Spill Valve Solenoid Electrical Fault Puzzle

[Maddox]

Hi all am new on this site,jus thought ill start it off in its own thread,have read on all the posts in hear hoping to find similar and have the following issue also posted in a similar site but need your help here too.This is relation to Toyota Estima 2.2 TD (96) which I believe has an indentical Injector pumpt to the 1KZTE Engine (some one has infact used a pump from the 1KZTE on the 3C-TE.

Here goes,I had the Injector pump replaced in my 1996 3C-TE Estima last year in April reason being the original once caused rough engine idle,http://www.youtube.com/watch?v=GPaVfb4x5j8&feature=channel&list=ULand check engine light would come on but disappear when engine was revved up.

The replacement pump arrived and was fitted in and upon turning the ignition in the 'ON' position,there there was an ODD continuous ticking sound right on the spill control valve. see video>>http://www.youtube.com/watch?v=cBuSB3SsSfU#ws

The Engine would crank but would not turn over.(no diesel coming to the injectors)
When the black wire (Earth) from the spill control valve is disconnected from the ECU feed and grounded directly to the body,the ticking sound stops and eventually Diesel comes to the injectors(bleed) and the bus starts,but the engine revs itself up to 2000 RPMs with Diesel Knock and excess whitish smoke which i presume means excess fuel presumably as a result of the valve not being correctly controlled by the ECU.

>>We first suspected that the spill control valve on the new pump was faulty and swapped it with the one on the old pump but oddly it also made the same tick sound.We also tried reconnecting the original injector pump and oddly the same happened which we found puzzling.All fuses were inspected and non were found to be playing up.We tried another ECU borrowed from the local garages breaking the same vehicle type but still no luck (we left it at that as I had to return to the UK in August 2010)

>>To further trouble shoot,I recently got another ECU (exact part number) from the UK and sent it back home but the same still happened.

Is there anyone who has ever come across such a problem as its really puzzled me including my mechanics and would this issue have to do with sensors such as a engine speed sensor or some other sensor?The wiring harness from the injector pump to the ECU has been inspected for any faults but have not found any issues.
To this day,the vehicle has never started and one back home has come across this problem
Could have the replacement injector pump cause a short some were as even swapping it back with the original one including spill valve swaps still has it ticking.

Many thanks!

 

[roscoFJ73]

Thats a difficult one and I suspect there was nothing wrong with your original pump. I think it is something electrical, maybe a sensor,but its just a guess.

Whitish smoke usually means excess air.

 

[GTSSportCoupe]

If you don't find the answers you need here, the people here http://www.toyotadiesel.com/forums/forum.php have more experience with your engine.

Also, here are the manual pdf's for your injection pump which may help you in your troubleshooting:

http://www.kovsh.com/media/library/231/V 3 P5ZGR01.pdf
http://www.kovsh.com/media/library/231/V 3 AAC02V3D.pdf

Good luck.

 

[BRIXPASCUAL]

Ikz-te rpm goes wild when spill valve connected directly to the battery

I had the same experience just yesterday with 1kz-te engine. The toyota supercustom van just arrived from a long distance travel from where it was bought. There wasn't any problem encountered along the way. The next day it used around the town the whole day. Third day went to market, turned it off upon parking. When it was started, it cranked ok at normal starting speed but wont start. Done it many times but wont start till battery drained. The driver replaced the battery with a new one but it wont start. That's the time that i was called to look for it. It was my first time to meet such electronic engine. Since there wasn't fuel coming out from the injector connector, i presumed the spill valve is not working. I tested for power going through it. No power. So i did some series connection from the battery. It started ok at first with good idle for at least 2 minutes then turned it off. When it was started the second time, the rpm went wild i think 2000 rpm with gray smoke and engine knocking. Turned it off. I said i cant fix the problem. We called another mechanic, a toyota mechanic. He did some sort of inspection and testing and said the ecu have been damaged due to the series connection that we did. I am thinking, could it be possible that i have done wrong by connecting the battery to the spill valve? Your problem maybe has something to do with the ecu. Have it inspected by a certified toyota mechanic.

 

[Maddox]

To this day problem has not been solved.Got another working ECU of the same Model Year and part number and still no luck.Decided to pull out the Injector pump to have it diagnosed or try a 3rd Injector Pump.

 

[Xena99]

To this day problem has not been solved.Got another working ECU of the same Model Year and part number and still no luck.Decided to pull out the Injector pump to have it diagnosed or try a 3rd Injector Pump.

Just crossing fingers in hopes that this has been resolved?
Unfortunately for me, I am having the same problem.
The 1KZTE was working properly then one day after a trip, it was idling nicely and then it suddenly went super wild with rpm going beyond 4K redline and so much toxic smoke! I immediately turned off the ignition in hopes of preventing damage. Upon starting it up again, it still went super wild
Initial check found the #2 and #1 wire on the turbo boost sensor connector in the engine bay got cut but when it was soldered back the engine still went wild at startup!
Every sensor on the pump was checked and likewise the other sensors on the engine. The wiring harness from the sensors going to ECU checked okay. Spill valve and timing control valve wiring was also ok. Resistance reading on both the spill valve and timing control valve solenoids were also up to spec.
ECU was swapped from a good working engine
TPS was also swapped with a known good spare
Its been two weeks now and I don't have a clue as to what is the problem.
I am just hoping that the thread owner, Maddox and BrixPascual were both able to solve the issue and I am so hoping that they could see my message and share the resolution
Desperately searching for a fix
Jim Philippines
+639189424850

 

[Xena99]

Problem solved!! SPV faulty. Case closed

 

[Nkomo]

Ikz-te rpm goes wild when spill valve connected directly to the battery

I had the same experience just yesterday with 1kz-te engine. The toyota supercustom van just arrived from a long distance travel from where it was bought. There wasn't any problem encountered along the way. The next day it used around the town the whole day. Third day went to market, turned it off upon parking. When it was started, it cranked ok at normal starting speed but wont start. Done it many times but wont start till battery drained. The driver replaced the battery with a new one but it wont start. That's the time that i was called to look for it. It was my first time to meet such electronic engine. Since there wasn't fuel coming out from the injector connector, i presumed the spill valve is not working. I tested for power going through it. No power. So i did some series connection from the battery. It started ok at first with good idle for at least 2 minutes then turned it off. When it was started the second time, the rpm went wild i think 2000 rpm with gray smoke and engine knocking. Turned it off. I said i cant fix the problem. We called another mechanic, a toyota mechanic. He did some sort of inspection and testing and said the ecu have been damaged due to the series connection that we did. I am thinking, could it be possible that i have done wrong by connecting the battery to the spill valve? Your problem maybe has something to do with the ecu. Have it inspected by a certified toyota mechanic.

Greetings sorry to take you back am having the same problem with my 1995 Toyota surf with 1kz engine.
Have no power to the Spill valve, ha checked all fuse, they seem to be OK.