96 FJ80 not running CAT and EGR monitors

[KricianD]

I am a tech at a foreign shop working on a 96 Toyota LandCruiser. This one needs to be smogged and the customer was failed for readiness incomplete for CAT and EGR. This is a CA vehicle. Tail pipe readings were great but the CAT and EGR monitors was a automatic fail. The customer has drove 300+ miles with the drive cycles for the FZ1-FE in hand since then, brought it back to me and the monitors are still not ready. I drive it with the drive cycle for 200 miles for a week and still not ready either. I fire up TechStream and find no fault codes, I drove monitoring the front and rear oxygen sensors to determine if it has a bad CAT, the rear oxygen sensor was reading a smoothed curve while the front was spiky which shows the CAT is doing it's job.. I don't know why it won't run. As for the EGR, I test the valve with a vacuum pump while off, it holds vacuum, I run the engine and test again, kills/lowers the idle which is correct, test the modulator according to the service manual, found good, test the vsv, works and the internal plunger is good. Just to see if I may have a ECU problem, I swap the ECU from a 97 that I had from my personal vehicle, run the drive cycles again and same thing, only CAT and EGR won't complete, the others complete right away. No codes. Just for checking, I also tried the EGR bypass relay, clicks as it should with the resistors tricking the ECU on EGR temps (showing on TechStream live data) yet it still did not complete the monitor with the bypass.

 

[KricianD]

I just noticed right now my phone kept auto correcting the year to 95, the vehicle is a 96***

 

[KricianD]

I may have a solution to this.... Drove 3k miles total, drive cycle correct every drive. It bugged me last night remembering seeing the OBD1 port on the firewall.. Come this morning, I go to open the cover of the OBD1 port and guess what- Someone left the pins jumped with a paperclip......... back to square 1.

 

[PDoyle]

A 96 FZJ80 has an OBDII port not OBD1. Which pins were jumped?

 

[KricianD]

A 96 FZJ80 has an OBDII port not OBD1. Which pins were jumped?

"DIAGNOSTIC" port on the firewall in the engine bay, Passenger side. Pins E1 and TE1 had a paperclip jumpering it and the cover closed. OBD2 port is ontop of the driver fusebox.

 

[LC4LIFE]

"DIAGNOSTIC" port on the firewall in the engine bay, Passenger side. Pins E1 and TE1 had a paperclip jumpering it and the cover closed. OBD2 port is ontop of the driver fusebox.

Someone was probably adjusting the timing and forgot to remove the jumper.

 

[Wompom]

There's a protocol in the FSM to get the monitors to ready faster than just driving it aimlessly around.
I can't find it right now, but it exists. I went from 0 ready to all in one night of doing the drives as outlined. It was like 5 min at 40-45mph, 5 min at x mph, etc.
Some I had to attempt a few times to get to establish as ready. It can be tricky even when there are no mechanical faults to get them to status as ready.

 

[KricianD]

There's a protocol in the FSM to get the monitors to ready faster than just driving it aimlessly around.
I can't find it right now, but it exists. I went from 0 ready to all in one night of doing the drives as outlined. It was like 5 min at 40-45mph, 5 min at x mph, etc.
Some I had to attempt a few times to get to establish as ready. It can be tricky even when there are no mechanical faults to get them to status as ready.

As I stated, I drove using the FSM drive cycle. The 3k miles were all driven using the drive cycle. I also used "Check Mode" drive cycle. I am going to take the vehicle again tonight, hopefully it was all due to the jumper in the OBD1 port.

 

[PDoyle]

How many miles on the truck? is the exhaust newer?

 

[KricianD]

Success! After removing the forgotten jumper, within 5 miles of the drive cycle, the check engine light came on and had EGR Insufficient flow. Seems like after I tested the EGR system in the first post, the vacuum line from Modulator to the EGR valve tore underneath. Quick fix. Cleared codes, another 5 miles of drive cycle and all readiness monitors have completed. So the main problem was- when driving with the OBD1 port being jumpered for "Codes read" mode, the OBD2 will never run it's monitors/ never set any DTC's because theoretically it is being reset every key cycle/ every time a fault DOES happen. This vehicle was a tough one because using Techstream, it shows for each readiness monitor what actual values have been captured during each monitor's test and what the specification should be. With the CAT and EGR not completing, it DOES show the actual values captured and they were IN spec.

 

[mingles]

There's a protocol in the FSM to get the monitors to ready faster than just driving it aimlessly around...

See attached for Monitor Drive Cycles. '96-'97 FZJ80s are on page 11-12 for the EGR and CAT monitors.

FWIW - Even after all other monitors were READY, I had to log over 600 miles, following the drive cycles religiously, for my CAT monitor to finally go READY.

 

[KricianD]

See attached for Monitor Drive Cycles. '96-'97 FZJ80s are on page 11-12 for the EGR and CAT monitors.

FWIW - Even after all other monitors were READY, I had to log over 600 miles, following the drive cycles religiously, for my CAT monitor to finally go READY.

Thank you, but I do not want to keep repeating myself that I DID used the FSM drive cycle. All I can say is I invite anyone else to try- Jumper the OBDI port, create a fault in the EGR system, and go drive. Let me know if you're able to log a DTC and if you're able to complete the CAT and EGR monitor.

 

[mingles]

^^^. Understood you followed the drive cycle

My point in posting the actual document is so that others that turn up this thread in a search have some official documentation to refer to.

 

[Wompom]

As I stated, I drove using the FSM drive cycle. The 3k miles were all driven using the drive cycle. I also used "Check Mode" drive cycle. I am going to take the vehicle again tonight, hopefully it was all due to the jumper in the OBD1 port.

And as i stated sometimes it takes a few tries. Just cause you think you followed the proper drive cycle doesn't mean the ECU agrees. Just trying to lend a hand. Next time i'll just give ya a .

Glad you got it sorted. It can be a pain.

 

[Tools R Us]

I think the point of the thread is, readiness wont happen in test mode, E1 and TE1 shorted. This is true, can drive however, for as long as you want, and it will never happen.

 

[ISFFUN]

I know I'm bumping a crazy old thread, but just wanted to say this post saved my life today! Went through the same thing - EGR / cat monitors not ready on a 1997 Lexus SC300. Replaced all O2s, fixed exhaust leak, replaced thermostat, ran Toyota/Lexus FSB procedures numerous times (400+ miles) - turns out I forgot to unplug the jumper when I did my timing belt last year. Unplugged, went for a drive and monitors completed!

TY KricianD!!!!