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 1KZ ECU fault/ECD relay

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grimpanda
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Home City : East Gippsland, VIC
Registration date : 2013-03-18

PostSubject: 1KZ ECU fault/ECD relay   Fri Apr 24, 2015 2:16 am

Hi everyone,

I'm troubleshooting a KZH106 with a suspected ECU/ECM problem and have a couple of questions.
Looking on this forum it seems to be a common problem, but not always the same cause. Hopefully this thread may be of help to others with similar problems in the future.

The fault:
When the key is turned to ON, there is usually a constant ticking audible from near the injection pump. I haven't been able to put my finger on exactly what makes this noise (i.e: i can hear but not feel the tick).

At the same time, often (but not always) the SPL relay in the passenger footwell will tick on and off sporadically, along with one other relay which I'm yet to identify/find, but suspect is the ECD relay. (see Questions below)

When the car is in this state it will crank, fire once, and then stall.

Sometimes the van just seems to snap out of it. All of the ticking will stop, and it will start with relative ease and idle/run for a time, but billows putrid-smelling white smoke under throttle, and then always stalls, accompanied with the return of the ticking IP and relays. The longest it has run is about a 30 seconds.

Questions

1.)
Where is the ECD relay? There is nothing labeled as such on either of the relay/fuse blocks in the driver or passenger footwells.

2.)
Is it generally safe to swap an ECU from an identical model Super Custom into my van for testing? I have access to another working van which has the same ECU (89661-26180 A/T with 26p 16p 12p configuration), but don't want to risk cooking it if the fault is related to a dodgy relay/sensor or other electrical fault. One dead van is bad enough.

Cheers,
Gabe
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grimpanda
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PostSubject: Re: 1KZ ECU fault/ECD relay   Fri Apr 24, 2015 9:36 am

Bit of an update:
The ECU's I have access to might not be identical after all.

Both mine and the one I've got access to (out of a 1993 KZH106) are labeled 89661-26180, but have an additional identifying number.

1996 model: 175800-1346 12V
1993 model: 175800-1343 12V

They both have the same harness configuration of 26p, 16p, 12p, but have some differences in how they are wired at the harness - mainly the odd different coloured wire, and the occasionally missing/additional one.

If anyone with experience can lend their opinion I'd be very grateful... I'd really like to be able to swap the ECU's over and confirm the fault before sending mine off for repair.
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grimpanda
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PostSubject: Re: 1KZ ECU fault/ECD relay   Mon Apr 27, 2015 1:46 am

Alrighty... Progress.

Opened up the ECU and found two leaky capacitors and a section of corroded trace nearby.
I'll be repairing this as soon as I can get my hands on the components and will report back.
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gonzo1963
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Model and year : 1995 SC Limited 3.0L TD 4WD
Registration date : 2011-07-11

PostSubject: Re: 1KZ ECU fault/ECD relay   Sat Jul 11, 2015 3:00 am

Grimpanda, Burnt Caps on the ECU Mainboard is a common problem with these ECU's. I had the same problem. Started out with it cutting out and restarting after 10 minutes, then ran for 5 km then cut out. Finally it got to the stage of Starting, running for about 2-3 seconds then cutting out.
After some research I come across a place in Sydney that does ECU Repairs. Only cost $215 (Including Freight) to be fixed. Fixed the problem straight away. Very fast Turn Around of 2 business days. Sent on a Wednesday, fixed and returned by the Friday.
I highly recommend them.

Here are the details of the place.

SPECIALISED AUTOMOTIVE ELECTRONICS
12/10 Foundry Rd
Seven Hills NSW 2147
Ph: 0423 399 286

E-Mail: enquiry@autoelctronics.com.au

Web: www.autoelectronics.com.au

Hope this helps.

Cheers
Geoff.
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grimpanda
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PostSubject: Re: 1KZ ECU fault/ECD relay   Sun Jul 12, 2015 7:52 am

Hi Geoff,

Thanks for the reply.
I've been a bit slack reporting back on my progress.

I recorded the capacitor values and ordered replacements from RS components. I have a good soldering iron, and replaced them myself. I used isopropyl alcohol to clean the leaked electrolyte from the PCB, and then tidied things up with a fibreglass pen. Fortunately the PCB trace had not corroded through, so no repairs were needed, though I was prepared to do this.

It's worth noting that not all Super Custom ECUs are equal. At our household we currently have 3 (yes, three) SC's - a 1993, a 1996 and a 1997. They all have slightly different ECU's. The 1993 and 1996 have the same pin configuration, but different coloured wiring looms, and the 1997 has a totally different configuration.

After swapping the caps over the van now starts first crank and purrs like a kitten.

Here's a pic of the culprit caps. Only these two had leaked, but I replaced all of them to future-proof things a little.



Oh, and lastly, here's a list of the capacitor values if anyone needs to replace theirs, but I'd recommend double-checking your ECU as it COULD be different.

Main board:
C008: 220uF 10v (~6mm)
C006: 100uF 10v (5mm)
C402: 1uF 50v BP (5mm)
C425: 220uF 50v (10mm)
C424: 100uF 50v (8mm)
C211: 3.3uF 50v (4mm)
C001: 47uF 63v (8mm)
C003: 33uF 35v (4mm)

Secondary board
C601: 100uF 10v (5mm)
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SlowAce
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Model and year : 1993 SC 3.0L TD. 4wd
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PostSubject: Re: 1KZ ECU fault/ECD relay   Thu Jul 16, 2015 10:04 am

Good to see you got it sorted. I had my upgrade van for about a month and it started cutting out soon after starting on idle. It did that for about a month and then stated cutting out while driving. It became very dangerous as sometime during a corner it would cut out and loose all power...start heading straight in a bend!
Lucky it was under warranty and got it repaired.
Faulty ECU - leaking capacitors ,
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dobstar0039
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Model and year : 1994 Hiace Super Custom Limited 4x4
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PostSubject: Re: 1KZ ECU fault/ECD relay   Mon Apr 04, 2016 1:13 pm

Hey all, sorry to keep this thread going after such a long time, but mine has just died and I need help. I have a 1994 SC that has the same issue, van will crank but not start, and has ticking noise coming from injector pump area, if you keep the key turned she will go to start, but not run. This happened on her maiden flight after having the rear main seal, suspension, and a heap of underside bushes replaced. I didn't even get to make it home. So back to topic, after reading through countless amounts of info both here and else where, I believe it to be the ECU fault as you describe above, can you please tell me where the ECU is in these vans (with pics if possible), and is it hard to get out? as I am a mechanical nightmare. Any help would be great thanks in advance.
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grimpanda
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PostSubject: Re: 1KZ ECU fault/ECD relay   Fri Apr 08, 2016 3:37 pm

Hi Dobstar,

The ECU is located in the passenger side door pillar (i.e: right next to the front passenger seat). Fairly easy to get to - you need to undo the lower seatbelt retaining bolt (14mm) and the little plastic catch (that holds up the engine bay cover) in order to remove the plastic trim/cover. You might need to raise up the engine bay cover/seat in order to get to these.

I don't have any photos, but there are three electrical connections to the ECU - make sure to pull on the connectors and not on the cables themselves.

Good luck.
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dobstar0039
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PostSubject: Re: 1KZ ECU fault/ECD relay   Sat Apr 09, 2016 10:24 pm

Hi grimpanda,

Thanks for the help, will have a look today once I get the fuel tank back in. I hope that this fixes the the issue and I get get the old girl running again.
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dobstar0039
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PostSubject: Re: 1KZ ECU fault/ECD relay   Thu Apr 14, 2016 11:40 am

G'gay all,

Just wanted to give an update on the old girl, got the ECU out and took it in to Townsville Electronics, $25 later and $2 for the capacitor from Solex, she is know up and running and ready to be tested tomorrow after work.

I would just like to thank you all for having this post up still, so people to get the help they need.
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JT69
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PostSubject: Re: 1KZ ECU fault/ECD relay   Fri Dec 09, 2016 1:13 pm

Well ECU seems to be a issue on SCs pulled mine out to check caps everything pristine as new refitted it, would not start prior to this, so tried it and started first time can only conclude there was a bad connection on one off the plug pins. Electronics are great when they work.
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GPW
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Model and year : Model: KD-KZH100G-MRPGT
Year: 1996
Colour: 4K1
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Registration date : 2016-07-16

PostSubject: Re: 1KZ ECU fault/ECD relay   Fri Dec 09, 2016 5:42 pm

johntidmarsh wrote:
Well ECU seems to be a issue on SCs pulled mine out to check caps everything pristine as new refitted it, would not start prior to this, so tried it and started first time can only conclude there was a bad connection on one off the plug pins. Electronics are great when they work.  

I had a look at mine (175800-1336) the other day and it look fine too, from what I could see (there is a board in the way but what I could see was pristine, and had conformal coating on it too.

I do wonder if there were a couple of suppliers, one of whom went with the problem caps of the era, the other that used Japanese caps only.

BTW I added this pic in case anyone else wanted to find theirs.

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PostSubject: Re: 1KZ ECU fault/ECD relay   Mon Aug 28, 2017 12:40 am

I just wanted to bump this to say thanks. Was pulling my hair out trying to figure out why it wouldn't start with the exact same injector pump ticking and then found this. Replaced all the caps and she's perfect! Top blokes you lot.

For what it's worth at a glance my capacitors looked perfect. Upon desoldering them though 4 were leaking at the bottom. There was a slight discoloration on one side of the board from one of the leaky ones too, but was quite hard to see.
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GPW
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PostSubject: Re: 1KZ ECU fault/ECD relay   Mon Aug 28, 2017 9:55 am

Nuzzie wrote:
I just wanted to bump this to say thanks. Was pulling my hair out trying to figure out why it wouldn't start with the exact same injector pump ticking and then found this. Replaced all the caps and she's perfect! Top blokes you lot.

For what it's worth at a glance my capacitors looked perfect. Upon desoldering them though 4 were leaking at the bottom. There was a slight discoloration on one side of the board from one of the leaky ones too, but was quite hard to see.

Glad anything I posted helped!
Interesting about the caps looking fine until unsoldered, one to remember so maybe a winter project there to replace just in case,
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