05–547

DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004) 05M58–02

DTC P0200/97 INJECTOR CIRCUIT / OPEN

HINT:
S For more information on the EDU, refer to the system description (see page 05–422).
S If P0200/97 is present, refer to the ”Diagnostic Trouble Codes (DTCs) Table for Common Rail System”
(see page 05–547).
CIRCUIT DESCRIPTION
The EDU has been adopted to drive the injectors at high speeds. The EDU delivers high–speed driving under
highly–pressurized fuel conditions using the DC/DC converter that provides a high–voltage, and the quick–
charging system.
Soon after the EDU receives an injection command (IJT) signal from the ECM, the EDU responds to the com-
mand with an injector injection confirmation (IJF) signal when the current is applied to the injector.

EDU Wiring Diagram

EDU
COM3

From DC/DC COM2

Battery Converter

Maximum 150 V
Command
Pulse
COM1

Injector

IJT#1 INJ#1
IJT#4 INJ#4
ECM
IJT#2 Control INJ#2
IJT#3 Circuit INJ#3
INJF (IJF)

Confirmation
Pulse

GND

EDU Connector

I5 I6

Warning: Terminals I, H, K, L, M, N are high voltage

G38712
05–548
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

DTC No. DTC Detection Condition Trouble Area

Open or short in EDU or injector circuit S Open or short in EDU circuit
After engine is started, there is no IJF signal from EDU to S Injector
P0200/97
ECM, despite ECM sending IJT signal to EDU S EDU
(1 trip detection logic) S ECM

MONITOR DESCRIPTION
P0200/97 (Open or short in EDU or injector circuit):
The ECM continuously monitors both injection command (IJT) signals and injection confirmation (IJF) sig-
nals. This DTC will be set if the ECM judges that the number of IJT signals and IJF signals are inconsistent.
The injectors are grounded over a Field Effect Transistor (FET) and a serial resistor. This resistor creates
a voltage drop, which is monitored by the EDU (injector drive circuit), in relation to the current drawn by the
injector. When the injector current becomes too high, the voltage drop over the resistor exceeds a specified
level and no IJF signal for that cylinder is sent to the ECM.
P0200/97 refers to a malfunction in the EDU or injector circuit.
If this DTC is set, the ECM enters fail–safe mode and limits the engine power. The fail–safe mode continues
until the engine switch is turned OFF.
Malfunction Detection:
Command Signal (IJT)
ECM EDU
Confirmation Signal (IJF)

ON
Injection
OFF
Command Signal IJT
Injection Abnormal
Confirmation Signal IJF

A81495
Y
Normal G37535

MONITOR STRATEGY
Required sensors IJF signal from EDU
Frequency of operation Continuous
Duration 10 seconds
MIL operation 1 driving cycle

TYPICAL ENABLING CONDITIONS

Specification Specification
Item Minimum Maximum
Engine speed Engine is running (except engine start) –
Battery voltage 11 V –
Ignition switch ON ON

TYPICAL MALFUNCTION THRESHOLDS

Threshold
The injection missing counter* for all the cylinders, or for one individual cylinder, reaches a specified number (taking approximately 1 second from
starting the engine)
*: Increments when no IJF signal is received from the EDU despite the ECM sending IJT signals
 05–549
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

WIRING DIAGRAM
J22 ECM
(*1) (*2) J/C
10 C4 1
B B B
IM4 IC4 E14 +B
C C
Engine Room R/B C17 8
W–G W–G
B IC4 E14 MREL
2
B EF1 Relay J/C
D D D D 2
L L
L J22 J23 J22 J23 E15 BATT
2
5 3 (*1) (*2) (*1) (*2)
W–B A5 10
2 2 B–W B–W
2 1 IC4 E14 IREL
C/OPN or EDU Relay EDU 7 25
B BR
2 2 IJF E4 E17 INJF
1 2
6 24
B B–W #1
2 2 IJT#1 E4 E17
B 5 3
3 23
L #2
EF1 IJT#2 E4 E17
L B
2 1 2 2 22
1 2 R–L
B IJT#3 E4 E17 #3
5 21
8 C8 Y
IJT#4 E4 E17 #4
L L
IM4 IC4
(*1) (*2) I6
4 Injector 1
W B
W–B (*3) INJ#1 E3
2 1
5
COM1 E3
I9
B 2 EB1 3 Injector 4
J2 BR
INJ#4 E3
J/C 1 EB1
B B
B BR
I7
2 Injector 2
(*3) P L
INJ#2 E3
2 1
8
COM2 E3
W–B B I8
1 Injector 3
Y L
INJ#3 E3
BR 8 2 2
E3 +B
E
1
W–B W–B
GND E4
E
EB Battery
EG *1: LHD EF J11
*2: RHD J/C
*3: Shielded
G38697
05–550
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

PULSE GENERATION INSPECTION

HINT:
Problem areas can be located by checking the waveform at the following terminals.

Warning: Terminals COM1, COM2, and INJ#1 to 4 are high–voltage High–voltage Area

ECM EDU

INJF D C IJF COM2

COM1 Injector

#1 IJT#1 INJ#1

#4 IJT#4 INJ#4
A B
#2 IJT#2 INJ#2

#3 IJT#3 INJ#3

A81508

HINT:
In order to save time during the inspection, follow these instructions. When checking the ECM side first, in-
spect the trouble areas listed to the right of A to D (in that order).
Malfunction Point Trouble Area
A ECM
B (if A is normal) Open or short in ”#1 to #4 (ECM)” – ”IJT#1 to IJT#4 (EDU)” harness or connector
S Open or short in ”INJ#1 to INJ#4 (EDU)” – ”COM1 and/or COM2” (EDU) circuit
C (if A and B are normal) S Injector
S EDU
D (if A, B and C are normal) Open or short in ”INJ (EDU)” – ”INJF (ECM)” circuit

Signal Waveform (a) Reference:

Inspection using an oscilloscope.
#1 While idling the engine, the correct waveform is shown in
the diagram on the left.
#3 5 V/
Inspection Points Specified Condition
Division
A and B Correct waveform is shown
#4

#2
20 msec./Division A09438
 05–551
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

(b) Reference:
Signal Waveform
Inspection using an oscilloscope.
While idling the engine, the correct waveform is shown in
the diagram on the left.
2 V/
INJF Inspection Points Specified Condition
Division
C and D Correct waveform is shown

20 msec./Division A09437

INSPECTION PROCEDURE
HINT:
Read freeze frame data using the intelligent tester II. Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was
running or stopped, if the engine was warmed up or not, and other data from the time the malfunction oc-
curred.
1 INSPECT INJECTOR ASSY

(a) Disconnect the I6, I7, I8 and I9 injector connectors.

(b) Measure the resistance of the injector.
Injector Assy
Standard:
Tester Connection Specified Condition
2 1 1–2 0.85 to 1.05 Ω at 20_C (68_F)

NG REPLACE INJECTOR ASSY (See page 11–52)

A81503

OK
05–552
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

2 CHECK WIRE HARNESS (EDU – INJECTOR ASSY)

Wire Harness Side (a) Check the wire harness between the injector and EDU
(INJ terminal).
I6 (1) Disconnect the I6, I7, I8 and I9 injector connectors.
I7 (2) Disconnect the E3 EDU connector.
1 2 (3) Measure the resistance of the wire harness side
I8
I9 connectors.
Injector Standard:
Tester Connection Specified Condition
I6–2 – E3–4 (INJ#1) Below 1 Ω
I7–2 – E3–2 (INJ#2) Below 1 Ω
E3
I8–2 – E3–1 (INJ#3) Below 1 Ω
EDU
I9–2 – E3–3 (INJ#4) Below 1 Ω
INJ#2 INJ#4 INJ#1 COM1 I6–1 – E3–5 (COM1) Below 1 Ω
I7–1 – E3–6 (COM2) Below 1 Ω
I8–1 – E3–6 (COM2) Below 1 Ω
I9–1 – E3–5 (COM1) Below 1 Ω
I6–2 or E3–4 (INJ#1) – Body ground 10 kΩ or higher
I7–2 or E3–2 (INJ#2) – Body ground 10 kΩ or higher
INJ#3 COM2
A80992
I8–2 or E3–1 (INJ#3) – Body ground 10 kΩ or higher
A84815 A99847
I9–2 or E3–3 (INJ#4) – Body ground 10 kΩ or higher
I6–1 or E3–5 (COM1) – Body ground 10 kΩ or higher
I7–1 or E3–6 (COM2) – Body ground 10 kΩ or higher
I8–1 or E3–6 (COM2) – Body ground 10 kΩ or higher
I9–1 or E3–5 (COM1) – Body ground 10 kΩ or higher

NG REPAIR OR REPLACE HARNESS AND

CONNECTOR

OK
 05–553
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

3 CHECK WIRE HARNESS (EDU – ECM)

Wire Harness Side (a) Disconnect the E4 EDU connector.

E4 (b) Disconnect the E17 ECM connector.
EDU (c) Measure the resistance of the wire harness side connec-
IJF
tors.
Standard:
Tester Connection Specified Condition
E4–6 (IJT#1) – E17–24 (#1) Below 1 Ω
IJT#3 IJT#2 IJT#4 IJT#1 E4–3 (IJT#2) – E17–23 (#2) Below 1 Ω
E4–2 (IJT#3) – E17–22 (#3) Below 1 Ω
E4–5 (IJT#4) – E17–21 (#4) Below 1 Ω
E4–7 (IJF) – E17–25 (INJF) Below 1 Ω
E4–6 (IJT#1) or E17–24 (#1) – Body ground 10 kΩ or higher
E17
E4–3 (IJT#2) or E17–23 (#2) – Body ground 10 kΩ or higher

#2 E4–2 (IJT#3) or E17–22 (#3) – Body ground 10 kΩ or higher

E4–5 (IJT#4) or E17–21 (#4) – Body ground 10 kΩ or higher
INJF
#4 E4–7 (IJF) or E17–25 (INJF) – Body ground 10 kΩ or higher

#1
#3
A80994
A80456 A99849 NG REPAIR OR REPLACE HARNESS AND
CONNECTOR

OK

4 CHECK INJECTOR DRIVER (BATTERY VOLTAGE)

Wire Harness Side (a) Disconnect the E3 and E4 EDU connectors.

(b) Turn the ignition switch ON.
BATTERY (+) (c) Measure the voltage of the wire harness side connectors.
Standard:
E3 Tester Connection Specified Condition
EDU E3–8 (BATTERY) – E4–1 (GND) 9 to 14 V

GND (–)

E4
EDU

A81845
A80994 NG CHECK INJECTOR DRIVER POWER SOURCE
A99850 CIRCUIT (BATTERY – EDU)

OK
05–554
DIAGNOSTICS – ECD SYSTEM (1KD–FTV)(From August, 2004)

5 CHECK ECM (INJECTOR VOLTAGE)

(a) While idling the engine, check the waveform of the ECM
connectors using an oscilloscope.
E17 E16 Standard:
INJF
Tester Connection Specified Condition
E17–24 (#1) – E16–7 (E1) Correct waveform is shown
E17–23 (#2) – E16–7 (E1) Correct waveform is shown
E17–22 (#3) – E16–7 (E1) Correct waveform is shown
#1 #2 #3 #4 E1 E17–21 (#4) – E16–7 (E1) Correct waveform is shown
E17–25 (INJF) – E16–7 (E1) Correct waveform is shown

#1

#3 5 V/
Division
#4

#2
20 msec./Division

2 V/
INJF
Division

A66060
A09438
A09437 20 msec./Division
A99851 NG REPLACE ECM (See Pub. No. RM990E, page
10–34)

NOTICE:
After replacing the ECM, allow for ECM learning start the
engine and idle it until it is fully warmed up.
OK

6 REPLACE INJECTOR DRIVER

NEXT

CHECK IF DTC OUTPUT RECURS (DTC P0200/97)

HINT:
After clearing the DTC, start the engine and let it idle for 30 seconds. Confirm that P0200/97 is not output
again.