Accelerator position sensor
P2121 19 With With
(out-of-range)
Atmospheric pressure sensor
P2226 / P2228 / P2229 A5 With With
(open circuit, direct board installation)
With
U0001 A2 With CAN communication malfunction
out
B2799 99 With With Immobilizer (2-line separate type)
P0500 21 With With Vehicle speed sensor (open circuit)
Vehicle speed sensor
P0503 23 With With
(noise, power flicker)
P0571 52 With With Stop light switch (open circuit, short)
With With Stop light switch input circuit malfunction
54
P0607 With With Cancel circuit malfunction
56 With With System circuit malfunction
6

5.3. ECU
(1) External Wiring Diagram
a. Wiring Diagram (1)

Main Relay
EFI PCV
+B
MREL PCV +

PCV –
BATT EDU
E1 PRD
E01
E02 Drive Monitor
Automatic Transmission Vehicles Only
WFSE DM
ECT
CAN + DC Motor Driver (For Turbo)
CAN – VNTO
DIAGNOSIS VNTI
CANH
CANL
VCPA
VCP2
VC

+B Turbo Pressure PIM Cruise Indicator Light

Sensor
VCS PI +B
Airflow Rail Pressure
Sensor (Main)

RCR1
Sensor Sensor (Main) MIL
Accelerator

VPA W +B

Rail Pressure Glow Indicator Light

Sensor (Sub) RCR2
Sensor (Sub)

GIND
Accelerator

VPA2
Intake Air Temperature Sensor

THIA
Coolant Temperature Sensor
EGR Lift Sensor

THW EDU Relay

VG IREL +B
EGLS
Fuel Temperature Sensor

THF
Intake Air Temperature Sensor E-VAV
(Built-In Airflow Meter)
EGR +B
THA
Glow Relay
Cruise Control Switch CCS
GREL
E2S
E2
EVG MREL Main Relay
EPA2
EPA

Q000993E
 7

b. Wiring Diagram (2)

Engine Speed Sensor

NE +

EGR Cut-Off VSV +B

EGRC
Cam Position Sensor G+
NE –
TACH Meter
+B #4 EDU
G– #3 EDU
IGSW IGSW #2 EDU
ST1 – #1 EDU
BATT STP Swirl Control Valve +B
Brake Switch Manual Transmission Vehicles Only
SCV
+B
Clutch Switch
Active Mountain VSV
CLSW
ACM
Throttle Full Switch
THOP
EDU
P/S Oil Pressure Switch INJF
PSW

Automatic Transmission Vehicles Only

Neutral Start Switch Vehicle Speed Sensor

SPD
NSW

Manual Transmission Vehicles Only

L4 Switch Test Terminal
L4M TC

Heater Idle-Up Switch

HSW
AC1
A/C Amplifier
A/C Amplifier THWO
+B
A/C Amplifier ACT LU+A
Immbirazer ECU IMI
LU–A
Immbirazer ECU IMO

Viscous Amplifier VCH LU+B

Viscous Amplifier VCT
LU–B
Alternator ALT
Step Motor
(For Electronically Controlled Throttle)
Starter Relay
STA

Q000994E
8

(2) Connector Terminal Layout

a. 175800-7241
34P 35P 35P 31P
1 7 35 41 70 75 105 111

28 34 62 69 97 104 130 135

Q000995E

b. 175800-7251-
34P 35P 35P 31P
1 7 35 41 70 75 105 111

28 34 62 69 97 104 130 135

Q000996E

No. Code Terminal Description No. Code Terminal Description

1 E01 Power Ground 22 #2
2 E02 (Engine Ground) 23 #3 EDU
3 - - 24 #4
Intake Air Temperature
4 - - 25 THIA
Sensor (Intake Manifold)
5 - - 26 THW Coolant Temperature Sensor
6 PCV+ 27 VC Sensor Power Supply
Pump Control Valve Crankshaft Position Sensor
7 PCV- 28 NE-
(-)
8 VNTI Turbo Driver 29 PCR2 Rail Pressure Sensor (Sub)
9 - - 30 PRD EDU
Intake Air Temperature
10 SCV Swirl Control Valve 31 THA
Sensor (Airflow Meter)
11 LU+A 32 - -
Step Motor
12 LU-A 33 THF Fuel Temperature sensor
(for Electronically Controlled
13 LU+B 34 E2 Sensor Ground
Throttle)
14 LU-B 35 E1 Ground (Engine Ground)
15 VNTO VN Turbo Driver 36 - -
16 THOP Full Throttle Switch 37 - -
17 ALT Alternator 38 - -
Crankshaft Position Sensor
18 NE+ 39 - -
(-)
Rail Pressure Sensor (Sub)
19 PCR1 Rail Pressure Sensor (Main) 40 VCS
Power Supply
Rail Pressure Sensor (Sub)
20 INJF 41 E2S
EDU Ground
21 #1 42 ACM Active Mount VSV
 9

No. Code Terminal Description No. Code Terminal Description

43 EGRC EGR Cut-Off VSV 77 STP
Stop Light Switch
44 - - 78 ST1-
45 L4M L4 Switch 79 VCH Viscous Amplifier
46 - - 80 - -
47 - - 81 - -
48 - - 82 CLSW Clutch Switch
49 - - 83 - -
50 - - 84 - -
51 - - 85 - -
52 EGR E-VRV 86 - -
53 - - 87 - -
54 - - 88 - -
55 - - 89 CANH CAN1 Communication
56 - - 90 CANL (Diagnosis)
57 VG Airflow Meter 91 CAN+
CAN2 Communication
Cylinder Recognition (ECT)
58 G+ 92 CAN-
Sensor (+) (TDC Sensor)
59 - - 93 - -
60 - - 94 ACT
Air Conditioning Amplifier
61 - - 95 AC1
Vehicle Speed Sensor
62 - - 96 SPD
(Meter)
63 - - 97 - -
64 EGLS EGR Lift Sensor 98 - -
65 EVG Airflow Meter (Ground) 99 - -
Cylinder Recognition
66 G- 100 - -
Sensor (-) (TDC Sensor)
67 - - 101 - -
68 - - 102 IMI
Immobilizer ECU
69 PIM Intake Air Pressure Sensor 103 IMO
70 - - 104 - -
Power Steering Hydraulic
71 PSW 105 STA Starter Relay
Pressure Switch
72 VCT Viscous Amplifier 106 NSW Neutral Start Switch
73 PI Cruise Indicator 107 - -
74 BATT Battery (+) 108 TACH Tachometer
75 - - 109 DM Multi-Display
76 HSW Heater Idle-Up Switch 110 THWO Air Conditioning Amplifier
10

No. Code Terminal Description No. Code Terminal Description

Accelerator Position
111 +B Battery (+) Main Relay 124 VPA2
Sensor (Sub)
Accelerator Position
112 - - 125 VPA
Sensor (Main)
113 - - 126 CCS Cruise Control Switch
114 GREL Glow Relay 127 - -
115 GIND Glow Indicator Light 128 WFSE Flash Write Tool
116 - - 129 - -
117 W MIL 130 - -
118 TC Test Terminal 131 - -
119 IREL EDU Relay 132 EPA2 -
120 IGSW Ignition Switch 133 EPA -
Accelerator Position
121 MREL Main Relay 134 VCP2 Sensor Power Supply
(Sub)
Accelerator Position
122 - - 135 VCPA Sensor Power Supply
(Main)
123 - - - - -