4hk1 - Engine Manual - TM PDF [PDF]

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65722_Maegaki 10.12.16 6:15 PM ページ 1



This Workshop Manual deals only with the screen toned section(s) in the table below.



Section ENGINE



ETM



0 14A 15B 15C 15D 15E 1A 1B 1C 1D 1E 1F 1G 1H 1J -



Sub Section Introduction Service Information Guide Maintenance Information Functional Inspection Sympton DTC Information Engine Control Mechanical Fuel System Cooling Lubrication Induction Exhaust Aux. Emission Control Devices Electrical Using the Wiring Diagram Engine Location Diagram Connector list



65722_Maegaki 10.12.16 6:15 PM ページ 2



Introduction (All) 0-1



Introduction Introduction (All) Table of Contents Introduction........................................................................0-2 Safety Information.........................................................0-2



0-2 Introduction (All)



Introduction Safety Information Repair work Safety Information



1. 1.



Use an engine stand when demounting the engine from the equipment. Be sure not to place the engine directly on the ground or allow the oil pan to come into contact with the ground.



2.



When performing a procedure with two or more people, make sure to ensure each other's safety.



3.



When repairing the electrical system, make sure to disconnect the cable from the negative (-) battery terminal before working. Keep fire away when removing the battery cover.



9.



2.



4.



Do not leave the engine running for an extended period of time or perform painting in a poorly ventilated working environment.



5.



Make sure to use only the special tools if the procedure requires them for the work. Performing the procedure using other tools may cause damage to parts or personal injury.



6.



Inspect the tools, instruments, and special tools regularly, and prepare them before working. Do not use tools such as a wrench that has lost its edges, a hammer with frayed edges, or a chipped chisel.



7.



When performing work using a device such as a grinder, crane or welder, make sure to pay sufficient attention to the handling precautions. Wear work clothes and safety equipments in the other operations as well.



8.



Be sure to check that there is no fuel leaks when performing maintenance on fuel systems.



When handling volatile materials, be extremely careful to not let them catch fire. Also make sure to wipe away any oil that sticks to rubber parts, as it can cause deterioration. Replacement parts and parts number Safety Information



1.



Whenever disassembly is performed, make sure to replace the packing, oil seals, O-rings, crimping lock nuts, bending lock plate, and split pins, etc., with new ones.



2.



Since the part numbers indicated in this manual may differ from the supply system and are subject to change, make sure to check the supply system and part numbers in the parts catalog.



Service Information Guide (All) 14A-1



Description General Information Service Information Guide (All) Table of Contents Contents included in service information.....................14A-2 Plastic gauge..................................................................14A-4 Recommended liquid gasket.........................................14A-6 Thread locking adhesive agent......................................14A-8 Term..............................................................................14A-9 Abbreviations .............................................................14A-10 Standard bolts..............................................................14A-14



14A-2 Service Information Guide (All)



Contents included in service information 1.



Precautions Includes the content-specific maintenance precautions.



Contents included in service information Removal Includes the removal procedure for repairing parts and devices, etc.



Disconnection Includes the disconnection method for wirings and pipings.



Installation Includes the installation procedure for repairing parts and devices, etc.



Connection Includes the connection method for wirings and pipings.



Disassembly Includes the disassembly procedure for performing an overhaul of a unit or assembly part, etc.



Setting Includes the setting method if necessary when replacing the ECM, etc.



Assembly Includes the assembly procedure for performing an overhaul of a unit or assembly part, etc.



Replacement Includes the replacement method for parts, oil, grease, etc. DTC priority Includes the DTC priority according to each code.



Inspection Includes the inspection items for the parts that particularly require inspection to ensure the performance of parts or devices, etc. Includes the standard values, set values, and limits for use of parts if they have these specifications set.



Diagnosis Includes the diagnostic procedure for checking the cause of the symptom. DTCs are listed in order of priority. Checking to see if the symptom has been resolved Includes the diagnostic procedure for when it is necessary to check whether the symptom is resolved by a method other than checking if the DTC has been cleared (such as checking numerical values, etc.).



Cleaning Includes the cleaning procedure for parts and devices, etc. Preparation Includes the necessary preparations before removing parts and devices, etc.



Description of the function Includes detailed information on functions for function inspection.



Adjustment Includes the adjustment method when adjustments to set values or standard values have to be made when performing assembly or installation.



Description of the symptom Includes detailed information on symptoms for diagnosis according to symptoms.



Measurement Includes the measuring method when checking if parts are installed at the proper locations, etc.



DTC description　Includes circuit description for DTC.



Discharge Includes the discharging method for oil, grease, etc.



Setting condition Includes information for DTC setting conditions.



Supply Includes the adding method for oil, grease, etc.



Action taken when DTC is set Includes information on the controlling operation taken by ECU, etc. when DTC is set.



Air removal Includes the air removal method if necessary when replacing oil, grease, etc. Inscription Includes the inscription method if necessary when replacing the ECM or supply pump.



Contents regarding ETM Contents regarding ETM is included in “Using the wiring diagram”. 2.



Arrows and symbols



Service Information Guide (All) 14A-3



1. 2. 3. 4. 5. 6. 7. 8.



Vehicle front Upper Operating section or operating direction Detail on a section Detailed view from the direction of A Arrow indicates measurement Arrow indicates cross-section Outside air or cold air



9. Gas or warm air 10. Mixing of outside air and gas, or cold air and warm air 11. Rotation direction 12. Oil feeding 13. Lubrication 14. Application area of liquid gasket



14A-4 Service Information Guide (All)



Plastic gauge 1.



Using the plasti-gauge Type PG・ (Green) PR・ (Red) PB・ (Blue)



Measurable range ： 0.025 to 0.076 mm { 0.00098 to 0.00299 in } ： 0.051 to 0.152 mm { 0.00201 to 0.00598 in } ： 0.102 to 0.229 mm { 0.00402 to 0.00902 in }



Method for measuring the gap between the connecting rod bearing and crank pin Clean the connecting rod and bearing, and assemble them on the connecting rod. Cut the plastic gauge to the width of the crank pin and lay it parallel avoiding the crank pin oil hole. Align the markings on the connecting rod and on the cap to assemble it on the crank pin. Apply molybdenum disulfide to the threaded portion and seat surface of the tightening bolts. Alternately tighten them so that the cap is at the specified torque. Caution： ・ Never move the connecting rod when the plastic gauge is in use. Gently remove the cap and connecting rod and use a scale printed on the packaging of the plastic gauge to measure the flattened plastic gauge.



Method for measuring the gap between the crank bearing and crank journal Clean the installation surfaces of the cylinder block and crankcase bearing, and assemble them on the cylinder block and crankcase. Gently place the crankshaft on the cylinder block, and lock it into place by turning it approximately 30 degrees. Cut the plastic gauge to the width of the crank journal and lay it parallel avoiding the journal oil hole. Gently place the crankcase on the cylinder block, and apply molybdenum disulfide to the threaded portion and seat surface of the tightening bolts. Tighten in the specified order at the specified torques. Caution： ・ Never move the connecting rod when the plastic gauge is in use. Gently remove the crankcase and use a scale printed on the packaging of the plastic gauge to measure the flattened plastic gauge.



Service Information Guide (All) 14A-5



14A-6 Service Information Guide (All)



Recommended liquid gasket 1.



Using the thread liquid gasket Type



Product name



Silicon type (room temperature vulcanization process) Water–soluble



ThreeBond 1207B ThreeBond 1207C ThreeBond 1215 ThreeBond 1216 ThreeBond 1141 ThreeBond 1104 ThreeBond 1194 Loctite 515 Loctite 518 FMD127 (Loctite 5127) Loctite 271



Solvent type



Anaerobic



Manufacturer name ThreeBond ThreeBond ThreeBond ThreeBond ThreeBond ThreeBond ThreeBond Loctite Loctite Loctite Loctite Loctite



Caution： ・ Make sure to use a liquid gasket with the above product name or equivalent. ・ Use an appropriate amount of liquid gasket. ・ Follow the handling precautions for the product. ・ Do not use Loctite 515/518 or FMD 127 (Loctite 5127), as they are anaerobic, and do not provide sufficient effect when there is a gap larger than 0.25 mm {0.0098 in} between the contact surfaces of metals. Whenever disassembling, completely remove old liquid gasket using a scraper, and clean by removing any oil, moisture, filth, etc. from the locations of parts and the mating parts where liquid gasket was used by using a rag, etc. After cleaning, apply the specified liquid gasket to each location and assemble them. Note： ・ It is better to start the removal operation approximately 10 minutes after applying when using gasket remover to make the operation easier while cleaning. Caution： ・ Do not apply gasket remover to plastic parts and painted parts. Apply liquid gasket of the specified bead width to one side of the contact surface thoroughly.



Area used (reference) Engine oil seal retainer engine oil pan timing gear case cylinder head cover fuel pump water pump etc. Engine oil seal retainer water pump plug etc.



Caution： ・ Be careful to apply a proper amount of the liquid gasket to avoid an excess or lack in application. ・ Be sure to overlap the beginning and ending of the liquid gasket application. ・ Be careful not to misalign the applied part with the mating part when assembling. Note： ・ When there is a misalignment, apply again. ・ Use the same size studs as a guide when using with a section which has no positioning such as a knock pin. Caution： ・ After applying the liquid gasket, assemble within 15 minutes. Note： ・ When more than 15 minutes have passed after applying liquid gasket, remove the liquid gasket and apply it again. Caution： ・ Wait at least 30 minutes before starting the engine after assembling each part.



Service Information Guide (All) 14A-7



Caution： ・ If the workshop manual specifies an application method, follow that method.



14A-8 Service Information Guide (All)



Thread locking adhesive agent 1.



Using the thread locking adhesive agent Type Loctite 242 Loctite 262 Loctite 271



Color Blue Red Red



Caution： ・ Remove grime, fluid, oil, and grease off thoroughly from the bolts, bolt holes, and screw thread section of nuts to which thread locking adhesive agent will be applied. Note： ・ Check if the cleaned sections are dry. Caution： ・ After tightening, do not apply excessive torque or vibrations for at least an hour until the thread locking adhesive agent hardens. Apply thread locking adhesive agent to the end 1/3 of the screw and tighten at the specified torque.



Service Information Guide (All) 14A-9



Term 1.



Term Nominal dimensions Refers to standard values for production. Standard value Refers to standard values for inspection, adjustment, assembly, and installation. Limit Refers to a maximum or minimum value that should not be exceeded during maintenance. If this value is exceeded, replacement or repair must be made. Warning Refers to something which may cause serious injuries if it is not performed properly. CAUTION Refers to something which may cause physical loss or damage if it is not performed properly. NOTE Instruction, guidance, and usage conditions regarding usage, operation, and repair in the additional information.



14A-10 Service Information Guide (All)



Abbreviations 1.



Abbreviations



Service Information Guide (All) 14A-11 Abbreviation A/D ABDC AC ACC ACG ACT API ASM ATDC ATF B+ BAT BBDC BKT BRG BTDC C/B C/U CAN CKP CMP CO CPU DC DI DLC DPD DTC DMM ECM ECT ECU EEPROM EGR EMI EVRV EXH F/B F/C F/L FLW FRT FT FWD



Description Analog/Digital After bottom dead center Alternating current Accessory Alternating current generator Actuator American Petroleum Industry Assembly After top dead center Automatic transmission fluid Battery + terminal Battery Before bottom dead center Bracket Bearing Before the top dead center Circuit breaker Control unit A control unit communication method (Control area network) Crankshaft position Camshaft position Carbon monoxide CPU (Central processing unit) Direct current Direct injection type Data link connector Diesel particulate diffuser Self-diagnosis code Digital multi–meter Engine control module Engine coolant temperature Electronic control unit Electrically erasable/programmable ROM EGR (Exhaust gas recirculation) Electromagnetic interference Electric vacuum regulating valve Exhaust Feedback Fuel cut Fusible link Fusible link wire Front Fuel temperature Front



14A-12 Service Information Guide (All) GEN GND HC HO2S IAC IAT IC ID Plate IDSS IMT INL INJ ISO ISP ITP J/C JIS KW LH LLC M/V MAF MAP Max MIL Min MPU NC NC NO NOx N–TDC O2S OBD OEM OPT OT P/L PCV P–I PM PTO PWM QOS QWS



Generator Ground Hydrocarbon Superheat O2 sensor Idle air control Intake air temperature Integrated circuit ID plate (Name plate) ISUZU　Diagnostic　Service　System Intake manifold temperature Intake Injection International Organization for Standardization Intake shutter position Intake throttle position Joint connector Japan Industrial Standard A communication method (Keyword) Left side Long life coolant Electromagnetic valve Mass air flow Manifold air pressure Maximum Warning light (Diagnostic light) Minimum Micro processing unit Normally closed Normally closed Normally open Nitrogen oxide Top dead center revolution speed O2 sensor On–board diagnosis Original equipment manufacturer Option Oil temperature Pilot light Pump control valve/Positive crankcase ventilation Proportion–integration Particle material Power take–off Pulse width modulation wave QOS (Quick on start system) QWS (Quick warming up system)



Service Information Guide (All) 14A-13 RH R/L RAM REF ROM RP Rr Rr RWD SAE SBF SCV SIG SLD ST STD SW TDC TEMP TP VB VGS Turbo W/H W/L W/S WOT



Right side Relay RAM (Random access memory) Reference ROM (Read only memory) Rail pressure Rear Rear Rear Society of Automotive Engineers Slow blow fuse Suction control valve Signal Shield Starter/start Standards Switch Top dead center Temperature Throttle position Battery voltage Variable geometry system turbo, VGS turbo Wire/harness Warning light (Warning light) Weld splice Wide open throttle



14A-14 Service Information Guide (All)



Standard bolts 1.



List of standard bolt and nut tightening torques



Note： ・ The tightening torque values in the following table apply to locations where tightening torques are not specified.



Service Information Guide (All) 14A-15 Strength category Bolt head shape



4.8 4T Hex bolt



： 3.9 to 7.8 N・m { 0.4 to M6 x 1 0.8 kgf・m / 35 to 69 lb・ in } ： 7.8 to 17.7 N・m { 0.8 M8 x 1.25 to 1.8 kgf・m / 69 to 157 lb・in } ： 20.6 to 34.3 N・m { 2.1 M10 x 1.25 to 3.5 kgf・m / 15 to 25 lb・ft } ： 19.6 to 33.3 N・m { 2.0 *M10 x 1.5 to 3.4 kgf・m / 14 to 25 lb・ft } ： 49.0 to 73.5 N・m { 5.0 M12 x 1.25 to 7.5 kgf・m / 36 to 54 lb・ft } ： 45.1 to 68.6 N・m { 4.6 *M12 x 1.75 to 7.0 kgf・m / 33 to 51 lb・ft } ： 76.5 to 114.7 N・m M14 x 1.5 { 7.8 to 11.7 kgf・m / 56 to 85 lb・ft } ： 71.6 to 106.9 N・m *M14 x 2 { 7.3 to 10.9 kgf・m / 53 to 79 lb・ft } ： 104.0 to 157.0 N・m M16 x 1.5 { 10.6 to 16.0 kgf・m / 77 to 116 lb・ft } ： 100.0 to 149.1 N・m *M16 x 2 { 10.2 to 15.2 kgf・m / 74 to 110 lb・ft } ： 151.0 to 225.6 N・m M18 x 1.5 { 15.4 to 23.0 kgf・m / 111 to 166 lb・ft } ： 151.0 to 225.6 N・m *M18 x 2.5 { 15.4 to 23.0 kgf・m / 111 to 166 lb・ft } ： 206.0 to 310.0 N・m M20 x 1.5 { 21.0 to 31.6 kgf・m / 152 to 229 lb・ft } ： 190.2 to 286.4 N・m *M20 x 2.5 { 19.4 to 29.2 kgf・m / 140 to 211 lb・ft } ： 251.1 to 413.8 N・m M22 x 1.5 { 25.6 to 42.2 kgf・m / 185 to 305 lb・ft } ： 217.7 to 327.5 N・m *M22 x 2.5 { 22.2 to 33.4 kgf・m / 161 to 242 lb・ft }



7T Flange bolt



Hex bolt



Flange bolt



： 4.6 to 8.5 N・m { 0.5 to 0.9 kgf・m / 41 to 75 lb・ in } ： 10.5 to 19.6 N・m { 1.1 to 2.0 kgf・m / 93 to 173 lb・in } ： 23.1 to 38.5 N・m { 2.4 to 3.9 kgf・m / 17 to 28 lb・ft } ： 22.3 to 37.2 N・m { 2.3 to 3.8 kgf・m / 16 to 27 lb・ft } ： 54.9 to 82.3 N・m { 5.6 to 8.4 kgf・m / 40 to 61 lb・ft } ： 51.0 to 76.5 N・m { 5.2 to 7.8 kgf・m / 38 to 56 lb・ft } ： 83.0 to 124.5 N・m { 8.5 to 12.7 kgf・m / 61 to 92 lb・ft } ： 77.2 to 115.8 N・m { 7.9 to 11.8 kgf・m / 57 to 85 lb・ft } ： 115.6 to 173.3 N・m { 11.8 to 17.7 kgf・m / 85 to 128 lb・ft } ： 109.4 to 164.2 N・m { 11.2 to 16.7 kgf・m / 81 to 121 lb・ft }



： 4.9 to 9.8 N・m { 0.5 to 1.0 kgf・m / 43 to 87 lb・ in } ： 11.8 to 22.6 N・m { 1.2 to 2.3 kgf・m / 9 to 17 lb・ ft } ： 27.5 to 46.1 N・m { 2.8 to 4.7 kgf・m / 20 to 34 lb・ft } ： 27.5 to 45.1 N・m { 2.8 to 4.6 kgf・m / 20 to 33 lb・ft } ： 60.8 to 91.2 N・m { 6.2 to 9.3 kgf・m / 45 to 67 lb・ft } ： 56.9 to 84.3 N・m { 5.8 to 8.6 kgf・m / 42 to 62 lb・ft } ： 93.2 to 139.3 N・m { 9.5 to 14.2 kgf・m / 69 to 103 lb・ft } ： 88.3 to 131.4 N・m { 9.0 to 13.4 kgf・m / 65 to 97 lb・ft } ： 135.3 to 204.0 N・m { 13.8 to 20.8 kgf・m / 100 to 150 lb・ft } ： 129.4 to 194.2 N・m { 13.2 to 19.8 kgf・m / 95 to 143 lb・ft } ： 195.2 to 293.2 N・m { 19.9 to 29.9 kgf・m / 144 to 216 lb・ft } ： 196.1 to 294.2 N・m { 20.0 to 30.0 kgf・m / 145 to 217 lb・ft } ： 269.7 to 405.0 N・m { 27.5 to 41.3 kgf・m / 199 to 299 lb・ft } ： 249.1 to 374.6 N・m { 25.4 to 38.2 kgf・m / 184 to 276 lb・ft } ： 362.8 to 544.3 N・m { 37.0 to 55.5 kgf・m / 268 to 401 lb・ft } ： 338.3 to 507.0 N・m { 34.5 to 51.7 kgf・m / 250 to 374 lb・ft }



： 5.7 to 10.6 N・m { 0.6 to 1.1 kgf・m / 50 to 94 lb・in } ： 13.5 to 25.0 N・m { 1.4 to 2.5 kgf・m / 10 to 18 lb・ft } ： 31.0 to 51.7 N・m { 3.2 to 5.3 kgf・m / 23 to 38 lb・ft } ： 30.3 to 50.4 N・m { 3.1 to 5.1 kgf・m / 22 to 37 lb・ft } ： 68.1 to 102.1 N・m { 6.9 to 10.4 kgf・m / 50 to 75 lb・ft } ： 62.7 to 94.0 N・m { 6.4 to 9.6 kgf・m / 46 to 69 lb・ft } ： 100.8 to 151.1 N・m { 10.3 to 15.4 kgf・m / 74 to 111 lb・ft } ： 94.9 to 142.3 N・m { 9.7 to 14.5 kgf・m / 70 to 105 lb・ft } ： 150.1 to 225.2 N・m { 15.3 to 23.0 kgf・m / 111 to 166 lb・ft } ： 142.5 to 213.8 N・m { 14.5 to 21.8 kgf・m / 105 to 158 lb・ft }



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14A-16 Service Information Guide (All) ： 358.9 to 539.4 N・m { 36.6 to 55.0 kgf・m / 265 to 398 lb・ft } ： 338.3 to 507.0 N・m *M24 x 3 { 34.5 to 51.7 kgf・m / 250 to 374 lb・ft } M24 x 2



-



-



： 430.5 to 711.0 N・m { 43.9 to 72.5 kgf・m / 318 to 524 lb・ft } ： 406.0 to 608.0 N・m { 41.4 to 62.0 kgf・m / 299 to 448 lb・ft }



-



-



Service Information Guide (All) 14A-17 Strength category Bolt head shape



9.8 9T



8.8 Hex bolt



： 5.6 to 11.2 N・m { 0.6 M6 x 1 to 1.1 kgf・m / 50 to 99 lb・in } ： 13.4 to 25.7 N・m { 1.4 M8 x 1.25 to 2.6 kgf・m / 10 to 19 lb・ft } ： 31.3 to 52.5 N・m { 3.2 M10 x 1.25 to 5.4 kgf・m / 23 to 39 lb・ft } ： 31.3 to 51.4 N・m { 3.2 *M10 x 1.5 to 5.2 kgf・m / 23 to 38 lb・ft } ： 69.3 to 104.0 N・m M12 x 1.25 { 7.1 to 10.6 kgf・m / 51 to 77 lb・ft } ： 64.8 to 96.1 N・m { 6.6 *M12 x 1.75 to 9.8 kgf・m / 48 to 71 lb・ft } ： 106.2 to 158.8 N・m M14 x 1.5 { 10.8 to 16.2 kgf・m / 78 to 117 lb・ft } ： 100.6 to 149.8 N・m *M14 x 2 { 10.3 to 15.3 kgf・m / 74 to 110 lb・ft } ： 154.3 to 232.5 N・m M16 x 1.5 { 15.7 to 23.7 kgf・m / 114 to 171 lb・ft } ： 147.6 to 221.4 N・m *M16 x 2 { 15.1 to 22.6 kgf・m / 109 to 163 lb・ft } ： 222.5 to 334.3 N・m M18 x 1.5 { 22.7 to 34.1 kgf・m / 164 to 247 lb・ft } ： 223.6 to 335.4 N・m *M18 x 2.5 { 22.8 to 34.2 kgf・m / 165 to 247 lb・ft } ： 307.4 to 461.7 N・m M20 x 1.5 { 31.3 to 47.1 kgf・m / 227 to 341 lb・ft } ： 284.0 to 472.1 N・m *M20 x 2.5 { 29.0 to 48.1 kgf・m / 209 to 348 lb・ft } ： 413.6 to 620.5 N・m M22 x 1.5 { 42.2 to 63.3 kgf・m / 305 to 458 lb・ft } ： 385.7 to 578.0 N・m *M22 x 2.5 { 39.3 to 58.9 kgf・m / 284 to 426 lb・ft }



Flange bolt ： 6.6 to 12.2 N・m { 0.7 to 1.2 kgf・m / 58 to 108 lb・in } ： 15.3 to 28.4 N・m { 1.6 to 2.9 kgf・m / 11 to 21 lb・ft } ： 35.4 to 58.9 N・m { 3.6 to 6.0 kgf・m / 26 to 43 lb・ft } ： 34.5 to 57.5 N・m { 3.5 to 5.9 kgf・m / 25 to 42 lb・ft } ： 77.7 to 116.5 N・m { 7.9 to 11.9 kgf・m / 57 to 86 lb・ft } ： 71.4 to 107.2 N・m { 7.3 to 10.9 kgf・m / 53 to 79 lb・ft } ： 114.9 to 172.3 N・m { 11.7 to 17.6 kgf・m / 85 to 127 lb・ft } ： 108.2 to 162.2 N・m { 11.0 to 16.5 kgf・m / 80 to 120 lb・ft } ： 171.1 to 256.7 N・m { 17.4 to 26.2 kgf・m / 126 to 189 lb・ft } ： 162.5 to 243.8 N・m { 16.6 to 24.9 kgf・m / 120 to 180 lb・ft } -



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Hex bolt



Flange bolt



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-



： 16.7 to 30.4 N・m { 1.7 to 3.1 kgf・m / 12 to 22 lb・ft } ： 37.3 to 62.8 N・m { 3.8 to 6.4 kgf・m / 28 to 46 lb・ft } ： 36.3 to 59.8 N・m { 3.7 to 6.1 kgf・m / 27 to 44 lb・ft } ： 75.5 to 113.8 N・m { 7.7 to 11.6 kgf・m / 56 to 84 lb・ft } ： 71.6 to 106.9 N・m { 7.3 to 10.9 kgf・m / 53 to 79 lb・ft } ： 113.8 to 170.6 N・m { 11.6 to 17.4 kgf・m / 84 to 126 lb・ft } ： 106.9 to 160.0 N・m { 10.9 to 16.3 kgf・m / 79 to 118 lb・ft } ： 160.0 to 240.3 N・m { 16.3 to 24.5 kgf・m / 118 to 177 lb・ft } ： 153.0 to 229.5 N・m { 15.6 to 23.4 kgf・m / 113 to 169 lb・ft } ： 229.5 to 345.2 N・m { 23.4 to 35.2 kgf・m / 169 to 255 lb・ft } ： 230.5 to 346.2 N・m { 23.5 to 35.3 kgf・m / 170 to 255 lb・ft } ： 293.2 to 440.3 N・m { 29.9 to 44.9 kgf・m / 216 to 325 lb・ft } ： 293.2 to 440.3 N・m { 29.9 to 44.9 kgf・m / 216 to 325 lb・ft } ： 424.6 to 636.5 N・m { 43.3 to 64.9 kgf・m / 313 to 469 lb・ft } ： 394.2 to 592.3 N・m { 40.2 to 60.4 kgf・m / 291 to 437 lb・ft }



： 18.1 to 33.6 N・m { 1.8 to 3.4 kgf・m / 13 to 25 lb・ft } ： 42.3 to 70.5 N・m { 4.3 to 7.2 kgf・m / 31 to 52 lb・ft } ： 40.1 to 66.9 N・m { 4.1 to 6.8 kgf・m / 30 to 49 lb・ft } ： 85.0 to 127.5 N・m { 8.7 to 13.0 kgf・m / 63 to 94 lb・ft } ： 79.5 to 119.2 N・m { 8.1 to 12.2 kgf・m / 59 to 88 lb・ft } ： 123.4 to 185.1 N・m { 12.6 to 18.9 kgf・m / 91 to 137 lb・ft } ： 115.5 to 173.3 N・m { 11.8 to 17.7 kgf・m / 85 to 128 lb・ft } ： 176.9 to 265.3 N・m { 18.0 to 27.1 kgf・m / 130 to 196 lb・ft } ： 168.5 to 252.7 N・m { 17.2 to 25.8 kgf・m / 124 to 186 lb・ft } -



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14A-18 Service Information Guide (All) ： 490.8 to 810.5 N・m { 50.0 to 82.6 kgf・m / 362 to 598 lb・ft } ： 462.8 to 693.1 N・m *M24 x 3 { 47.2 to 70.7 kgf・m / 341 to 511 lb・ft } M24 x 2



Note： ・ Those indicated with an asterisk ( * ) are used for the female threaded portion of soft materials such as castings.



1. 2. 3. 4. 5. 6. 7. 8. 9.



Hex bolt, 4.8, 4 T Hex bolt, 4.8, 4 T Flange bolt, 4.8, 4 T Flange bolt, 4.8, 4 T Hex bolt, 7 T Flange bolt, 7 T Hex bolt, thermal refining 8.8 Hex bolt, thermal refining 8.8 Hex bolt, non-thermal refining 8.8



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： 554.1 to 830.6 N・m { 56.5 to 84.7 kgf・m / 409 to 613 lb・ft } ： 520.7 to 781.6 N・m { 53.1 to 79.7 kgf・m / 384 to 576 lb・ft }



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-



・ Refer to the following diagram regarding the marking on the top of standard bolts.



10. 11. 12. 13. 14. 15. 16.



Hex bolt, non-thermal refining 8.8 Flange bolt 8.8 Flange bolt 8.8 Hex bolt, 9.8, 9 T Hex bolt, 9.8, 9 T Flange bolt, 9.8, 9 T Flange bolt, 9.8, 9 T



Service Information Guide (All) 14A-19 Pipe diameter ： 4.6 mm { 0.181 in } ： 6.35 mm { 0.25 in } Tightening torque of ： 8.0 mm { 0.31 in } the flare nut Service standard value ： 10.0 mm { 0.39 in } ： 12.0 mm { 0.47 in } ： 15.0 mm { 0.59 in }



Flare nut width across flat Previous New ： 12.8 to 18.6 N・m { 1.3 to 1.9 kgf・ ： 14 mm ： 14 mm m / 9 to 14 lb・ft } { 0.55 in } { 0.55 in } ： 23.5 to 49.0 N・m { 2.4 to 5.0 kgf・ ： 17 mm ： 17 mm m / 17 to 36 lb・ft } { 0.67 in } { 0.67 in } ： 23.5 to 49.0 N・m { 2.4 to 5.0 kgf・ ： 19 mm ： 17 mm m / 17 to 36 lb・ft } { 0.75 in } { 0.67 in } ： 44.1 to 93.2 N・m { 4.5 to 9.5 kgf・ ： 22 mm ： 19 mm m / 33 to 69 lb・ft } { 0.87 in } { 0.75 in } ： 58.8 to 137.3 N・m { 6.0 to 14.0 kgf・ ： 27 mm ： 24 mm m / 43 to 101 lb・ft } { 1.06 in } { 0.94 in } ： 78.5 to 156.9 N・m { 8.0 to 16.0 kgf・ ： 30 mm ： 30 mm m / 58 to 116 lb・ft } { 1.18 in } { 1.18 in } Tightening torque for large/medium size vehicles



Tapered thread for connectors and brass products Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12 ： 2.0 to 14.7 N・m ： 4.9 to 15.7 N・m ： 9.8 to 16.7 N・m ： 9.8 to 17.7 N・m { 0.20 to 1.50 kgf・m / { 0.5 to 1.6 kgf・m / 43 { 1.0 to 1.7 kgf・m / 87 { 1.0 to 1.8 kgf・m / 87 18 to 130 lb・in } to 139 lb・in } to 148 lb・in } to 157 lb・in } Tapered thread for products other than connectors and brass products Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 -



PT (R) 3/4 ： 58.8 to 98.0 N・ ： 5.9 to 11.8 N・m ： 14.7 to 29.4 N・ ： 29.4 to 39.2 N・ ： 29.4 to 58.8 N・ m { 6.0 to 10.0 { 0.6 to 1.2 kgf・m / m { 1.5 to 3.0 kgf・ m { 3.0 to 4.0 kgf・ m { 3.0 to 6.0 kgf・ kgf・m / 43 to 72 52 to 104 lb・in } m / 11 to 22 lb・ft } m / 22 to 29 lb・ft } m / 22 to 43 lb・ft } lb・ft }



Note： ・ The tightening torque of the tapered thread for products other than connectors and brass products is only applied when the opposite side is not made of aluminum.



PT (R) 1/2



Note： ・ Tighten the elbow connector until it is aligned with the right angle after tightening according to the minimum torque indicated above. ・ Apply Loctite 575 to the threaded portion and tighten. Completely dry then let air in after tightening. ・ Do not use seal tape, etc.



Maintenance Information (4HK1) 15B-1



Description Engine Maintenance Information (4HK1) Table of Contents Primary specifications...................................................15B-2 Function, Structure, Operation......................................15B-5 Maintenance precautions.............................................15B-57 Introduction to the trouble diagnosis...........................15B-60



15B-2 Maintenance Information (4HK1)



Primary specifications 1.



Primary specifications



Engine main specifications



Maintenance Information (4HK1) 15B-3 Item Type Shape of combustion chamber Cylinder liner type Cylinder bore x stroke Displacement Compression ratio Compression pressure Idling rotation speed valve clearance



Intake Exhaust



Ignition method Injection order Lubricant system Lubricating type Oil pump type Lubrication oil amount Oil filter type Oil cooling type Cooling system Cooling type Radiator type Water pump type Thermostat type Open valve temperature of the thermostat valve Coolant container fuel system Injection pump type Governor type Timer type Injection nozzle type Charging system Generator type Output Regulator type Starting system Starter type Output Preheat system type Glow plug standard voltage/current Cleaning system main specifications



Engine model 4HK1 Diesel/ 4-cycle /water cooling, inline 4 cylinder OHC Direct injection type Dry type 115 mm {4.53 in} × 125 mm {4.92 in} 5.193 L ｛316.88 cu・in｝ 17.5 ： 3.23 MPa { 32.9 kgf/cm2 / 468 psi } 3.23 MPa {32.9 kgf/cm2 / 468 psi} 800 r/min ： 0.4 mm { 0.016 in } While cool ： 0.4 mm { 0.016 in } While cool Compression ignition 1,3,4,2 Pressure type Gear type ： 20 to 27 L { 5.2 to 7.1 US gal } Full-flow / partial-flow united filter (cartridge type) Built-in type, water cooled Water cooling Corrugated fin (pressure type) Centrifugal, belt type 2 wax type unit ： 82.0 ℃ { 180 °F } Without jiggle valve ： 85.0 ℃ { 185 °F } With jiggle valve ： 14.5 L { 3.8 US gal } Electronic control common rail type Electronic type Electronic type Multi-hole type 7 holes, inner diameterφ0.14mm {0.0055 in} AC type 24 V/50 A IC Reduction type 24 V/5.0 kW glow plug 23 V/3.5 A



15B-4 Maintenance Information (4HK1) Item



Specifications Centrifugal impeller method 0.950 Wax pellet type ： 85.0 ℃ { 185 °F } With jiggle valve ： 82.0 ℃ { 180 °F } Without jiggle valve ： 100.0 ℃ { 212 °F } With jiggle valve ： 95.0 ℃ { 203 °F } Without jiggle valve



water pump Pulley ratio thermostat Open valve temperatur Full-open temperature Electrical system main specifications generator Item Isuzu parts number Nominal output Rated rotation count Regulator type Regulated voltage weight



Specifications 8980921161 24 V/50 A 5,000 r/min IC type 28.5 V±1 ： 9.5 kg { 20.9 lb } starter



Type (Manufacturer) Rating voltage Output Time Number of pinion teeth Rotational direction (facing the pinion) Weight (Approx.) Current/voltage No-load characteristics Revolution speed Current/voltage Load characteristics Torque Revolution speed Current/voltage Locking characteristics Torque



Nikko 24V 5 KW 30 sec 13 Right ： 8.0 kg { 17.6 lb } 85 A or less/24 V 3,300 r/min or more 400 A/18.5 V 28.4N・m{2.9kgf・m} or more 1,250 r/min or more 1,400 A or less/9 V 88.2N・m{9.0kgf・m} or more glow plug



Item Preheat device model Glow plug rated voltage/current



Type glow plug 23 V/3.5 A



Maintenance Information (4HK1) 15B-5



Function, Structure, Operation 1.



Engine number



1. Engine number stamping 2.



Function, Structure, Operation



1.



Engine structural diagram



15B-6 Maintenance Information (4HK1)



Maintenance Information (4HK1) 15B-7



2.



Description of functions and operations



Engine electronic control The control provided by the control unit applies to the range from injection to air intake and exhaust including fuel injection amount, injection timing, air intake restriction, EGR and idling speed. Cylinder block The cylinder block is made of cast iron, and it has the equal center distance for each bore and a high rigidity, and the center of the crankshaft matches the center of the block. The bearing cap has the ladder frame structure, and is tightened using the plastic region rotational angle tightening method. Cylinder liner The cylinder liner is selected in accordance with the inner diameter of the cylinder block bore, and its identification number is stamped on the left side of the cylinder. Piston The piston is a strut cast autothermatic piston made of aluminum alloy, and the combustion chamber is the round re-entrant type. Cylinder head The cylinder head is made of cast iron, and has four valves per each cylinder. The angle tightening method has been adopted to the cylinder head bolt to further improve its reliability and durability.



Crankshaft The tufftrided steel is being used, and the grade of each journal diameter is engraved on the No. 1 balance weight. EGR system The EGR system is controlled by the engine control module (ECM) according to various data including the water temperature, engine RPM, and engine load to recirculate the exhaust gas for purification. The primary components are the EGR valve, EGR cooler, and various sensors. Connecting rod cap bolt The angle tightening method has been adopted to the connecting rod cap bolt to further improve its reliability and durability. Common rail type electronic control injection system The common rail type electronic control injection system consists of the supply pump that sets the target pressure of high-pressure fuel to supply the fuel, the common rail that measures the high-pressure fuel and the fuel injector that injects the fuel in the form of a fine mist. Each of these are controlled by the ECM based on various signals to control the injection timing and injection amount in accordance with the driving condition. Fuel injector The fuel injector has adopted the 7-hole nozzle, and adjusts the fuel injection amount and injection timing by



15B-8 Maintenance Information (4HK1) opening or closing the electromagnetic valve on the injector head portion. The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance with the ID code data in the memory. When adjusting the fuel injector, the ID code date must be recorded in the ECM. Fuel filter with sedimenter The fuel filter with sedimenter removes the water by using the difference in the relative density between diesel oil and water, and notifies the operator through the indicator when it becomes full of water. Preheat system The preheat system consists of the ECM, glow relay, glow plug and glow indicator light. The preheat system is



1. 2. 3. 4. 5.



Electromagnetic pump Fuel filter Common rail Fuel injector Supply pump



Caution： ・ Since the high-precision fuel system has been adopted, take care to prevent any foreign matter from entering the fuel system.



activated when the engine coolant temperature is low to help engine start. Lubricating system It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler and the oil jet. DPD An integrated DPD oxidation catalyst is installed for reducing exhaust gas. 3.



Fuel system



Fuel system diagram



6. Fuel tank 7. Fuel return pipe 8. Pre-fuel filter



Common rail



Maintenance Information (4HK1) 15B-9



1. Pressure sensor Fuel supply pump



2. Pressure limiter



15B-10 Maintenance Information (4HK1)



1. 2. 3. 4.



Fuel temperature sensor Suction control valve High pressure pipe Camshaft key



Caution： ・ There is a gauze filter assembled inside the union of the fuel supply pump, but the union should not be removed to prevent any foreign matter from entering.



5. Camshaft nut 6. Union 7. Joint bolt



Maintenance Information (4HK1) 15B-11 1. 2. 3. 4. 5. 6. 7.



ID plate Terminal stud Injector drive section Injector assembly Gasket O-ring Leak-off pipe installation section



Fuel filter



1. 2. 3. 4. 5.



Union Gauze filter Supply pump Strainer Joint bolt



Injector



1. 2. 3. 4. 4.



Priming pump Plug Case Drain plug



Cooling system



The coolant system is the forced-circulation system, and its main components are the water pump, thermostat and radiator.



15B-12 Maintenance Information (4HK1)



1. 2. 3. 4. 5. 6. 7. 8. 9.



Water jacket Drain plug Oil cooler Water pump Drain cock Radiator Cooling fan Radiator cap Heater core



Water pump



10. 11. 12. 13. 14. 15. 16. 17.



Radiator reserve tank Air removal plug Water outlet pipe Thermostat, 2 units Water temperature sensor Bypass route Turbocharger EGR cooler



The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.



Maintenance Information (4HK1) 15B-13



1. Fan guide 2. Bearing 3. Impeller Thermostat The thermostat is the wax pellet type, and consists of 2 units. One unit is the bottom bypass type and its initial open valve temperature is 82ºC {185 °F}, and the other unit is the inline type and its initial open valve



4. Seal unit



temperature is 85ºC {185 °F}. The structure allows the water temperature to be fine adjusted, and it is assembled inside the thermostat housing unit.



15B-14 Maintenance Information (4HK1)



1. Jiggle valve 2. Stamp mark (initial open valve temperature) 3. Valve 5.



Lubrication system



4. Gasket 5. Piston A full-flow bypass integrated filter element, water cooling oil cooler, and piston coolant oil jet are adopted for the lubrication system.



Maintenance Information (4HK1) 15B-15



Oil pump structural diagram



15B-16 Maintenance Information (4HK1)



1. 2. 3. 4. 5. 6.



Driven gear assembly Oil pump body Drive gear assembly Oil pump drive gear Oil pump body



Induction system



6. Drive gear assembly 7. Driven gear assembly 8. Oil pump drive gear



Turbocharger structural diagram



Maintenance Information (4HK1) 15B-17



1. 2. 3. 4. 5. 7.



Connector Rod Oil inlet Turbine housing Exhaust adapter



Exhaust system



6. 7. 8. 9.



Coolant inlet Coolant outlet Oil outlet Compressor housing



15B-18 Maintenance Information (4HK1)



1. DPD assembly 2. Exhaust temperature sensor 1 3. Exhaust temperature sensor 2 8.



Emission control device



EGR The EGR system recirculates a part of the exhaust gas to the intake manifold, and the generation of NOx is suppressed. By controlling the EGR system, high operability and exhaust gas reduction are both achieved. The control current from the ECM activate the solenoid to control the EGR valve lift amount. The EGR position sensor detects the actual valve lift amount and the data is used for precise control of the EGR amount.



4. DPD differential pressure sensor



The EGR operates when the engine RPM, engine coolant temperature, intake temperature, and atmospheric pressure satisfy certain criteria. Thereafter, the valve opening angle is calculated according to the engine RPM and the desired fuel injection amount. The calculated valve opening angle is used to determine the motor drive duty and the valve is driven accordingly. The intake throttle valve closes when the EGR operates to ensure an appropriate internal pressure of the intake manifold.



Maintenance Information (4HK1) 15B-19



9.



Electrical system



Charging system The main components of the charging system are the battery, generator, and battery discharge indicator light circuit. Generator is a self-rectifier type with a regulator built in. Generator The generator is the brushless type. The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator, bearing, pulley, etc. The moving parts are the rotor and pulley. The field coil is fixed to the rear bracket. 6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated in the stator coil to a direct current.



3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode. In addition, 3 small diodes that are referred to as triodiode are used to supply the field current. This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal. Since the L terminal is connected to the field coil, it works as an input terminal together with the R terminal until the generator starts generating power. Also, it functions as an output terminal. (current capacity is 1 A) When the L terminal voltage reaches the battery voltage, the charge light turns off. Since the both bearings are sealed, periodic lubrications are not required. The IC regulator cannot be disassembled, so it should be handled as an assembly.



15B-20 Maintenance Information (4HK1)



1. 2. 3. 4. 5. 6.



Rectifier Field coil Stator Bearing Pulley Front bracket



Starter system The starter is 5 kW and uses a reduction type. Gear housing and armature end bearing housing are made of aluminum. Brush assembly is an replaceable type. Starter circuit is started using a battery. The battery cable is connected to a large terminal on the starter. The wiring is connected from the terminal to the engine control switch and the starter relay. Starter The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type.



7. 8. 9. 10.



Rotor Rear bracket Regulator Bearing



When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch closes and the armature rotates. At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear. When the ring gear rotates, the crankshaft is turned to start the engine. After the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature stops rotating when the starter switch is turned OFF. When the engine rotation becomes faster than the pinion, the pinion is caused to turn in reverse, but the pinion just idles due to the one-way clutch function, so the armature is not driven.



Maintenance Information (4HK1) 15B-21



1. 2. 3. 4. 5.



Lever assembly Magnetic switch assembly Yoke Armature Brush holder



Preheat system The preheat system has adopted the QOS system glow plug type. Also, the energization control is performed by the ECM. 10. Engine control system Engine control system overview and implementation The engine control system is an electronic control system that controls the engine to be always in the optimal combustion state according to the driving condition, and



6. Internal gear 7. Clutch 8. Pinion



consists of the electronic control fuel injection system, EGR, and idling control. Also, besides controlling the engine, the engine control system has the QOS system, engine RPM signal output, self-diagnosing function, and CAN communication SAE J1939/21 and SAE J1939/11 system control functions. System control schematic The specifications vary depending on the actual unit, so refer to the manual of the actual unit.



15B-22 Maintenance Information (4HK1)



Fuel injection correction The ECM calculates the basic injection amount based on the signals from the accelerator position sensor, boost sensor, crankshaft position sensor, camshaft position sensor, etc. At this time, the open or close timing of the SCV and the energizing time of the injector are controlled based on the conditions such as the common rail pressure and engine coolant temperature to make optimal corrections to the injection timing and injection amount. About initial Q correction ECM implements the initial Q correction when the initial Q correction is under the specified engine rotation during engine start. Also, ECM cannot implement the initial about initial Q correction and cannot start the engine because it does not recognize the engine rotation when it is under the engine rpm the system can recognize. About high altitude correction



Maintenance Information (4HK1) 15B-23 ECM calculates the current altitude using signals from the atmospheric pressure sensor. According to the conditions such as the current altitude, the fuel amount is corrected properly.



Control during overheat To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100 ℃ {212 °F}. When the engine coolant temperature increases further, the fuel flow is also restricted further. When the temperature reaches 110 ℃ {230 °F}, a failure is recorded in the ECM. When the temperature is near 120 ℃ {248 °F}, the fuel flow is restricted to a certain level. The setting varies depending on the actual unit manufacturer. The actual unit is designed to issue an alarm from 105 ℃ {221 °F}. By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation condition with fuel flow restriction.



If the ECM is equipped with an emergency stop function by a high engine coolant temperature, it stops the engine when the temperature has reached 105 ℃ {221 °F}.



Engine emergency stop function The ECM is designed to make an emergency engine stop when an input from the engine stop switch, decrease in the engine oil pressure, increase in the engine coolant temperature or overrun occurs. As for emergency stop made due to decrease in the engine oil pressure, increase in the engine coolant temperature or overrun, the control is performed when the corresponding function is added to the calibration of the ECM. Input from engine stop switch The engine stops when the battery voltage is applied to the ECM terminal No. 121.



Decrease in engine oil pressure



15B-24 Maintenance Information (4HK1) When the engine oil pressure drops to 100 kPa {1.02 kgf/ cm2 / 14 psi} or lower, an alarm for engine oil pressure decrease is issued and the engine is stopped. Increase in engine coolant temperature When the engine coolant temperature increases to 105ºC {221 °F} or higher, an alarm for engine coolant temperature increase is issued and the engine is stopped.



Electronic control fuel injection system This is the system in which the ECM obtains information such as the engine RPM and engine load and sends the electrical signals based on the information to the supply pump, injectors, etc. to properly control the fuel injection amount and injection timing for each cylinder.



Overrun When the engine RPM reaches to the specified value, an alarm for overrun is issued and the engine is stopped. It varies depending on the actual unit manufacturer. I/O Table



Injection amount control To make the injection amount optimal, the fuel injection amount is controlled by regulating the injector based on mainly the signals from the engine RPM and accelerator opening angle or the instructed rotation from the control unit in the actual unit.



Maintenance Information (4HK1) 15B-25



Injection pressure control The injection pressure is controlled by regulating the fuel pressure inside the common rail. The proper pressure inside the common rail is controlled by calculating from the engine RPM, fuel injection amount, etc., and the appropriate amount of the fuel is discharged by regulating the supply pump to be force-fed to the common rail. Injection timing control This control is performed by calculating the proper fuel injection timing mainly from the engine RPM or injection amount in substitution for the timer function to regulate the injector. Injection rate control To improve combustion inside the cylinder, only a small amount of the fuel is injected first to be ignited, and then



the second injection is performed when ignition is made. This control for injection timing and injection amount is performed through regulating the injector. Maximum fuel injection amount The maximum fuel injection amount is the amount of fuel injection calculated by adjustment of initial injection amount under certain water temperature, limitation of maximum injection amount for the boost pressure, and control of injection amount for the high altitude due to the atmospheric pressure. Inter-cylinder correction It is not used for this engine. System schematic



15B-26 Maintenance Information (4HK1)



Fuel system The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before supplied to the common rail. At this time, the fuel amount to be



1. 2. 3. 4. 5.



Electromagnetic pump Fuel filter Common rail Fuel injector Supply pump



supplied to the common rail is controlled by regulating the suction control valve based on the signal from the ECM.



6. Fuel tank 7. Fuel return pipe 8. Pre-fuel filter



Maintenance Information (4HK1) 15B-27 Fuel filter clog warning function and engine RPM restriction function When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is implemented. The first stage In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the output value from the fuel filter pressure sensor falls below the specified threshold value. The alarm stops when the output value exceeds the threshold value. The second stage The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below the threshold value even after the first stage alarm occurs. The second stage alarm remains as issued until the starter switch is turned OFF. At the same time as the second stage alarm is issued, the target engine RPM is reduced gradually at a constant rate. When the output value from the sensor exceeds the specified threshold value, reduction of the restricted engine RPM is stopped, and the regulation is continued maintaining the restricted engine RPM at that time. When the output value from the sensor falls below the threshold value again, the restricted engine RPM is reduced further. When the starter switch is turned OFF and then turned back ON, the restriction is once cancelled.



1. 2. 3. 4. 5. 6. 7. 8. 9.



Supply pump Warning light Monitor Monitor, CAN communication Fuel tank Pre-filter Electromagnetic pump Fuel filter pressure sensor Main filter



15B-28 Maintenance Information (4HK1)



1. First stage Removing air from fuel system Place an appropriate pan under the air removal plug. Turn the starter switch ON, and activate the electromagnetic pump. Loose the air removal plug of the fuel filter sufficiently, and operate the priming pump 20 times or more until the fuel comes out from near the plug. Tighten the plug, and operate the priming pump 10 times or more until the fuel permeates.



2. Second stage Wait for approx. 1 minute, and then loosen the plug to remove the air in the fuel filter. This should be repeated at least 3 times until no air comes out from the plug. Securely tighten each plug, and wipe off the fuel spilled around. Operate the priming pump 10 - 15 times until the fuel permeates and then is fed to the engine.



Maintenance Information (4HK1) 15B-29



EGR The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed. The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust manifold and intake manifold. The EGR amount is determined from the engine RPM and engine load ratio and the EGR valve is operated to control the EGR amount. By installing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR cooler and then mixed with fresh air to further lower the burning temperature in order to reduce NOx amount. Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the opposite direction to increase the EGR amount. EGR control The ECM controls the EGR valve lift amount by operating the motor according to the engine status such as the engine RPM and engine load. The valve lift amount is detected by the EGR position sensor.



Darker portions in the diagram represent large valve lift amounts and the darkest portion represents the lift amount of nearly 100 %.



EGR system schematic diagram



15B-30 Maintenance Information (4HK1)



EGR and turbine noise Some engines may generate high frequency noise due to the turbine rotation. This high frequency noise can be muted using an appropriate silencer. For some OEMs which use in residential areas is not assumed, the silencer for muting the high frequency noise may be omitted from the specifications, leaving the noise. The high frequency noise tends to become lower while controlling the EGR and louder when EGR control is not provided.



Turbocharger control



Maintenance Information (4HK1) 15B-31 The turbocharger is a system that provides efficient supercharge to archive the turbo effect by overcoming the turbo’s weakness of low exhaust energy during low engine revolution. The turbocharger optimizes the turbine revolution by varying the nozzle opening angle within the turbine housing to adjust the turbo inlet area according to the revolution and load of the engine and control the supercharging pressure. The ECM sends the target nozzle opening angle based on the information from each sensor to the turbo control unit through CAN communication to control the boost pressure properly in accordance with the engine load requirements. The turbo control unit drives the turbo actuator based on the information received from the ECM and controls the nozzle vane through the control rod. The turbo actuator has a position sensor installed. The turbo control unit performs feedback control based on the information from the position sensor, etc. The actual nozzle opening angle is determined at this time, and the nozzle vane opening angle is optimally adjusted through the nozzle control rod.



Turbo actuator activation The actuator is activated based on the signal from the turbo control unit to move the nozzle control rod. The



nozzle vane operates the nozzle control rod through the operation plate.



15B-32 Maintenance Information (4HK1)



Engine operation control There are the following 4 types of operation control instructions, and the selection varies depending on each specification. Voltage input by APS, 1 - 4 V Accelerator opening angle instruction given through CAN communication control, 0 - 100 %, RPM instruction RPM instruction given through mode map switch control, RPM instruction and change instruction given by APS Increase and decrease instruction for each rotation given by the idle switch Mode map switch The mode map switch has 6 rotation control mode types of H, S, L, B, I and LM. The rotation settings are H > S > L > B, I > LM. For H, S, L and B, the rotation speed can be decreased by the APS, but any change cannot be made from the APS for I and LM.



When the regulation mode switch input is present in addition to the mode map switch, the following 2 types of control methods are available.



Maintenance Information (4HK1) 15B-33 Meaning of mode map switch and each mode In the APS, a change toward the engine RPM decrease direction can be made from each mode point. The specified engine RPM for H, S, L and B are determined depending on the calibration of the ECM.



CAN communication When CAN controller does not exist on the actual unit side



H, S, L and B of the mode map switch change as follows depending on the APS input.



When CAN controller exists on the actual unit side



15B-34 Maintenance Information (4HK1)



Mode map switch control Operation mode H



S L I B LM



MAP0 OFF OFF ON ON OFF OFF ON ON



Outer switch MAP1 OFF ON ON OFF ON OFF ON OFF



MAP2 OFF ON ON OFF OFF ON OFF ON



Control Basic operations



Maximum rotation count control #1 Maximum rotation count control #2 Constant rotation operation #1 Maximum rotation count control #3 Constant rotation operation #2



I, LM and H modes



H, S, L, and B modes (irrigation pump) H, S, L, and B modes



Maintenance Information (4HK1) 15B-35



Accelerator position switch By operating the accelerator position switch, the output voltage changes between 1 V and 4 V. Voltages between 0.2 V and 1.05 V are recognized as 1 V. When the voltage is lowered below 0.2 V or raised above 1.05 V, an error is detected. In addition, if the ECM terminals 85 and 86 are not at the same potential, DTC P2138 is detected.



Accelerator position switch, with APS learning control If the APS learning control is available, for example, when the ignition cycle ends with the accelerator position as 2 V (1), the accelerator position learning causes the 2 V status to be recognized as the opening angle 0 % and the control range is set to 2 V to 4 V (2).



Regulation mode switch When an input from the regulation mode switch is present, the engine RPM changes as follows.



Idling control By operating the idling control change switch during the warm-up operation, the minimum idling RPM can be adjusted. In addition, by operating the idling control change switch, the minimum idling RPM can be automatically set to the optimum value in accordance with the engine coolant temperature. Note： ・ The specifications vary depending on the actual unit, so availability of functions also differ. Idling control change switch By operating the idling control change switch, the idling control functions can be switched. The idling control switch



15B-36 Maintenance Information (4HK1) By operating idling control switch, the idling RPM can be adjusted. Note： ・ As for the installation positions of the idling control change switch and idling control switch, refer to the manual of the actual unit. The engine RPM upper limit varies depending on the engine model, actual unit specifications and engine warming-up condition. Up While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised. Down While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can be lowered. However, the engine RPM cannot be decreased below the minimum idling RPM.



Engine RPM output to tachometer The ECM outputs the engine rpm pulse to the tachometer as a tachometer output. The tachometer displays the



Control during starter switch OFF state There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch is operated, and either one of them is performed depending on the specification. The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is performed with the engine RPM at the time when the starter switch is turned OFF. The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation is performed with the default engine RPM. As for confirmation and questions regarding the specifications, contact an Isuzu service related person. Idle manual control



engine RPM based on the engine RPM pulse sent from the ECM.



Maintenance Information (4HK1) 15B-37



Preheat control QOS system The ECM determines the glow time according to the engine coolant temperature, and activates the glow relay and the QOC indicator light.. The QOS system is a system to facilitate engine start in a low temperature as well as reducing the amount of white smoke and noise generated immediately after engine start. When the starter



switch is turned ON, the ECM detects the temperature of the engine coolant based on the signal sent from the water temperature sensor to change the glow time, so the engine can be always started under the optimum conditions. Also, the after-glow function can stabilize the idling immediately after engine start.



DPD DPD uses the oxidation catalyst to clean NOx and HC, and uses a dedicated filter to collect PM emitted from the engine. When PM has accumulated on the filter, the filter regeneration is performed. The ECM detects the accumulation status of PM from the DPD differential pressure sensor or mileage. When the accumulated amount of PM or mileage has reached a certain value, automatic regeneration of the filter is performed. During regeneration, the filter is heated up to burn the accumulated PM. To adjust the burning temperature to



the optimum value, the ECM detects the exhaust temperature using the the exhaust temperature sensor and control fuel injection to raise the temperature to burn the accumulated PM. When regeneration has started, it must complete within a certain period of time. After regeneration has completed, the purification status of the filter can be determined by checking the exhaust differential pressure. When excessive amount of accumulated PM has been detected, regeneration is not performed because burning cannot be controlled, but the check engine warning light is turned ON instead.



15B-38 Maintenance Information (4HK1)



1. 2. 3. 4. 5. 6.



Engine MAF sensor Air cleaner Various sensors ECM DPD switch



ECM About ECM function The ECM constantly monitors the information sent from various sensors, and controls the each system of the powertrain. The ECM performs the diagnostic functions of the system, detects operational problems of the system, warns the operator via the diagnostic light, and records the DTC. The DTC identifies the area where the problem has occurred to assist the repair operation performed by the technician. The ECM outputs voltages (e.g., 5 V) to supply power to various sensors and switches. The ECM controls the



7. 8. 9. 10. 11.



Silencer Filter Oxidation catalyst Exhaust gas temperature sensor DPD differential pressure sensor



output circuit by controlling the ground or power supply circuit via one of the devices. Note： ・ As for the ECM installation position, refer to the manual of the actual unit.



Maintenance Information (4HK1) 15B-39 Notes on ECM maintenance The ECM has been designed to withstand the regular current consumption associated with the actual unit operation. Make sure that the circuit does not overload. When performing tests for an open circuit or short circuit, do not ground or apply voltage to the circuit of the ECM, unless otherwise instructed. When performing these circuit tests, make sure to use the digital multimeter 5-8840-2691-0. Note： ・ Use the ECM which has the part No. corresponding to the actual unit. When performing welding work on the actual unit, start the work after disconnecting the negative terminal of the battery.



ECM and components The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent fuel efficiency. The ECM monitors various engine functions via the sensors such as the crankshaft position sensor.



Turning OFF of the ECM power supply In approximately 10 seconds after turning the starter switch to OFF, the internal power supply of the ECM is not turned to OFF. When it is necessary to turn OFF the ECM power supply, e.g., when clearing the memory, it is required to wait for 10 seconds or longer after turning the starter switch OFF.



ECM voltage The ECM applies the standard voltage to various switches and sensors. The ECM is able to apply voltage in such a way because the ECM resistance value is very high. The voltage that is actually applied to the circuit is low. Therefore, the test light may not illuminate even if it is connected to the circuit. The voltmeter that is normally used at maintenance factories may not display a correct reading because its input impedance is too low. An accurate voltage reading can be obtained by using a digital multimeter with an input impedance of 10MΩ (for example, 5-8840-2691-0). Electrically Erasable Programmable Read Only Memory, EEPROM EEPROM contains various programs and calibration information necessary for the ECM to control the power train operations. If abnormalities are found with the EEPROM, replace the ECM. The program and calibration information for the ECM power train control includes the engine type, engine number, ECM part number, DTC, inter-cylinder correction learning value, QR, Q tune, and EGR correction learning value.



Engine components location diagram Locations, shapes and existence or nonexistence of components vary depending on the specifications of the actual unit.



15B-40 Maintenance Information (4HK1)



1. 2. 3. 4. 5. 6. 7. 8.



Overheat switch Water temperature sensor Glow plug Injector Boost sensor IMT sensor Boost temperature sensor Fuel temperature sensor



Supply pump The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the common rail. Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on the supply pump.



9. 10. 11. 12. 13. 14. 15.



Suction control valve Oil pressure sensor Fuel pressure sensor EGR valve CMP sensor Oil level switch CKP sensor



Maintenance Information (4HK1) 15B-41



1. Suction control valve 2. Fuel temperature sensor 3. Feed pump Suction control valve The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the common rail. The ECM controls the fuel discharge amount by regulating the energizing time to the suction control valve.



Fuel temperature sensor The fuel temperature sensor is installed on the supply pump, and the thermistor changes the resistance value according to the temperature change. The resistance value becomes lower when the fuel temperature is high, and it becomes higher when the fuel temperature is low. The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and it calculates the fuel temperature from changes in the voltage and uses it for controlling the supply pump, etc. The voltage becomes lower when the resistance is lower, and it becomes higher when the resistance is higher. Note： ・ Do not replace the fuel temperature sensor. When an abnormality is found, replace the supply pump assembly.



1. Suction control valve



Common rail The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel to each



15B-42 Maintenance Information (4HK1) cylinder. The fuel pressure sensor and the pressure limiter are installed on the common rail.



1. Pressure limiter 2. Fuel pressure sensor 3. Common rail Pressure limiter The pressure limiter is activated when the pressure in the common rail becomes abnormally high to release the pressure inside the common rail.



signal sent from the sensor, and uses it to control the fuel injection, etc.



1. Fuel pressure sensor Injector The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection. The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel injection amount control and injection timing control by regulating the energizing time of the injector.



1. Pressure limiter Fuel pressure sensor The fuel pressure sensor is installed on the common rail, and detects the fuel pressure inside the common rail to convert into the voltage signal and sends it to the ECM. The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower. The ECM calculates the actual fuel pressure from the voltage



Water temperature sensor Water temperature sensor is installed on the engine block, and the thermistor changes the resistance value according to the temperature change. The resistance value becomes smaller when the engine coolant temperature is high, and the value becomes larger when the engine coolant temperature is low. The ECM applies 5 V to the water temperature sensor through the pull-up resistor, and calculates the engine coolant temperature from changes in



Maintenance Information (4HK1) 15B-43 the voltage. This value is used in various control mechanisms, such as for fuel injection control. The voltage becomes higher when the resistance is higher, and it becomes lower when the resistance is lower.



Overheat switch The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant temperature exceeds 105ºC {221 °F}.



Crankshaft position sensor The crankshaft position sensor is installed on the flywheel housing and the CKP signal is generated every time when the protruding section of the flywheel passes the sensor. The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the camshaft position sensor, and uses the information for the fuel injection control and calculation of the engine RPM. While this control is usually performed using the CKP signal, the CMP signal is used instead when the crankshaft position sensor is faulty.



Camshaft position sensor The camshaft position sensor is installed behind the cylinder head, and generates a CMP signal when the camshaft cam passes by it. The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the camshaft position sensor, and uses the information for the fuel injection control and calculation of the engine RPM. While this control is usually performed using the CKP signal, the CMP signal is used instead when the crankshaft position sensor is faulty.



1. Camshaft gear 2. Rotational direction 3. CMP sensor Oil pressure sensor The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects the pressure of the engine oil to convert into the voltage signal and send it to the ECM.



15B-44 Maintenance Information (4HK1) The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower.



Accelerator position sensor The accelerator position sensor is installed on the console panel of the actual unit to supply the voltage signal which varies in accordance with the accelerator volume angle to the ECM. The ECM calculates the accelerator pedal position from the voltage signal, and uses it for fuel injection control and many other controls.



EGR position sensor This sensor is installed inside the EGR valve to detect the EGR valve lift amount. Note： ・ Do not disassemble the EGR position sensor. When an abnormality is found, replace the EGR valve assembly.



Note： ・ As for the installation position of the accelerator position sensor, refer to the manual of the actual unit. Atmospheric pressure sensor The atmospheric pressure sensor is installed on the actual unit side, and it replaces the atmospheric pressure with the voltage signal. The ECM calculates the atmospheric pressure from the voltage signal, and uses the atmospheric pressure to correct the fuel injection amount. Note： ・ As for the installation position of the atmospheric pressure sensor, refer to the manual of the actual unit. Boost sensor The boost sensor detects the boost using the pressure hose between the boost sensor and intake pipe to convert into the voltage signal and sends it to the ECM. The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower. The ECM calculates the boost from the voltage signal sent from the sensor, and uses it to control the fuel injection, etc.



Maintenance Information (4HK1) 15B-45



The boost temperature sensor The boost temperature sensor is installed to the EGR valve upstream side of the intake manifold. The sensor is the thermistor type, and the resistance value inside the sensor changes in accordance with the change in the temperature.



Fuel filter pressure sensor The fuel filter pressure sensor is installed on the fuel filter, and converts the negative pressure in the fuel filter into the voltage signal. The ECM calculates the negative pressure in the fuel filter based on the voltage signal to determine clogging in the fuel filter.



Intake air temparture and mass air flow sensors Intake air temperature sensor The intake air temperature sensor is installed on the duct between the air cleaner and turbocharger. The intake air temperature sensor is variable resistance inside the mass air flow sensor to measure the temperature of air taken into the engine. When the intake air temparture sensor is cold, the resistance of the sensor is high. When the air temperature rises, the resistance of the sensor becomes low. For high sensor resistance, the ECM detects a high voltage of the signal circuit. For low sensor resistance, the ECM detects a low voltage of the signal circuit. Mass air flow sensor The mass air flow sensor measures the amount of air taken into the engine, and it is installed on the duct between the air cleaner and turbocharger. The mass air flow sensor consists of the mass air flow sensor and intake air temperature sensor to measure some of air flowing in the duct. A small amount of air taken into the engine indicates deceleration or idle RPM. A large amount of air indicates acceleration or high load.



15B-46 Maintenance Information (4HK1) Intake throttle valve The intake throttle valve is installed on the inlet of the inlet manifold. The ECM controls the opening angle of the intake throttle valve according to the condition of engine operation. The motor inside the intake throttle valve is controlled based on the duty ratio signals sent from the ECM. The opening angle of the intake throttle valve is adjusted when the duty ratio is changing from 0 % to the appropriate ratio. The valve closes when the duty signal increases, and the valve opens when the duty signal decreases. The opening angle of the intake throttle valve is detected by the position sensor. The position sensor outputs the signal representing the intake throttle valve opening angle. The ECM detects a low signal voltage when the opening angle is small or the valve is at the closed position. Also, the ECM detects a high signal voltage when the opening angle is large.



DPD differential pressure sensor The DPD differential pressure sensor is installed near DPD. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. The ECM detects a lower signal voltage when the differential pressure is small due to a small amount of accumulated PM. The ECM detects a higher signal voltage when the differential pressure is large due to a large amount of accumulated PM. The ECM uses this voltage signal for controlling DPD regeneration and determining purification after regeneration. It also uses the signal voltage to detect filter failures such as a too low differential pressure.



Exhaust gas temperature sensor The exhaust gas temperature sensors are the variable resistors that are installed at 2 locations on the DPD housing, and one is installed in front of the DPD oxidation catalyst, and the other is installed in front of the filter. The exhaust gas temperature sensor 1 that is located in front of the filter measures the temperature of the exhaust gas before entering the DPD filter, and the exhaust gas temperature sensor 2 that is located in front of the oxidation catalyst measures the temperature of the exhaust gas before entering the oxidation catalyst. When the exhaust gas temperature sensor is cold, the resistance of the sensor is high. When the exhaust temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage in the signal circuit when the sensor resistance is high. Also, the ECM detects a low voltage in the signal circuit when the sensor resistance is low. The ECM uses this voltage signal for temperature control during the DPD regeneration.



IMT sensor



Maintenance Information (4HK1) 15B-47 The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature of the intake manifold. When the sensor is cold, the sensor resistance is high. When the intake temperature rises, the sensor resistance decreases. For low sensor resistance, the ECM detects a low voltage of the signal circuit.



the engine load, etc., and the turbo control unit performs control by operating the motor built into the the turbo actuator. Also, it receives the signal from the position sensor built into the turbo actuator, and provides the ECM with feedback on the turbocharger operation amount through communication with the ECM.



Turbo actuator The turbo actuator is installed on the turbocharger. The ECM communicates with the turbo control unit based on the engine load, etc., and the turbo control unit controls the turbo actuator. The nozzle control of the turbocharger is activated by the operation of the motor built into to the turbo actuator to control the variable nozzle. The ECM performs control that changes the boost pressure by adjusting the variable nozzle opening angle in accordance with the load requirement for the engine.



Diagnostic light By turning ON the diagnostic switch, the DTC is indicated by blinking. Note： ・ As for the installation position of the diagnostic light, refer to the manual of the actual unit. DLC DLC is the connector for communication and connection between the trouble diagnosis scanning tool and various controllers. Note： ・ As for the DLC installation position, refer to the manual of the actual unit.



Turbo control unit The turbo control unit is installed on the actual unit. The ECM communicates with the turbo control unit based on



15B-48 Maintenance Information (4HK1) Note： ・ As for the installation position of the mode change switch, refer to the manual of the actual unit.



Diagnostic switch The diagnostic switch shorts the DLC terminal No. 1 and No. 4 or No.5 and flashes the diagnostic light to indicate the DTC. Note： ・ As for the installation position and shape of the diagnostic switch, refer to the manual of the actual unit. Memory clear switch This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the memory clear switch. Note： ・ As for the installation position of the memory clear switch, refer to the manual of the actual unit. Mode change switch (0, 1, 2) The operation can be performed at the engine RPM specified for each mode by switching the mode change switch.



1. 2. 3. 4. 5. 6. 7. 8.



Starter switch Engine stop switch Fuel meter Memory clear switch Mode switch Water temperature gauge Oil temperature gauge Hour meter



ECM power distribution diagram Some sensors may not be connected to the ECM depending on the specifications of the actual unit. Since some sensors may perform input/output with the ECM depending on the CAN communication, confirm the specifications of the actual unit.



Maintenance Information (4HK1) 15B-49



15B-50 Maintenance Information (4HK1)



ECM pin assignment



Maintenance Information (4HK1) 15B-51



60 pin connector



15B-52 Maintenance Information (4HK1) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25



Pin name OP-COM1A OP-COM1B OM-EBM3 SP-5V4 SP-5V8 IA-MAT IA-THL IA-THBST IA-PFUEL IA-OILPRESS IA-MAP IA-IDMPOS OP-SCVHI OP-COM2A OP-COM2B OM-EBM2 SP-5V5 SP-5V6 SP-5V7 IA-THW



26



SG-5VRT4



27 28 29 30 31 32 33 34 35 36 37 38 39 40



SG-SLD5 IA-OPLO OP-SCVHI OS-INJ1 OS-INJ4 OM-EBM1 SG-5VRT7



41



SG-5VRT5



42 43



SG-5VRT6 SG-SLD6



Connection Injector power supply 1, First cylinder Injector power supply 1, Fourth cylinder EGR valve DC servomotor power input W Boost sensor power supply IMT sensor signal Fuel temperature sensor signal Boost temperature sensor signal Fuel pressure sensor signal Oil pressure sensor signal Boost sensor signal Intake throttle position sensor signal SCV-HI drive Injector power supply 2, Third cylinder Injector power supply 2, Second cylinder EGR valve DC servomotor power input V Crankshaft position sensor, fuel pressure sensor power supply Camshaft position sensor power supply Oil pressure sensor power supply Water temperature sensor signal Boost sensor, EGR position sensor, intake throttle position sensor, fuel temperature sensor GND Crankshaft position sensor shield SCV-HI drive Injector 1, First cylinder Injector 4, Second cylinder EGR valve DC servomotor power input U Oil pressure sensor, water temperature sensor GND Intake air temperature sensor, crankshaft position sensor, fuel pressure sensor GND Camshaft position sensor, boost temperature sensor GND Camshaft position sensor GND



Maintenance Information (4HK1) 15B-53 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 94 pin connector



IA-SCVLO OS-INJ3 OS-INJ2 OM-IDM1 OM-IDM2 IS-EBMPOS1 IS-EBMPOS2 IS-EBMPOS3 SG-5VRT8 IF-CAM IF-CRANK SG-SLD8 IA-SCVLO



SCV-LO drive Injector 3, Fourth cylinder Injector 2, Third cylinder Intake throttle motor, + Intake throttle motor, EGR position sensor signal U EGR position sensor signal V EGR position sensor signal W IMT sensor GND Camshaft position sensor signal Crankshaft position sensor signal Fuel pressure sensor shield SCV-LO drive



15B-54 Maintenance Information (4HK1) Pin No. 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104



Pin name PG-POWER PG-POWER PG-POWER PG-POWER PG-POWER PG-POWER PS-+B SP-5V1 SP-5V2 SP-5V3 CC-KW2000 (CC-BOOTRX) IA-THE1 IA-THE2 IA-IAT IA-MAF IA-FIPRESS IA-EXHP IA-ACCEL1 IA-ACCEL2 IA-BARO CC-ISOCAN-L PS-+B SG-5VRT1 (CC-BOOTTX) (MOD1) PG-SIGN IS-SCVSW IS-START IS-LOAD IS-REG IS-SWLO1 IS-IDLMNL



Connection GND GND GND GND GND GND Power supply Accelerator position sensor power supply Atmospheric pressure sensor power supply DPD differential pressure sensor, fuel filter pressure sensor power supply Data link connector Exhaust gas temperature sensor 1 signal Exhaust gas temperature sensor 2 signal Intake air temperature sensor signal Mass air flow sensor signal Fuel filter pressure sensor signal DPD differential pressure sensor signal Accelerator pedal position sensor 1 signal Accelerator pedal position sensor 2 signal Atmospheric pressure sensor signal ISO CAN-Low Power supply Accelerator position sensor GND GND SCV switch signal Starter switch start signal Load advance switch signal Regulation mode switch signal Idling control change selector switch signal



Maintenance Information (4HK1) 15B-55 105 106 107 108 109 110 111



IS-MDMAP0 IS-IDLUP IS-MDMAP1 IS-MDMAP2 IS-IDLDWN CC-ISOCAN-H PS-+B



112



SG-5VRT3



113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149



SG-12VRT OS-MAINR SG-SLD1 SP-12V PG-SIGN IS-ENGSTP IS-DPDREG OS-OVRL OS-OILPL OS-BOOSTL OS-OVHL OS-OPL1 OF-TACHO OS-DPDREG OS-DIAGL OS-EGRTL CC-CAN-L PS-+B IS-IGKEY SG-5VRT2 OS-MAINR PG-CASE PS-MAFBAT IS-SWHI1 IS-DIAG IS-MEMCL IS-DGSEL IS-SWHI2 OS-GLOWL OS-OPL2 OS-FIPRESSL OS-THLL OS-DPDSL



Mode map switch 0 signal Idling control switch Up signal Mode map switch 1 signal Mode map switch 2 signal Idling control switch Down signal ISO CAN-High Power supply DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas temperature sensor 1, exhaust gas temperature sensor 2 GND Mass air flow sensor GND ECM main relay Accelerator position sensor shield Mass air flow sensor power supply GND Engine stop switch signal DPD switch Engine overrun light Engine oil pressure light Boost temperature sensor pilot light Overheat light Tachometer DPD regeneration light Diagnosis light CAN-Low Power supply Starter switch ON signal Atmospheric pressure sensor GND ECM main relay signal GND dropping resistor Diagnostic switch signal Memory clear switch signal Diagnostic switch signal Glow light Fuel filter clogging light Fuel temperature light DPD light



15B-56 Maintenance Information (4HK1) 150 151 152 153 154



OS-HOUR OS-STARTR OS-GLOWR CC-CAN-H



Hour meter relay Starter cut relay glow relay CAN-High



Maintenance Information (4HK1) 15B-57



Maintenance precautions 1.



Maintenance precautions 1.



Precautions on maintenance



To prevent the engine from being damaged and to ensure the reliability of engine performance, be careful of the following points when performing maintenance works. When placing the engine on the ground, make sure that the bearing surface of the oil pan does not directly contact the ground. Use an appropriate wood frame, etc. to support the engine at the engine foot portion and the flywheel housing portion. There is only a small gap between the oil pan and oil pump strainer, so be careful not to damage the oil pan and oil strainer. ・While the air duct or air cleaner is removed, cover the open section of the intake to prevent foreign matters from entering the cylinder. If a foreign matter enters the cylinder, it may seriously damage the cylinder when the engine starts. ・When maintaining the engine, be sure to disconnect the negative battery cable. Failure to do this may cause the harness or electrical components to be damaged. If energizing is required for inspection, be careful not to cause a short. ・Before assembly, apply the engine oil to the slide contact surface of the engine. This work ensures appropriate lubrication when first starting the engine. ・When the valve train component, piston, piston ring, connecting rod, connecting rod bearing, and/or crankshaft journal bearing are removed, line them up in the correct order so that their original positions are clear. ・When installing, install it in the same position as when it was removed. ・When assembling the engine, replace the gasket, oil seal, and O-ring with new ones. ・For a component with the liquid gasket applied, carefully remove the old liquid gasket and clean the component so that no oil, water, and/or dust remain. Thereafter, apply the specified liquid gasket to each component before assembly.



Important precautions for handling this engine The holes and gaps in the fuel system including inside the injector where the fuel passes through are manufactured with high precision. Therefore, these are extremely sensitive to any foreign matter, and may be severely damaged due to foreign matter accidentally intruded. For this reason, extreme care must be taken to prevent any foreign matter from entering. When performing maintenance on the fuel system, take extreme care to prevent any foreign matter from entering the system. ・Before starting maintenance, clean the fuel line and its surroundings. ・Be sure to wash your hands before starting maintenance. Do not put on cotton work gloves. ・When the fuel hose or fuel pipe is removed, cover the opening with a plastic bag and fix it with a piece of tape. ・When the high-pressure piping of the fuel system is removed, be sure to replace it with a new one. If it is reused, the sealing surface may be damaged to cause fuel leakage. ・When replacing the fuel hose and/or fuel pipe, do not unpack new components before starting installation. ・When the fuel pipe, injection pipe, fuel injector, fuel supply pump, and/or common rail are removed, seal each opening immediately. ・Store the eyebolt and gasket in a clean parts box with a cover so that foreign matter does not attach to them. ・Fuel leakage may cause a fire. Therefore, be sure to wipe spilled fuel after completing the maintenance work and confirm that there is no fuel leakage before starting the engine. 2.



Cautions on electronic system



Using circuit test tools Unless specifically instructed in the diagnostic procedure, do not use a test light when diagnosing the powertrain electronic system. When a probe connector is required in the diagnostic procedure, use the connector test adapter kit.



・Assemble components with the liquid gasket applied within 5 minutes of applying the liquid gasket. If 5 minutes have passed, remove the old liquid gasket and apply liquid gasket again. ・When assembling or installing a component, make sure to tighten them at the specified torque to ensure secure installation.



SST: 5-8840-2835-0 - connector test adapter kit Commercial electronic equipment



15B-58 Maintenance Information (4HK1) Commercial electronic equipment refers to commercially available electronic equipment attached to the unit after it has been shipped from the factory. Be careful, as such accessories are not taken into particular consideration at the machine design stage. Commercial electronic equipment may cause malfunctions in the electronic control system, even if the equipment is properly attached. This includes equipment not connected to the electronic system of the machine, such as mobile telephones and radios. Therefore, when diagnosing power train problems, confirm whether such commercial electronic equipment is attached first and then remove them from the machine if such equipment is attached. If the problem has not been resolved after removing the equipment, perform the diagnosis using the regular procedure.



・ To prevent damage due to electrostatic discharge, do not open the packaging of a replacement part until installation preparation for the replacement part is completed. ・ To prevent damage due to electrostatic discharge, connect the part packaging to a properly working ground connection of the actual unit before removing the part from its packaging. ・ To prevent damage due to electrostatic discharge, when handling a part while sliding across the seat, sitting down from a standing position, or walking a certain distance, touch a properly working ground connection before attaching the part.



Caution： ・ Make sure that commercial electronic equipment is connected to a circuit that is not involved with the circuits of the electronic control system for both power and ground.



Fuel injection system Fuel piping The high pressure pipe and injector pipe in the fuel system should not be reused. When it is once removed, make sure to replace it with new one. The pressure limiter or fuel pressure sensor should not be replaced individually. When a failure is found, the common rail assembly and all fuel pipes should be replaced.



Welding operation for the actual unit When performing welding to the actual unit, make sure to disconnect the battery in prior to the operation. Current that occurred during welding may lead to failure and/or damage to the electronic control system. Damage caused by electrostatic discharge As the electronic components used in the electronic control system are designed to operate at extremely low voltages, they can be easily damaged by electrostatic discharge, and some types of electronic components can be damaged by static electricity of 100 V or less, which cannot be felt by a person. Note that a voltage of 4000 V is required for a person to be able to detect electrostatic discharge. There are various ways a person can build up an electrostatic charge. The most common way to build up an electrostatic charge is through methods based on friction or induction. An example of when a person builds an electrostatic charge by friction is when he/she slides across the seat of the machine. A person wearing insulated shoes can build an electrostatic charge by induction if he/she momentarily touches the ground while standing near a highly charged object. A charge of the same polarity flows out, and with a highly opposing polarity, that person becomes charged. As static electricity causes damage, be cautious when handling or testing electronic components. Caution： ・ To prevent damage due to electrostatic discharge, do not touch the connector pins of the ECM or the electronic components soldered onto the circuit board of the ECM.



1. 2. 3. 4. 3.



Injector pipe Fuel pressure sensor Pressure limiter Common rail



Programming



Programming guideline When the ECM or injector has been replaced, use the trouble diagnosis scan tool to write each data into the ECM. As for the programming method, refer to the instruction manual of the trouble diagnosis scan tool.



Maintenance Information (4HK1) 15B-59 Prior confirmation item for programming When performing programming, check the ECM part No. as necessary. When performing programming, check the engine type as necessary. When performing programming, check the engine No. as necessary. When performing programming, check the injector ID code as necessary. Items require programming When the ECM has been replaced, perform programming. When the engine has been replaced, perform programming. When the injector has been replaced, perform programming.



15B-60 Maintenance Information (4HK1)



Introduction to the trouble diagnosis 1.



Introduction to the trouble diagnosis 1.



2.



About trouble diagnosis The following trouble diagnosis procedure is extremely important to resolve problems of all electric/electronic systems. Neglecting to implement these steps may result in requiring unnecessary repairs. Read and understand the procedure carefully and proceed with the trouble diagnosis. Also, use available functions and the trouble diagnosis scan tool to perform the trouble diagnosis and system check. Trouble diagnosis procedure Checking complaints from customer ・Use the check sheet to organize the trouble situation.



Performing preliminary inspection ・Perform overall visual inspection. ・Check the past maintenance history. ・Detect any abnormality such as abnormal noise, smell, etc. ・Collect the failure trouble DTC information to provide effective repair. ・Inspect for an abnormality by comparing to the standard value. Inspect the service information ・Check the market service bulletin. Perform inspection for the displayed code. ・Inspect the item shown by DTC. Perform an inspection for problems according to symptoms ・Check the item that is not displayed in the DTC. NOTE System trouble diagnosis type The system diagnosis method is a standardized method applied for repairing all electric/electronic systems. Failures in electric/electronic systems often occur in the following steps unlike common actual unit failures. Initial stage of failure The failure occurs sporadically and for a short time, often times the driver does not notice it. At this stage, the customer's complaint is unclear, and the malfunction cannot be reproduced. However, the ECM may have recorded the failure. Past malfunction, past failures Middle stage of failure The failure occurs sporadically and for a short time, but may occur repeatedly at intervals, and occurs under specific conditions.



The customer complaint is clear, but the failure conditions are unclear. Therefore, the person performing the diagnosis can reproduce the failure by understanding its conditions. Intermittent failures, intermittent Stage where failure is realistic The occurrence of the failure is set, and the customer complaint is real and clear. Therefore, the person performing the diagnosis can reproduce the failure. However, there may sometimes be more than 2 causes for the failure. Current malfunction, Current failures 3.



Diagnosis Fully understand the description given by the customer using the Engine Control System Check Sheet.



Note： ・ When questioning, do not ask randomly but focus on the system that is inferred to be defective based on the malfunction phenomenon. Determine failure information accurately. Have concrete understanding based on 5W1H. Low air temperature, at start or on a steady basis, near the engine parts, metallic sound, etc. Check points ・Failure symptoms ・Month and Date, Time, Frequency of occurrence ・Road conditions ・Driving conditions, Operation conditions, Weather ・Feeling of symptom Engine control system check sheet When receiving the actual unit from the customer at the service factory, the failure symptoms and the data on occurrence of failure must be confirmed with the customer based on the engine control check sheet. ・Failure symptoms may not be able to be reproduced at the service factory. ・The customer's complaint may not always be a malfunction. ・Notification of incorrect malfunction conditions to the person in charge of repairs may result in unnecessary man-hours for repairs. ・ The check sheet assists actual unit diagnosis, repair, and repair confirmation at the vehicle servicing station.



Maintenance Information (4HK1) 15B-61 1. Failure symptoms 2. Failure frequency・failure conditions



15B-62 Maintenance Information (4HK1)



4.



Preparatory check Visual inspection of engine room



When implementing the diagnostic procedures, carefully make a visual inspection of the engine



Maintenance Information (4HK1) 15B-63 room. This inspection can often lead to solving a problem without taking extra steps. ・Visually inspect all air hoses for punched holes, cuts, disconnections, and appropriate piping. ・Visually inspect the hoses that are difficult to see behind other components. ・For every harness in the engine room, visually inspect that all harnesses are properly connected. Inspect that there are no burned or worn areas, that the harnesses are properly fastened and that they are not in contact with sharp edges or the hot exhaust manifold or pipes. Checking the machine maintenance status if the actual unit is not maintained properly, the diagnostic light is turned on. Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual unit faults that were not previously monitored prior to OBD. Poor vehicle maintenance cannot be classified as a nonmachine failure, but since the sensitivity of OBD system checks is high, actual unit maintenance schedules must be further closely followed. Non-OEM parts All the OBD system checks are adjusted to operate with the genuine parts. Therefore, when a commercially sold sensor or switch, etc. is installed, a wrong diagnosis is made, and the diagnostic light comes on. Commercial electronics, such as mobile phones, stereos, and anti-theft devices, may emit EMI into the control system when they are improperly installed. As the result, false sensor information is generated causing the diagnostic light to come on. When conducting a trouble diagnoses, either turn OFF the power for all commercially sold parts or remove them, and then check the failure again. NOTE Related system failure Many OBD system checks go into the backup operation mode based on the instruction from the ECM which is given when the ECM detects a failure in the related systems or components. When the backup operation mode is activated, the output is reduced to protect the actual unit. 5.



Trouble diagnosis Basic knowledge of tools required



Note： ・ When performing the diagnostic procedure, lack of basic knowledge regarding this powertrain could result in an incorrect diagnosis or damage to the powertrain components. Do not attempt to diagnose a problem related to the powertrain without having the basic knowledge. A basic



understanding of hand tools, such as the trouble diagnosis scan tools, is required to utilize the service manual effectively. About the diagnostic test performed on the actual unit Past failures ・The diagnostic tests of the previous ignition cycle have been completed. ・The diagnostic tests of the current ignition cycle have passed. ・Problems identified in the diagnostic tests currently do not exist. Current failures ・The diagnostic tests of the previous ignition cycle have been completed. ・Problems identified in the diagnostic tests currently exist. ・Problems exist in the current ignition cycle. Glossary DTC Every time the starter switch is turned ON, the ECM performs the self-test on most of the wiring and components, records any detected system failure in the memory of the ECM, and performs the backup control, depending on the DTC. Also, as for an abnormality that can affect driving, the diagnostic light is turned on to inform the operator. Ignition cycle Because the actual unit activates with a method to satisfy a predetermined diagnosis standard, an ignition cycle is defined as turning the starter switch ON, running, then turning the starter switch OFF. Diagnostic light Basically, the diagnostic light is turned on when a DTC is detected due to a failure occurred in the electronic control system such as ECM. DLC The equipment for communicating with the control unit is the Data Link Connector (DLC). The DLC is also provided to establish a connection with the scan tool. Identification of recorded DTC Reading the serial data Note： ・ The installation position of the DLC and existence or nonexistence of the DLC vary depending on the actual unit, so refer to the manual of the actual unit. ECM OFF Turn the ECM off starter switch off and the ECM power supply completely tops in approximately 10 seconds to disable the ECM. General diagnostic operations of the components monitor To run the engine normally, a general diagnosis of the components is required.



15B-64 Maintenance Information (4HK1) Input components Inspect the input components to see whether an open in the circuit or outside range value exists. Crankshaft position sensor Camshaft position sensor Water temperature sensor Boost sensor Fuel pressure sensor Accelerator position sensor Output components The output components are inspected to diagnose whether responses to commands from the control unit are appropriate. Inspect whether the circuits have disconnections and whether their values are within the range. Suction control valve Light, Relay control Magnetic valve Diagnostic light 6.



DTC reading procedure Reading DTC with diagnostic light Current and past DTCs recorded in the ECM can be displayed by connecting the diagnostic switch and blinking the diagnostic light. ・Turn the starter switch ON and check that the diagnostic light turns on.



DTC indicated by diagnostic light blinking display The current and past DTCs are both displayed while the engine is being stopped. While the engine is in operation, the light is turned on only when a current DTC exists. Using the trouble display monitor to read the DTC When a DTC occurs, the DTC can be displayed on the trouble display monitor of the actual unit. Using the scan tool to read the DTC The DTC can be read using the trouble diagnosis scan tool.



・Turn the starter switch ON, but the engine off. ・Connect the diagnostic switch. For an actual unit with no diagnostic switch, short the DLC No. 1 and No. 4 or No. 5. ・Read the blinking count of the diagnostic light. ・The DTC determines the failure contents from the diagnostic trouble code list. If the trouble diagnostic scan tool is connected, the diagnostic codes can be read by operating the trouble diagnostic scan tool. Note： ・ As for the installation position of the diagnostic light, refer to the manual of the actual unit. Display code when no DTC is recorded Code 1 (indicating the start of code display) continues to be displayed. Display when a DTC is recorded The recorded trouble codes are displayed 3 times. If more than 2 or more trouble codes have been recorded, the DTCs will be output in ascending order with each DTC being displayed three times. After displaying all codes, the codes will be displayed again starting with the smallest code number. This display continues while the diagnosis connector is connected.



Note： ・ For the work procedure, refer to the manual of the trouble diagnosis scan tool. When the DTC is recorded Perform repairs accurately according to the specified DTC chart. If no DTC is available Select the symptom from "Diagnosis By Symptom". Complete the repair according to the diagnostic



Maintenance Information (4HK1) 15B-65 procedure. It is also possible to perform the inspection by referring to the functional diagnosis. When the appropriate symptom is not found; Investigate the complaint in detail. Create a diagnosis plan. Utilize the schematics and operation principles. When repair history for similar cases are available, request technical assistance. Combine technical knowledge and effective utilization of available service information.



confirmation test performed on the actual unit or other methods to confirm that the complaint has been resolved. Confirm by testing under the conditions given by the customer. When a DTC is diagnosed, confirm that the failure has been repaired by reproducing the condition that appeared when the DTC was set while checking the scan tool data. 7.



Intermittent A failure condition that does not necessarily always appear is referred to as intermittent. Check the DTC information and the data display. Verify the symptoms and conditions reported by the customer. Use a check sheet or other method to check the circuit or electronic system components. When no trouble is detected This status indicates that the actual unit is determined as operating properly. The condition reported by the customer may be normal. Check the customer complaint by comparing to other actual unit that is operating properly. However, depending on the condition, it may be an intermittent. Before returning the actual unit, check the complaint under the conditions given by the customer. Investigate the complaint again. If the complaint cannot be adequately detected or confirmed , it is necessary to perform the diagnosis again to verify the complaint. As stated above in "Intermittent", the complaint may be an intermittent or normal condition. Repair and confirm. Perform the repair when the cause has been confirmed. Confirm that the operation is performed properly, and that the symptom has been corrected. This includes the



Check after repair Check repair on actual unit When an repair has been performed for the electronic control system, it is necessary to check that the repair is accurate after repairing the actual unit. If this check is not adequate, the diagnostic light may light again while returning the actual unit to the customer, or drivability problems may occur. Especially for an intermittent failure, it is necessary to perform the check by reproducing the conditions of the customer complaint.



About confirmation of the actual unit repairs It is effective to use the OBD system check for confirming actual unit repairs. After the repair is completed, the person who have performed the actual unit diagnosis shall review either the DTC that was diagnosed or scan tool data, or both, and record it. Clear the DTC. Run the actual unit based on the scan tool data. Check the DTC status information of the specified DTC that was diagnosed until the diagnosis test related to that DTC is implemented by the control unit. The implementation of these steps is extremely important when checking the repair status with the OBD system check. Neglecting to implement these steps may result in unnecessary repairs. 8.



Final check item list



15B-66 Maintenance Information (4HK1) Item



Item



Objective



1



DTC check



Confirm the DTC display after the repair



2



Idling speed check after warming up the engine



To check whether the idling control is operating normally.



3



Confirm the scan tool data list



Check the engine control, communication status error and abnormality under the standard condition.



4



Re-startability check



To check whether the starting control is normal.



5



Check powerful electromagnetic transmitters



Caution： ・ Follow the steps when performing the OBD system checks to confirm the repair. Failure to follow these steps may result in performing unnecessary repair works. ・ Review the scan tool data relating to the DTC that was diagnosed and make a record. ・ Clear the DTC. ・ Operate the actual unit while checking the related scan tool data. DTC clearing method



Monitor the scan tool data list, and check the values using a typical value sheet. Confirm the typical values of the scan tool data list.



After warming up the engine, confirm that the cranking time is 5 seconds or less when restarting the vehicle, and that the engine revolution is stable after starting. Check whether turning the electromagnetic When electromagnetic transmitter such as a transceiver ON and OFF transmitters such as a transceiver causes the idling engine rpm to change. If a have been added to the vehicle, problem is found, let the customer know that the confirm that no interfering waves installation position and output of the are being emitted. electromagnetic transmitter need to be changed.



Supplementary information regarding the check for powerful electromagnetic transmitters If you discover a problem in this item, convey it to the customer as necessary. ・Install the antenna to the a place distant from the electronic control system of the actual unit such as the control units and sensors. ・Install the antenna cord at least 20 cm away from the electronic systems of the actual unit, such as the control units and sensors. ・Do not wire other cables together with antenna. Also, locate the antenna cord as far away from other wiring as possible. ・Make sure to attach retrofitted equipment in accordance with their respective installation manuals. ・Do not install high-output mobile communication devices.



9.



Method Clear the previous DTCs. Keep the engine idling to warm up, then perform a racing run to increase the engine rpm to No Load Max to secure the test conditions. Check whether the idling rotation speed is constant under the no load condition after engine is warmed up. If a problem is detected, refer to Idling Unstable in Diagnosis by Symptom.



Clearing DTC If an error occurs in the system and the DTC is recorded in the ECU, that DTC is not deleted from the memory even when the malfunctioning part is repaired, so use the following measures to execute a forced deletion. Using the scan tool to delete the DTC If the trouble diagnosis scan tool is connected, you can delete codes by performing turning off of the trouble diagnosis scan tool. Clearing method with use of harness for memory clear HITACHI Construction Machinery Company 1, Connect the harness for memory clear to the data link connector.



Maintenance Information (4HK1) 15B-67 The ECM is reflashed by automatically searching for the ECM part number compatible with the part number currently reflashed. Forced reflash The ECM is reflashed by specifying an arbitrary ECM part number. In this case, a password dedicated for forced reflash is necessary. Campaign reflash The ECM is reflashed by selecting the part number during a campaign carried out by the manufacturer. Rewriting injector QR code The injector QR code that is required when replacing the injector can be rewritten. This allows fuel compensation to be performed on each injector to optimize the engine condition. 2. Turn the starter switch ON. 3. Connect the Memory Clear terminal to the Ground for one second or longer. 4. Turn the starter switch OFF. When the starter switch is turned OFF, the memory is cleared. 5. Disconnect the Diagnostic switch terminal. Erasure by ECM A DTC recorded in the ECM is erased if the same DTC has not been satisfied for 40 consecutive ignition cycles. About trouble diagnosis scan tool This tool is effective for diagnosing electrical failures in engine control units and performing system checks. If you connect the SAE 16/19 adapter to the DLC installed in the unit, it performs communication with the control units of the machine, and enables various diagnoses and tests to be performed. Functions of the trouble diagnosis scan tool. Data display Snapshot Programming Actuator test Caution： ・ When conditions such as the running state of the actual unit or the engine, water temperature, switches and gear position are not met, or when a DTC has been detected, each test may possibly not operate. ECM reflash The ECM can be updated by overwriting its control program using the most recent control data issued every 3 months. Normal reflash



Engine replacement mode This should be used when changing back to the old ECM part number which requires hardware changes such as addition of actual unit wiring is performed along with engine replacement, etc. ECM replacement When replacing the ECM within the same model, the data can be updated from the current ECM to a trouble diagnosis scan tool and then downloaded it from the trouble diagnosis scan tool to the new ECM after replacement. Factory shipment settings Based on the engine serial number, data such as ECM injector QR code can be downloaded to ECM. Actuator test The injector test, fuel injection test, rail pressure test, glow plug test, and EGR control test are performed to inspect the operation and function of each target component. Caution： ・ When conditions such as the running state of the actual unit or the engine, water temperature, switches and gear position are not met, or when a DTC has been detected, each test may possibly not operate. Links with the HTML manual display DTC to display the manual along with the failure diagnosis procedure. Reading saved data Read in the saved snapshot data to display reproduction. Caution： ・ When using the trouble diagnosis scan tool, refer to the separate instruction manual for the trouble diagnosis scan tool. 10. Reference data value



15B-68 Maintenance Information (4HK1) HITACHI Construction Machinery Company The purpose of data list is for checking the status of the actual unit and equipment. This data is used in trouble diagnosis by comparing the each unit data with standard values, and checking



whether the vehicle data is temporarily or always different from the reference values. This display menu is subject to change without notice. Non-operational P rotation



Data display items



Units



Battery voltage Target engine rpm Engine rpm Accelerator pedal position sensor 1 (APP1) Accelerator pedal position sensor 2 (APP2) Accelerator pedal position (APP) Fuel rail pressure sensor Fuel rail pressure feedback Coolant temperature sensor Coolant temperature Intake temperature sensor Intake air temperature Fuel temperature sensor Fuel temperature barometric pressure sensor Atmospheric pressure Boost temperature sensor voltage Boost pressure sensor First cylinder fuel correction amount Second cylinder fuel correction amount Third cylinder fuel correction amount Fourth cylinder fuel correction amount Engine mode EGR valve 1 drive duty



V RPM RPM V V ％ V



EGR position 1



ON/OFF



EGR position 2



ON/OFF



EGR position 3



ON/OFF



Ignition switch starter switch



ON/OFF ON/OFF



glow relay



ON/OFF



Q adjustment compensation data 1 Q adjustment compensation data 2 Q adjustment compensation data 3



V ℃ V ℃ V ℃ V kPa V kPa mm3/st mm3/st mm3/st mm3/st ％



Non operation P rotation reference value It varies depending on the actual machine condition 28.3 - 28.5 500 1,797 - 1,801 0..0 0..0 0 2.0 - 2.1 Feedback mode 0.4 - 0.5 80 - 83 2.4 27 1.3 44 1.9 100 4.4 118 - 119 Fuel mode 0 Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) ON OFF OFF ON immediately after the starter switch ON - This differs depending on the actual unit. - This differs depending on the actual unit. - This differs depending on the actual unit.



Maintenance Information (4HK1) 15B-69 Two pump relief Data display items



Units



Battery voltage Target engine rpm Engine rpm Accelerator pedal position sensor 1 (APP1) Accelerator pedal position sensor 2 (APP2) Accelerator pedal position (APP) Fuel rail pressure difference (actual – target) Fuel rail pressure sensor Fuel rail pressure feedback Coolant temperature sensor Coolant temperature Intake temperature sensor Intake air temperature Fuel temperature sensor Fuel temperature barometric pressure sensor Atmospheric pressure Boost temperature sensor voltage Boost pressure sensor First cylinder fuel correction amount Second cylinder fuel correction amount Third cylinder fuel correction amount Fourth cylinder fuel correction amount Engine mode EGR valve 1 drive duty



V RPM RPM V V ％



Two Pump Relief reference value varies according to actual unit conditions 28.4 - 28.5 500 1,898 - 1,901 0..0 0..0 0



MPa



-



V



EGR position 1



ON/OFF



EGR position 2



ON/OFF



EGR position 3



ON/OFF



Ignition switch starter switch



ON/OFF ON/OFF



glow relay



ON/OFF



3.3 - 3.5 Feedback mode 0.4 83 - 85 2.2 27 1.3 43 - 44 1.9 Approx. 100 4.3 203 - 210 Fuel mode 19 Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) ON OFF OFF ON immediately after the starter switch ON - This differs depending on the actual unit. - This differs depending on the actual unit. - This differs depending on the actual unit.



Q adjustment compensation data 1 Q adjustment compensation data 2 Q adjustment compensation data 3



V ℃ V ℃ V ℃ V kPa V kPa mm3/st mm3/st mm3/st mm3/st ％



Functional Inspection (4HK1) 15C-1



Description Engine Functional Inspection (4HK1) Table of Contents Starting system check....................................................15C-2 Fuel system check.........................................................15C-3 Air intake system check................................................15C-4 Exhaust system check....................................................15C-5 EGR control system check............................................15C-6 Glow control system check...........................................15C-7 DPD control system check............................................15C-8 OBD system check......................................................15C-11 Inspection of the diagnostic light warning light illumination circuit system...............................................................15C-12 Inspection of the diagnostic light warning light blinking circuit system...............................................................15C-13 Inspection of the starter circuit system........................15C-14 Engine compression pressure inspection.....................15C-15 Lubrication system check............................................15C-17



15C-2 Functional Inspection (4HK1)



Starting system check 1.



Starting system check Description of Function



10. Inspect the engine coolant temperature sensor.



This diagnosis chart is an organized approach to identifying a condition that causes the status for when an engine does not start. The appropriate system diagnosis can be performed with this diagnostic chart.



11. Inspect the fuel pressure sensor.



･ The battery should be fully charged when performing this diagnosis. ･ The battery cable should be securely connected when performing this diagnosis. ･ The rotation speed during cranking should be normal when performing this diagnosis. ･ The appropriate fuel should be sufficiently supplied when performing this diagnosis. ･ No fuel leaks should be found when performing this diagnosis. ･ No air should be mixed into the fuel when performing this diagnosis. ･ The air cleaner element should be clean when performing this diagnosis. ･ The fuel filter should be clean when performing this diagnosis.



14. Inspect the engine mechanical timing.



2.



Starting system check Inspection Inspection when the starter operates and cranks but the engine does not start 1.



Turn the emergency stop switch to OFF.



Note： ・ If the actual unit does not have an emergency stop switch setting, do not perform this operation. 2.



Inspect the overheat switch circuit.



Note： ・ If the actual unit does not have a overheat switch setting, do not perform this operation. 3.



Repair the circuit if a problem is discovered.



4.



Check the DTC.



Note： ・ If the DTC is detected, inspect the corresponding DTC. 5.



Check the SCV F/B display using a trouble diagnosis scan tool while cranking the engine.



standard： 900 mA 6.



Repair the SCVLO drive circuit if it is below the standard value.



7.



Remove the harness connector from the SCV.



8.



Crank the engine.



Note： ・ If the engine starts, diagnose the DTC P0090. 9.



Inspect the fuel system if the engine does not start.



12. Inspect the EGR position sensor. 13. Inspect the injector. 15. Inspect the installation status of the flywheel. 16. Inspect the air intake system. 17. Inspect the exhaust piping for collapsing, damage, and exhaust leakage. 18. Repair or replace the part found to have a problem.



Functional Inspection (4HK1) 15C-3



Fuel system check 1.



Fuel system check Description of Function The fuel system is composed of the fuel filter, supply pump, common rail, and injector, and each of them connects with the fuel pipe.



2.



Fuel system check Inspection Inspection when there is a possibility that there is an abnormality in the fuel system 1.



Inspect the quality of fuel.



Appropriate fuel should be used. 2.



Check the amount of fuel.



Sufficient amount should be supplied. 3.



Perform the fuel discharge inspection for the supply pump.



Fuel discharge inspection The fuel discharge should be normal and no air should be mixed. 4.



Confirm that the genuine fuel filter, pre filter, and filters other than for the electromagnetic pump are added to the fuel piping of the actual unit.



Note： ・ A problem such as the detection of the DTC P0093 may occur as the resistance of fuel increases due to the added filter. 5.



Remove it if the filter is added.



6.



Inspect the main fuel filter, pre-fuel filter, and electromagnetic pump filter.



･ No excessive contamination or clogging should be found. ･ No air should be mixed in. 7.



Clean or replace if a problem is discovered.



8.



Inspect the fuel pipe.



No damage, clogging, or improper connections should be found. 9.



Repair or replace if a problem is discovered.



10. Inspect the fuel tank. ･ No dust should be mixed in. ･ The fuel supply pipe should have no misalignment or damage. ･ The tank should have no collapsing or damage. ･ The fuel pipe should not be arranged incorrectly. ･ The fuel filler should have no clogging. ･ No water should be mixed into the tank. 11. Repair or replace the fuel tank if a problem is discovered. 12. Remove air.



15C-4 Functional Inspection (4HK1)



Air intake system check 1.



Air intake system check Description of Function Caution： ・ If the air intake system part is installed by the actual unit manufacturer, refer to the manual of the actual unit. The air intake system is comprised of the air cleaner, air intake piping, turbocharger, etc. The intake air is supplied to the engine through the air cleaner and intake manifold.



2.



Air intake system check Inspection Inspection when there is a possibility that there is an abnormality in the air intake system 1.



Inspect the air cleaner.



･ No excessive contamination or clogging should be found. 2.



Clean or replace if a problem is discovered.



3.



Inspect the air intake piping.



･ No collapsing, damage, or air leakage should be found. ･ There are no distorted or improper piping arrangements which may lead to an increase in the air intake resistance. ･ The lead valve should have no damage. 4.



Repair or replace if a problem is discovered.



5.



Inspect the turbocharger.



･ The turbine axis should have no abnormal looseness. ･ There are no oil leaks. 6.



Repair or replace if a problem is discovered.



Functional Inspection (4HK1) 15C-5



Exhaust system check 1.



Exhaust system check Description of Function The exhaust system is comprised of the exhaust pipe, tail pipe, etc.



2.



Exhaust system check Inspection Inspection when there is a possibility that there is an abnormality in the exhaust system 1.



Inspect the exhaust pipe and tail pipe.



･ No collapsing, damage, or exhaust leakage should be found. 2.



Repair or replace if a problem is discovered.



3.



Repair the actual unit.



15C-6 Functional Inspection (4HK1)



EGR control system check 1.



EGR control system check Description of Function The ECM controls the EGR valve based on the engine revolution speed, engine coolant temperature, intake air temperature, fuel injection amount, and atmospheric pressure. The EGR valve is driven by the EGR motor, and the EGR valve opening is detected by the EGR position sensor.



2.



EGR control system check Inspection Inspection when there is a possibility that there is an abnormality in the locations relating to the EGR. 1.



Check the DTC.



Note： ・ If the DTC is detected, inspect the corresponding DTC. 2.



Start the engine and warm it up until the coolant temperature exceeds the standard value.



Specified value： 70 ℃ { 158 °F } 3.



Check the EGR position display using a trouble diagnosis scan tool.



Specified value： -3 to 3 % 4.



Perform the actuator test EGR control using a trouble diagnosis scan tool if the EGR position display is outside the standard value.



5.



Execute an Up and Down command to the EGR valve and check the EGR position display.



Specified value： -3 to 3 % 6.



Inspect the EGR piping if the EGR position display is outside the standard value.



No damage or gas leaks should be found. 7.



Repair or replace if a problem is discovered.



8.



Start the engine and warm it up until the coolant temperature exceeds the standard value.



Specified value： 70 ℃ { 158 °F } 9.



Check the EGR position display using a trouble diagnosis scan tool.



Specified value： -3 to 3 % 10. Replace the EGR valve if the EGR position display is outside the standard value. EGR valve Removal EGR valve Installation 11. When replacing the EGR valve, perform EGR learning to the ECM.



Functional Inspection (4HK1) 15C-7



Glow control system check 1.



Glow control system check Description of Function Caution： ・ The starter ECM control specification and safety relay specification are the same for the QOS circuit. The QOS system is comprised of the ECM, glow relay, glow plug, and QOS indicator light. When the starter switch is turned to ON under low engine coolant temperature, the ECM determines the glow time according to the engine coolant temperature, and starts the glow relay and QOS indicator light. The ECM will turn to OFF the glow relay and QOS indicator light after a certain period of time.



2.



Glow control system check Inspection Inspection when there is a possibility that there is an abnormality in the locations relating to the QOS system control 1.



Perform the OBD system check.



2.



Check the DTC.



Note： ・ If the DTC P0117, P0118, P0380, or P0381 is detected, inspect the corresponding DTC. 3.



Turn ON the starter switch.



4.



Check the operation of the QOS indicator light.



Note： ・ If the QOS does not operate, the QOS indicator light will illuminate when the starter switch is turned to ON by the light check function. ・ The QOS indicator light turns off within 10 seconds. 5.



Inspect the circuit if the QOS indicator light does not illuminate or turn off.



･ No fuse should be blown. ･ No open circuit should be found between the fuse and QOS indicator light. ･ No open circuit or short circuit should be found between the QOS indicator light and ECM. ･ The QOS indicator light should not have a burned-out bulb.



standard： 6 Ω At room temperature Note： ・ If it is outside the standard value, inspect the corresponding glow plug. 11. Replace the glow plug if a problem is discovered. 12. Connect the DMM to the glow plug connector and GND. 13. Turn ON the starter switch. 14. Perform the actuator test glow plug relay using a trouble diagnosis scan tool. Note： ・ Turn the command to OFF and check the voltage value of the DMM. standard： 0 V 15. Inspect the circuit if it is outside the standard value. Note： ・ No short circuit to battery or ignition power supply should be found between the glow relay and glow plug. 16. Repair or replace the circuit if a problem is discovered. 17. Perform the actuator test glow plug relay using a trouble diagnosis scan tool. Note： ・ Turn the command to ON and check the voltage value of the DMM. standard： 18 V 18. Inspect the circuit if it is below the standard value. ･ No fuse should be blown. ･ No open circuit should be found between the fuse and glow relay. ･ No open circuit should be found between the glow relay and glow plug. ･ No open circuit should be found between the glow relay and ECM. 19. Repair or replace the circuit if a problem is discovered. 20. Replace the ECM.



6.



Repair or replace the circuit if a problem is discovered.



7.



Inspect the glow relay.



Installation of ECM



8.



Replace the relay if a problem is discovered.



21. After replacing the ECM, perform EGR learning.



9.



Remove all glow plugs.



10. Measure the resistance between the glow plug terminal and GND using the DMM.



Removal of ECM



15C-8 Functional Inspection (4HK1)



DPD control system check DPD control system check Description of Function



6.



Connect the trouble diagnosis scan tool to the DTC.



The ECM detects the condition of PM accumulations from the DPD differential pressure sensor. The DPD differential pressure sensor changes the signal voltage in accordance with changes in the exhaust gas pressure difference between the front and the rear of the DPD filter. When the DPD differential pressure sensor reaches to a certain amount of PM accumulation, or a certain period of operating hours, DPD automatic regeneration starts. If the automatic regeneration cannot be completed due to driving, the DPD manual regeneration indicator light in the monitor panel blinks to prompt the driver to perform manual regeneration. When regeneration has once started, it must be completed within a certain period of time. After completion of DPD regeneration, purification status of the filter is determined based on the exhaust differential pressure. When the ECM detects excessive amount of PM accumulation, it becomes so hot that it is eroded during regeneration process and cannot control combustion; therefore, DPD regeneration is not allowed to start.



7.



Start the engine.



8.



Display the scan tool data DPD regeneration switch using a trouble diagnosis scan tool.



9.



Check if the data displayed on the DPD regeneration switch of the trouble diagnosis scan tool is turned to ON or OFF when changing each switch.



1.



2.



DPD control system check Inspection Inspection for determining the failure location in the DPD system 1.



Perform the inspection of the engine control system.



2.



Turn the starter switch ON for 30 seconds.



3.



Check that the monitor panel functions normally.



･ DPD automatic regeneration indicator light illuminates in green ･ DPD manual regeneration indicator light illuminates in orange Note： ・ If it dose not illuminate, inspect the circuit of the DPD indicator light. ・ Not all are displayed depending on actual unit manufacturers. 4.



Turn the starter switch OFF for 30 seconds.



5.



Inspect the amount of engine oil.



Note： ・ If the ON or OFF operation does not link, inspect the DPD switch and harness. 10. Inspect the installation condition of the DPD differential pressure sensor. 11. Inspect the exhaust differential pressure sensor. ･ Damage on the DPD differential pressure sensor ･ Foreign matter or contamination which interferes with the DPD differential pressure sensor inlet ･ Wrong detection or slow response for the DPD differential pressure sensor 12. Inspect the exhaust system. 13. Inspect the air intake system. 14. Start the engine and maintain idling for 30 seconds. 15. Confirm that the DPD manual regeneration indicator light blinks. Note： ・ If it is not blinking, use the trouble diagnosis scan tool to confirm DPD accumulation status and DPD time status and applicable area based on the DPD status table. ・Compare DPD accumulation status and DPD time status and use the DPD status table to determine DPD regeneration process status. ・To use the DPD status table, confirm the data display values on the trouble diagnosis scan tool and readings in the DPD status table.



Functional Inspection (4HK1) 15C-9



Note： ・ The area where 2 status values meets will point to either A, B, C, or D. 16. Operate the trouble diagnosis scan tool. Note： ・ Use a trouble diagnosis scan tool to reset the DPD status. ･ If it is range A or B, perform the DPD forced regeneration test with the trouble diagnosis scan tool. ･ If it is range C or D, perform the DPD forced slow regeneration test with the trouble diagnosis scan tool. Note： ・ After the DPD forced slow regeneration is completed, replace the engine oil. 17. Check the DTC detection with the trouble diagnosis scan tool if the regeneration does not start. Note： ・ If no DTC is detected, confirm data display related to DPD regeneration control. 18. Inspect the corresponding DTC if the regeneration is not completed and the scan tool displays an error message. Note： ・ If no error message has been displayed, inspect the DPD filter for damage, cracks, or melting. ・ If no error message has been displayed, inspect the oxidation catalyst for degradation, damage, cracks, melting, or excessive sediment. ・ If no error message has been displayed, inspect for the cause of overheating.



・ If no error message has been displayed, inspect for a problem in the fuel system. 19. Confirm that the data display of exhaust temperature 1 is below the standard value using a trouble diagnosis scan tool if the regeneration completed. Specified value： 130 ℃ { 266 °F } Note： ・ If it is the standard value or greater, idle the engine until it reaches the standard value or lower. 20. Accelerate the engine revolution to maximum revolution speed without load. 21. Check the data display of the exhaust differential pressure when the data display of exhaust temperature 1 reaches the standard value. Specified value： 150 ℃ { 302 °F } 22. Check the exhaust differential pressure data display using a trouble diagnosis scan tool. specified pressure： 0.5 to 1.8 kPa { 0.01 to 0.02 kgf/ cm2 / 0.07 to 0.26 psi } Note： ・ If it is the standard value or lower, perform ash removal. ・ If it is the standard value or greater, inspect for the abnormalities in the DPD differential pressure sensor system. 23. Replace the ECM if any problem can be seen through the inspections above. ECM Removal ECM Installation 24. Set the injector ID code on the ECM.



15C-10 Functional Inspection (4HK1) 25. Perform the unit difference learning of the fuel supply pump to the ECM.



Functional Inspection (4HK1) 15C-11



OBD system check 1.



OBD system check Description of Function The OBD system check is a systematic method for checking problems caused by functional failures in the engine control system, and is also the starting point for all diagnoses for driveability complaints. By correctly using this diagnostic step, it is possible to reduce the time for diagnosis and prevent the replacement of parts that are not defective. Note： ・ Points to remember regarding the OBD system check



･ If there are no complaints on driveability, do not perform these diagnostic steps unless otherwise instructed in other sections. ･ Check the service technical report before starting the diagnosis. ･ Do not delete the DTCs unless it is instructed in a diagnostic step. ･ If a malfunction is found in the engine starting system, inspect the starting system. ･ The battery should be fully charged. ･ The battery cable should be normal and securely connected. ･ The GND of the ECM should be securely connected in the correct position. ･ The harness connector of the ECM should be clean and correctly connected. 2.



OBD system check Inspection Inspection for determining the failure location in the OBD system 1.



Turn ON the starter switch.



2.



Check if the diagnostic light is illuminated.



Note： ・ If the actual unit does not have a diagnostic light setting, do not perform this operation. ・ If the diagnostic light is not illuminated, inspect the diagnostic light illumination circuit system. 3.



Short the DTC.



Note： ・ Short the No.4 terminal and No.12 terminal. ・ If the actual unit does not have a diagnostic light setting, do not perform this operation. 4.



Check if the diagnostic light is blinking.



Note： ・ If the actual unit does not have a diagnostic light setting, do not perform this operation. ・ If the diagnostic light is not blinking, inspect the diagnostic light blinking circuit system.



5.



Use the trouble diagnosis scan tool to confirm the DTCs of the ECU that has communication established. Loss of communication with the trouble diagnosis scan tool occurs due to the abnormalities in the communication circuit of ECM and the trouble diagnosis scan tool.



6.



Start the engine.



Note： ・ If the starter does not operate, inspect the starter circuit system. ・ If the engine does not start, check the DTC. ・ If the DTC is detected, inspect the corresponding DTC. ・ If no DTC has been detected, inspect the starting system. 7.



Check the engine stalling for problems.



8.



Check the engine hunching and rough idling for problems.



9.



Check if there are problems with insufficient engine output, blowup failure, or engine hesitation.



10. Check for problems with sudden stopping. 11. Check for problems with sudden change. 12. Check for problems with insufficient output or blowup failure. 13. Check for problems with engine hesitation or acceleration failure. 14. Check for problems with dark smoke. 15. Check for problems with white smoke. 16. Check for problems with the idling revolution speed maladjustment. 17. Check for problems with the idling revolution speed not decreasing. 18. Check for problems with frequent DPD regeneration by the manual regeneration. 19. Check for problems with long DPD regeneration time.



15C-12 Functional Inspection (4HK1)



Inspection of the diagnostic light warning light illumination circuit system 1.



Inspection of the diagnostic light warning light illumination circuit system Description of Function The diagnostic light supplies power voltage via the starter switch and is lit by a signal from the ECM. The ECM lights the diagnostic light at the light check and at the time the DTC is set when the starter switch is turned to ON. It also blinks the diagnostic light depending on the detected DTC when the body ground terminal and diagnostic switch terminal of the DLC are shorted. A monitor circuit is incorporated inside the ECM and monitors operation of the light.



2.



Inspection of the diagnostic light warning light illumination circuit system Inspection Inspection when the diagnostic light is not illuminated when the starter switch is turned to ON 1.



Perform the OBD system check.



2.



Inspect the diagnostic light bulb.



3.



Replace the valve if a problem is discovered.



4.



Inspect the diagnostic light circuit.



･ No open circuit or high resistance should be found between the fuse and diagnostic light. ･ No open circuit or high resistance should be found between the diagnostic light and ECM. 5.



Repair the circuit if a problem is discovered.



6.



Replace the ECM.



Removal of ECM Installation of ECM 7.



After replacing the ECM, perform EGR learning.



Functional Inspection (4HK1) 15C-13



Inspection of the diagnostic light warning light blinking circuit system 1.



Inspection of the diagnostic light warning light blinking circuit system Description of Function The diagnostic light supplies power voltage via the starter switch and is lit by a signal from the ECM. The ECM lights the diagnostic light at the light check and at the time the DTC is set when the starter switch is turned to ON. It also blinks the diagnostic light depending on the detected DTC when the body ground terminal and diagnostic switch terminal of the DLC are shorted. A monitor circuit is incorporated inside the ECM and monitors operation of the warning light.



2.



Inspection of the diagnostic light warning light blinking circuit system Inspection Inspection when the diagnostic light does not blink but continues to light when the diagnostic switch is turned to ON 1.



Perform the OBD system check.



2.



Turn OFF the starter switch.



3.



Connect the DMM between the DLC diagnostic switch terminal and GND.



4.



Turn ON the starter switch.



5.



Confirm that the voltage displayed on the DMM exceeds the standard value.



standard： 18 V 6.



Inspect the diagnostic switch circuit between the ECM and DLC using the DMM if it is under the standard value.



･ No open circuit or high resistance should be found. Standard value: 100Ω or less ･ No short circuit with GND should be found. Standard value: 10MΩ or more 7.



Repair if a problem is discovered.



8.



Turn OFF the starter switch.



9.



Confirm that there is continuity between the DLC body ground and GND.



10. Turn ON the starter switch. 11. Short the DTC. Note： ・ Short the No.4 terminal and No.12 terminal. 12. Check if the diagnostic light is blinking. Note： ・ If it does not blink, inspect the diagnostic light blinking circuit system. 13. Replace the ECM.



Removal of ECM Installation of ECM 14. After replacing the ECM, perform EGR learning. 15. Turn ON the starter switch. 16. Short the body ground terminal and diagnostic switch terminal of the DLC. 17. Check if the diagnostic light is blinking. 18. Perform the OBD system check.



15C-14 Functional Inspection (4HK1)



Inspection of the starter circuit system 1.



Inspection of the starter circuit system Description of Function



･ No open circuit should be found between the starter relay and starter.



The starter relay on the ECM is turned to ON when the starter switch moves to the START position. When the starter relay is turned to ON, the starter operates to start the engine.



13. Repair the circuit if a problem is discovered.



Inspection of the starter circuit system Inspection



15. Replace the starter if a problem is discovered.



2.



14. Inspect the starter. Inspection of the starter



Inspection when the starter does not operate



16. Replace the ECM.



1.



Removal of ECM



Turn the emergency stop switch to OFF.



Note： ・ If the actual unit does not have an emergency stop switch setting, do not perform this operation. 2.



Check the DTC.



Note： ・ If the DTC P0117, P0340, P0341, P0615, P0651, or P1625 is detected, inspect the corresponding DTC. 3.



Turn OFF the starter switch.



4.



Remove the starter cut relay.



5.



Inspect the starter cut relay.



･ Check the continuity between the switch side terminals. Standard value: 100Ω or less 6.



Replace the relay if a problem is discovered.



7.



Remove the starter relay.



8.



Inspect the starter relay.



･ Connect the battery between the coil side terminals and check the continuity between the switch side terminals. Standard value: 100Ω or less 9.



Replace the relay if a problem is discovered.



10. Inspect the starter switch start signal circuit. ･ No open circuits or high resistance should be found between the starter switch and ECM. Standard value: 100Ω or less ･ No short circuits with the GND should be found between the starter switch and ECM. Standard value: 10MΩ or more 11. Repair the circuit if a problem is discovered. 12. Inspect the starter circuit. ･ No open circuit should be found between the starter switch and starter cut relay. ･ No open circuit should be found between the starter cut relay and starter relay. ･ No open circuit should be found between the starter relay and GND.



Installation of ECM 17. After replacing the ECM, perform EGR learning.



Functional Inspection (4HK1) 15C-15



Engine compression pressure inspection 1.



Engine compression pressure inspection Inspection Note： ・ Warm-up the engine. 1.



SST: 5-8840-2675-0（5-8531-7002-0） - compression gauge



Remove the glow plug from the cylinder head assembly.



Note： ・ Remove all glow plugs. 2.



Remove the injector harness connector from the lower cover.



1. Injector harness connector 3.



Install the special tool to the cylinder head assembly.



Note： ・ Insert the compression gauge adapter into the installation hole of the glow plug to install the compression gauge.



1. Compression gauge 2. Compression gauge adapter Note： ・ Measure the compression pressure. ・ Rotate the starter, and read the indication of the compression pressure when the compression gauge needle stabilizes at approximately 200 rpm. ・ Measure the compression pressure of all cylinders. specified value： 2840.0 to 3240.0 kPa { 28.96 to 33.04 kgf/cm2 / 412 to 470 psi } limit： 1960.0 kPa { 19.99 kgf/cm2 / 284 psi }



SST: 5-8840-2815-0 - compression gauge adapter



difference between each cylinder： 294.0 kPa { 3.00 kgf/ cm2 / 43 psi } Caution： ・ Note that air will burst out through the glow plug hole during rotation.



15C-16 Functional Inspection (4HK1) Note： ・ When the starter switch is turned to ON with the injector harness connector removed, the ECM determines a malfunction and records a DTC, so make sure the DTC has been cleared after the inspection is completed.



Functional Inspection (4HK1) 15C-17



Lubrication system check 1.



Lubrication system check Inspection Note： ・ Oil pressure inspection 1.



Inspect whether the engine oil is dirty, or contains water, etc.



Note： ・ If oil is dirty or contains water, change the oil after investigating the causes and taking appropriate measures. 2.



Inspect the engine oil level.



Note： ・ When the oil level is low, replenish it. 3.



Remove the oil pressure switch.



4.



Install the oil pressure gauge.



SST: 5-8840-2843-0 - oil pressure gauge 5.



Start the engine.



Note： ・ Warm-up the engine. 6.



Measure and confirm that the oil pressure is 550 kPa (5.6 kg/cm2 / 80 psi) or higher at 2000 r/min.



7.



Turn OFF the starter switch.



8.



Remove the oil pressure gauge.



9.



Install the oil pressure switch.



10. Start the engine. Note： ・ Check for oil leakage. ・ Check for engine oil leakage Inspect for oil leaks from the cylinder head cover and oil pan, etc. while the vehicle is lifted up.



Symptom (4HK1) 15D-1



Description Engine Symptom (4HK1) Table of Contents DPD system manual regeneration frequently...............15D-2 DPD system regeneration long time.............................15D-3 Engine start failure........................................................15D-4 Engine stalling...............................................................15D-6 Engine hunching, rough idling......................................15D-8 Excessive white smoke in the exhaust gas....................15D-9 Excessive black smoke in the exhaust gas..................15D-10 Abnormal noise...........................................................15D-11 Large fuel consumption...............................................15D-12 Large oil consumption.................................................15D-14 Insufficient engine output...........................................15D-15



15D-2 Symptom (4HK1)



DPD system manual regeneration frequently 1.



DPD system manual regeneration frequently Description of Symptom The manual regeneration is frequently requested by blinking the DPD manual regeneration lamp or indicating Press DPD switch. Or, it is requested more frequently than before. {Automatic regeneration cannot be performed frequently} Note： ・ Depending on the manufacturer of the actual unit, the indication may not be shown.



2.



DPD system manual regeneration frequently Diagnostics ･ Preliminary inspection Inspect the fuel quality. Inspect the engine oil level and quality. Inspect whether the odometer operates correctly. If excessive amount of black smoke is observed, inspect the black smoke. Inspect the inside of the DPD filter for excessive ash deposits. Check the scan tool data list. Check the service technical report. Confirm the ECM carry part number. Check the operator's operating habits and conditions. Recommend the owner to voluntarily carry out regeneration as necessary. Check whether the idling time is too long under the normal operation conditions. Check whether operation is frequently performed at low speed under the normal operation conditions. Check whether long downhill driving is performed under the normal operation conditions. Check whether the idling time is too long in DPD regeneration. Check whether operation is frequently performed at low speed in DPD regeneration. Check whether PTO is activated frequently and for long period of time in DPD regeneration. Check whether the engine operating time is short in DPD regeneration. Check whether accelerator is switched frequently between ON and OFF in DPD regeneration. ･ Inspection of the sensor Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off. {The hose of the DPD differential pressure sensor has a specified installation direction} 　Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting. Inspect the DPD differential pressure sensor for incorrect



installation. Inspect the DPD differential pressure sensor for damage. Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its inlet. Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display exhaust differential pressure. Check the exhaust temperature sensor at various temperatures, and inspect for the possibility of sensor abnormalities. Check the mass air flow sensor for abnormalities and operation delay with the scan tool data display MAF. Check the boost pressure and atmospheric pressure when the starter switch is ON and the engine is not started. It is normal if both data displays are within 7.0kPa {0.07 kgf/cm2 / 1.0 psi}. ･ Inspection of the air intake system Inspect the air cleaner and air intake duct for clogging, holes, and leakage. Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted. Inspect the intake throttle valve for anchoring. Inspect the inside of the intake manifold for clogging or air leaks. Inspect the air intake system for modification. Inspect the mass air flow sensor for contamination and damage. Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage. ･ Inspection of the exhaust system Inspect for any condition that restricts the flow of the exhaust system. Inspect for absence or damage of the exhaust system gasket. Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust temperature sensor, and DPD differential pressure sensor's hose and pipe. Inspect the exhaust system for modification. Inspect the inside of the DPD filter for excessive ash deposits. Inspect the DPD filter for damages, cracks, melt and excessive deposits. Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits. If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deteriorated or damaged.



Symptom (4HK1) 15D-3



DPD system regeneration long time 1.



DPD system regeneration long time Description of Symptom The regeneration requires more time than expected. Or, it takes longer than before.



2.



DPD system regeneration long time Diagnostics ･ Preliminary inspection Inspect the fuel quality. Check the scan tool data list. Check the service technical report. Check whether DPD regeneration and engine warm up control are mixed up. Check the operator's operating habits and conditions. Check whether the manual regeneration is started when the engine is cold in DPD regeneration. Check whether the idling time is too long in DPD regeneration. Check whether operation is frequently performed at low speed in DPD regeneration. Check whether the engine operating time is short in DPD regeneration. Check whether accelerator is switched frequently between ON and OFF in DPD regeneration. Check whether the temperature in the work environment is excessively high in DPD regeneration. ･ Inspection of the sensor Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off. {The hose of the DPD differential pressure sensor has a specified installation direction} Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting. Inspect the DPD differential pressure sensor for incorrect installation. Inspect the DPD differential pressure sensor for damage. Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its inlet. Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display exhaust differential pressure. Check the exhaust gas temperature sensor at various temperatures, and inspect for the possibility of sensor abnormalities. ･ Inspection of the cooling system Inspect the engine coolant level. Inspect the engine coolant leakage. Inspect the cooling fan belt slip. Inspect the operation of the cooling fan clutch. Inspect the operation of the thermostat. Inspect the operation of the water pump. Inspect the radiator for clogging. Inspect whether the cooling amount of the cooling system is not low due to modification. ･ Inspection of the air intake system



Inspect the air cleaner, air intake duct, and intercooler for clogging, holes, or leakage. Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted. Inspect the intake throttle valve for anchoring. Inspect the inside of the intake manifold for clogging or air leaks. Inspect the air intake system for modification. Inspect the mass air flow sensor for contamination and damage. Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage. ･ Inspection of the exhaust system Inspect for any condition that restricts the flow of the exhaust system. Inspect for absence or damage of the exhaust system gasket. Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust gas temperature sensor, and DPD differential pressure sensor's hose and pipe. Inspect the exhaust system for modification. Inspect the inside of the DPD filter for excessive ash deposits. Inspect the DPD filter for damages, cracks, melt and excessive deposits. Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits. If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deteriorated or damaged. ･ Other inspections Inspect for possible factors of overheat.



15D-4 Symptom (4HK1)



Engine start failure 1.



Engine start failure Description of Symptom The cranking revolution is low. The cranking revolution is normal, but the engine does not start. The engine starts but cannot maintain its revolution stably or does not reach normal revolution speeds.



2.



Engine start failure Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Check whether the actual unit has a significant load. The ECM and diagnostic light are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. ･ Visual inspection



･ Diagnostic aids



Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is grime or clogging of the fuel filter. Whether there is an improper connection of connectors. Particularly for the crankshaft position sensor and camshaft position sensor. Whether the battery terminal voltage has dropped. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumulates easily.



Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc. Use of low-viscosity fuel such as kerosene causes wear on the supply pump plunger and may result in the discharge abnormalities and cause start failure. In such cases, replacement of the supply pump is required. When a start failure has occurred, check with the customer about the fuel used. If low-viscosity fuel such as kerosene has been used, instruct the customer not to use lowviscosity fuel because the malfunction recurs even after replacing the supply pump. A mixed oil biofuel containing long-term storage fuel and organic substances is easily oxidizable. An oxidized fuel causes wear on the camshaft related parts in the supply pump and may result in start failure due to discharge abnormalities. In such cases, replacement of the supply pump is required. Since the replacement of the supply pump due to the use of mixed oil biofuel containing long-term storage fuel and organic substances is at the customer’s expense, instruct the customer not to use mixed oil biofuel containing long-term storage fuel and organic substances. When using fuel with a high water content, add the larger sedimenter to the pre-fuel filter to prevent water from entering into the fuel system. Abnormalities of the supply pump, non-pressure fuel supply The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a condition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute pressure is below 15 MPa{153 kgf/cm2 / 2175 psi}. Therefore, the DTC will not be detected when the engine does not start



Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any plugs for air removal. Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout. Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion direction of the actual unit. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts



Symptom (4HK1) 15D-5 with non-pressure fuel supply due to the supply pump abnormalities. Note： ・ Since the crankshaft position sensor abnormalities will not be diagnosed unless cranking is performed 14 revolutions or more, crank for more than 14 seconds at 60 r/min or more. For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may not be detected. For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft position sensor related DTC is detected.



Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing degradation Abnormalities of the injector, no fuel injection System down due to failure



Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc. Effect of the post-installed accessories such as wireless devices and lights, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.



15D-6 Symptom (4HK1)



Engine stalling 1.



Engine stalling Description of Symptom Engine cranks but takes a long time to start. The engine ultimately operates, or starts but stops soon.



2.



Engine stalling Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Check whether the actual unit has a significant load. The ECM and diagnostic light are operating correctly. Since the crankshaft position sensor abnormalities will not be diagnosed with cranking less than 14 revolutions, crank for more than 14 seconds at 60 r/min or more. DTC check. For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may not be detected. For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft position sensor related DTC is detected. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. Check whether fuel is contained. ･ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is an improper connection of connectors. Particularly for the crankshaft position sensor and camshaft position sensor. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumulates easily. Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any plugs for air removal. Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout. Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion direction of the actual unit. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts



･ Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as filter clogging and air intake piping abnormalities, etc. Abnormalities of the supply pump, non-pressure fuel supply The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a condition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}. Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to supply pump abnormalities.



Symptom (4HK1) 15D-7



Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing degradation Abnormalities of the injector, no fuel injection System down due to failure Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc. Effect of the post-installed accessories such as wireless devices and lights, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.



15D-8 Symptom (4HK1)



Engine hunching, rough idling 1.



Engine hunching, rough idling Description of Symptom The engine has variable engine idling, or has change in idling revolution speed. In a severe case, the engine or the actual unit may vibrate. In either case, the engine stall may occur if the symptom gets worse.



2.



Engine hunching, rough idling Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. The ECM and diagnostic light are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. ･ Visual inspection



･ Diagnostic aids



Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is an improper connection of connectors. Whether the battery terminal voltage has dropped. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumulates easily.



Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc. Abnormalities of the supply pump, non-pressure fuel supply Switch input circuit system abnormalities Abnormalities of the sensor input circuit system such as the accelerator position sensor, harness, and water temperature sensor Accelerator position sensor system abnormalities Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. Failure related to the actual unit equipment such as the oil pressure pump, etc. Effect of the post-installed accessories such as wireless devices and lights, etc. Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.



Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any plugs for air removal. Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout. Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion direction of the actual unit. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts



Symptom (4HK1) 15D-9



Excessive white smoke in the exhaust gas 1.



Excessive white smoke in the exhaust gas Description of Symptom Excessive white smoke when driving.



2.



Excessive white smoke in the exhaust gas Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. The ECM and diagnostic light are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. ･ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is an improper connection of injector connectors. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts ･ Diagnostic aids Fuel quality when using a product with a low cetane number or a product other than those specified Use of low-viscosity fuel such as kerosene may result in abnormal wear on the seat area of the injector and cause abnormal spray and white smoke. In such cases, replacement of the injector is required. Since the replacement of the injector due to the use of low-viscosity fuel such as kerosene is at the customer's expense, instruct the customer not to use low-viscosity fuel such as kerosene. Idling for a long time Failure of the water temperature sensor, fuel temperature sensor, intake air temperature sensor, boost sensor failure, or air pressure sensor Engine body failure such as insufficient compression pressure, piston related failure, turbocharger failure, and raised oil or sucked down oil, etc. ECM failure



15D-10 Symptom (4HK1)



Excessive black smoke in the exhaust gas 1.



Excessive black smoke in the exhaust gas Description of Symptom Excessive black smoke when driving.



2.



Excessive black smoke in the exhaust gas Diagnostics Note： ・ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. The ECM and diagnostic light are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. Note： ・ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is grime or clogging in the air cleaner element. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts Note： ・ Diagnostic aids Fuel quality when using a product other than those specified, etc. Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc. Abnormalities of the EGR control system Abnormalities of the exhaust system such as exhaust pipe abnormalities, etc. Water temperature sensor malfunction Boost sensor failure Engine body failure such as insufficient compression pressure, piston related failure, turbocharger failure, and raised oil, etc.



Symptom (4HK1) 15D-11



Abnormal noise 1.



Abnormal noise Description of Symptom Engine combustion noise is abnormal.



2.



Abnormal noise Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Refer to the actual unit manual and inspect the abnormal noise. The ECM and diagnostic light are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. ･ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Proper wiring connections, tightening, and disconnection Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts ･ Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as EGR valve abnormalities, etc. Abnormalities of the injector, no fuel injection Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. Failure related to the actual unit equipment such as the oil pressure pump, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.



15D-12 Symptom (4HK1)



Large fuel consumption 1.



Large fuel consumption Description of Symptom Fuel consumption is significantly larger than indicated in the actual unit manual.



2.



Large fuel consumption Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Since the fuel consumption varies widely depending on the handling of the actual unit, check the reference fuel consumption (A) of the actual unit manufacturer. Reference fuel consumption (L {qts}/hour) Check the actual fuel consumption (B). Actual fuel consumption (L {qts}/hour) If B is greater than A, refer to the actual unit manual and check the setting of the unit. Check whether the actual unit does not have a significant load. Refer to the inspections and maintenance list in the operation manual and perform the inspection based on the operation time of the actual unit. Refer to the actual unit manual to inspect an actual unit whose operation time exceeds 3,000 hours. The ECM and diagnostic light are operating correctly. DTC check. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. Check whether engine oil change or periodical maintenance for the air cleaner filter or fuel filter, etc. has been performed. ･ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Proper wiring



connections, tightening, and disconnection Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts ･ Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as EGR valve abnormalities, etc. Abnormalities of the injector such as excessive fuel injection Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. Failure related to the actual unit equipment such as the oil pressure pump, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found. For the inspection locations of the engine air intake and exhaust system Inspect the air intake and exhaust system for abnormalities such as clogging, collapsing and damage. Other than the inspection locations of the engine body, inspect the air cleaner, intercooler, and muffler.



Symptom (4HK1) 15D-13



1. 2. 3. 4.



EGR valve From the intercooler From the air cleaner To the intercooler



5. Exhaust pipe 6. EGR cooler



15D-14 Symptom (4HK1)



Large oil consumption 1.



Large oil consumption Description of Symptom The oil consumption amount described in the manual of the actual unit is significantly exceeded.



2.



Large oil consumption Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Since the oil consumption varies widely by handling of the actual unit, check the reference oil consumption (A) of the actual unit manufacturer. Reference oil consumption/hour Reference oil consumption per engine: 4L {4.2 qts}/100 hours Check the actual oil consumption (B). Actual oil consumption/hour Refer to the inspections and maintenance list in the operation manual and perform the inspection based on the operation time of the actual unit. Refer to the actual unit manual to inspect an actual unit whose operation time exceeds 3,000 hours. The ECM and diagnostic light are operating correctly. DTC check. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. ･ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether bluish white smoke continuously comes out. Whether blow-by gas comes out excessively. Whether oil is mixed into the coolant. Proper connections, cracks, and twists in the pipes and hoses related to oil. Extensively check for any leaks or blockage. Whether there is any fuel leak, pipe damage, or dents in the lubricant system. Abnormalities of the air intake system parts such as the turbocharger inspection ･ Diagnostic aids Air intake system abnormalities such as sucked down oil or raised oil and excessive blow-by gas Engine body abnormalities such as oil combustion and excessive blow-by gas Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.



Symptom (4HK1) 15D-15



Insufficient engine output 1.



Insufficient engine output Description of Symptom The engine output is lower than expected, the output does not change when the accelerator lever (throttle lever) is lifted up, the operation is not effective.



2.



Insufficient engine output Diagnostics ･ Preliminary inspection Before using this section, perform the functional inspection, OBD system check to confirm the following all items. The ECM and the diagnostic light are operating properly. DTC check. The scan tool data is within the normal operating range. Check the actual unit condition, and locate the corresponding symptom. Check with the customer if the customer is using the specified engine oil and fuel. For insufficient output, various causes can be suspected, so thoroughly investigate the relationship between the engine and the actual unit side. Check what kind of operations cause insufficient output. If hesitation or lug-down is included in the symptoms of insufficient output, it is related to the control on the actual unit side, so contact the manufacturer of the actual unit. If a trouble diagnosis scan tool is available, the engine output at the rated point can be easily verified by checking the boost at the rated point. ･ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is grime or clogging in the air cleaner element. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Increased resistance due to grime, clogging, or air intake piping collapsing particularly in the air cleaner element among the air intake system parts Abnormalities of the exhaust system parts



Exhaust system abnormalities such as exhaust pipe abnormality Abnormalities of the sensor input circuit system including the accelerator position sensor and the harness Abnormalities of the switch input circuit system Engine unit abnormalities including other mechanical failures such as compression pressure, valve clearance, turbocharger, supply pump, injector, and common rail Failures related to actual unit side equipment such as hydraulic pump Influence of the post-mounted electrical components such as wireless devices and lights Inspect for connector improper connections, harness abnormalities such as abrasions and bends, and short circuits with other circuits due to wire split inside harness. Also, perform inspections for functional diagnosis, and check the operation and control of each part. Make repairs if any abnormality is found. Output reduction due to fuel flow restriction imposed upon overheat Insufficient output due to fuel flow restriction during operation at high altitude ･ Control when overheating To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100 ºC (212 ºF). When the engine coolant temperature increases further, the fuel flow is also restricted further. When the temperature is near 120 ºC (248 ºF), the fuel flow is restricted to a certain level. The setting varies depending on the actual unit manufacturer. The actual unit is designed to issue an alarm from 105 ºC (221 ºF). By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation condition with fuel flow restriction.



･ Diagnostic aids Fuel system abnormalities such as running out of fuel, fuel freezing, air intrusion in the fuel pipe, filter abnormality, pipe abnormality, fuel quality, and fuel tank Air intake system abnormalities such as filter clogging and air intake pipe abnormality



･ High altitude correction



15D-16 Symptom (4HK1) The ECM calculates the current altitude in accordance with the signal from the atmospheric pressure sensor. Depending on the conditions of altitude, etc. at this time, the SCV opening and closing timing and injector energizing time are controlled and the fuel flow is corrected to be optimum.



DTC Information (4HK1) 15E-1



Description Engine DTC Information (4HK1) Table of Contents DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation.......................................................15E-3 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit.............................................................15E-4 DTC P0087 (Flash Code 225) Fuel Rail/System Pressure Too Low........................................................................15E-5 DTC P0088 (Flash Code 118) Fuel Rail/System Pressure Too High........................................................................15E-6 DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance...................................................................15E-7 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low.......................................................15E-8 DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High......................................................15E-9 DTC P0093 (Flash Code 227) Fuel System Leak Detected .....................................................................................15E-10 DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input.............................................................................15E-11 DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input.............................................................................15E-12 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low..................................................................15E-13 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High.................................................................15E-14 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low......................................................15E-15 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High.....................................................15E-16 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low..................................................................15E-17 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High.................................................................15E-18 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low..................................................................15E-19 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High.................................................................15E-20 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low..................................................................15E-21 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High.................................................................15E-22 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 .....................................................................................15E-23



DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 .....................................................................................15E-24 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 .....................................................................................15E-25 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 .....................................................................................15E-26 DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition................................................15E-27 DTC P0219 (Flash Code 543) Engine Overspeed Condition .....................................................................................15E-28 DTC P0234 (Flash Code 42) Turbocharger Overboost Condition.....................................................................15E-29 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low..................................................................15E-30 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High.................................................................15E-31 DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit..........................................................................15E-32 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance.........................................15E-33 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit..........................................................................15E-34 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance............................15E-35 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit..............................................................15E-36 DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High.....................................................15E-37 DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low......................................................15E-38 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1..........................15E-39 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1...................................................15E-40 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1..................................................15E-41 DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2..........................15E-42 DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2...................................................15E-43



15E-2 DTC Information (4HK1) DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2..................................................15E-44 DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low..............................................................................15E-45 DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High.............................................................................15E-46 DTC P0560 (Flash Code 155) System Voltage...........15E-47 DTC P0563 (Flash Code 35) System Voltage High....15E-48 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error..........................................15E-49 DTC P0602 (Flash Code 154) Control Module Programming Error......................................................15E-50 DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error......................15E-51 DTC P0606 (Flash Code 51) ECM/PCM Processor. . .15E-52 DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance..............................................15E-53 DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance.....................................................15E-54 DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit..........................................................................15E-55 DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL) Control Circuit..................................................15E-56 DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit..........................................................................15E-57 DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open...................................................15E-58 DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High....................................................15E-59 DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit..........................................................................15E-60 DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low..............................................................................15E-61 DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low..................................................................15E-62 DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High.................................................................15E-63 DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1...............................................15E-64 DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2...............................................15E-65 DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low..............................................................................15E-66 DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High.............................................................................15E-67 DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance...........................15E-68 DTC P1455 (Flash Code 132) PM Over Accumulation .....................................................................................15E-69 DTC P1471 (Flash Code 149) DPD Insufficient Regeneration................................................................15E-70



DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance..................................................15E-71 DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit..........................................................................15E-72 DTC P1669 (Flash Code 75) DPD Lamp Control Circuit .....................................................................................15E-73 DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input........................................................15E-74 DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input........................................................15E-75 DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input........................................................15E-76 DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input........................................................15E-77 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation.....................................................15E-78 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit............................................................15E-79 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit............................................................15E-80 DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low..............................................................................15E-81 DTC P2229 (Flash Code 71) Barometric Pressure Circuit High.............................................................................15E-82 DTC P242F (Flash Code 131) DPD Restriction.........15E-83 DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit..............................................................15E-84 DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance.............................15E-85 DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low......................................................15E-86 DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High.....................................................15E-87 DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position..............................................15E-88 DTC P2458 (Flash Code 139) DPD Regeneration Duration .....................................................................................15E-89 DTC U0001 (Flash Code 84) CAN-Bus Malfunction.15E-90 DTC U0073 (Flash Code 84) Control Module Communication Bus Off..............................................15E-91 DTC U0101 (Flash Code 85) Lost Communication with TCM.............................................................................15E-92 DTC U0110 (Flash Code 87) Lost Communication with VNT System................................................................15E-93 DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction......................................................15E-94 DTC mapping table.....................................................15E-95



DTC Information (4HK1) 15E-3



DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation 1.



DTC P0016 Description of DTC The crankshaft position sensor is installed on the upper position of the flywheel housing. The sensor rotor is fixed to the flywheel. There are 56 notches arranged at 6 degree intervals and an opening of 30 degrees. This opening allows detecting the top dead center of the cylinder No.1. The camshaft position sensor is installed behind the cylinder head. The camshaft position sensor detects 5 protrusions per 1 rotation of the engine. The camshaft gear has 4 protrusions arranged at 90 degree intervals and 1 reference protrusion. By detecting the opening section from the crankshaft position sensor and a single reference protrusion from the camshaft position sensor, the ECM can determine the compression top dead center of the cylinder No.1 and confirm that they are related to each other. When the ECM has detected that both signals are out of synchronization, it sets DTC.



2.



DTC P0016 Condition for setting the DTC DTC P0335, P0336, P0340, and P0341 have not been detected The starter switch has been ON The crankshaft position sensor signal pulse has been detected The camshaft position sensor signal pulse has been detected When the ECM has detected that the crankshaft position sensor signal and camshaft position sensor signal have been out of synchronization, while the engine has been running



3.



DTC P0016 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



15E-4 DTC Information (4HK1)



DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit 1.



DTC P0045 Description of DTC The opening angle of the variable nozzle on the turbocharger is controlled by the turbo control unit through operating the motor built into the actuator to activate the control rod in accordance with the signal received from the ECM. The ECM controls the variable nozzle based on the boost pressure, and detects the operation amount of the variable nozzle with the position sensor built into the turbo actuator. When the engine is not under load, the variable nozzle is in the open condition, or the boost pressure is not present. When the engine is under load, the turbo actuator is controlled to close the variable nozzle. As the result, the boost pressure increases. The ECM performs control that changes the boost pressure in accordance with the load requirements for the engine. The ECM communicates with the turbo control unit through CAN communication to perform control. The DTC is set when the ECM detects an open circuit or short circuit in the circuit between the turbo actuator and turbo control unit or an abnormality in communication with the turbo control unit.



2.



DTC P0045 Condition for setting the DTC The battery voltage is between 20 and 32 V The starter switch is ON Any of the following conditions is satisfied When the turbo control unit has detected 34V or higher for longer than 60 seconds When the turbo control unit detects that no change has been made in the position sensor signal or that all signals have remained in the Low or High state without any change When the turbo control unit has detected an open circuit or short circuit in the motor circuit for longer than 3 seconds



3.



DTC P0045 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



DTC Information (4HK1) 15E-5



DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low 1.



DTC P0087 Description of DTC The general common rail system is comprised of the following two fuel pressure sections. The suction side between the fuel tank and the supply pump and the highpressure side between the supply pump and the fuel injectors. The fuel is drawn from the fuel tank and supplied to the common rail by the two plungers located inside the supply pump. The common rail pressure is adjusted by the ECM through controlling the suction control valve based on the signal from the common rail pressure sensor. When the common rail pressure becomes in excess, the common rail pressure limiter valve opens to release the excessive pressure and return the fuel back to the fuel tank. The ECM sets the DTC when the common rail pressure increases more than necessary and then drops drastically. This DTC detects that the pressure limiter valve has been activated.



2.



DTC P0087 Condition for setting the DTC DTC P0192 and P0193 are not detected The starter switch is ON When the ECM has detected that the pressure limiter valve operated due to an excessive pressure of 180 MPa {1835 kgf/cm2 / 26100 psi} or higher inside the common rail　for longer than 1 second



3.



DTC P0087 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



15E-6 DTC Information (4HK1)



DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High 1.



DTC P0088 Description of DTC The general common rail system is comprised of the following 2 fuel pressure sections. The suction side between the fuel tank and the supply pump and the highpressure side between the supply pump and the fuel injectors. The fuel is drawn from the fuel tank and supplied to the common rail by the 3 plungers located inside the supply pump. The common rail pressure is adjusted by the ECM through controlling the suction control valve based on the signal from the common rail pressure sensor. As for the first stage, this DTC is set when the ECM detects an abnormally high fuel pressure for a certain period of time. Also, as for the second stage, the check engine warning light turns on when the ECM from the first stage, a period of time even if it detects a high fuel pressure. When the check engine warning light turns on, this DTC sets a DTC if the fuel pressure becomes abnormally high because the pressure limiter valve is not operated or is not operated immediately.



2.



DTC P0088 Condition for setting the DTC DTC P0091, P0092, P0192, and P0193 have not been detected The starter switch the ignition switch has been ON While the engine has been running First Stage When the ECM has detected that the common rail pressure has been 185 MPa {1886 kgf/cm2 / 26825 psi} or higher for 5 seconds or longer Second Stage When the ECM has detected that the common rail pressure has been 190 MPa {1937 kgf/cm2 / 27550 psi} or higher for 5 seconds or longer



3.



DTC P0088 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-7



DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 1.



DTC P0089 Description of DTC The general common rail system is comprised of the following two fuel pressure sections. The suction side between the fuel tank and the supply pump and the highpressure side between the supply pump and the fuel injectors. The fuel is drawn from the fuel tank and supplied to the common rail by the two plungers located inside the supply pump. The common rail pressure is adjusted by the ECM through controlling the suction control valve based on the signal from the common rail pressure sensor. This DTC is set when the ECM detects that the fuel pressure is higher than the target fuel pressure.



2.



DTC P0089 Condition for setting the DTC DTC P0091, P0092, P0192, P0193, P060B, P0651, P0201-P0204, P1261, P1262, P2146, and P2149 have not been detected The battery voltage has been between 18 and 32 V Starter switch the ignition switch has been ON While the engine has been running When the ECM has detected that the common rail pressure has been higher than the target fuel pressure for 40 MPa {408 kgf/cm2 / 5800 psi} or more for 5 seconds or longer



3.



DTC P0089 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



15E-8 DTC Information (4HK1)



DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low 1.



DTC P0091 Description of DTC The suction control valve is installed on the supply pump, and controls the fuel amount to be taken into the common rail. The suction control valve is normally fully open, and the opening of the regulator becomes smaller when the drive current becomes larger. The ECM calculates the common rail target pressure and fuel flow, and determine the opening angle of the suction control valve by comparing the calculated common rail pressure with the actual pressure value. When the actual common rail pressure is higher than the target pressure, the suction control valve closes to reduce the fuel flow. The DTC is set when the ECM detects that the feedback current of the suction control valve is abnormally low.



2.



DTC P0091 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the feedback current has been 50 mA or below for longer than 2 seconds or has fallen below the target current by 1000 mA or more



3.



DTC P0091 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-9



DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 1.



DTC P0092 Description of DTC The suction control valve is installed on the supply pump, and controls the fuel amount to be taken into the common rail. The suction control valve is normally fully open, and the opening of the regulator becomes smaller when the drive current becomes larger. The ECM calculates the common rail target pressure and fuel flow, and determine the opening angle of the suction control valve by comparing the calculated common rail pressure with the actual pressure value. When the actual common rail pressure is higher than the target pressure, the suction control valve closes to reduce the fuel flow. The DTC is set when the ECM detects that the feedback current of the suction control valve is abnormally high.



2.



DTC P0092 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the feedback current has been 2400 mA or above for longer than 2 seconds or has exceeded the target current by 1000 mA or more



3.



DTC P0092 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



15E-10 DTC Information (4HK1)



DTC P0093 (Flash Code 227) Fuel System Leak Detected 1.



DTC P0093 Description of DTC The general common rail system is comprised of the following two fuel pressure sections. The suction side between the fuel tank and the supply pump and the highpressure side between the supply pump and the fuel injectors. The fuel is drawn from the fuel tank and supplied to the common rail by the two plungers located inside the supply pump. The common rail pressure is adjusted by the ECM through controlling the suction control valve based on the signal from the common rail pressure sensor. The DTC is set when the ECM detects that the common rail pressure is low compared to the engine RPM.



2.



DTC P0093 Condition for setting the DTC DTC P0087, P0091, P0092, P0192, P0193, P0201, P0202, P0203, P0204, P060B, P0651, P1261, P1262, P2146, and P2149 have not been detected The battery voltage has been between 18 and 32 V Starter switch the ignition switch has been ON The engine RPM has been 900 r/min or more When the ECM has detected that the actual common rail pressure has been 15 MPa {153 kgf/cm2 / 2175 psi} or lower for 3 seconds or longer (this may not be a prerequisite depending on the device manufacturer)



3.



DTC P0093 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-11



DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input 1.



DTC P0102 Description of DTC The mass air flow sensor is an air flow meter to measure the amount of air taken into the engine. It is installed between the air cleaner and turbocharger. A small amount of air taken into the engine indicates deceleration or idle RPM. A large amount of air indicates acceleration or high load. The sensor has the following circuits 12 V voltage circuit GND circuit Mass air flow sensor signal circuit The ECM monitors the voltage of the mass air flow sensor signal. The scan tool displays the air flow as g/cyl for each voltage and cylinder from this output voltage. When the ECM has detected that the signal voltage is absolutely low, it sets DTC.



2.



DTC P0102 Condition for setting the DTC P060B has not been detected The battery voltage has been between 18 and 32 V The starter switch the ignition switch is ON While the engine is rotating When the ECM has detected that the mass air flow sensor signal voltage has been 0.1 V or lower for 3 seconds



3.



DTC P0102 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value for the MAF sensor. Limit the fuel injection amount. Stop the EGR control.



15E-12 DTC Information (4HK1)



DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input 1.



DTC P0103 Description of DTC The mass air flow sensor is an air flow meter to measure the amount of air taken into the engine. It is installed between the air cleaner and turbocharger. A small amount of air taken into the engine indicates deceleration or idle RPM. A large amount of air indicates acceleration or high load. The sensor has the following circuits 12 V voltage circuit GND circuit Mass air flow sensor signal circuit The ECM monitors the voltage of the mass air flow sensor signal. The scan tool displays the air flow as g/cyl for each voltage and cylinder from this output voltage. When the ECM has detected that the signal voltage is absolutely low, it sets DTC.



2.



DTC P0103 Condition for setting the DTC P060B has not been detected The battery voltage has been between 18 and 32 V The starter switch the ignition switch is ON While the engine is rotating When the ECM has detected that the mass air flow sensor signal voltage has been 4.9 V or lower for 3 seconds



3.



DTC P0103 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value for the MAF sensor. Limit the fuel injection amount. Stop the EGR control.



DTC Information (4HK1) 15E-13



DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low 1.



DTC P0112 Description of DTC The intake air temperature sensor is a thermistor type sensor to measure the temperature of air taken into the engine. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the intake air temperature sensor is cold, the resistance of the sensor is high. When the air temperature rises, the resistance of the sensor becomes low. The ECM detects the high voltage when the sensor resistance is high. The ECM detects the low voltage when the sensor resistance is low. When the ECM has detected that the DPD differential pressure is abnormally low, it sets DTC.



2.



DTC P0112 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the intake air temperature sensor signal voltage has been 0.1 V or lower for 4 seconds



3.



DTC P0112 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value for intake air temperature sensor. Limit the fuel injection amount. Stop the EGR control.



15E-14 DTC Information (4HK1)



DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High 1.



DTC P0113 Description of DTC The intake air temperature sensor is a thermistor type sensor to measure the temperature of air taken into the engine. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to the GND. When the intake air temparture sensor is cold, the resistance of the sensor is high. When the air temperature rises, the resistance of the sensor becomes low. The ECM detects the high voltage when the sensor resistance is high. The ECM detects the low voltage when the sensor resistance is low. When the ECM has detected that the DPD differential pressure is abnormally high, it sets DTC.



2.



DTC P0113 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON The engine is running for 3 minutes or longer When the ECM has detected that the signal voltage of the intake air temperature sensor has been 4.85 V or higher for 4 seconds



3.



DTC P0113 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value for intake air temperature sensor. Limit the fuel injection amount. Stop the EGR control.



DTC Information (4HK1) 15E-15



DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 1.



DTC P0117 Description of DTC The water temperature sensor is installed in the thermostat housing. The water temperature sensor is a thermistor type sensor, and measures the temperature of the engine coolant. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the water temperature sensor is cold, the resistance of the sensor is high. When the engine coolant temperature rises, the resistance of the sensor becomes low. The ECM detects the high voltage when the sensor resistance is high. The ECM detects the low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0117 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal voltage of the water temperature sensor has been 0.1 V or lower for 4 seconds



3.



DTC P0117 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of water temperature. Limit the fuel injection amount. Stop the EGR control. Prohibit the DPD regeneration.



15E-16 DTC Information (4HK1)



DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High 1.



DTC P0118 Description of DTC The water temperature sensor is installed in the thermostat housing. The water temperature sensor is a thermistor type sensor, and measures the temperature of the engine coolant. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the water temperature sensor is cold, the resistance of the sensor is high. When the engine coolant temperature rises, the resistance of the sensor becomes low. The ECM detects the high voltage when the sensor resistance is high. The ECM detects the low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally high signal voltage.



2.



DTC P0118 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON The engine is running for 3 minutes or longer When the ECM has detected that the signal voltage of the water temperature sensor has been 4.85 V or higher for 4 seconds



3.



DTC P0118 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of water temperature. Limit the fuel injection amount. Stop the EGR control.



DTC Information (4HK1) 15E-17



DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 1.



DTC P0122 Description of DTC The intake throttle position sensor is installed on the intake throttle valve body together with the solenoid. The intake throttle position sensor changes the signal voltage in accordance with the opening angle of the intake throttle valve. The sensor has the following circuits. 5 V power supply circuit GND circuit Intake throttle position sensor signal circuit The intake throttle position sensor sends the change signal of the intake throttle valve opening angle to the ECM.The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0122 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the intake throttle position sensor signal voltage has been 0.3 V or lower for 3 seconds



3.



DTC P0122 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



15E-18 DTC Information (4HK1)



DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High 1.



DTC P0123 Description of DTC The intake throttle position sensor is installed on the intake throttle valve body together with the solenoid. The intake throttle position sensor changes the signal voltage in accordance with the opening angle of the intake throttle valve. The sensor has the following circuits. 5 V power supply circuit GND circuit Intake throttle position sensor signal circuit The intake throttle position sensor sends the change signal of the intake throttle valve opening angle to the ECM. The DTC is set when the ECM detects an abnormally high signal voltage.



2.



DTC P0123 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the intake throttle position sensor signal voltage has been 4.9 V or higher for 3 seconds



3.



DTC P0123 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



DTC Information (4HK1) 15E-19



DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low 1.



DTC P0182 Description of DTC The fuel temperature sensor is installed on the supply pump. The fuel temperature sensor is a thermistor type sensor, and measures the temperature of the fuel entering the supply pump. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the fuel temperature sensor is cold, the resistance of the sensor is high. When the fuel temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage when the sensor resistance is high. The ECM detects a low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0182 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal voltage of the fuel temperature sensor has been 0.1 V or lower for 4 seconds



3.



DTC P0182 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of fuel temperature sensor.



15E-20 DTC Information (4HK1)



DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High 1.



DTC P0183 Description of DTC The fuel temperature sensor is installed on the supply pump. The fuel temperature sensor is a variable resistor, and measures the temperature of the fuel entering the supply pump. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the fuel temperature sensor is cold, the resistance of the sensor is high. When the fuel temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage when the sensor resistance is high. The ECM detects a low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally high signal voltage.



2.



DTC P0183 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON The engine is running for 3 minutes or longer When the ECM has detected that the signal voltage of the fuel temperature sensor has been 4.85 V or higher for 4 seconds



3.



DTC P0183 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of fuel temperature sensor.



DTC Information (4HK1) 15E-21



DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low 1.



DTC P0192 Description of DTC Common rail pressure sensor is installed on the common rail, and it detects the fuel pressure in the common rail to covert into the voltage signal. The sensor has the following circuits. 5 V power supply circuit GND circuit Common rail pressure sensor signal circuit The ECM monitors the voltage of the common rail pressure sensor signal. The signal voltage becomes higher when the pressure of the common rail is higher, and it becomes lower when the pressure is lower. The ECM calculates the actual common rail pressure from the voltage signal, and uses the result for various controls such as the fuel injection control. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0192 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the common rail pressure sensor signal voltage has been 0.7 V or lower for longer than 0.16 seconds



3.



DTC P0192 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of common rail pressure. Limit the fuel injection amount. Limit the fuel flow. Stop the EGR control. Stop the DPD regeneration.



15E-22 DTC Information (4HK1)



DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 1.



DTC P0193 Description of DTC pressure in the common rail to covert into the voltage signal. The sensor has the following circuits. 5 V power supply circuit GND circuit Common rail pressure sensor signal circuit The ECM monitors the voltage of the common rail pressure sensor signal. The signal voltage becomes higher when the pressure of the common rail is higher, and it becomes lower when the pressure is lower. The ECM calculates the actual common rail pressure from the voltage signal, and uses the result for controls such as the fuel injection control. The DTC is set when the ECM detects an abnormally high signal voltage.



2.



DTC P0193 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the common rail pressure sensor signal voltage has been 4.8 V or higher for longer than 1 second



3.



DTC P0193 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of common rail pressure. Limit the fuel injection amount. Limit the fuel flow. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-23



DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 1.



DTC P0201 Description of DTC The ECM calculates the optimum fuel injection ON time using data transmitted from the sensor. The injector power circuit supplies the high voltage while the ECM grounds the injector solenoid control circuit as well as drives the injector of each cylinder. The ECM sets a DTC when an abnormality is detected in the first cylinder injector circuit.



2.



DTC P0201 Condition for setting the DTC DTC P1261 and P2146 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running Any of the following conditions is satisfied When the ECM has detected an open circuit with the injector solenoid When the ECM has detected that a short of the injector solenoid control circuit to the voltage circuit or charge voltage circuit has occurred



3.



DTC P0201 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop the injection of the first cylinder. Stop the EGR control. Stop the DPD regeneration.



15E-24 DTC Information (4HK1)



DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 1.



DTC P0202 Description of DTC The ECM calculates the optimum fuel injection ON time using the data transmitted from the sensor. The injector power supply circuit supplies the high voltage while the ECM grounds the injector solenoid control circuit as well as drives the injector of each cylinder. The ECM sets a DTC when an abnormality is detected in the second cylinder injector circuit.



2.



DTC P0202 Condition for setting the DTC DTC P1262 and P2149 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running Any of the following conditions is satisfied When the ECM has detected an open circuit with the injector solenoid When the ECM has detected that a short of the injector solenoid control circuit to the voltage circuit or charge voltage circuit has occurred



3.



DTC P0202 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop the injection of the second cylinder. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-25



DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 1.



DTC P0203 Description of DTC The ECM calculates the optimum fuel injection ON time using the data transmitted from the sensor. The injector power supply circuit supplies the high voltage while the ECM grounds the injector solenoid control circuit as well as drives the injector of each cylinder. The ECM sets a DTC when an abnormality is detected in the third cylinder injector circuit.



2.



DTC P0203 Condition for setting the DTC DTC P1262 and P2149 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running Any of the following conditions is satisfied When the ECM has detected an open circuit with the injector solenoid When the ECM has detected that a short of the injector solenoid control circuit to the voltage circuit or charge voltage circuit has occurred



3.



DTC P0203 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop the injection of the third cylinder. Stop the EGR control. Stop the DPD regeneration.



15E-26 DTC Information (4HK1)



DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 1.



DTC P0204 Description of DTC The ECM calculates the optimum fuel injection ON time using the data transmitted from the sensor. The injector power supply circuit supplies the high voltage while the ECM grounds the injector solenoid control circuit as well as drives the injector of each cylinder. The ECM sets a DTC when an abnormality is detected in the fourth cylinder injector circuit.



2.



DTC P0204 Condition for setting the DTC DTC P1261 and P2146 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running Any of the following conditions is satisfied When the ECM has detected an open circuit with the injector solenoid When the ECM has detected that a short of the injector solenoid control circuit to the voltage circuit or charge voltage circuit has occurred



3.



DTC P0204 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop the injection of the fourth cylinder. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-27



DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition 1.



DTC P0217 Description of DTC The water temperature sensor is installed in the thermostat housing. The water temperature sensor is a thermistor type, and measures the temperature of the engine coolant. The DTC is set when the ECM detects an abnormally high temperature in the coolant.



2.



DTC P0217 Condition for setting the DTC DTC P0117 and P0118 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running Any of the following conditions is satisfied When the ECM has detected that the engine coolant temperature has been 110 ℃ (230 ℉) or higher for 5 seconds When the ECM has detected that the engine coolant temperature has been 110 ℃ (230 ℉) or higher for 5 seconds during DPD regeneration



15E-28 DTC Information (4HK1)



DTC P0219 (Flash Code 543) Engine Overspeed Condition 1.



DTC P0219 Description of DTC The crankshaft position sensor is installed on the upper position of the flywheel housing. The ECM calculates the engine RPM and the correct position of the crankshaft using the signal pulses from the crankshaft position sensor. When the ECM has detected that the engine has overrun, it sets DTC.



2.



DTC P0219 Condition for setting the DTC When the ECM detects that the engine RPM is 2500 r/ min or above for longer than 3 seconds



3.



DTC P0219 Action taken when the DTC sets When it has been detected for 2 consecutive times, the failure is displayed on the monitor of the main device or the Diagnostic light illuminates. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



DTC Information (4HK1) 15E-29



DTC P0234 (Flash Code 42) Turbocharger Overboost Condition 1.



DTC P0234 Description of DTC The boost sensor is located in the air intake pipe. This sensor changes the signal voltage in accordance with the change in the air pressure inside the air intake pipe. The ECM monitors the boost sensor signal. The DTC is set when the ECM detects an abnormally high sensor signal. This indicates that the boost pressure is abnormally high.



2.



DTC P0234 Condition for setting the DTC DTC P0045, P0237, P0238, U0001,U0110, and U0411 are not set The starter switch is ON When the ECM has detected that the boost pressure has been 270 kPa {3 kgf/cm2 / 39 psi} or higher for 5 seconds or longer



3.



DTC P0234 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. The highest engine RPM is restricted to 1200 r/min. Stop the EGR control. Stop the DPD regeneration.



15E-30 DTC Information (4HK1)



DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low 1.



DTC P0237 Description of DTC The boost sensor is located in the air intake pipe. This sensor changes the signal voltage in accordance with the change in the air pressure inside the air intake pipe. The boost sensor has the following circuits. 5 V power supply circuit GND circuit Boost sensor circuit The boost sensor sends the change signal of the pressure inside the air intake pipe to the ECM. The ECM detects an high voltage signal when the air pressure is high due to the high load applied to the engine, etc. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0237 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the boost sensor signal voltage has been 0.1 V or lower for 3 seconds



3.



DTC P0237 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of boost pressure. Stop the EGR control.



DTC Information (4HK1) 15E-31



DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High 1.



DTC P0238 Description of DTC The boost sensor is located in the air intake pipe. This sensor changes the signal voltage in accordance with the change in the air pressure inside the air intake pipe. The boost sensor has the following circuits. 5 V power supply circuit GND circuit Boost sensor circuit The boost sensor sends the change signal of the pressure inside the air intake pipe to the ECM. The ECM detects an high voltage signal when the air pressure is high due to the high load applied to the engine, etc. The DTC is set when the ECM detects an abnormally high signal voltage.



2.



DTC P0238 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the boost sensor signal voltage has been 4.9 V or lower for 3 seconds



3.



DTC P0238 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of boost pressure. Stop the EGR control.



15E-32 DTC Information (4HK1)



DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit 1.



DTC P0335 Description of DTC The crankshaft position sensor is installed on the flywheel housing. The sensor rotor is fixed to the flywheel. There are 56 notches arranged at 6 degree intervals and an opening of 30 degrees. This opening allows detecting the top dead center of the cylinder No.1. The crankshaft position sensor generates the pulse signal. The sensor has following circuits. 5 V power supply circuit GND circuit Crankshaft position sensor signal circuit. The ECM monitors the signal pulses from the crankshaft position sensor and camshaft position sensor to confirm that they are related to each other. While no crankshaft position sensor signal pulse is detected, the ECM sets DTC when it has received a certain amount of camshaft position sensor signal pulses.



2.



DTC P0335 Condition for setting the DTC DTC P0016, P0336, P0340, and P0341 are not set The starter switch is ON The CMP sensor signal pulse is detected When the ECM has detected that the CKP sensor signal pulse has not been generated, while the engine has been running



3.



DTC P0335 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-33



DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance 1.



DTC P0336 Description of DTC The crankshaft position sensor is installed on the upper position of the flywheel housing. The sensor rotor is fixed to the flywheel. There are 56 notches arranged at 6 degree intervals and an opening of 30 degrees. This opening allows detecting the top dead center of the cylinder No.1. The ECM monitors the signal pulses from the crankshaft position sensor and camshaft position sensor, and confirms that they are related to each other. When the ECM has received excessive or insufficient crankshaft position sensor signal pulses, it sets DTC.



2.



DTC P0336 Condition for setting the DTC DTC P0016, P0335, P0340, and P0341 are not set The starter switch is ON The CKP sensor signal pulse is detected When the ECM has detected excessive or insufficient of CKP sensor signal pulse, while the engine has been running



3.



DTC P0336 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



15E-34 DTC Information (4HK1)



DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 1.



DTC P0340 Description of DTC The camshaft position sensor is installed behind the cylinder head with the camshaft gear. The camshaft position sensor detects 5 protrusions per 1 revolution of the engine. The camshaft gear has 4 protrusions arranged at 90 degree intervals and 1 reference protrusion. The crankshaft position sensor generates the pulse signal. The sensor has following circuits. 5 V power supply circuit GND circuit Crankshaft position sensor signal circuit The ECM monitors the signal pulses from the crankshaft position sensor and camshaft position sensor to confirm that they are related to each other. While no crankshaft position sensor signal pulse is detected, the ECM sets DTC when it has received a certain amount of camshaft position sensor signal pulses.



2.



DTC P0340 Condition for setting the DTC DTC P0016, P0335, P0336, and P0341 are not set The starter switch is ON The CKP sensor signal pulse is detected When the ECM has detected that the CMP sensor signal pulse has not been generated, while the engine has been running



3.



DTC P0340 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



DTC Information (4HK1) 15E-35



DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance 1.



DTC P0404 Description of DTC The ECM controls the EGR valve opening and closing based on the engine running condition and by controlling the EGR solenoid. The EGR valve lift amount is detected by the position sensor and transmitted to the ECM. If the ECM has detected a variance between the actual EGR valve position and desired EGR valve position for a certain period of time while the EGR valve is commanded ON, it sets DTC.



2.



DTC P0404 Condition for setting the DTC DTC P0409 is not set The battery voltage is between 20 and 32 V The starter switch is ON The ON instruction is issued for EGR control When the ECM has detected that the difference between the actual and desired EGR valve positions has been 20 % or more for 10 seconds or longer



3.



DTC P0404 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



15E-36 DTC Information (4HK1)



DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit 1.



DTC P0409 Description of DTC The EGR position sensor is provided on the EGR valve together with the control solenoid. The sensor consists of three individual sensors within one housing. The EGR position sensor 1, EGR position sensor 2, and EGR position sensor 3 are hall IC type sensors with the following circuits. 5 V power supply circuit GND circuit Signal circuit The EGR position sensor transmits The high/low status of the signals related to changes of the EGR valve position. When the ECM has detected that the signals are not related to each other (e.g., all signals are high or low), it sets DTC.



2.



DTC P0409 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal from the EGR valve position sensor has been kept low or high for longer than 3 seconds



3.



DTC P0409 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-37



DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High 1.



DTC P041C Description of DTC The IMT sensor is installed on the intake manifold. The IMT sensor is a thermistor type sensor to measure the temperature of intake air mixed with EGR gas. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the IMT sensor is cold, the resistance of the sensor is high. When the EGR gas amount increases, the intake air temperature rises and the sensor resistance decreases. The ECM detects the high voltage when the sensor resistance is high. The ECM detects the low voltage when the sensor resistance is low. When the ECM has detected that the DPD differential pressure is abnormally high, it sets DTC.



2.



DTC P041C Condition for setting the DTC DTC P060B is not detected The engine is running for 3 minutes or longer When the ECM has detected that the signal voltage of the IMT sensor has been 4.94 V or higher for 4 seconds



3.



DTC P041C Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value for the IMT sensor.



15E-38 DTC Information (4HK1)



DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low 1.



DTC P041D Description of DTC The IMT sensor is installed on the intake manifold. The IMT sensor is a thermistor type sensor to measure the temperature of intake air mixed with EGR gas. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the IMT sensor is cold, the resistance of the sensor is high. When the EGR gas amount increases, the intake air temperature rises and the sensor resistance decreases. The ECM detects the high voltage when the sensor resistance is high. The ECM detects the low voltage when the sensor resistance is low. When the ECM has detected that the DPD differential pressure is abnormally low, it sets DTC.



2.



DTC P041D Condition for setting the DTC DTC P060B has not been detected When the ECM has detected that the signal voltage of the IMT sensor has been 0.1 V or lower for 4 seconds or longer



3.



DTC P041D Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value for the IMT sensor.



DTC Information (4HK1) 15E-39



DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 1.



DTC P0426 Description of DTC The exhaust gas temperature sensor 1 is installed on the DPD housing. The exhaust gas temperature sensor 1 is a variable resistor, and measures the temperature of the exhaust gas before entering the DPD filter. The DTC is set when the ECM detects an abnormally high exhaust temperature.



2.



DTC P0426 Condition for setting the DTC DTC P0427 and P0428 are not detected The starter switch is ON When the ECM has detected that the measure value of the exhaust gas temperature sensor 1 has been 880 ℃ {1616 °F} or more for 5 seconds



3.



DTC P0426 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restricts the fuel injection amount.



15E-40 DTC Information (4HK1)



DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1 1.



DTC P0427 Description of DTC The exhaust temperature sensor 1 is installed on the DPD housing. The exhaust gas temperature sensor 1 is a variable resistor, and measures the temperature of the exhaust gas before entering the DPD filter. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the DPD exhaust temperature sensor 1 is cold, the resistance of the sensor is high. When the exhaust temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage when the sensor resistance is high. The ECM detects a low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0427 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal voltage of the exhaust temperature sensor 1 has been 0.2 V or lower for 3 seconds



3.



DTC P0427 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



DTC Information (4HK1) 15E-41



DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 1.



DTC P0428 Description of DTC The exhaust temperature sensor 1 is installed on the DPD housing. The exhaust gas temperature sensor 1 is a variable resistor, and measures the temperature of the exhaust gas before entering the DPD filter. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the DPD exhaust temperature sensor 1 is cold, the resistance of the sensor is high. When the exhaust temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage when the sensor resistance is high. The ECM detects a low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P0428 Condition for setting the DTC DTC P0112, P0113, P0117, P0118, P060B, P2228, and P2229 are not set The battery voltage is between 18 and 32 V The starter switch is ON The engine coolant temperature is 70 ℃ (158 ℉) or higher The fuel injection amount is a certain value or more The engine operating time is 0.5 - 10 minutes or longer When the ECM has detected that the signal voltage of the exhaust temperature sensor 1 has been 4.85 V or higher for 5 seconds



3.



DTC P0428 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



15E-42 DTC Information (4HK1)



DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 1.



DTC P042B Description of DTC The exhaust temperature sensor 2 is installed on the DPD housing. The exhaust temperature sensor 2 is a variable resistor, and measures the temperature of the exhaust gas before entering the oxidation catalyst. The DTC is set when the ECM detects an abnormally high exhaust temperature.



2.



DTC P042B Condition for setting the DTC DTC P042C and P042D are not set The starter switch is ON When the ECM has detected that the exhaust temperature 2 has been 870 ℃ (1600 ℉) or higher for 5 seconds



3.



DTC P042B Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restricts the fuel injection amount.



DTC Information (4HK1) 15E-43



DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 1.



DTC P042C Description of DTC The exhaust temperature sensor 2 is installed on the DPD housing. The exhaust temperature sensor 2 is a variable resistor, and measures the temperature of the exhaust gas before entering the oxidation catalyst. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the exhaust temperature sensor 2 is cold, the resistance of the sensor is high. When the exhaust temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage when the sensor resistance is high. The ECM detects a low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P042C Condition for setting the DTC DTC P060B7 is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal voltage of the exhaust temperature sensor 2 signal voltage has been 0.2 V or lower for 3 seconds



3.



DTC P042C Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



15E-44 DTC Information (4HK1)



DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 1.



DTC P042D Description of DTC The exhaust temperature sensor 2 is installed on the DPD housing. The exhaust temperature sensor 2 is a variable resistor, and measures the temperature of the exhaust gas before entering the oxidation catalyst. This sensor has a signal circuit and GND circuit. The ECM supplies 5 V to the signal circuit, and the GND circuit connects to GND. When the exhaust temperature sensor 2 is cold, the resistance of the sensor is high. When the exhaust temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage when the sensor resistance is high. The ECM detects a low voltage when the sensor resistance is low. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P042D Condition for setting the DTC DTC P0112, P0113, P0117, P0118, P060B, P2228, and P2229 are not set The battery voltage is between 18 and 32 V The starter switch is ON The engine coolant temperature is 70 ℃ (158 ℉) or higher The fuel injection amount is a certain value or more The engine operating time is 0.5 - 10 minutes or longer When the ECM has detected that the signal voltage of the exhaust temperature sensor 2 has been 4.85 V or higher for 5 seconds



3.



DTC P042D Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



DTC Information (4HK1) 15E-45



DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low 1.



DTC P0522 Description of DTC The oil pressure sensor detects the engine oil pressure. The oil pressure sensor is installed near the starter motor of the cylinder block. The internal resistance of the oil pressure sensor changes in accordance with the change in the pressure. The resistance value is low when the pressure is high, and the resistance value is high when the pressure is low. The ECM is connected to the oil pressure sensor through the power supply circuit, signal circuit and GND circuit, and applies +5 V power to the power supply circuit. The ECM detects the change in the signal voltage that is occurred according to the resistance change based on the pressure of the oil pressure sensor as a signal.



2.



DTC P0522 Condition for setting the DTC DTC P060B is not detected The battery voltage is between 18 and 32 V When the ECM has detected that the signal voltage of the oil pressure sensor has been 0.1 V or lower for 4 seconds



3.



DTC P0522 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of the oil pressure sensor.



15E-46 DTC Information (4HK1)



DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High 1.



DTC P0523 Description of DTC The oil pressure sensor detects the engine oil pressure. The oil pressure sensor is installed near the starter motor of the cylinder block. The internal resistance of the oil pressure sensor changes in accordance with the change in the pressure. The resistance value is low when the pressure is high, and the resistance value is high when the pressure is low. The ECM is connected to the oil pressure sensor through the power supply circuit, signal circuit and GND circuit, and applies +5 V power to the power supply circuit. The ECM detects the change in the signal voltage that is occurred according to the resistance change based on the pressure of the oil pressure sensor as a signal.



2.



DTC P0523 Condition for setting the DTC DTC P060B is not detected The battery voltage is between 18 and 32 V When the ECM has detected that the signal voltage of the oil pressure switch has been 4.85 V or higher for 4 seconds



3.



DTC P0523 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of the oil pressure sensor.



DTC Information (4HK1) 15E-47



DTC P0560 (Flash Code 155) System Voltage 1.



DTC P0560 Description of DTC The ECM supplies 12 V power to the mass air flow sensor. The battery power is supplied to the ECM via the dropping register and converted into 12 V. The ECM monitors the 12 V power supply circuit voltage. When the ECM has detected that the voltage is abnormally low or high, it sets DTC.



2.



DTC P0560 Condition for setting the DTC P060B is not set The battery voltage is between 16 and 32 V The starter switch is ON Any of the following conditions is satisfied When the ECM has detected that 12 V power supply circuit voltage has been 7 V or lower for longer than 1.2 seconds When the ECM has detected that 12 V power supply circuit voltage has been 19 V or higher for longer than 1.2 seconds



3.



DTC P0560 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control.



15E-48 DTC Information (4HK1)



DTC P0563 (Flash Code 35) System Voltage High 1.



DTC P0563 Description of DTC The ECM monitors ignition voltage of the ignition feed terminal and makes sure that the voltage stays within the appropriate range. When the ECM has detected that the ignition power voltage is abnormally high, it sets DTC.



2.



DTC P0563 Condition for setting the DTC DTC P060B is not set When the ECM has detected that ignition power supply circuit voltage has been 32 V or higher for 5 seconds



3.



DTC P0563 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



DTC Information (4HK1) 15E-49



DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error 1.



DTC P0601 Description of DTC This diagnosis applies to the microprocessor inside the ECM.



2.



DTC P0601 Condition for setting the DTC When ECM detects that the calculated checksum does not correspond with the checksum that is registered into ROM.



3.



DTC P0601 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop the engine. Restrict the fuel flow.



15E-50 DTC Information (4HK1)



DTC P0602 (Flash Code 154) Control Module Programming Error 1.



DTC P0602 Description of DTC The EEPROM inside the ECM records the injector ID code information. When the ECM has detected that the injector ID code is not programmed in the EEPROM or found an error in the programmed injector ID code, it sets DTC.



2.



DTC P0602 Condition for setting the DTC The starter switch is ON Any of the following conditions is satisfied When the ECM has detected that the injector ID code has not been programmed When the ECM has detected an error of the programmed injector ID code



3.



DTC P0602 Action taken when the DTC sets When it has been detected for 2 consecutive times, the failure is displayed on the monitor of the main device or the Diagnostic light illuminates. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



DTC Information (4HK1) 15E-51



DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error 1.



DTC P0604 Description of DTC This diagnosis applies to the microprocessor inside the ECM.



2.



DTC P0604 Condition for setting the DTC The battery voltage is 16 V or above When the ECM detects an abnormality in the internal RAM



3.



DTC P0604 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop the engine. Restrict the fuel flow.



15E-52 DTC Information (4HK1)



DTC P0606 (Flash Code 51) ECM/PCM Processor 1.



DTC P0606 Description of DTC This diagnosis applies to the microprocessor inside the ECM.



2.



DTC P0606 Condition for setting the DTC The battery voltage is 16 V or higher The starter switch is ON When the internal sub CPU has detected an abnormality in the main CPU



3.



DTC P0606 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Upon returning to CPU, it limits the fuel injection amount. Limit the fuel flow. Limit the maximum engine RPM to 1700 r/min. Stop EGR control. Stop DPD regeneration.



DTC Information (4HK1) 15E-53



DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance 1.



DTC P060B Description of DTC This diagnosis applies to the microprocessor inside the ECM.



2.



DTC P060B Condition for setting the DTC When the ECM has detected an abnormality of the internal A/D converter



3.



DTC P060B Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



15E-54 DTC Information (4HK1)



DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance 1.



DTC P0638 Description of DTC The ECM controls the intake throttle solenoid to open and close the intake throttle valve according to the engine operating status. The intake throttle valve opening angle is detected by the position sensor and transmitted to the ECM. While the ON command to the intake throttle solenoid is being executed, if the ECM has detected a difference between the actual opening angle and desired opening angle of the intake throttle, it sets DTC.



2.



DTC P0638 Condition for setting the DTC DTC P0122, P0123 are not set The battery voltage is between 18 and 32 V The starter switch is ON The desired opening angle of the intake throttle is constant The ON instruction has been issued for the intake throttle solenoid When the ECM has detected that the difference between the actual and desired opening angles of the intake throttle has been 40 % or more for 5 seconds or longer



3.



DTC P0638 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-55



DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit 1.



DTC P0641 Description of DTC The ECM supplies 5 V power to the following sensors via the power supply circuit 1. Accelerator position sensor The ECM also supplies 5 V power to the following sensors via the power supply circuit 5. Intake air temperature sensor Crankshaft position sensor Fuel pressure sensor The 5 V power supply circuits 1 and 5 are independent of each other outside the ECM, but they share the bus inside the ECM. Therefore, when one of the sensor 5 V power supply circuits is shorted, the entire 5 V power supply circuits 1 and 5 may be affected. The ECM monitors the voltage of the 5 V power supply circuits 1 and 5, and sets DTC when the ECM has detected that the voltage is abnormally low or high.



2.



DTC P0641 Condition for setting the DTC DTC P060B is not set The battery voltage is between 16 and 32 V The starter switch is ON When the ECM has detected that voltages of the 5 V power supply circuits 1 and 5 have been 4.5 V or lower or 5.5 V or higher for longer than 0.4 seconds



3.



DTC P0641 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



15E-56 DTC Information (4HK1)



DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL) Control Circuit 1.



DTC P0650 Description of DTC The check engine warning light is located in the display. The check engine warning light informs the machine operator that an abnormality is occurred in the engine control system and repair is required. The ECM monitors the check engine warning light control circuit to see whether a condition different from the commanded condition of the check engine warning light exists. If the ECM detects a low voltage when the OFF command is executed or a high voltage when the ON command is executed to the check engine warning light, there is a failure in the circuit. The DTC is set when the ECM detects an abnormal value in the voltage of the control circuit.



2.



DTC P0650 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON Any of the following conditions is satisfied When the ECM detects a low voltage condition in the check engine warning light control circuit when the ECM executes the OFF command When the ECM detects a high voltage condition in the check engine warning light control circuit when the ECM executes the ON command



DTC Information (4HK1) 15E-57



DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit 1.



DTC P0651 Description of DTC The ECM supplies 5 V power to the following sensors via the 5 V power supply circuit 2. Atmospheric pressure sensor The ECM also supplies 5 V power to the following sensors via the 5 V power supply circuit 6. Camshaft position sensor Boost temperature sensor The 5 V power supply circuits 2 and 6 are independent of each other outside the ECM, but they share a bus inside the ECM. Therefore, when one of the sensor 5 V power supply circuits is shorted, the entire 5 V power supply circuits 2 and 6 may be affected. The ECM monitors the voltage of the 5 V power supply circuits 2 and 6, and sets DTC when the ECM has detected that the voltage is abnormally low or high.



2.



DTC P0651 Condition for setting the DTC DTC P060B is not set The battery voltage is between 16 and 32 V The starter switch is ON When the ECM has detected that voltages of the 5 V power supply circuit 2 or 6 has been 4.5 V or lower or 5.5 V or higher for longer than 0.4 seconds



3.



DTC P0651 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the DPD regeneration.



15E-58 DTC Information (4HK1)



DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open 1.



DTC P0685 Description of DTC When the ECM has received the starter switch ON signal, power is applied to the ECM main relay and the battery power is supplied to the ECM via the relay switch side. When the starter switch was turned to OFF, power applied to the ECM main relay is discontinued after a certain period of time. If the ECM has detected a low voltage with the relay voltage supply circuit when the ON command has been executed for the ECM main relay, it sets DTC.



2.



DTC P0685 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected the voltage condition in the ECM main relay voltage supply circuit has been 1V or lower for 3 seconds while the ON command is being executed to the relay



3.



DTC P0685 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



DTC Information (4HK1) 15E-59



DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High 1.



DTC P0687 Description of DTC When the ECM has received the starter switch ON signal, power is applied to the ECM main relay and the battery power is supplied to the ECM via the relay switch side. When the starter switch was turned to OFF, power applied to the ECM main relay is discontinued after a certain period of time. If the ECM has detected that the ECM is ON when the OFF command has been executed for the ECM main relay, it sets DTC.



2.



DTC P0687 Condition for setting the DTC The starter switch is ON When the ECM has detected that the ECM has been ON for 5 seconds when the OFF command to the relay



3.



DTC P0687 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



15E-60 DTC Information (4HK1)



DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit 1.



DTC P0697 Description of DTC The ECM supplies 5 V power to the following sensors via the power supply circuit 3. DPD differential pressure sensor Exhaust gas temperature sensors １ and ２ Fuel filter pressure sensor The ECM also supplies 5 V power to the following sensors via the power supply circuit 7. Oil pressure sensor ECT sensor Water temperature sensor The 5 V power supply circuits 3 and 7 are independent of each other outside the ECM, but they share a bus inside the ECM. Therefore, when one of the sensor 5 V power supply circuits is shorted, the entire 5 V power supply circuits 3 and 7 may be affected. The ECM monitors the voltage of the 5 V power supply circuits 3 and 7, and sets DTC when the ECM has detected that the voltage is abnormally low or high.



2.



DTC P0697 Condition for setting the DTC DTC P060B is not set The battery voltage is between 16 and 32 V The starter switch is ON When the ECM has detected that voltages of the 5 V power supply circuit 3 or 7 has been 4.5 V or lower or 5.5 V or higher for longer than 0.4 seconds



3.



DTC P0697 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-61



DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low 1.



DTC P1093 Description of DTC The general common rail system is comprised of the following two fuel pressure sections. The suction side between the fuel tank and the fuel supply pump and the high-pressure side between the fuel supply pump and the injectors. The fuel is drawn from the fuel tank through the fuel supply pump and supplied to the common rail by the two plungers located inside the fuel supply pump. The common rail pressure is regulated by the ECM through controlling the suction control valve based on the signal from the common rail pressure sensor. This DTC is set when the ECM detects that the actual fuel pressure is lower than the target fuel pressure.



2.



DTC P1093 Condition for setting the DTC DTC P0087, P0091, P0092, P0192, P0193, P0201-P0204, P1261, P1262, P2146, and P2149 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running The suction control valve instructs a certain fuel flow amount or more When the ECM has detected that the common rail pressure has been lower than the target fuel pressure for 50 MPa (7250 psi) or more for 5 seconds or longer



3.



DTC P1093 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Restrict the fuel flow. Stop the EGR control. Stop the DPD regeneration.



15E-62 DTC Information (4HK1)



DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low 1.



DTC P1112 Description of DTC The boost temperature sensor is installed on the intake manifold. The resistance value of the boost temperature sensor changes depending on the temperature inside the intake manifold. The resistance value becomes lower when the intake air temperature is high, and higher when the intake air temperature is low. The ECM applies 5 V to the boost temperature sensor through the pull-up resistor, and calculates the boost temperature from the change in the voltage to use it for various controls such as the fuel injection control. The voltage becomes lower when the resistance is small (the temperature is high), and higher when the resistance is large (the temperature is low).



2.



DTC P1112 Condition for setting the DTC DTC P060B is not detected The battery voltage is between 18 and 32 V When the ECM has detected that the boost temperature sensor voltage has been 0.1 V or lower for 4 seconds or longer



3.



DTC P1112 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of boost temperature sensor.



DTC Information (4HK1) 15E-63



DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High 1.



DTC P1113 Description of DTC The boost temperature sensor is installed on the intake manifold. The resistance value of the boost temperature sensor changes depending on the temperature inside the intake manifold. The resistance value becomes lower when the intake air temperature is high, and higher when the intake air temperature is low. The ECM applies 5 V to the boost temperature sensor through the pull-up resistor, and calculates the boost temperature from the change in the voltage to use it for various controls such as the fuel injection control. The voltage becomes lower when the resistance is small (the temperature is high), and higher when the resistance is large (the temperature is low).



2.



DTC P1113 Condition for setting the DTC DTC P060B is not detected The battery voltage is between 18 and 32 V The water temperature is 50 ℃ {122 °F} or higher The engine has been running for 3 minutes or longer When the ECM has detected that the boost temperature sensor voltage has been 4.94 V or higher for 4 seconds or longer



3.



DTC P1113 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of boost temperature sensor.



15E-64 DTC Information (4HK1)



DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 1.



DTC P1261 Description of DTC The charge voltage circuit inside the ECM increases the voltage applied to the injector. The charge voltage circuit is divided into 2 banks; the common power supply 1 and common power supply 2. The common power supply 1 supplies power to the injectors of the No. 1 and No. 4 cylinders while the common power supply 2 supplies power to the injectors of the No. 2 and No. 3 cylinders. When the injector charge voltage circuit of the common power supply 1 or 2 of the ECM has been opened, the ECM sets DTC.



2.



DTC P1261 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has been detected an open or short circuit in the ECM internal common power 1 injector charge voltage circuit for longer than 1.3 seconds



3.



DTC P1261 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control. Stop DPD regeneration. Stop the fuel injection for the No. 1 and No. 4 cylinders.



DTC Information (4HK1) 15E-65



DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 1.



DTC P1262 Description of DTC The charge voltage circuit inside the ECM increases the voltage applied to the injector. The charge voltage circuit is divided into 2 banks; the common power supply 1 and common power supply 2. The common power supply 1 supplies power to the injectors of the No. 1 and No. 4 cylinders while the common power supply 2 supplies power to the injectors of the No. 2 and No. 3 cylinders. When the injector charge voltage circuit of the common power supply 1 or 2 of the ECM has been opened, the ECM sets DTC.



2.



DTC P1262 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has been detected an open or short circuit in the ECM internal common power 2 injector charge voltage circuit for longer than 1.3 seconds



3.



DTC P1262 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control. Stop DPD regeneration. Stop the fuel injection for the No. 2 and No. 3 cylinders.



15E-66 DTC Information (4HK1)



DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low 1.



DTC P1293 Description of DTC The fuel filter pressure sensor detects the negative pressure in the fuel filter. The fuel filter pressure sensor is installed on the fuel filter. The output voltage becomes lower when the negative pressure in the fuel filter is smaller and becomes higher when the negative pressure is larger. The output voltage of the fuel filter pressure sensor changes as the negative pressure in the fuel filter changes. The ECM reads this change in the output voltage to convert into the fuel negative pressure, and uses it for control.



2.



DTC P1293 Condition for setting the DTC DTC P060B is not detected The battery voltage is between 18 and 32 V When the ECM has detected that the fuel filter pressure sensor voltage has been 0.1 V or lower for 4 seconds



3.



DTC P1293 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of fuel filter pressure sensor.



DTC Information (4HK1) 15E-67



DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High 1.



DTC P1294 Description of DTC The fuel filter pressure sensor detects the negative pressure in the fuel filter. The fuel filter pressure sensor is installed on the fuel filter. The output voltage becomes lower when the negative pressure in the fuel filter is smaller and becomes higher when the negative pressure is larger. The output voltage of the fuel filter pressure sensor changes as the negative pressure in the fuel filter changes. The ECM reads this change in the output voltage to convert into the fuel negative pressure, and uses it for control.



2.



DTC P1294 Condition for setting the DTC DTC P060B is not detected The battery voltage is between 18 and 32 V When the ECM has detected that the fuel filter pressure sensor voltage has been 4.9 V or higher for 4 seconds



3.



DTC P1294 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Substitute the default value of fuel filter pressure sensor.



15E-68 DTC Information (4HK1)



DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance 1.



DTC P1404 Description of DTC The ECM controls the EGR valve opening and closing based on the engine running condition and by controlling the EGR solenoid. The EGR opening angle is detected by the position sensor and transmitted to the ECM. For the closed position error DTC, when the ECM has detected that the actual EGR valve opening angle is greater than a certain value, it sets this DTC. For the learned position error DTC, when the ECM has detected a difference between the learned closed position and the actual closed position, it sets DTC.



2.



DTC P1404 Condition for setting the DTC When the ECM has detected that the EGR-learned closed position is not within the specific range when the starter switch was turned to OFF



3.



DTC P1404 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-69



DTC P1455 (Flash Code 132) PM Over Accumulation 1.



DTC P1455 Description of DTC The ECM detects PM accumulation failures from the DPD differential pressure sensor installed near the DPD itself. When it is reached to a certain amount of PM accumulations or a certain length of operating time, the automatic regeneration of the DPD starts. If the automatic regeneration cannot be completed by some reason, the manual regeneration is requested to the operator by displaying a message requesting for pressing the DPD switch on the display. When DPD regeneration continues for longer than the specified period of time, it sets DTC.



2.



DTC P1455 Condition for setting the DTC The starter switch is ON The operation time from the last DPD regeneration has been 8 hours or longer



3.



DTC P1455 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



15E-70 DTC Information (4HK1)



DTC P1471 (Flash Code 149) DPD Insufficient Regeneration 1.



DTC P1471 Description of DTC The ECM detects PM accumulation failures from the DPD differential pressure sensor installed near the DPD itself. When it is reached to a certain amount of PM accumulations or a certain length of operating time, the automatic regeneration of the DPD starts. If the automatic regeneration cannot be completed by some reason, the manual regeneration is requested to the operator by blinking the orange DPD indicator light on the display. After DPD regeneration is finished, the DPD differential pressure sensor monitors a purification of the filter. When purification determination after the DPD regeneration has failed for 2 consecutive times, the ECM sets DTC.



2.



DTC P1471 Condition for setting the DTC DTC P2454 and P2455 are not set DPD regeneration has been completed The ECM detects that purification determination after the DPD regeneration has failed for 2 consecutive times



3.



DTC P1471 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-71



DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance 1.



DTC P1621 Description of DTC This diagnosis applies to the microprocessor inside the ECM.



2.



DTC P1621 Condition for setting the DTC The starter switch is ON When the ECM has detected that the calculated checksum has not matched the check sum internally registered in the EEPROM



3.



DTC P1621 Action taken when the DTC sets When it has been detected for 2 consecutive times, the failure is displayed on the monitor of the main device or the Diagnostic light illuminates. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



15E-72 DTC Information (4HK1)



DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit 1.



DTC P1655 Description of DTC The ECM supplies 5 V power to the following sensors via the power supply circuit 4. Boost sensor EGR position sensor Intake throttle position sensor Fuel temperature sensor The ECM also supplies 5 V power to the following sensors via the power supply circuit 8. IMT sensor The 5 V power supply circuits 4 and 8 are independent of each other outside the ECM, but they share a bus inside the ECM. Therefore, when one of the sensor 5 V power supply circuits is shorted, the entire 5 V power supply circuits 4 and 8 may be affected. The ECM monitors the voltage of the 5 V power supply circuits 4 and 8, and sets DTC when the ECM has detected that the voltage is abnormally low or high.



2.



DTC P1655 Condition for setting the DTC DTC P060B is not set The battery voltage is between 16 and 32 V The starter switch is ON When the ECM has detected that 5 V power supply circuit 4 or 8 voltage has been 4.5 V or lower or 5.5 V or higher for longer than 0.4 seconds



3.



DTC P1655 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-73



DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 1.



DTC P1669 Description of DTC The DPD orange indicator light is located in the display and informs the operator that manual regeneration is necessary because automatic regeneration is incomplete. The ECM monitors to see if the DPD orange indicator light control circuit has status different from the DPD orange indicator light command. For example, if the ECM has detected a low voltage after issuing the OFF command to the DPD orange indicator light or a high voltage after issuing the ON command to the DPD orange indicator light, the circuit is faulty. When the ECM has detected an abnormal voltage with the control circuit, it sets DTC.



2.



DTC P1669 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON Any of the following conditions is satisfied The ECM detects a low voltage condition in the DPD orange indicator light control circuit when the ECM executes the OFF command to the DPD orange indicator light The ECM detects a high voltage condition in the DPD orange indicator light control circuit when the ECM executes the ON command to the DPD orange indicator light



3.



DTC P1669 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



15E-74 DTC Information (4HK1)



DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input 1.



DTC P2122 Description of DTC The accelerator position sensor consists of 2 sensors installed within a single housing. The ECM uses the accelerator position sensor to calculate the desired acceleration and deceleration amounts. The accelerator position sensor 1 has the following circuits 5 V power supply circuit GND circuit Accelerator position sensor 1 signal circuit The accelerator position sensor 1 transmits the signal related to changes of the accelerator pedal angle position to the ECM via the signal circuit. When the ECM has detected that the signal voltage is abnormally low, it sets DTC.



2.



DTC P2122 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the accelerator pedal position sensor 1 signal voltage has been 0.2 V or lower for longer than 0.3 seconds



3.



DTC P2122 Action taken when the DTC sets When the accelerator position sensors 1 and 2 are faulty, the accelerator opening angle is limited to 0 %.



DTC Information (4HK1) 15E-75



DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input 1.



DTC P2123 Description of DTC The accelerator position sensor consists of 2 sensors installed within a single housing. The ECM uses the accelerator position sensor to calculate the desired acceleration and deceleration amounts. The accelerator position sensor 1 has the following circuits. 5 V power supply circuit GND circuit Accelerator position sensor 1 signal circuit The accelerator position sensor 1 transmits the signal related to changes of the accelerator pedal angle position to the ECM via the signal circuit. When the ECM has detected that the signal voltage is abnormally high, it sets DTC.



2.



DTC P2123 Condition for setting the DTC DTC P060B and P0641 are not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the accelerator pedal position sensor 1 signal voltage has been 4.9 V or higher for longer than 0.3 seconds



3.



DTC P2123 Action taken when the DTC sets When the accelerator position sensors 1 and 2 are faulty, the accelerator opening angle is limited to 0 %.



15E-76 DTC Information (4HK1)



DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input 1.



DTC P2127 Description of DTC The accelerator position sensor consists of 2 sensors installed within a single housing. The ECM uses the accelerator position sensor to calculate the desired acceleration and deceleration amounts. The accelerator position sensor 2 has the following circuits. 5 V power supply circuit GND circuit Accelerator position sensor 2 signal circuit The accelerator position sensor 2 transmits the signal related to changes of the accelerator pedal angle position to the ECM via the signal circuit. When the ECM has detected that the signal voltage is abnormally low, it sets DTC.



2.



DTC P2127 Condition for setting the DTC DTC P060B and P0651 are not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the accelerator pedal position sensor 2 signal voltage has been 0.2 V or lower for longer than 0.3 seconds



3.



DTC P2127 Action taken when the DTC sets When the accelerator position sensors 1 and 2 are faulty, the accelerator opening angle is limited to 0 %.



DTC Information (4HK1) 15E-77



DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input 1.



DTC P2128 Description of DTC The accelerator position sensor consists of 2 sensors installed within a single housing. The ECM uses the accelerator position sensor to calculate the desired acceleration and deceleration amounts. The accelerator position sensor 2 has the following circuits. 5 V power supply circuit GND circuit Accelerator position sensor 2 signal circuit The accelerator position sensor 2 transmits the signal related to changes of the accelerator pedal angle position to the ECM via the signal circuit. When the ECM has detected that the signal voltage is abnormally high, it sets DTC.



2.



DTC P2128 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the accelerator pedal position sensor 2 signal voltage has been 4.9 V or higher for longer than 0.3 seconds



3.



DTC P2128 Action taken when the DTC sets When the accelerator position sensors 1 and 2 are faulty, the accelerator opening angle is limited to 0 %.



15E-78 DTC Information (4HK1)



DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation 1.



DTC P2138 Description of DTC The accelerator position sensor consists of 2 sensors installed within a single housing. The accelerator position sensor 1 and accelerator position sensor 2 are hall IC type sensors and each has the following circuits. 5 V power supply circuit GND circuit Signal circuit The ECM supplies 5 V to the accelerator position sensor via the 5 V power supply circuit and the GND circuit connects to the GND. The accelerator position sensor transmits the signal related to changes of the accelerator pedal angle position to the ECM via the signal circuit. The signal voltage of the accelerator position sensor 1 is kept low first, and then increases as the pedal is depressed. The signal voltage of the accelerator position sensor 2 is kept high first, and then decreases as the pedal is depressed. When the ECM has detected that the accelerator position sensor 1 signal and accelerator position sensor 2 signal voltages are not related to each other, it sets DTC.



2.



DTC P2138 Condition for setting the DTC DTC P060B, P2122, P2123, P2127, and P2128 are not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that both the accelerator pedal position sensors 1 and 2 have been outside the specified range for 45 % or more for longer than 2.6 seconds



3.



DTC P2138 Action taken when the DTC sets When the accelerator position sensors 1 and 2 are faulty, the accelerator opening angle is limited to 0 %.



DTC Information (4HK1) 15E-79



DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 1.



DTC P2146 Description of DTC The ECM calculates the optimum fuel injection ON time using the data transmitted from the various sensors. The injector charge voltage circuits of the common power supplies 1 and 2 supply the high voltage while the ECM grounds the injector solenoid control circuit as well as drives the injector of each cylinder. The common power supply 1 supplies power to the injectors of the No. 1 and No. 4 cylinders while the common power supply 2 supplies power to the injectors of the No. 2 and No. 3 cylinders. When the injector charge voltage circuit of the common power supply 1 or 2 has been opened or shorted to the GND or voltage circuit, the faulty injector common power supply circuit sets DTC. Also when the injector solenoid control circuit has been shorted to the GND, the ECM sets DTC.



2.



DTC P2146 Condition for setting the DTC DTC P0201 and P0204 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running When the ECM has detected that an open circuit with the injector charge voltage circuit of the common power supply 1, a short to GND or voltage circuit, or a short of the injector solenoid coil control circuit of the cylinder No. 1 or No. 4 to GND has occurred for longer than 2.6 seconds



3.



DTC P2146 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control. Stop DPD regeneration. Stop the fuel injection for the No. 1 and No. 4 cylinders.



15E-80 DTC Information (4HK1)



DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 1.



DTC P2149 Description of DTC The ECM calculates the optimum fuel injection ON time using the data transmitted from the sensor. The injector charge voltage circuits of the common power supplies 1 and 2 supply the high voltage while the ECM grounds the injector solenoid control circuit as well as drives the injector of each cylinder. The common power supply 1 supplies power to the injectors of the No. 1 and No. 4 cylinders while the common power supply 2 supplies power to the injectors of the No. 2 and No. 3 cylinders. When the injector charge voltage circuit of the common power supply 1 or 2 has been opened or shorted to the GND or voltage circuit, the faulty injector common power supply circuit detects DTC P2149. When the injector solenoid control circuit has been shorted to the GND, the ECM also sets DTC.



2.



DTC P2149 Condition for setting the DTC DTC P0201 and P0204 are not set The battery voltage is between 18 and 32 V The starter switch is ON While the engine is running When the ECM has detected that an open circuit with the injector charge voltage circuit of the common power supply 2, a short to GND or voltage circuit, or a short of the injector solenoid coil control circuit of the cylinder No. 2 or No. 3 to GND has occurred for longer than 2.6 seconds



3.



DTC P2149 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control. Stop DPD regeneration. Stop the fuel injection for the No. 2 and No. 3 cylinders.



DTC Information (4HK1) 15E-81



DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low 1.



DTC P2228 Description of DTC The atmospheric pressure sensor changes the signal voltage in accordance with the change in the atmospheric pressure. The sensor has the following circuits. 5 V power supply circuit GND circuit Atmospheric pressure sensor signal circuit Atmospheric pressure sensor sends to ECM the signal with regard to the change in the atmospheric pressure. The ECM detects a low signal voltage when the altitude is high and the atmospheric pressure is low. The ECM detects a high signal voltage when the atmospheric pressure is high. The ECM uses the voltage signal to adjust the amount and timing of fuel injection, and performs the altitude correction. The DTC is set when the ECM detects an abnormally low signal voltage.



2.



DTC P2228 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal voltage of the atmospheric sensor has been 0.5 V or lower for 5 seconds



3.



DTC P2228 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Limit the fuel injection amount. Stop the EGR control. Stop the DPD regeneration. Substitute the default value of atmospheric pressure.



15E-82 DTC Information (4HK1)



DTC P2229 (Flash Code 71) Barometric Pressure Circuit High 1.



DTC P2229 Description of DTC The atmospheric pressure sensor changes the signal voltage in accordance with the change in the atmospheric pressure. The sensor has the following circuits. 5 V power supply circuit GND circuit Atmospheric pressure sensor signal circuit Atmospheric pressure sensor sends to ECM the signal with regard to the change in the atmospheric pressure. The ECM detects a low signal voltage when the altitude is high and the atmospheric pressure is low. The ECM detects a high signal voltage when the atmospheric pressure is high. The ECM uses the voltage signal to adjust the amount and timing of fuel injection, and performs the altitude correction. The DTC is set when the ECM detects an abnormally high signal voltage.



2.



DTC P2229 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the signal voltage of the atmospheric sensor has been 4.0 V or higher for 5 seconds



3.



DTC P2229 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Limit the fuel injection amount. Stop the EGR control. Stop the DPD regeneration. Substitute the default value of atmospheric pressure.



DTC Information (4HK1) 15E-83



DTC P242F (Flash Code 131) DPD Restriction 1.



DTC P242F Description of DTC The ECM detects PM accumulation failures from the DPD differential pressure sensor installed near the DPD itself. When it is reached to a certain amount of PM accumulations or a certain length of operating time, the automatic regeneration of the DPD starts. If the automatic regeneration cannot be completed by some reason, the manual regeneration is requested to the operator by blinking the orange DPD indicator light on the display. If the ECM detects that learned exhaust differential pressure is not within a predetermined range, it sets DTC.



2.



DTC P242F Condition for setting the DTC The starter switch is ON The DPD differential pressure has been above the calculated range for 30 seconds or longer



3.



DTC P242F Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



15E-84 DTC Information (4HK1)



DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit 1.



DTC P2452 Description of DTC The DPD differential pressure sensor is installed near DPD itself. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. If the ECM detects that the DPD differential pressure is certain pressure low under certain conditions, it sets DTC.



2.



DTC P2452 Condition for setting the DTC DTC P2454 and P2455 are not detected The battery voltage is between 18 and 32 V The starter switch is ON The engine RPM is 2200 r/min or more When the ECM has detected that the DPD differential pressure has been 0.5 kPa {0.01 kgf/cm2 / 0.1 psi} or lower for longer than 13 seconds



3.



DTC P2452 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



DTC Information (4HK1) 15E-85



DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance 1.



DTC P2453 Description of DTC The DPD differential pressure sensor is installed near DPD itself. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. When the ECM has detected that the DPD differential pressure is abnormally high, it sets DTC.



2.



DTC P2453 Condition for setting the DTC DTC P2454 and P2455 are not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the DPD differential pressure has been 60 kPa {0.61 kgf/cm2 / 8.7 psi} or higher for longer than 2.4 seconds



3.



DTC P2453 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. Stop the EGR control. Stop the DPD regeneration.



15E-86 DTC Information (4HK1)



DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low 1.



DTC P2454 Description of DTC The DPD differential pressure sensor is installed near DPD itself. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. The sensor has the following circuits. 5 V power supply circuit GND circuit DPD differential pressure sensor signal circuit The DPD differential pressure sensor transmits signals concerning changes of the DPD differential pressure to the ECM via the signal circuit. The ECM detects a lower signal voltage when the differential pressure is small due to a small amount of accumulated PM. The ECM also uses this voltage signal for controlling DPD regeneration. When the ECM has detected that the DPD differential pressure is abnormally low, it sets DTC.



2.



DTC P2454 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the DPD differential pressure sensor signal voltage has been 0.18 V or lower for longer than 1 second



3.



DTC P2454 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Limit the fuel injection amount. Stop the EGR control. Stop the DPD regeneration. Substitute the default value of DPD differential pressure sensor.



DTC Information (4HK1) 15E-87



DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High 1.



DTC P2455 Description of DTC The DPD differential pressure sensor is installed near DPD itself. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. The sensor has the following circuits. 5 V power supply circuit GND circuit DPD differential pressure sensor signal circuit The DPD differential pressure sensor transmits signals concerning changes of the DPD differential pressure to the ECM via the signal circuit. The ECM detects a lower signal voltage when the differential pressure is small due to a small amount of accumulated PM. The ECM also uses this voltage signal for controlling DPD regeneration. When the ECM has detected that the DPD differential pressure is abnormally low, it sets DTC.



2.



DTC P2455 Condition for setting the DTC DTC P060B is not set The battery voltage is between 18 and 32 V The starter switch is ON When the ECM has detected that the DPD differential pressure sensor signal voltage has been 4.9 V or higher for longer than 1 second



3.



DTC P2455 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Limit the fuel injection amount. Stop the EGR control. Stop the DPD regeneration. Substitute the default value of DPD differential pressure sensor.



15E-88 DTC Information (4HK1)



DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position 1.



DTC P2456 Description of DTC The DPD differential pressure sensor is installed near DPD itself of the actual unit. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. The ECM learns a variance of the exhaust differential pressure sensor signal at every ignition cycle after the starter switch has been ON with the engine OFF for 30 seconds. If the ECM detects that learned exhaust differential pressure is not within a predetermined range, it sets DTC.



2.



DTC P2456 Condition for setting the DTC The battery voltage is between 18 and 32 V The starter switch is ON The engine is stopped When the ECM has detected that the learned absolute value of　differential pressure has been 4.5 kPa {0.05 kgf/cm2 / 0.7 psi} or higher



3.



DTC P2456 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Limit the fuel injection amount. Stop the EGR control. Stop the DPD regeneration. Substitute the default value of DPD differential pressure sensor.



DTC Information (4HK1) 15E-89



DTC P2458 (Flash Code 139) DPD Regeneration Duration 1.



DTC P2458 Description of DTC The ECM detects PM accumulation failures from the DPD differential pressure sensor installed near the DPD itself. When it is reached to a certain amount of PM accumulations or a certain length of operating time, the automatic regeneration of the DPD starts. If the automatic regeneration cannot be completed by some reason, the manual regeneration is requested to the operator by blinking the orange DPD indicator light on the display. Once the DPD filter regeneration starts, it must be finished within a certain time. When DPD regeneration continues for longer than the specified period of time, it sets DTC.



2.



DTC P2458 Condition for setting the DTC The starter switch is ON The DPD filter regeneration has been completed When the ECM detected that the DPD filter regeneration process took time longer than a certain period of time for 3 consecutive times



3.



DTC P2458 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restricts the fuel injection amount.



15E-90 DTC Information (4HK1)



DTC U0001 (Flash Code 84) CAN-Bus Malfunction 1.



DTC U0001 Description of DTC The ECM communicates with the turbo control unit and the actual unit control unit via the CAN communication circuit. The ECM outputs data via the CAN-High circuit and input data from other ECUs from the CAN-Low circuit. CAN communication is continuously performed at a constant rate and the data output count and input count are always identical. The ECM sets DTC when it has detected a CAN communication failure.



2.



DTC U0001 Condition for setting the DTC The battery voltage is 12 V or higher The starter switch is ON When the ECM has detected an abnormality in the CAN communication circuit



3.



DTC U0001 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control.



DTC Information (4HK1) 15E-91



DTC U0073 (Flash Code 84) Control Module Communication Bus Off 1.



DTC U0073 Description of DTC The ECM communicates with the actual unit control unit via the CAN communication circuit. The ECM outputs data via the CAN-High circuit and input data from other ECUs from the CAN-Low circuit. CAN communication is continuously performed at a constant rate and the data output count and input count are always identical. The ECM sets DTC when it has detected a CAN communication failure.



2.



DTC U0073 Condition for setting the DTC The battery voltage is 22 V or higher The starter switch is ON When the ECM detects an abnormality in the CAN communication circuit



3.



DTC U0073 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown.



15E-92 DTC Information (4HK1)



DTC U0101 (Flash Code 85) Lost Communication with TCM 1.



DTC U0101 Description of DTC The ECM communicates with the actual unit control unit via the CAN communication circuit. The ECM outputs data via the CAN-High circuit and input data from other ECUs from the CAN-Low circuit. CAN communication is continuously performed at a constant rate and the data output count and input count are always identical. ECM sets DTC when it has lost CAN communication with the actual unit control unit.



2.



DTC U0101 Condition for setting the DTC The battery voltage is 22 V or higher When the ECM has detected that CAN data reception for 5 seconds or longer has not been satisfied



3.



DTC U0101 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control. Stop DPD regeneration. Limit the engine RPM to the idle RPM.



DTC Information (4HK1) 15E-93



DTC U0110 (Flash Code 87) Lost Communication with VNT System 1.



DTC U0110 Description of DTC The ECM and turbo control unit communicate the control and diagnostic information via CAN communication. The ECM outputs data via the CAN-High circuit and input data from other ECUs from the CAN-Low circuit. CAN communication is continuously performed at a constant rate and the data output count and input count are always identical. ECM sets DTC when it has lost CAN communication with the turbo control unit.



2.



DTC U0110 Condition for setting the DTC The battery voltage is 12 V or higher The starter switch is ON When the ECM has detected that No CAN Bus message has been received from the turbocharger controller unit for longer than 5 seconds



3.



DTC U0110 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Restrict the fuel injection amount. The highest engine RPM is restricted to 1200 r/min. Stop the EGR control. Stop the DPD regeneration.



15E-94 DTC Information (4HK1)



DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction 1.



DTC U0411 Description of DTC The ECM and turbo control unit communicate the control and diagnostic information via CAN communication. The ECM outputs data via the CAN-High circuit and input data from other ECUs from the CAN-Low circuit. CAN communication is continuously performed at a constant rate and the data output count and input count are always identical. ECM sets DTC when it has received a CAN communication failure message from the turbo control unit.



2.



DTC U0411 Condition for setting the DTC The battery voltage is between 20 and 32 V When ECM has received the error message from the turbo control unit



3.



DTC U0411 Action taken when the DTC sets Failure is indicated in the monitor on the actual unit, or the diagnostic light is turned on. Note： ・ Depending on the manufacturer of the actual unit, the failure indication may not be shown. Stop EGR control.



DTC Information (4HK1) 15E-95



DTC mapping table 1.



DTC mapping table



15E-96 DTC Information (4HK1) SPN-FMI 636-7 10023-12 633-7 157-16 157-0 157-15 1347-4 1347-3 1239-1 132-4 132-3 172-4 172-3 110-4 110-3 10022-4 10022-3 174-4 174-3 157-4 157-3 651-5 652-5 653-5 654-5 110-0 190-0 102-0 102-4 102-3 723-2 723-2 636-2 10002-2 10001-2 1131-3 1131-4 173-0 173-4 173-3 10028-0 10024-4 10024-3 100-4



P code P0016 P0045 P0087



Crankshaft Position - Camshaft Position Correlation Turbocharger Boost Control Solenoid Circuit Fuel Rail/System Pressure - Too Low



P0088



Fuel Rail/System Pressure - Too High



P0089 P0091 P0092 P0093 P0102 P0103 P0112 P0113 P0117 P0118 P0122 P0123 P0182 P0183 P0192 P0193 P0201 P0202 P0203 P0204 P0217 P0219 P0234 P0237 P0238 P0335 P0336 P0340 P0404 P0409 P041C P041D P0426 P0427 P0428 P042B P042C P042D P0522



Fuel Pressure Regulator Performance Fuel Pressure Regulator Control Circuit Low Fuel Pressure Regulator Control Circuit High Fuel System Leak Detected Mass Air Flow Circuit Low Input Mass Air Flow Circuit High Input Intake Air Temperature Sensor Circuit Low Intake Air Temperature Sensor Circuit High Engine Coolant Temperature Sensor Circuit Low Engine Coolant Temperature Sensor Circuit High Throttle Position Sensor Circuit Low Throttle Position Sensor Circuit High Fuel Temperature Sensor Circuit Low Fuel Temperature Sensor Circuit High Fuel Rail Pressure Sensor Circuit Low Fuel Rail Pressure Sensor Circuit High Injector Circuit - Cylinder 1 Injector Circuit - Cylinder 2 Injector Circuit - Cylinder 3 Injector Circuit - Cylinder 4 Engine Coolant Over Temperature Condition Engine Overspeed Condition Turbocharger Overboost Condition Turbocharger Boost Sensor Circuit Low Input Turbocharger Boost Sensor Circuit High Input Crankshaft Position Sensor Circuit Crankshaft Position Sensor Circuit Range/Performance Camshaft Position Sensor Circuit Exhaust Gas Recirculation Control 1 Circuit Range/Performance Exhaust Gas Recirculation 1 Sensor Circuit Manifold Air Temperature Circuit High Input Manifold Air Temperature Circuit Low Input Catalyst Temperature 1 Too High Catalyst Temperature Sensor Circuit Low Sensor 1 Catalyst Temperature Sensor Circuit High Sensor 1 Catalyst Temperature 2 Too High Catalyst Temperature Sensor Circuit Low Sensor 2 Catalyst Temperature Sensor Circuit High Sensor 2 Oil Pressure Sensor Circuit Low Input



DTC Information (4HK1) 15E-97 100-3 10012-2 158-3 628-2 10032-2 10033-2 1077-2 10007-2 10008-2 10022-2 1079-2 987-5 1080-2 1485-5 1485-6 10009-2 1239-17 105-4 105-3 10005-1 10006-1 1381-4 1381-3 10001-13 10026-0 10027-0 10013-2 10010-2 10025-5 91-4 91-3 91-4 91-3 91-2 10003-2 10004-2 108-4 108-3 10026-15 81-1 81-0 81-4 81-3 81-2 10029-0



P0523 P0560 P0563 P0601 P0602 P0604



Oil Pressure Sensor Circuit High Input System Voltage System Voltage High Internal Control Module Memory Check Sum Error Control Module Programming Error Internal Control Module Random Access Memory (RAM)



P0606



ECM/PCM Processor



P060B P0638 P0641 P0650 P0651 P0685 P0687 P0697 P1093 P1112 P1113 P1261 P1262 P1293 P1294 P1404 P1455 P1471 P1621 P1655 P1669 P2122 P2123 P2127 P2128 P2138 P2146 P2149 P2228 P2229 P242F P2452 P2453 P2454 P2455 P2456 P2458



Internal Control Module A/D Processing Performance Throttle Actuator Control Range/Performance Sensor Reference Voltage 1 Circuit Malfunction Indicator Lamp (MIL) Control Circuit Sensor Reference Voltage 1 Circuit ECM/PCM Power Relay Control Circuit /Open ECM/PCM Power Relay Control Circuit High Sensor Reference Voltage 1 Circuit Fuel Rail Pressure (FRP) Too Low Boost Temperature Sensor Circuit Low Input Boost Temperature Sensor Circuit High Input Fuel Injector Group 1 Supply Voltage Circuit Fuel Injector Group 2 Supply Voltage Circuit Fuel Intake Pressure Sensor Circuit Low Input Fuel Intake Pressure Sensor Circuit High Input Exhaust Gas Recirculation (EGR) 1 Closed Position Performance PM Over Accumulation DPD Insufficient Regeneration Control Module Long Term Memory Performance Sensor Reference Voltage 1 Circuit DPD Lamp Control Circuit Pedal Position Sensor 1 Circuit Low Input Pedal Position Sensor 1 Circuit High Input Pedal Position Sensor 2 Circuit Low Input Pedal Position Sensor 2 Circuit High Input Pedal Position Sensor 1 - 2 Voltage Correlation Fuel Injector Group 1 Supply Voltage Circuit Fuel Injector Group 2 Supply Voltage Circuit Barometric Pressure Circuit Low Barometric Pressure Circuit High DPD Restriction DPD Differential Pressure Sensor Circuit DPD Differential Pressure Sensor Circuit Range/Performance DPD Differential Pressure Sensor Circuit Low DPD Differential Pressure Sensor Circuit High DPD Differential Pressure Sensor Learned Position DPD Regeneration Duration



15E-98 DTC Information (4HK1) 10040-19



U0001



639-19



U0073



639-2 10023-2 10023-19



U0101 U0110 U0411



CAN Bus Error (ISO-CAN) CAN Bus Error (J1939) Control Module Communication Bus Off Lost Communication With Transmission Control Module Lost Communication With VNT System VNT Communication



Engine Control (4HK1) 1A-1



Engine Control Engine Control (4HK1) Table of Contents DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation........................................................1A-3 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit..............................................................1A-4 DTC P0087 (Flash Code 225) Fuel Rail/System Pressure Too Low..........................................................................1A-6 DTC P0088 (Flash Code 118) Fuel Rail/System Pressure Too High.........................................................................1A-9 DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance..................................................................1A-12 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low......................................................1A-14 DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High.....................................................1A-15 DTC P0093 (Flash Code 227) Fuel System Leak Detected .......................................................................................1A-16 DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input..............................................................................1A-19 DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input..............................................................................1A-20 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low...................................................................1A-21 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High...................................................................1A-22 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low.......................................................1A-23 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High.......................................................1A-24 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low...................................................................1A-25 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High...................................................................1A-26 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low...................................................................1A-27 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High...................................................................1A-28 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low...................................................................1A-29 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High...................................................................1A-30 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 .......................................................................................1A-31



DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 .......................................................................................1A-33 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 .......................................................................................1A-35 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 .......................................................................................1A-37 DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition.................................................1A-39 DTC P0219 (Flash Code 543) Engine Overspeed Condition .......................................................................................1A-40 DTC P0234 (Flash Code 42) Turbocharger Overboost Condition.......................................................................1A-41 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low...................................................................1A-42 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High...................................................................1A-43 DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit............................................................................1A-44 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance...........................................1A-46 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit............................................................................1A-47 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance..............................1A-49 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit................................................................1A-50 DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High.......................................................1A-52 DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low.......................................................1A-53 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1............................1A-54 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1....................................................1A-55 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1....................................................1A-56 DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2............................1A-57 DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2....................................................1A-58



1A-2 Engine Control (4HK1) DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2....................................................1A-59 DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low...............................................................................1A-61 DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High...............................................................................1A-62 DTC P0560 (Flash Code 155) System Voltage............1A-63 DTC P0563 (Flash Code 35) System Voltage High.....1A-64 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error............................................1A-65 DTC P0602 (Flash Code 154) Control Module Programming Error.......................................................1A-66 DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error........................1A-67 DTC P0606 (Flash Code 51) ECM/PCM Processor.....1A-68 DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance................................................1A-69 DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance.......................................................1A-70 DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit............................................................................1A-72 DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL) Control Circuit...................................................1A-74 DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit............................................................................1A-75 DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open.....................................................1A-76 DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High.....................................................1A-77 DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit............................................................................1A-78 DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low...............................................................................1A-80 DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low...................................................................1A-83 DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High...................................................................1A-84 DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1................................................1A-85 DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2................................................1A-86 DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low...............................................................................1A-87 DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High...............................................................................1A-88 DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance............................1A-89 DTC P1455 (Flash Code 132) PM Over Accumulation .......................................................................................1A-90 DTC P1471 (Flash Code 149) DPD Insufficient Regeneration.................................................................1A-92



DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance....................................................1A-94 DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit............................................................................1A-95 DTC P1669 (Flash Code 75) DPD Lamp Control Circuit .......................................................................................1A-97 DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input..........................................................1A-98 DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input.........................................................1A-99 DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input........................................................1A-100 DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input.......................................................1A-101 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation.....................................................1A-102 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit............................................................1A-103 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit............................................................1A-105 DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low.............................................................................1A-107 DTC P2229 (Flash Code 71) Barometric Pressure Circuit High.............................................................................1A-108 DTC P242F (Flash Code 131) DPD Restriction.........1A-109 DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit..............................................................1A-111 DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance.............................1A-113 DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low.....................................................1A-115 DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High.....................................................1A-116 DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position..............................................1A-117 DTC P2458 (Flash Code 139) DPD Regeneration Duration .....................................................................................1A-118 DTC U0001 (Flash Code 84) CAN-Bus Malfunction 1A-120 DTC U0073 (Flash Code 84) Control Module Communication Bus Off.............................................1A-121 DTC U0101 (Flash Code 85) Lost Communication with TCM............................................................................1A-123 DTC U0110 (Flash Code 87) Lost Communication with VNT System................................................................1A-124 DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction......................................................1A-125



Engine Control (4HK1) 1A-3



DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation 1.



DTC P0016 Priority DTC DTC P0335 DTC P0336 DTC P0340



2.



DTC P0016 Diagnostics 1.



Inspect the CKP sensor.



Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Inspection". 2.



If a problem is discovered, replace the crankshaft position sensor.



Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Installation". 3.



Inspect the CMP sensor.



Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Inspection". 4.



If a problem is discovered, replace the camshaft position sensor.



Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Installation". 5.



Inspect the flywheel.



・The sensor rotor should not be damaged. ・The ring gear should be installed correctly. 6.



If a problem is discovered, repair the flywheel.



7.



Inspect the camshaft gear.



・The camshaft gear should not be damaged ・The camshaft gear should be installed correctly. 8. 3.



If a problem is discovered, repair the camshaft gear. DTC P0016 Confirm Resolution



1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



Note： ・ When the engine does not start, crank the engine for 10 seconds. 4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-4 Engine Control (4HK1)



DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit 1.



DTC P0045 Priority DTC DTC P0563



2.



DTC P0045 Diagnostics 1.



Turn OFF the starter switch.



2.



Inspect the turbocharger assembly.



Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Inspection". 3.



If a problem is discovered, replace the turbocharger assembly.



Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Installation". 4.



Disconnect the harness connector from the turbo actuator.



5.



Connect the test light between the motor operation terminal and GND of the turbo actuator harness connector.



6.



Turn ON the starter switch.



7.



Check if the test light does not come on or remains on.



Note： ・ The inspection with a test light should be performed on each terminal. ・ When it is normal, the test light comes on after the key switch is turned ON, and then goes out after a few seconds. 8.



If the test light does not come on or remains on, inspect the motor operation circuit between the turbo actuator and turbo control unit.



・There should be no open circuit or high resistance. ・There should be no short to the battery power supply or ignition power supply circuit. ・There should be no short to GND. 9.



If a problem is discovered, repair the motor operation circuit.



10. If the test light operates properly, inspect to see if a short with other circuit exists in the motor operation circuit between the turbo actuator and turbo control unit. 11. If a problem is discovered, repair the motor operation circuit. 12. Turn ON the starter switch.



13. Measure the voltage between the position sensor power supply terminal and GND of the turbo actuator harness connector. voltage： 8.0 to 11.0 V 14. If the voltage is outside the standard range, inspect the position sensor power supply circuit between the turbo actuator and the turbo control unit. ・There should be no open circuit or high resistance. ・There should be no short to the battery power supply or ignition power supply circuit. ・There should be no short to GND. 15. If a problem is discovered, repair the position sensor power supply circuit. 16. If the circuit is normal, inspect to the turbo control unit harness connector for a contact failure. 17. If a problem is discovered, repair the harness connector. 18. If the harness connector is normal, replace the turbo control unit. 19. If the voltage is within the standard range, measure the voltage between the position sensor signal terminal of the turbo actuator harness connector and GND. Note： ・ Measurement of voltage value should be taken on each terminal. voltage： 4.0 to 6.0 V 20. If the voltage is outside the standard range, inspect the position sensor signal circuit between the turbo actuator and the turbo control unit. ・There should be no open circuit or high resistance. ・There should be no short to the battery power supply or ignition power supply circuit. ・There should be no short to GND. 21. If a problem is discovered, repair the position sensor signal circuit. 22. If the circuit is normal, inspect to the turbo control unit harness connector for a contact failure. 23. If a problem is discovered, repair the harness connector. 24. If the harness connector is normal, replace the turbo control unit. 25. If the voltage is within the standard range, inspect to see if there is a short circuit with the position sensor



Engine Control (4HK1) 1A-5 signal circuit between the turbo actuator and turbo control unit. 26. If a problem is discovered, repair the position sensor signal circuit. 27. Turn ON the starter switch. 28. Measure the voltage between the position sensor power supply terminal and position sensor GND terminal of the turbo actuator harness connector. voltage： 8.0 to 11.0 V 29. If the voltage is outside the standard range, inspect the position sensor GND circuit between the turbo actuator and the turbo control unit. ・There should be no open circuit or high resistance. ・There should be no short to the battery power supply or ignition power supply circuit. ・There should be no short to GND. 30. If a problem is discovered, repair the position sensor GND circuit. 31. If the circuit is normal, inspect to the turbo control unit harness connector for a contact failure. 32. If a problem is discovered, repair the harness connector. 33. If the harness connector is normal, replace the turbo control unit. 34. If the voltage is within the standard range, inspect to see if there is a contact failure with the turbo actuator harness connector. 35. If a problem is discovered, repair the harness connector. 36. If the harness connector is normal, replace the turbocharger. Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Installation". 3.



DTC P0045 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-6 Engine Control (4HK1)



DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low 1.



DTC P0087 Priority DTC DTC P0088 DTC P0089 DTC P0091



10. If a problem is discovered, repair the harness connector. 11. Inspect the ECM harness connector for a contact failure.



DTC P0092



12. If a problem is discovered, repair the harness connector.



DTC P0192



13. Inspect each circuit for high resistance.



DTC P0193



14. Repair the circuit if a problem is discovered.



DTC P0201



15. If the harness connector and each circuit are normal, replace the fuel pressure sensor.



DTC P0202 DTC P0203 DTC P0204 DTC P2146 DTC P2149 2.



DTC P0087 Diagnostics



Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation". Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.



1.



Start the engine.



2.



Rev the engine a few times in neutral while checking for a DTC with the trouble diagnosis scan tool.



16. If the fuel rail pressure sensor display is within the standard range, start the engine.



3.



Check to see if the DTC P0087 is detected.



4.



If the DTC P0087 is not detected, replace the fuel filter element.



17. Perform the injector stop test with the trouble diagnosis scan tool.



Note： ・ An intermittent problem due to foreign matter in the fuel is suspected.



18. Command each injector OFF, and confirm that the engine RPM changes on each injector. 19. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal".



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation".



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation".



5.



Turn OFF the starter switch.



6.



Wait for the specified period of time until the fuel pressure is released from the common rail.



specified time： 2 min 7.



Turn ON the starter switch.



8.



Check the fuel rail pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.9 to 1.0 V 9.



If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure.



20. When the injector has been replaced, set the injector ID code on the ECM. 21. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. 22. If a problem is discovered, repair the clogging of the fuel system. 23. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack. 24. If a problem is discovered, replace the fuel hose.



Engine Control (4HK1) 1A-7 Note： ・ The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine is running. ・ When the fuel hose is not connected securely, the air can enter. ・ When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P0087 may be detected. 25. Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. 26. If a problem is discovered, replace the clamp. 27. Operate the priming pump until the handle becomes heavy. Note： ・ When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy.



Note： ・ Confirm that the fuel system is connected securely. 34. Remove the air using the priming pump, and crank the engine for the specified period of time or shorter. specified time： 5 s Note： ・ Repeat this until the engine starts. 35. Leave the engine idling for the specified period of time or longer. specified time： 1 min 36. While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. specified time： 1 min rotational speed： 2500 r/min 37. Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection.



28. Start the engine.



specified value： 17.0 kPa { 128 mmHg / 5 inHg }



29. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail.



Note： ・ Fuel clogging is checked with the negative pressure amount in the fuel system.



Note： ・ The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. ・ The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. ・ Inspect for fuel leaks into the engine oil. 30. If fuel leak if found, fix the problem. 31. Turn OFF the starter switch. 32. Remove the fuel hose on the fuel supply pump side from the fuel filter. Note： ・ Use a pan to catch the fuel from the removed fuel hose. ・ Clean the pressure gauge and connection hose before connecting to the fuel pipe. ・ The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose. 33. Connect the pressure gauge between the fuel filter and the removed fuel hose.



38. If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank. 39. If a problem is discovered, repair the fuel system. 40. Inspect the fuel tank bent hose. 41. If a problem is discovered, repair the bent hose. 42. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging. 43. If a problem is discovered, repair it. 44. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". 45. If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow.



1A-8 Engine Control (4HK1) Note： ・ When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time.



Note： ・ The fuel pipe can be disconnected and clogged with a plug. 46. Start the engine and use the idling control switch to increase the RPM to the highest level.



60. Perform the unit difference learning of the fuel supply pump to the ECM.



47. Check the pressure gauge. specified value： 27.0 kPa { 203 mmHg / 8 inHg } Note： ・ When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. ・ Air mixture is checked with the negative pressure amount while the fuel flow is being blocked. 48. If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. 49. If a problem is discovered, replace the fuel hose. 50. Inspect to see if appropriate clamp is used. 51. If a problem is discovered, replace the clamp with an appropriate one. 52. Turn OFF the starter switch. 53. Inspect the suction control valve harness connector for a contact failure. 54. If a problem is discovered, repair the harness connector. 55. Inspect the ECM harness connector for a contact failure. 56. If a problem is discovered, repair the harness connector. 57. Inspect each circuit for high resistance. 58. Repair the circuit if a problem is discovered. 59. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation".



3.



DTC P0087 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-9



DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High 1.



DTC P0088 Priority DTC DTC P0089 DTC P0091 DTC P0092



10. If a problem is discovered, repair the harness connector. 11. Inspect the ECM harness connector for a contact failure.



DTC P0192



12. If a problem is discovered, repair the harness connector.



DTC P0193



13. Inspect each circuit for high resistance.



DTC P0201



14. If a problem is discovered, repair the circuit.



DTC P0202



15. If the harness connector and each circuit are normal, replace the fuel pressure sensor.



DTC P0203 DTC P0204 DTC P2146 DTC P2149 2.



DTC P0088 Diagnostics



Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation". Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.



1.



Start the engine.



2.



Rev the engine a few times in neutral while checking the actual fuel rail pressure display with the trouble diagnosis scan tool.



16. Start the engine.



Check the actual fuel rail pressure display with the trouble diagnosis scan tool.



17. Perform the injector stop test with the trouble diagnosis scan tool.



3.



Standard value ：(-5) - 5 MPa 4.



If it is at or below the standard value, replace the fuel filter element.



Note： ・ An intermittent problem due to foreign matter in the fuel is suspected. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". 5.



Turn OFF the starter switch.



6.



Wait for the specified period of time until the fuel pressure is released from the common rail.



specified time： 2 min 7.



Turn ON the starter switch.



8.



Check the fuel rail pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.9 to 1.0 V 9.



If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure.



18. Command each injector OFF, and confirm that the engine RPM changes on each injector. 19. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 20. When the injector has been replaced, set the injector ID code on the ECM. 21. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. 22. If a problem is discovered, repair the clogging of the fuel system. 23. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack. 24. If a problem is discovered, replace the fuel hose. Note： ・ The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine is running.



1A-10 Engine Control (4HK1) ・ When the fuel hose is not connected securely, the air can enter. ・ When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P0088 may be detected. 25. Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. 26. If a problem is discovered, replace the clamp. 27. Operate the priming pump until the handle becomes heavy. Note： ・ When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy. 28. Start the engine. 29. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail. Note： ・ The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. ・ The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. ・ Inspect for fuel leaks into the engine oil.



specified time： 5 s Note： ・ Repeat this until the engine starts. 35. Leave the engine idling for the specified period of time or longer. specified time： 1 min 36. While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. specified time： 1 min rotational speed： 2500 r/min 37. Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. specified value： 17.0 kPa { 128 mmHg / 5 inHg } Note： ・ Fuel clogging is checked with the negative pressure amount in the fuel system. 38. If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank. 39. If a problem is discovered, repair the fuel system. 40. Inspect the fuel tank bent hose. 41. If a problem is discovered, repair the bent hose.



30. If fuel leak if found, fix the problem.



42. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging.



31. Turn OFF the starter switch.



43. If a problem is discovered, repair it.



32. Remove the fuel hose on the fuel supply pump side from the fuel filter.



44. Replace the fuel filter element.



Note： ・ Use a pan to catch the fuel from the removed fuel hose. ・ Clean the pressure gauge and connection hose before connecting to the fuel pipe. ・ The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose. 33. Connect the pressure gauge between the fuel filter and the removed fuel hose. Note： ・ Confirm that the fuel system is connected securely. 34. Remove the air using the priming pump, and crank the engine for the specified period of time or shorter.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". 45. If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow. Note： ・ The fuel pipe can be disconnected and clogged with a plug. 46. Start the engine and use the idling control switch to increase the RPM to the highest level. 47. Check the pressure gauge. specified value： 27.0 kPa { 203 mmHg / 8 inHg }



Engine Control (4HK1) 1A-11 Note： ・ When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. ・ Air mixture is checked with the negative pressure amount while the fuel flow is being blocked. 48. If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. 49. If a problem is discovered, replace the fuel hose. 50. Inspect to see if appropriate clamp is used. 51. If a problem is discovered, replace the clamp with an appropriate one. 52. Turn OFF the starter switch. 53. Inspect the suction control valve harness connector for a contact failure. 54. If a problem is discovered, repair the harness connector. 55. Inspect the ECM harness connector for a contact failure. 56. If a problem is discovered, repair the harness connector. 57. Inspect each circuit for high resistance. 58. Repair the circuit if a problem is discovered. 59. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". Note： ・ When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 60. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0088 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-12 Engine Control (4HK1)



DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 1.



DTC P0089 Priority DTC DTC P0091 DTC P0092 DTC P0192 DTC P0193 DTC P0201 DTC P0202 DTC P0203 DTC P0204 DTC P2146 DTC P2149



2.



DTC P0089 Diagnostics 1.



Wait for the specified period of time until the fuel pressure is released from the common rail.



specified time： 2 min 2.



Check the fuel rail pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.9 to 1.0 V 3.



If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure.



4.



If a problem is discovered, repair the harness connector.



5.



Inspect the ECM harness connector for a contact failure.



6.



If a problem is discovered, repair the harness connector.



7.



Inspect each circuit for high resistance.



8.



Repair the circuit if a problem is discovered.



9.



If the harness connector and each circuit are normal, replace the fuel pressure sensor.



Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation". Note： ・ ・Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.



10. Inspect the suction control valve harness connector for a contact failure. 11. If a problem is discovered, repair the harness connector. 12. Inspect the ECM harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. Inspect each circuit for high resistance. 15. Repair the circuit if a problem is discovered. 16. Turn the starter switch OFF for 30 seconds or longer. 17. Start the engine. 18. Rev the engine a few times in neutral while checking the actual fuel rail pressure display with the trouble diagnosis scan tool. 19. Use the trouble diagnosis scan tool to check if the actual fuel rail pressure display shows a value within the standard range at a sufficient rate. Standard values: (-5) - 5MPa Note： ・ If possible, compare with other actual unit equipped with the same model engine. 20. If it is within the standard range, replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". 21. If it is outside the standard range, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". Note： ・ When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time.



Engine Control (4HK1) 1A-13 22. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0089 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-14 Engine Control (4HK1)



DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low 1.



17. If it does not turn off, inspect the Low side circuit between the ECM and suction control valve.



DTC P0091 Diagnostics 1.



Check the rail pressure regulator feedback current display with the trouble diagnosis scan tool.



・There should be no open circuit or high resistance. ・There should be no short to the battery or ignition power supply.



current： 300 to 900 mA 2.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the High side circuit between the ECM and the suction control valve.



18. If a problem is discovered, repair the Low side circuit. 19. Inspect the suction control valve harness connector for a contact failure.



Note： ・ When the High side circuit is shorted to the voltage, the engine stalls and does not start. 3.



If a problem is discovered, repair the High side circuit.



4.



If it is within the standard range, inspect to see if there is a short circuit to the GND with the Low side circuit between the ECM and the suction control valve.



20. If a problem is discovered, repair the harness connector. 21. If the harness connector is normal, replace the suction control valve. Refer to "1.Engine 1C.Fuel System(4HK1) Suction control valve Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Suction control valve Installation".



Note： ・ When the Low side circuit is shorted to GND, DTC P0091 may not be detected. ・ When the Low side circuit is shorted to GND, the engine stalls and does not start. 5.



If a problem is discovered, repair the Low side circuit.



6.



Turn the starter switch OFF for 30 seconds or longer.



7.



Disconnect the harness connector from the suction control valve.



8.



Connect the test light between the suction control valve High side circuit and a normal GND.



9.



Turn ON the starter switch.



10. Check if the test light comes on and then goes off. 11. If it does not turn off, inspect the High side circuit between the ECM and the suction control valve. ・There should be no open circuit or high resistance. ・There should be no short to GND. ・There should be no short to the LOW side circuit. 12. If a problem is discovered, repair the High side circuit. 13. Turn the starter switch OFF for 30 seconds or longer. 14. Connect the test light between the suction control valve Low side circuit and battery power supply. 15. Turn ON the starter switch. 16. Check if the test light comes on and then goes off.



22. Inspect the ECM harness connector for a contact failure. 23. If a problem is discovered, repair the harness connector. 24. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 25. Set the injector ID code on the ECM. 26. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0091 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-15



DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 1.



17. If it does not turn off, inspect the Low side circuit between the ECM and suction control valve.



DTC P0092 Diagnostics 1.



Check the rail pressure regulator feedback current display with the trouble diagnosis scan tool.



・There should be no open circuit or high resistance. ・There should be no short to the battery or ignition power supply.



current： 300 to 900 mA 2.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the High side circuit between the ECM and the suction control valve.



18. If a problem is discovered, repair the Low side circuit. 19. Inspect the suction control valve harness connector for a contact failure.



Note： ・ When the High side circuit is shorted to the voltage, the engine stalls and does not start. 3.



If a problem is discovered, repair the High side circuit.



4.



If it is within the standard range, inspect to see if there is a short circuit to the GND with the Low side circuit between the ECM and the suction control valve.



20. If a problem is discovered, repair the harness connector. 21. If the harness connector is normal, replace the suction control valve. Refer to "1.Engine 1C.Fuel System(4HK1) Suction control valve Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Suction control valve Installation".



Note： ・ When the Low side circuit is shorted to GND, DTC P0092 may not be detected. ・ When the Low side circuit is shorted to GND, the engine stalls and does not start. 5.



If a problem is discovered, repair the Low side circuit.



6.



Turn the starter switch OFF for 30 seconds or longer.



7.



Disconnect the harness connector from the suction control valve.



8.



Connect the test light between the suction control valve High side circuit and a normal GND.



9.



Turn ON the starter switch.



10. Check if the test light comes on and then goes off. 11. If it does not turn off, inspect the High side circuit between the ECM and the suction control valve. ・There should be no open circuit or high resistance. ・There should be no short to GND. ・There should be no short to the LOW side circuit. 12. If a problem is discovered, repair the High side circuit. 13. Turn the starter switch OFF for 30 seconds or longer. 14. Connect the test light between the suction control valve Low side circuit and battery power supply. 15. Turn ON the starter switch. 16. Check if the test light comes on and then goes off.



22. Inspect the ECM harness connector for a contact failure. 23. If a problem is discovered, repair the harness connector. 24. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 25. Set the injector ID code on the ECM. 26. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0092 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-16 Engine Control (4HK1)



DTC P0093 (Flash Code 227) Fuel System Leak Detected 1.



DTC P0093 Priority DTC



3.



DTC P0087 DTC P0091 DTC P0092 DTC P0192



Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head assembly Removal". 4.



Inspect for fuel leaks into the combustion chamber



5.



Inspect to see if there is a cylinder from which fuel leaks into the combustion chamber.



6.



If fuel leak is found, replace the corresponding injector.



DTC P0193 DTC P0201 DTC P0202 DTC P0203 DTC P0204 DTC P2146 DTC P2149 2.



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 7.



When the injector has been replaced, set the injector ID code on the ECM.



8.



Turn OFF the starter switch.



9.



Wait for the specified period of time until the fuel pressure is released from the common rail.



DTC P0093 Diagnostics 1.



Inspect for fuel leaks on the high-pressure side between the fuel supply pump and injector.



・There should be no fuel leakage from the fuel supply pump. ・There should be no fuel leakage from the common rail. ・There should be no fuel leakage from the pressure limiter valve. ・There should be no fuel leakage from the fuel pressure sensor. ・There should be no fuel leakage from the fuel pipe between the fuel supply pump and common rail. ・There should be no fuel leakage from the fuel pipe between the common rail and injector. ・There should be no fuel leakage from the sleeve nut of the fuel pipe. 2.



If fuel leak if found, fix the problem.



Note： ・ The fuel may leak to the bottom section of the cylinder head cover from the high pressure pipe inlet. ・ The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. ・ Inspect for fuel leaks into the engine oil. ・ Remove and inspect the high pressure pipe joint connected to the injector for a fuel leakage from the sleeve nut. ・ When foreign matter has been attached, replace the injector and the high pressure pipe.



Remove each glow plug from the cylinder head assembly.



specified time： 2 min 10. Turn ON the starter switch. 11. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. voltage： 0.9 to 1.0 V 12. If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. Inspect the ECM harness connector for a contact failure. 15. If a problem is discovered, repair the harness connector. 16. Inspect each circuit for high resistance. 17. Repair the circuit if a problem is discovered. 18. If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation".



Engine Control (4HK1) 1A-17 Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 19. If the fuel rail pressure sensor display is within the standard range, start the engine. 20. Perform the injector stop test with the trouble diagnosis scan tool. 21. Command each injector OFF, and confirm that the engine RPM changes on each injector. 22. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 23. When the injector has been replaced, set the injector ID code on the ECM. 24. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. 25. If a problem is discovered, repair clogging. 26. Inspect to see if there is cut or crack with the fuel hose in the fuel system between the fuel tank and the fuel supply pump. 27. If a problem is discovered, replace the fuel hose. Note： ・ The fuel hose between the fuel tank and the supply pump becomes negative pressure state when the engine is running. ・ When the fuel hose is not connected securely, the air can enter. ・ When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P0093 may be detected. 28. Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. 29. If a problem is discovered, replace the clamp with an appropriate one. 30. Operate the priming pump until the handle becomes heavy. Note： ・ When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy.



31. Start the engine. 32. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail. Note： ・ The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. ・ The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. ・ Inspect for fuel leaks into the engine oil. 33. If fuel leak if found, fix the problem. 34. Turn OFF the starter switch. 35. Remove the fuel hose on the fuel supply pump side from the fuel filter. Note： ・ Use a pan to catch the fuel from the removed fuel hose. ・ Clean the pressure gauge and connection hose before connecting to the fuel pipe. ・ The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose. 36. Connect the pressure gauge between the fuel filter and the removed fuel hose. Note： ・ Confirm that the fuel system is connected securely. 37. Remove the air using the priming pump, and crank the engine for the specified period of time or shorter. specified time： 5 s Note： ・ Repeat this until the engine starts. 38. Leave the engine idling for the specified period of time or longer. specified time： 1 min 39. While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. specified time： 1 min rotational speed： 2500 r/min 40. Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. specified value： 17.0 kPa { 128 mmHg / 5 inHg }



1A-18 Engine Control (4HK1) Note： ・ Fuel clogging is checked with the negative pressure amount in the fuel system.



56. Inspect the suction control valve harness connector for a contact failure. 57. If a problem is discovered, repair the harness connector.



41. If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank.



58. Inspect the ECM harness connector for a contact failure.



42. If a problem is discovered, repair the fuel system.



59. If a problem is discovered, repair the harness connector.



43. Inspect the fuel tank bent hose.



60. Inspect each circuit for high resistance.



44. If a problem is discovered, repair the bent hose.



61. Repair the circuit if a problem is discovered.



45. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging.



62. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element.



46. If a problem is discovered, repair it.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal".



47. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal".



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation".



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation".



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal".



48. If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". Note： ・ When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time.



Note： ・ The fuel pipe can be disconnected and clogged with a plug.



63. Perform the unit difference learning of the fuel supply pump to the ECM.



49. Start the engine and use the idling control switch to increase the RPM to the highest level. 50. Check the pressure gauge.



3.



DTC P0093 Confirm Resolution



specified value： 27.0 kPa { 203 mmHg / 8 inHg }



1.



Clear the DTC using the trouble diagnosis scan tool.



Note： ・ When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. ・ Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



51. If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. 52. If a problem is discovered, replace the fuel hose. 53. Inspect to see if appropriate clamp is used. 54. If a problem is discovered, replace the clamp with an appropriate one. 55. Turn OFF the starter switch.



Engine Control (4HK1) 1A-19



DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input 1.



DTC P0102 Priority DTC DTC P0560



2.



DTC P0102 Diagnostics



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



1.



Turn OFF the starter switch.



4.



Perform a test-run.



2.



Disconnect the harness connector from the mass air flow sensor.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



3.



Inspect to see if there is an open circuit or high resistance in the 12 V power supply circuit between the ECM and the mass air flow sensor.



4.



If a problem is discovered, repair the 12 V power supply circuit.



5.



Connect the test cable with fuse between the 12 V power supply circuit and the signal circuit of the mass air flow sensor harness connector.



6.



Check the mass air flow sensor display with the trouble diagnosis scan tool.



voltage： 4.9 V 7.



If it is at or above the standard value, inspect to see if there is a contact failure with the mass air flow sensor harness connector.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the mass air flow sensor.



10. Inspect the signal circuit between the ECM and the mass air flow sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 11. If a problem is discovered, repair the signal circuit. 12. Inspect the ECM harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 15. Set the injector ID code on the ECM. 16. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



1.



DTC P0102 Confirm Resolution



1A-20 Engine Control (4HK1)



DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input 1.



DTC P0103 Priority DTC DTC P0560



2.



DTC P0103 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the mass air flow sensor.



3.



Check the mass air flow sensor display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the mass air flow sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 12 V or 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the mass air flow sensor.



7.



If a problem is discovered, repair the GND circuit.



8.



Inspect the mass air flow sensor harness connector for a contact failure.



9.



If a problem is discovered, repair the harness connector.



10. If the harness connector is normal, replace the mass air flow sensor. 11. Inspect the ECM harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 14. Set the injector ID code on the ECM. 15. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0103 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-21



DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low 1.



DTC P0112 Priority DTC DTC P0641



2.



DTC P0112 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the intake air temperature sensor.



3.



Check the intake air temperature sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the intake air temperature sensor.



5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the intake air temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Turn OFF the starter switch.



8.



Disconnect the harness connector from the ECM.



9.



Inspect the ECM harness connector for a contact failure.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 12. Set the injector ID code on the ECM. 13. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0112 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-22 Engine Control (4HK1)



DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High 1.



GND circuit between the ECM and the intake air temperature sensor.



DTC P0113 Priority DTC DTC P0641



2.



Note： ・ The intake air temperature sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected.



DTC P0113 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the intake air temperature sensor.



3.



Turn ON the starter switch.



17. If a problem is discovered, repair the GND circuit.



4.



Measure the voltage between the intake air temperature sensor signal circuit and a normal GND.



18. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the intake air temperature sensor.



voltage： 5.5 V 5.



19. If a problem is discovered, repair the signal circuit.



If it is at or above the standard value, inspect the signal circuit between the ECM and the intake air temperature sensor.



20. Inspect the ECM harness connector for a contact failure.



・There should be no short to the battery or ignition power supply ・There should be no short to the 12 V power supply. 6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the intake air temperature sensor signal circuit and the GND circuit.



8.



21. If a problem is discovered, repair the harness connector. 22. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



Check the intake air temperature sensor display with the trouble diagnosis scan tool.



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM.



voltage： 0.1 V 9.



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the intake air temperature sensor.



10. If a problem is discovered, repair the signal circuit. 11. Inspect the intake air temperature sensor harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the intake air temperature sensor. 14. Connect the test cable with fuse between the intake air temperature sensor signal circuit and a normal GND. 15. Check the intake air temperature sensor display with the trouble diagnosis scan tool. voltage： 0.1 V 16. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the



3.



DTC P0113 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-23



DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 1.



DTC P0117 Priority DTC DTC P0697



2.



DTC P0117 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the water temperature sensor.



3.



Check the coolant temperature sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the water temperature sensor.



Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Removal". Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Installation". 5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and water temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0117 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-24 Engine Control (4HK1)



DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High 1.



16. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the water temperature sensor GND circuit.



DTC P0118 Priority DTC DTC P0697



2.



DTC P0118 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the water temperature sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the water temperature sensor signal circuit and normal GND.



Note： ・ The water temperature sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 17. If a problem is discovered, repair the GND circuit. 18. Inspect to see if there is a breakage or high resistance in the signal circuit of the water temperature sensor.



voltage： 5.5 V 5.



19. If a problem is discovered, repair the signal circuit.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the water temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the water temperature sensor signal circuit and GND circuit.



8.



Check the coolant temperature sensor display with the trouble diagnosis scan tool.



20. Inspect the ECM harness connector for a contact failure. 21. If a problem is discovered, repair the harness connector. 22. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



voltage： 0.1 V 9.



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the water temperature sensor.



10. If a problem is discovered, repair the signal circuit. 11. Inspect to see if there is a contact failure with the water temperature sensor harness connector. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the water temperature sensor. Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Removal". Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Installation". 14. Connect the test cable with fuse between the water temperature sensor signal circuit and normal GND. 15. Check the coolant temperature sensor display with the trouble diagnosis scan tool. voltage： 0.1 V



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0118 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-25



DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 1.



13. If a problem is discovered, repair the signal circuit.



DTC P0122 Priority DTC



14. Inspect the ECM harness connector for a contact failure.



DTC P1655 2.



DTC P0122 Diagnostics 1.



Turn OFF the starter switch.



15. If a problem is discovered, repair the harness connector.



2.



Disconnect the harness connector from the intake throttle valve.



16. If the harness connector is normal, replace the ECM.



3.



Turn ON the starter switch.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



4.



Measure the voltage between the intake throttle position sensor 5 V power supply circuit and a normal GND.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 17. Set the injector ID code on the ECM.



voltage： 4.9 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the intake throttle position sensor.



Note： ・ The intake throttle position sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the intake throttle position sensor 5 V power supply circuit and the signal circuit.



8.



Check the intake throttle position sensor display with the trouble diagnosis scan tool.



voltage： 4.9 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the intake throttle valve harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation". 12. Inspect the signal circuit between the ECM and intake throttle position sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND.



18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0122 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-26 Engine Control (4HK1)



DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P0123 Priority DTC DTC P1655



2.



14. Set the injector ID code on the ECM.



DTC P0123 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the intake throttle valve.



3.



Check the intake throttle position sensor display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the intake throttle position sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Inspect the intake throttle valve harness connector for a contact failure.



7.



If a problem is discovered, repair the harness connector.



8.



If the harness connector is normal, replace the intake throttle valve.



Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation". 9.



Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the intake throttle position sensor.



Note： ・ The intake throttle position sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 10. If a problem is discovered, repair the GND circuit. 11. Check the ECM harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



15. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0123 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-27



DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low 1.



DTC P0182 Priority DTC DTC P1655



2.



DTC P0182 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the fuel temperature sensor.



3.



Check the fuel temperature sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the fuel temperature sensor.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation". Note： ・ Do not replace the fuel temperature sensor separately. If a problem is found, replace the fuel supply pump. 5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and fuel temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0182 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-28 Engine Control (4HK1)



DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High 1.



15. Check the fuel temperature sensor display with the trouble diagnosis scan tool.



DTC P0183 Priority DTC DTC P1655



2.



voltage： 0.1 V



DTC P0183 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the fuel temperature sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the fuel temperature sensor signal circuit and normal GND.



16. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and fuel temperature sensor. Note： ・ The fuel temperature sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the fuel temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the fuel temperature sensor signal circuit and GND circuit.



8.



17. If a problem is discovered, repair the GND circuit. 18. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the fuel temperature sensor. 19. If a problem is discovered, repair the signal circuit. 20. Inspect the ECM harness connector for a contact failure.



Check the fuel temperature sensor display with the trouble diagnosis scan tool.



21. If a problem is discovered, repair the harness connector.



voltage： 0.1 V 9.



22. If the harness connector is normal, replace the ECM.



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the fuel temperature sensor.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



10. If a problem is discovered, repair the signal circuit. 11. Inspect to see if there is a contact failure with the fuel temperature sensor harness connector. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the fuel temperature sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation". Note： ・ Do not replace the fuel temperature sensor separately. If a problem is found, replace the fuel supply pump. 14. Connect the test cable with fuse between the fuel temperature sensor signal circuit and normal GND.



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0183 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



Note： ・ Run the engine for 3 minutes or longer. 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-29



DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low 1.



12. Inspect the ECM harness connector for a contact failure.



DTC P0192 Priority DTC DTC P0641



2.



13. If a problem is discovered, repair the harness connector.



DTC P0192 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the fuel pressure sensor.



3.



Check the fuel rail pressure sensor display with the trouble diagnosis scan tool.



14. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



voltage： 4.5 V 4.



If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the fuel pressure sensor.



15. Set the injector ID code on the ECM. 16. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0192 Confirm Resolution



5.



If a problem is discovered, repair the signal circuit.



1.



Clear the DTC using the trouble diagnosis scan tool.



6.



Measure the voltage between the fuel pressure sensor 5 V power supply circuit and normal GND.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



voltage： 4.5 V 7.



If it is at or above the standard value, inspect to see if there is a contact failure with the fuel pressure sensor harness connector.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the fuel pressure sensor.



Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation". Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 10. Inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and fuel pressure sensor. Note： ・ The fuel pressure sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 11. If a problem is discovered, repair the 5 V power supply circuit.



1A-30 Engine Control (4HK1)



DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 1.



Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.



DTC P0193 Priority DTC DTC P0641



2.



DTC P0193 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the fuel pressure sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the fuel pressure sensor signal circuit and normal GND.



15. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the fuel pressure sensor. Note： ・ The fuel pressure sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the fuel pressure sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Measure the voltage between the fuel pressure sensor signal circuit and normal GND.



16. If a problem is discovered, repair the GND circuit. 17. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the fuel pressure sensor. 18. If a problem is discovered, repair the signal circuit. 19. Inspect the ECM harness connector for a contact failure.



voltage： 4.5 V 8.



9.



20. If a problem is discovered, repair the harness connector.



If it is at or above the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the fuel pressure sensor.



21. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



If a problem is discovered, repair the signal circuit.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



10. Connect the test cable with fuse between the fuel pressure sensor signal circuit and GND circuit.



22. Set the injector ID code on the ECM.



11. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool.



23. Perform the unit difference learning of the fuel supply pump to the ECM.



voltage： 0.1 V 12. If it is at or below the standard value, inspect to see if there is a contact failure with the fuel pressure sensor harness connector. 13. If a problem is discovered, repair the harness connector. 14. If the harness connector is normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation".



3.



DTC P0193 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-31



DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 1.



18. Inspect to see if any foreign matter is attached to the injector terminal.



DTC P0201 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the cylinder head injector intermediate harness connector.



3.



Turn ON the starter switch.



4.



Measure the voltage between the first cylinder injector charge voltage circuit and normal GND.



19. If any foreign matter is attached to the injector terminal, remove it. 20. Inspect the injector harness intermediate harness connector for a contact failure. 21. If a problem is discovered, repair the intermediate harness connector.



voltage： 1.0 V 5.



22. Inspect the first cylinder injector circuit between the injector and injector harness intermediate connector.



If it is at or above the standard value, inspect to see if there is a short circuit to the common power supply 1 charge voltage circuit with the control circuit between the ECM and the injector harness intermediate connector.



6.



If a problem is discovered, repair the control circuit.



7.



Measure the voltage between the solenoid control circuit of the first cylinder injector and normal GND.



・There should be no open circuit or high resistance. ・There should be no short between the circuits. 23. If a problem is discovered, repair the injector circuit. 24. If the first cylinder injector circuit between the injector and the injector intermediate connector is normal, replace the first cylinder injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



voltage： 16.0 V 8.



9.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the control circuit between the ECM and the injector harness intermediate connector.



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 25. When the injector has been replaced, set the injector ID code on the ECM.



If a problem is discovered, repair the control circuit.



26. Disconnect the harness connector from the ECM.



10. Measure the voltage between the solenoid control circuit of the first cylinder injector and normal GND.



27. Inspect the ECM harness connector for a contact failure.



voltage： 12.0 V



28. If a problem is discovered, repair the harness connector.



11. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the control circuit between the ECM and injector harness intermediate connector.



29. If the harness connector is normal, replace the ECM.



12. If a problem is discovered, repair the control circuit.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



13. Inspect the injector harness intermediate connector for a contact failure.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



14. If a problem is discovered, repair the injector harness intermediate connector.



30. Set the injector ID code on the ECM. 31. Perform the unit difference learning of the fuel supply pump to the ECM.



15. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head cover Removal". 16. Inspect the injector harness tightening nut for looseness. 17. If the injector harness tightening nut is loose, tighten it.



2.



DTC P0201 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



1A-32 Engine Control (4HK1) 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-33



DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 1.



18. Inspect to see if any foreign matter is attached to the injector terminal.



DTC P0202 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the cylinder head injector intermediate harness connector.



3.



Turn ON the starter switch.



4.



Measure the voltage between the second cylinder injector charge voltage circuit and normal GND.



19. If any foreign matter is attached to the injector terminal, remove it. 20. Inspect the injector harness intermediate harness connector for a contact failure. 21. If a problem is discovered, repair the intermediate harness connector.



voltage： 1.0 V 5.



22. Inspect the second cylinder injector circuit between the injector and injector harness intermediate connector.



If it is at or above the standard value, inspect to see if there is a short circuit to the common power supply 2 charge voltage circuit with the control circuit between the ECM and the injector harness intermediate connector.



6.



If a problem is discovered, repair the control circuit.



7.



Measure the voltage between the solenoid control circuit of the second cylinder injector and normal GND.



・There should be no open circuit or high resistance. ・There should be no short between the circuits. 23. If a problem is discovered, repair the injector circuit. 24. If the second cylinder injector circuit between the injector and the injector intermediate connector is normal, replace the second cylinder injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



voltage： 16.0 V 8.



9.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the control circuit between the ECM and the injector harness intermediate connector.



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 25. When the injector has been replaced, set the injector ID code on the ECM.



If a problem is discovered, repair the control circuit.



26. Disconnect the harness connector from the ECM.



10. Measure the voltage between the solenoid control circuit of the second cylinder injector and normal GND.



27. Inspect the ECM harness connector for a contact failure.



voltage： 12.0 V



28. If a problem is discovered, repair the harness connector.



11. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the control circuit between the ECM and injector harness intermediate connector.



29. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



12. If a problem is discovered, repair the control circuit.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



13. Inspect the injector harness intermediate connector for a contact failure.



30. Set the injector ID code on the ECM.



14. If a problem is discovered, repair the injector harness intermediate connector. 15. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head cover Removal". 16. Inspect the injector harness tightening nut for looseness. 17. If the injector harness tightening nut is loose, tighten it.



31. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0202 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



1A-34 Engine Control (4HK1) 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-35



DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 1.



18. Inspect to see if any foreign matter is attached to the injector terminal.



DTC P0203 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the cylinder head injector intermediate harness connector.



3.



Turn ON the starter switch.



4.



Measure the voltage between the third cylinder injector charge voltage circuit and normal GND.



19. If any foreign matter is attached to the injector terminal, remove it. 20. Inspect the injector harness intermediate harness connector for a contact failure. 21. If a problem is discovered, repair the intermediate harness connector.



voltage： 1.0 V 5.



22. Inspect the third cylinder injector circuit between the injector and injector harness intermediate connector.



If it is at or above the standard value, inspect to see if there is a short circuit to the common power supply 2 charge voltage circuit with the control circuit between the ECM and the injector harness intermediate connector.



6.



If a problem is discovered, repair the control circuit.



7.



Measure the voltage between the solenoid control circuit of the third cylinder injector and normal GND.



・There should be no open circuit or high resistance. ・There should be no short between the circuits. 23. If a problem is discovered, repair the injector circuit. 24. If the third cylinder injector circuit between the injector and the injector intermediate connector is normal, replace the third cylinder injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



voltage： 16.0 V 8.



9.



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation".



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the control circuit between the ECM and the injector harness intermediate connector.



25. When the injector has been replaced, set the injector ID code on the ECM.



If a problem is discovered, repair the control circuit.



26. Disconnect the harness connector from the ECM. 27. Inspect the ECM harness connector for a contact failure.



10. Measure the voltage between the solenoid control circuit of the third cylinder injector and normal GND.



28. If a problem is discovered, repair the harness connector.



voltage： 12.0 V



29. If the harness connector is normal, replace the ECM.



11. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the control circuit between the ECM and injector harness intermediate connector.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



12. If a problem is discovered, repair the control circuit.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



13. Inspect the injector harness intermediate connector for a contact failure.



30. Set the injector ID code on the ECM. 31. Perform the unit difference learning of the fuel supply pump to the ECM.



14. If a problem is discovered, repair the injector harness intermediate connector. 15. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head cover Removal". 16. Inspect the injector harness tightening nut for looseness. 17. If the injector harness tightening nut is loose, tighten it.



2.



DTC P0203 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



1A-36 Engine Control (4HK1) 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-37



DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 1.



18. Inspect to see if any foreign matter is attached to the injector terminal.



DTC P0204 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the cylinder head injector intermediate harness connector.



3.



Turn ON the starter switch.



4.



Measure the voltage between the fourth cylinder injector charge voltage circuit and normal GND.



19. If any foreign matter is attached to the injector terminal, remove it. 20. Inspect the injector harness intermediate harness connector for a contact failure. 21. If a problem is discovered, repair the intermediate harness connector.



voltage： 1.0 V 5.



22. Inspect the fourth cylinder injector circuit between the injector and injector harness intermediate connector.



If it is at or above the standard value, inspect to see if there is a short circuit to the common power supply 1 charge voltage circuit with the control circuit between the ECM and the injector harness intermediate connector.



6.



If a problem is discovered, repair the control circuit.



7.



Measure the voltage between the solenoid control circuit of the fourth cylinder injector and normal GND.



・There should be no open circuit or high resistance. ・There should be no short between the circuits. 23. If a problem is discovered, repair the injector circuit. 24. If the fourth cylinder injector circuit between the injector and the injector intermediate connector is normal, replace the fourth cylinder injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



voltage： 16.0 V 8.



9.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the control circuit between the ECM and the injector harness intermediate connector.



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 25. When the injector has been replaced, set the injector ID code on the ECM.



If a problem is discovered, repair the control circuit.



26. Disconnect the harness connector from the ECM.



10. Measure the voltage between the solenoid control circuit of the third cylinder injector and normal GND.



27. Inspect the ECM harness connector for a contact failure.



voltage： 12.0 V



28. If a problem is discovered, repair the harness connector.



11. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the control circuit between the ECM and injector harness intermediate connector.



29. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



12. If a problem is discovered, repair the control circuit.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



13. Inspect the injector harness intermediate connector for a contact failure.



30. Set the injector ID code on the ECM.



14. If a problem is discovered, repair the injector harness intermediate connector. 15. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head cover Removal". 16. Inspect the injector harness tightening nut for looseness. 17. If the injector harness tightening nut is loose, tighten it.



31. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0204 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



1A-38 Engine Control (4HK1) 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-39



DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition 1.



DTC P0217 Priority DTC DTC P0117



2.



DTC P0217 Diagnostics 1.



Inspect the engine cooling system.



Refer to "1.Engine 1D.Cooling(4HK1) Coolant Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Cooling fan belt Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Thermostat Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Water pump assembly Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Radiator Inspection". 2.



While checking the coolant temperature display with the trouble diagnosis scan tool, start the engine.



3.



Wait until the engine has been completely warmed up.



4.



Use the trouble diagnosis scan tool to check if the coolant temperature display is at or above the standard value.



Specified value： 110 ℃ { 230 °F } 5.



If it is at or below the standard value, check with the driver if the overheat occurred due to a cause such as low engine coolant level.



6.



Make sure to inspect the engine if it has experienced engine overheat in the past.



7.



Inspect the engine coolant temperature sensor.



Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Inspection". 8.



If any abnormality is found in the inspection results, replace the water temperature sensor.



Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Removal". Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant temperature sensor Installation". 3.



DTC P0217 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



While checking the coolant temperature display with the trouble diagnosis scan tool, start the engine and wait until it is completely warmed up.



4.



Confirm that the coolant temperature display does not show a value at or above the standard value.



Specified value： 110 ℃ { 230 °F } 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-40 Engine Control (4HK1)



DTC P0219 (Flash Code 543) Engine Overspeed Condition 1.



DTC P0219 Priority DTC DTC P0335 DTC P0336



2.



DTC P0219 Diagnostics 1.



Turn the starter switch OFF for 30 seconds.



2.



Start the engine.



3.



Check the engine RPM display with the trouble diagnosis scan tool.



4.



Increase the engine RPM, as needed.



5.



Check the engine RPM display with the trouble diagnosis scan tool.



rotational speed： 2500 RPM 6.



When the standard value has not been exceeded, check with the operator if an operation failure has occurred due to the overrun.



7.



Make sure to inspect the engine if it has experienced engine overrun in the past.



8.



Inspect the CKP sensor.



Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Inspection". 9.



If any abnormality is found in the inspection results, replace the crankshaft position sensor.



Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Installation". 3.



DTC P0219 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, and rev the engine a few times in neutral between the idling speed and the maximum revolution speed without load while checking the engine rpm display with the trouble diagnosis scan tool.



4.



Confirm that the engine RPM display does not exceed the standard value.



rotational speed： 2500 RPM 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-41



DTC P0234 (Flash Code 42) Turbocharger Overboost Condition 1.



Note： ・ The atmospheric pressure in the trouble diagnosis scan tool normally indicates a value close to the surrounding atmospheric pressure.



DTC P0234 Priority DTC DTC P0045 DTC P0237 DTC P0238



13. If the atmospheric pressure display is within the standard range, inspect the boost sensor system.



DTC P0638 DTC P2228



Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Inspection".



DTC P2229 2.



DTC P0234 Diagnostics 1.



Turn ON the starter switch.



2.



Check the difference between the boost pressure display and the atmospheric pressure display with the trouble diagnosis scan tool.



14. If the inspection result of the boost sensor has a problem, replace the boost sensor. Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Installation".



specified value： 10.0 kPa { 1.5 psi }



15. If the atmospheric pressure display is outside the standard range, inspect the atmospheric pressure sensor system.



Note： ・ The value is normal if the boost pressure indicated by the trouble diagnosis scan tool is close to the atmospheric pressure when the starter switch is ON and the engine is stopped. 3.



16. If the inspection result of the atmospheric pressure sensor has a problem, replace the atmospheric pressure sensor.



If it is at or below the standard value, inspect to see if there is a failure with the actuator which controls the turbocharger nozzle.



4.



If a problem is discovered, repair the actuator.



5.



Perform the intake throttle test with the trouble diagnosis scan tool to check the intake throttle valve for fixing.



6.



If a problem is discovered, repair the intake throttle valve.



7.



Check to see if there is oil mixing in the air intake piping.



8.



If oil is attached inside the pipe, the intercooler, or the turbocharger, wipe it off.



9.



Use the trouble diagnosis scan tool to confirm that the boost sensor signal is normal.



10. Compare the sensor values under various load conditions to check for an abnormally high value. 11. If it is at or above the standard value, compare the value of the atmospheric pressure with the surrounding atmospheric pressure. 12. Use the trouble diagnosis scan tool to check if the atmospheric pressure display is within the standard range.



17. Inspect the ECM harness connector for a contact failure. 18. If a problem is discovered, repair the harness connector. 3.



DTC P0234 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-42 Engine Control (4HK1)



DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low 1.



13. If a problem is discovered, repair the signal circuit.



DTC P0237 Priority DTC



14. Inspect the ECM harness connector for a contact failure.



DTC P1655 2.



DTC P0237 Diagnostics 1.



Turn OFF the starter switch.



15. If a problem is discovered, repair the harness connector.



2.



Disconnect the harness connector from the boost sensor.



16. If the harness connector is normal, replace the ECM.



3.



Turn ON the starter switch.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



4.



Measure the voltage between the 5 V power supply circuit of the boost sensor harness connector and a normal GND.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 17. Set the injector ID code on the ECM.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the boost sensor.



Note： ・ The boost sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the 5 V power supply circuit and the signal circuit of the boost sensor harness connector.



8.



Check the boost pressure sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the boost sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the boost sensor. Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Installation". 12. Inspect the signal circuit between the ECM and the boost sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND.



18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0237 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-43



DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P0238 Priority DTC DTC P1655



2.



14. Set the injector ID code on the ECM.



DTC P0238 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the boost sensor.



3.



Check the boost pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the boost sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the boost sensor.



Note： ・ The boost sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 7.



If a problem is discovered, repair the GND circuit.



8.



Inspect the boost sensor harness connector for a contact failure.



9.



If a problem is discovered, repair the harness connector.



10. If the harness connector is normal, replace the boost sensor. Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Installation". 11. Inspect the ECM harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



15. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0238 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-44 Engine Control (4HK1)



DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit 1.



DTC P0335 Priority DTC DTC P0340 DTC P0641



2.



DTC P0335 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the crankshaft position sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the 5 V power supply circuit and normal GND of the crankshaft position sensor harness connector.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the crankshaft position sensor.



Note： ・ The crankshaft position sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Measure the voltage between the signal circuit and normal GND of the crankshaft position sensor harness connector.



voltage： 5.5 V 8.



9.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the crankshaft position sensor. If a problem is discovered, repair the signal circuit.



10. Measure the voltage between the signal circuit of the crankshaft position sensor harness connector and a normal GND again. voltage： 4.5 V 11. If it is at or below the standard value, inspect the signal circuit between the ECM and the crankshaft position sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 12. If a problem is discovered, repair the signal circuit.



13. Connect the test light between the signal circuit and normal GND of the crankshaft position sensor harness connector. 14. Measure the voltage between the probe of the test light and a normal GND. voltage： 4.5 V 15. If it is at or above the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the crankshaft position sensor. 16. If a problem is discovered, repair the signal circuit. 17. Measure the voltage between the 5 V power supply circuit and GND circuit of the crankshaft position sensor harness connector. voltage： 4.50 V 18. If it is at or above the standard value, inspect to see if there is a contact failure with the crankshaft position sensor harness connector. 19. If a problem is discovered, repair the harness connector. 20. If the harness connector is normal, inspect the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Inspection". 21. If a problem is discovered, replace the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Installation". 22. Inspect the GND circuit between the ECM and the crankshaft position sensor for an open circuit and high resistance. Note： ・ The crankshaft position sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 23. If a problem is discovered, repair the GND circuit. 24. Inspect the ECM harness connector for a contact failure. 25. If a problem is discovered, repair the harness connector.



Engine Control (4HK1) 1A-45 26. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 27. Set the injector ID code on the ECM. 28. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0335 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-46 Engine Control (4HK1)



DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance 1.



DTC P0336 Priority DTC DTC P0335 DTC P0340 DTC P0641



2.



DTC P0336 Diagnostics 1.



Inspect the crankshaft position sensor circuit.



・There should be enough clearing from the wiring or component of the fuel injection unit. ・There should be enough clearing from additionally installed electronic components. ・There should be enough clearing from the solenoids and relays. 2.



If a problem is discovered, repair the crankshaft position sensor circuit.



3.



Turn OFF the starter switch.



4.



Disconnect the harness connector from the ECM.



5.



Inspect the ECM harness connector for a contact failure.



6.



If a problem is discovered, repair the harness connector.



7.



Disconnect the harness connector from the crankshaft position sensor.



8.



Inspect the crankshaft position sensor harness connector for a contact failure.



9.



If a problem is discovered, repair the harness connector.



10. Inspect the CKP sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Inspection". 11. If a problem is discovered, replace the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Installation". 3.



DTC P0336 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-47



DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 1.



DTC P0340 Priority DTC DTC P0601 DTC P0651



2.



DTC P0340 Diagnostics



voltage： 4.5 V 15. If it is at or above the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the camshaft position sensor.



1.



Turn OFF the starter switch.



16. If a problem is discovered, repair the signal circuit.



2.



Disconnect the harness connector from the camshaft position sensor.



3.



Turn ON the starter switch.



17. Measure the voltage between the 5 V power supply circuit and GND circuit of the camshaft position sensor harness connector.



4.



Measure the voltage between the 5 V power supply circuit and normal GND of the camshaft position sensor harness connector.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the camshaft position sensor.



6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Measure the voltage between the signal circuit and normal GND of the camshaft position sensor harness connector.



voltage： 5.5 V 8.



9.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the camshaft position sensor. If a problem is discovered, repair the signal circuit.



10. Measure the voltage between the signal circuit of the camshaft position sensor harness connector and a normal GND again. voltage： 4.5 V 11. If it is at or below the standard value, inspect the signal circuit between the ECM and the camshaft position sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 12. If a problem is discovered, repair the signal circuit. 13. Connect the test light between the signal circuit and normal GND of the camshaft position sensor harness connector. 14. Measure the voltage between the probe of the test light and a normal GND.



voltage： 4.5 V 18. If it is at or above the standard value, inspect to see if there is a contact failure with the camshaft position sensor harness connector. 19. If a problem is discovered, repair the harness connector. 20. If the harness connector is normal, inspect the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Inspection". 21. If a problem is discovered, replace the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Installation". 22. Inspect the camshaft gear. ・The camshaft gear should not be damaged ・The camshaft gear should be installed correctly. 23. If a problem is discovered, repair the camshaft gear. 24. Inspect the GND circuit between the ECM and the camshaft position sensor for an open circuit and high resistance. Note： ・ The camshaft position sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 25. If a problem is discovered, repair the GND circuit. 26. Inspect the ECM harness connector for a contact failure. 27. If a problem is discovered, repair the harness connector. 28. If the harness connector is normal, replace the ECM.



1A-48 Engine Control (4HK1) Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 29. Set the injector ID code on the ECM. 30. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0340 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-49



DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance 1.



Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Installation".



DTC P0404 Priority DTC DTC P0409



2.



15. Restore the actual unit.



DTC P0404 Diagnostics 1.



16. Turn ON the starter switch.



Remove the EGR valve assembly from the engine.



17. Clear the DTC using the trouble diagnosis scan tool.



Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal". 2.



18. Turn the starter switch OFF for 30 seconds or longer. 19. Start the engine.



Inspect the EGR valve.



20. Perform a test-run.



・There should be nothing to limit flow inside the EGR valve. ・There should be no excessive accumulates inside the EGR valve. ・There should be no bending with the valve shaft or valve itself inside the EGR valve.



21. Check the DTC using the trouble diagnosis scan tool. 22. If the DTC P0404 has been detected, replace the ECM.



3.



Turn OFF the starter switch.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



4.



Disconnect the harness connector from the EGR valve.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



5.



Inspect the EGR valve harness connector for a contact failure.



6.



If a problem is discovered, repair the harness connector.



7.



Disconnect the harness connector from the ECM.



8. 9.



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0404 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



Inspect the ECM harness connector for a contact failure.



2.



Turn the starter switch OFF for 30 seconds or longer.



If a problem is discovered, repair the harness connector.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



10. Inspect to see if there is an open circuit or high resistance in the EGR control circuit. 11. If a problem is discovered, repair the EGR control circuit. 12. Inspect the EGR solenoid circuit between the ECM and EGR valve. ・There should be no short to GND. ・There should be no short to the battery or ignition power supply circuit. ・There should be no short between the circuits. ・There should be no short to EGR position sensor circuit. 13. If a problem is discovered, repair the EGR solenoid circuit. 14. If the EGR solenoid circuit is normal, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal".



1A-50 Engine Control (4HK1)



DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit 1.



DTC P0409 Priority DTC DTC P1655



2.



DTC P0409 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the EGR valve.



3.



Turn ON the starter switch.



4.



Use the trouble diagnosis scan tool to check if any of the EGR position 1, EGR position 2, and EGR position 3 shows ON.



5.



If there is a data display showing ON, inspect the signal circuit between the ECM and EGR valve of the EGR showing ON.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 6.



If a problem is discovered, repair the signal circuit.



7.



Measure the voltage between the EGR position sensor 5 V power supply circuit and a normal GND.



voltage： 4.5 V 8.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the EGR position sensor.



Note： ・ The EGR position sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 9.



If a problem is discovered, repair the 5 V power supply circuit.



10. Measure the voltage between the EGR position sensor 5 V power supply circuit and the GND circuit. voltage： 4.5 V 11. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and EGR position sensor. Note： ・ The EGR position sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected.



12. If a problem is discovered, repair the GND circuit. 13. While momentarily disconnecting the test cable with fuse from the EGR position sensor 1 signal circuit and 5 V power supply circuit, check the EGR position 1 display with the trouble diagnosis scan tool. 14. While momentarily disconnecting the test cable with fuse from the EGR position sensor 2 signal circuit and 5 V power supply circuit, check the EGR position 2 display with the trouble diagnosis scan tool. 15. While momentarily disconnecting the test cable with fuse from the EGR position sensor 3 signal circuit and 5 V power supply circuit, check the EGR position 3 display with the trouble diagnosis scan tool. 16. Check to see if there is a data display which does not display ON when the EGR position sensor signal circuit and 5 V power supply circuit are shorted. 17. If there is a data display which does not display ON, inspect the EGR position sensor circuit which does not display ON. ・There should be no open circuit or high resistance between ECM and EGR position sensor. ・There should be no short to GND between ECM and EGR position sensor. 18. If a problem is discovered, repair the EGR position sensor circuit. 19. Inspect the EGR valve harness connector for a contact failure. 20. If a problem is discovered, repair the harness connector. 21. In the EGR solenoid circuit between the ECM and EGR valve, inspect to see if there is a short circuit with the EGR position sensor. 22. If a problem is discovered, repair the EGR solenoid circuit. 23. If the EGR solenoid circuit is normal, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Installation". 24. Inspect the ECM harness connector for a contact failure.



Engine Control (4HK1) 1A-51 25. If a problem is discovered, repair the harness connector. 26. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 27. Set the injector ID code on the ECM. 28. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0409 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-52 Engine Control (4HK1)



DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High 1.



16. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and IMT sensor.



DTC P041C Priority DTC DTC P1655



2.



DTC P041C Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the IMT sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the IMT sensor signal circuit and a normal GND.



Note： ・ The IMT sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 17. If a problem is discovered, repair the GND circuit. 18. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the IMT sensor.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the IMT sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the IMT sensor signal circuit and the GND circuit.



8.



19. If a problem is discovered, repair the signal circuit. 20. Inspect the ECM harness connector for a contact failure. 21. If a problem is discovered, repair the harness connector. 22. If the harness connector is normal, replace the ECM.



Check the intake manifold temperature sensor display with the trouble diagnosis scan tool.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



voltage： 0.1 V 9.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and IMT sensor.



10. If a problem is discovered, repair the signal circuit. 11. Inspect the IMT sensor harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the IMT sensor. Refer to "1.Engine 1F.Induction(4HK1) IMT sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) IMT sensor Installation". 14. Connect the test cable with fuse between the IMT sensor signal circuit and a normal GND. 15. Check the intake manifold temperature sensor display with the trouble diagnosis scan tool. voltage： 0.1 V



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P041C Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



Note： ・ Run the engine for 3 minutes or longer. 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-53



DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low 1.



DTC P041D Priority DTC DTC P1655



2.



DTC P041D Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the IMT sensor.



3.



Check the intake manifold temperature sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the IMT sensor.



Refer to "1.Engine 1F.Induction(4HK1) IMT sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) IMT sensor Installation". 5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the IMT sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P041D Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-54 Engine Control (4HK1)



DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 1.



DTC P0426 Priority DTC DTC P0093 DTC P0427 DTC P1093



2.



DTC P0426 Diagnostics 1.



Inspect the exhaust gas temperature sensor 1.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Inspection". 2.



If a problem is discovered, replace the exhaust gas temperature sensor 1.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 3.



Inspect the DPD filter for a damage.



Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 4.



If a problem is discovered, replace the DPD filter.



Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Reassembly". 5. 3.



Perform the DPD regeneration data reset with the trouble diagnosis scan tool. DTC P0426 Confirm Resolution



1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-55



DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1 1.



DTC P0427 Priority DTC DTC P0697



2.



DTC P0427 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the exhaust gas temperature sensor 1.



3.



Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the exhaust gas temperature sensor 1.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the exhaust gas temperature sensor 1.



6.



If a problem is discovered, repair the signal circuit.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0427 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-56 Engine Control (4HK1)



DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 1.



16. If it is at or above the standard value, inspect to see if there is an open circuit or high resistance with the signal circuit between the ECM and the exhaust gas temperature sensor 1.



DTC P0428 Priority DTC DTC P0697



2.



DTC P0428 Diagnostics 1.



Turn OFF the starter switch.



17. If a problem is discovered, repair the signal circuit.



2.



Disconnect the harness connector from the exhaust gas temperature sensor 1.



3.



Turn ON the starter switch.



18. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the exhaust gas temperature sensor 1.



4.



Measure the voltage between the exhaust gas temperature sensor 1 signal circuit and normal GND.



Note： ・ The exhaust gas temperature sensor 1 shares the GND circuit with other sensors. ・ The DTC may be detected on a sensor which shares this circuit.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the exhaust gas temperature sensor 1.



6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the exhaust gas temperature sensor 1 signal circuit and GND circuit.



8.



19. If a problem is discovered, repair the GND circuit. 20. Inspect the ECM harness connector for a contact failure. 21. If a problem is discovered, repair the harness connector. 22. If the harness connector is normal, replace the ECM.



Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



voltage： 0.1 V 9.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the exhaust gas temperature sensor 1.



10. If a problem is discovered, repair the signal circuit. 11. Inspect to see if there is a contact failure with the exhaust gas temperature sensor 1 harness connector. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the exhaust gas temperature sensor 1. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal".



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0428 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine and warm it up until the coolant temperature exceeds the standard value.



Specified value： 70 ℃ { 158 °F } 4.



Repeatedly rev the engine in neutral to increase the engine rpm while checking the exhaust temperature sensor (in front of the filter) display with the trouble diagnosis scan tool.



5.



Use the trouble diagnosis scan tool to confirm that the exhaust temperature sensor (before the filter) display does not exceed the standard value.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 14. Connect the test cable with fuse between the exhaust gas temperature sensor 1 signal circuit and normal GND. 15. Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool. voltage： 0.1 V



voltage： 4.8 V 6.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-57



DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 1.



DTC P042B Priority DTC DTC P0093 DTC P042C DTC P1093



2.



DTC P042B Diagnostics 1.



Inspect the exhaust gas temperature sensor 2.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Inspection". 2.



If a problem is discovered, replace the exhaust gas temperature sensor 2.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 3.



Inspect the DPD filter for a damage.



Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 4.



If a problem is discovered, replace the DPD filter.



Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Reassembly". 5. 3.



Perform the DPD regeneration data reset with the trouble diagnosis scan tool. DTC P042B Confirm Resolution



1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-58 Engine Control (4HK1)



DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 1.



DTC P042C Priority DTC DTC P0697



2.



DTC P042C Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the exhaust gas temperature sensor 2.



3.



Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the exhaust gas temperature sensor 2.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the exhaust gas temperature sensor 2.



6.



If a problem is discovered, repair the signal circuit.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P042C Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-59



DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 1.



voltage： 0.1 V



DTC P042D Priority DTC



16. If it is at or above the standard value, inspect to see if there is an open circuit or high resistance with the signal circuit between the ECM and the exhaust gas temperature sensor 2.



DTC P0697 2.



DTC P042D Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the exhaust gas temperature sensor 2.



3.



Turn ON the starter switch.



4.



Measure the voltage between the exhaust gas temperature sensor 2 signal circuit and normal GND.



17. If a problem is discovered, repair the signal circuit. 18. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the exhaust gas temperature sensor 2. Note： ・ The exhaust gas temperature sensor 2 shares the GND circuit with other sensors. ・ The DTC may be detected on a sensor which shares this circuit.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the exhaust gas temperature sensor 2.



6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the exhaust gas temperature sensor 2 signal circuit and GND circuit.



8.



19. If a problem is discovered, repair the GND circuit. 20. Inspect the ECM harness connector for a contact failure. 21. If a problem is discovered, repair the harness connector.



Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool.



22. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



voltage： 0.1 V 9.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the exhaust gas temperature sensor 2.



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM.



10. If a problem is discovered, repair the signal circuit. 11. Inspect to see if there is a contact failure with the exhaust gas temperature sensor 2 harness connector. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the exhaust gas temperature sensor 2. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal".



3.



DTC P042D Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, and warm it up until the coolant temperature reaches the standard value.



Specified value： 70 ℃ { 158 °F } 4.



Repeatedly rev the engine in neutral to increase the engine rpm while checking the exhaust temperature sensor (in front of the oxidation catalyst) display with the trouble diagnosis scan tool.



5.



Use the trouble diagnosis scan tool to confirm that the exhaust temperature sensor (before the oxidation catalyst) display does not exceed the standard value.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 14. Connect the test cable with fuse between the exhaust gas temperature sensor 2 signal circuit and normal GND. 15. Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool.



voltage： 4.8 V



1A-60 Engine Control (4HK1) 6.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-61



DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low 1.



15. If a problem is discovered, repair the harness connector.



DTC P0522 Priority DTC DTC P0697



2.



16. If the harness connector is normal, replace the ECM.



DTC P0522 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the oil pressure sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the 5 V power supply circuit and normal GND of the oil pressure sensor harness connector.



voltage： 4.5 V 5.



6.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the oil pressure sensor. If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the oil pressure sensor harness connector.



8.



Check the oil pressure sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the oil pressure sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the oil pressure sensor. Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure sensor Removal". Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure sensor Installation". 12. Inspect the signal circuit between the ECM and the oil pressure sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 13. If a problem is discovered, repair the signal circuit. 14. Inspect the ECM harness connector for a contact failure.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 17. Set the injector ID code on the ECM. 18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0522 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-62 Engine Control (4HK1)



DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P0523 Priority DTC DTC P0697



2.



14. Set the injector ID code on the ECM.



DTC P0523 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the oil pressure sensor.



3.



Check the oil pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the oil pressure sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the oil pressure sensor.



Note： ・ The oil pressure sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 7.



If a problem is discovered, repair the GND circuit.



8.



Inspect the oil pressure sensor harness connector for a contact failure.



9.



If a problem is discovered, repair the harness connector.



10. If the harness connector is normal, replace the oil pressure sensor. Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure sensor Removal". Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure sensor Installation". 11. Inspect the ECM harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



15. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0523 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-63



DTC P0560 (Flash Code 155) System Voltage 1.



voltage： 18.0 V



DTC P0560 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the mass air flow sensor.



3.



Use the trouble diagnosis scan tool to check if a DTC is detected.



4.



If a DTC has not been detected, inspect the mass air flow sensor harness connector for a contact failure.



5.



19. If it is at or below the standard value, inspect the fuse. 20. If the fuse is faulty, replace the fuse. 21. If it is at or below the standard value, repair an open circuit or high resistance in the ignition power supply circuit between the fuse and dropping register. 22. Measure the voltage between the voltage supply circuit of the dropping register and a normal GND.



If a problem is discovered, repair the harness connector.



6.



If the harness connector is normal, replace the mass air flow sensor.



7.



Turn OFF the starter switch.



8.



Leave the mass air flow sensor harness connector disconnected.



9.



Disconnect the harness connector from the dropping register.



voltage： 13.0 V 23. If it is at or above the standard value, inspect to see if there is a contact failure with the dropping register harness connector. 24. If a problem is discovered, repair the harness connector. 25. Inspect to see if there is an open circuit or high resistance in the voltage supply circuit between the ECM and the dropping register.



10. Use the trouble diagnosis scan tool to check if a DTC is detected.



26. If a problem is discovered, repair the voltage supply circuit.



11. If a DTC has been detected, inspect the voltage supply circuit between the ECM and dropping register.



27. Inspect the ECM harness connector for a contact failure. 28. If a problem is discovered, repair the harness connector.



・There should be no short to GND. ・There should be no short to the battery or ignition power supply.



29. If the harness connector is normal, replace the ECM.



12. If a problem is discovered, repair the voltage supply circuit.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



13. If the voltage supply circuit is normal, inspect the 12 V power supply circuit between the ECM and the mass air flow sensor.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 30. Set the injector ID code on the ECM.



・There should be no short to GND. ・There should be no short to the battery or ignition power supply. 14. If a problem is discovered, repair the 12 V power supply circuit. 15. Check the resistance value of the dropping register. resistance： 45.0 to 55.0 Ω 16. If the resistance value is outside the standard range, replace the dropping register. 17. Turn ON the starter switch. 18. Measure the voltage between the ignition power supply circuit of the dropping register and a normal GND.



31. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0560 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-64 Engine Control (4HK1)



DTC P0563 (Flash Code 35) System Voltage High 1.



DTC P0563 Diagnostics 1.



Check if the battery charger has been recently connected to the battery.



2.



Start the engine, and idle it.



3.



Check the ignition voltage display with the trouble diagnosis scan tool.



voltage： 32.0 V 4.



If it is at or above the standard value, inspect the charging system.



Refer to "1.Engine 1J.Electrical(4HK1) Generator Reassembly". 5.



If a problem is discovered, repair the charging system.



6.



If the charging system is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 7.



Set the injector ID code on the ECM.



8.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P0563 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, and idle it.



4.



Check the ignition voltage display with the trouble diagnosis scan tool, and confirm that the value does not exceed the standard value.



voltage： 32.0 V 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-65



DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error 1.



DTC P0601 Diagnostics 1.



Replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 2.



Set the injector ID code on the ECM.



3.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P0601 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-66 Engine Control (4HK1)



DTC P0602 (Flash Code 154) Control Module Programming Error 1.



DTC P0602 Diagnostics 1.



Confirm that the connecting sections of all tools are securely connected.



2.



Confirm that the programming device is operating normally.



3.



Use the trouble diagnosis scan tool to confirm that the correct injector ID code has been entered to the ECM.



Note： ・ When the injector ID code has been correctly input, clear the DTC using the trouble diagnosis scan tool. 4.



Turn the starter switch OFF for 30 seconds or longer.



5.



Turn ON the starter switch.



6.



Use the trouble diagnosis scan tool to check if a DTC has been detected.



7.



If a DTC has been detected, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 8.



Set the injector ID code on the ECM.



9.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P0602 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-67



DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error 1.



DTC P0604 Diagnostics 1.



Replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 2.



Set the injector ID code on the ECM.



3.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P0604 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-68 Engine Control (4HK1)



DTC P0606 (Flash Code 51) ECM/PCM Processor 1.



DTC P0606 Diagnostics 1.



Replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 2.



Set the injector ID code on the ECM.



3.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P0606 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-69



DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance 1.



DTC P060B Diagnostics 1.



Replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 2.



Set the injector ID code on the ECM.



3.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P060B Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-70 Engine Control (4HK1)



DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance 1.



・There should be no short to intake throttle position sensor circuit.



DTC P0638 Priority DTC DTC P0122



14. If a problem is discovered, repair the solenoid circuit.



DTC P0123 2.



DTC P0638 Diagnostics 1.



15. If the solenoid circuit is normal, replace the intake throttle valve.



Remove the air intake hose from the intake throttle valve.



Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal".



Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal". 2.



Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation".



Inspect the intake throttle valve.



・The intake throttle valve flow should not be limited. ・There should be no excessive deposit inside the throttle bore of the intake throttle valve. ・There should be no bending with the butterfly valve of the intake throttle valve. ・The intake throttle valve should not be locked. 3.



16. Restore the actual unit. 17. Turn ON the starter switch. 18. Turn the starter switch OFF for 30 seconds or longer. Note： ・ The starter switch must be once turned ON and then turned OFF before clearing the DTC.



If a problem is discovered, replace the intake throttle valve.



19. Clear the DTC using the trouble diagnosis scan tool.



Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal".



20. Turn the starter switch OFF for 30 seconds or longer. 21. Start the engine.



Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation". 4.



Turn OFF the starter switch.



5.



Disconnect the harness connector from the intake throttle valve.



6. 7.



22. Use the trouble diagnosis scan tool to check if a DTC has been detected. 23. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



Inspect the intake throttle valve harness connector for a contact failure.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



If a problem is discovered, repair the harness connector.



8.



Disconnect the harness connector from the ECM.



9.



Inspect the ECM harness connector for a contact failure.



10. If a problem is discovered, repair the harness connector. 11. Inspect the intake throttle valve circuit for high resistance. 12. Repair the circuit if a problem is discovered. 13. Inspect the solenoid circuit between the ECM and the intake throttle valve. ・There should be no short to GND. ・There should be no short to the battery or ignition power supply. ・There should be no short between the solenoid circuits.



24. Set the injector ID code on the ECM. 25. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P0638 Confirm Resolution 1.



Turn ON the starter switch.



2.



Turn the starter switch OFF for 30 seconds or longer.



Note： ・ The starter switch must be once turned ON and then turned OFF before clearing the DTC. 3.



Clear the DTC using the trouble diagnosis scan tool.



4.



Turn the starter switch OFF for 30 seconds or longer.



5.



Start the engine.



6.



Perform a test-run with the intake throttle solenoid drive duty of 20% or above.



Engine Control (4HK1) 1A-71 7.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-72 Engine Control (4HK1)



DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit 1.



DTC P0641 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the accelerator position sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the accelerator position sensor 5 V power supply circuit and GND of the accelerator position sensor harness connector.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the accelerator position sensor 5 V power supply circuit between the ECM and the accelerator position sensor.



6.



If a problem is discovered, repair the accelerator position sensor 5 V power supply circuit.



7.



Inspect to see if there is a short circuit to the battery or ignition power supply with the crankshaft position sensor 5 V power supply circuit between the ECM and the crankshaft position sensor.



8.



9.



If a problem is discovered, repair the crankshaft position sensor 5 V power supply circuit between the ECM and the crankshaft position sensor. Inspect to see if there is a short circuit to the battery or ignition power supply with the fuel pressure sensor 5 V power supply circuit between the ECM and the fuel pressure sensor.



10. If a problem is discovered, repair the fuel pressure sensor 5 V power supply circuit. 11. If it is at or below the standard value, measure the voltage between the 5 V power supply circuit and GND of the accelerator position sensor harness connector. voltage： 4.5 V 12. If it is at or above the standard value, replace the accelerator pedal assembly. 13. If it is at or below the standard value, turn the starter switch OFF. 14. Disconnect the harness connector from the crankshaft position sensor. 15. Turn ON the starter switch. 16. Measure the voltage between the accelerator position sensor 5 V power supply circuit and GND of the accelerator position sensor harness connector.



voltage： 4.5 V 17. If it is at or above the standard value, replace the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CKP sensor Installation". 18. If it is at or below the standard value, turn the starter switch OFF. 19. Disconnect the harness connector from the fuel pressure sensor. 20. Turn ON the starter switch. 21. Measure the voltage between the accelerator position sensor 5 V power supply circuit and GND of the accelerator position sensor harness connector. voltage： 4.5 V 22. If it is at or above the standard value, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation". Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 23. If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the accelerator position sensor 5 V power supply circuit between the ECM and the accelerator position sensor. 24. If a problem is discovered, repair the accelerator position sensor 5 V power supply circuit. 25. Inspect to see if there is a short circuit to the GND with the crankshaft position sensor 5 V power supply circuit between the ECM and the crankshaft position sensor. 26. If a problem is discovered, repair the crankshaft position sensor 5 V power supply circuit. 27. Inspect to see if there is a short circuit to the GND with the fuel pressure sensor 5 V power supply circuit between the ECM and the fuel pressure sensor.



Engine Control (4HK1) 1A-73 28. If a problem is discovered, repair the fuel pressure sensor 5 V power supply circuit. 29. Replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 30. Set the injector ID code on the ECM. 31. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0641 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-74 Engine Control (4HK1)



DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL) Control Circuit 1.



22. Set the injector ID code on the ECM.



DTC P0650 Diagnostics 1.



Confirm that the monitor panel operates properly.



2.



Turn OFF the starter switch.



3.



Inspect the fuse.



4.



If a problem is discovered, replace the fuse.



23. Perform the unit difference learning of the fuel supply pump to the ECM. 24. If the diagnostic light does not turn on, remove the diagnostic light bulb from the monitor panel. 25. Inspect the diagnostic light bulb.



Note： ・ When the fuse is blown again, repair the cause of fuse meltdown. 5.



Turn OFF the starter switch.



6.



Disconnect the harness connector from the ECM.



7.



Turn ON the starter switch.



8.



Check to see if the diagnosis light is off.



9.



If the diagnostic light is not turned off, repair the short circuit to GND in the diagnostic light control circuit between the ECM and the monitor panel.



26. Replace the valve if a problem is discovered. 27. Inspect to see if there is an open circuit or high resistance in the ignition power supply circuit between the fuse and the monitor panel. 28. If a problem is discovered, repair the ignition power supply circuit. 29. Inspect to see if there is an open circuit or high resistance in the diagnostic light control circuit between the ECM and the monitor panel. 30. If a problem is discovered, repair the control circuit. 31. Inspect the monitor panel harness connector for a contact failure.



10. Turn OFF the starter switch. 11. Remove the fuse. 12. Turn ON the starter switch.



32. If a problem is discovered, repair the harness connector.



13. Measure the voltage between the diagnostic light control circuit and GND of the ECM harness connector.



33. When the harness connector is normal, replace the monitor panel.



voltage： 1.0 V 14. If it is at or above the standard value, repair the short circuit to the battery or ignition power supply circuit in the diagnostic light control circuit between the ECM and the monitor panel. 15. Turn OFF the starter switch. 16. Install the fuse. 17. Connect the test cable with fuse between the diagnostic light control circuit and GND of the ECM harness connector. 18. Turn ON the starter switch. 19. If the diagnosis light comes on, inspect ECM harness connector for a contact failure. 20. If a problem is discovered, repair the harness connector. 21. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



2.



DTC P0650 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Turn the starter switch ON, and wait for 10 seconds.



4.



Start the engine.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-75



DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit 1.



15. If it is at or above the standard value, replace the atmospheric pressure sensor.



DTC P0651 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the camshaft position sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the camshaft position sensor 5 V power supply circuit and GND of the camshaft position sensor harness connector.



16. If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the camshaft position sensor 5 V power supply circuit between the ECM and the camshaft position sensor. 17. If a problem is discovered, repair the camshaft position sensor 5 V power supply circuit. 18. Inspect to see if there is a short circuit to the GND with the atmospheric pressure sensor 5 V power supply circuit between the ECM and the atmospheric pressure sensor.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the camshaft position sensor 5 V power supply circuit between the ECM and the camshaft position sensor.



19. If a problem is discovered, repair the atmospheric pressure sensor 5 V power supply circuit. 20. Replace the ECM.



6.



If a problem is discovered, repair the camshaft position sensor 5 V power supply circuit.



7.



Inspect to see if there is a short circuit to the battery or ignition power supply with the atmospheric pressure sensor 5 V power supply circuit between the ECM and atmospheric pressure sensor.



21. Set the injector ID code on the ECM.



8.



If a problem is discovered, repair the atmospheric pressure sensor 5 V power supply circuit.



22. Perform the unit difference learning of the fuel supply pump to the ECM.



9.



If it is at or below the standard value, measure the voltage between the camshaft position sensor 5 V power supply circuit and GND of the camshaft position sensor harness connector.



voltage： 4.5 V 10. If it is at or above the standard value, replace the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Removal". Refer to "1.Engine 1B.Mechanical(4HK1) CMP sensor Installation". 11. If it is at or below the standard value, turn the starter switch OFF. 12. Disconnect the harness connector from the atmospheric pressure sensor. 13. Turn ON the starter switch. 14. Measure the voltage between the camshaft position sensor 5 V power supply circuit and GND of the camshaft position sensor harness connector. voltage： 4.5 V



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



2.



DTC P0651 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-76 Engine Control (4HK1)



DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open 1.



DTC P0685 Diagnostics 1.



Turn the starter switch OFF for 30 seconds or longer.



2.



Replace the main relay with a glow relay or normal relay.



3.



Turn ON the starter switch.



4.



Use the trouble diagnosis scan tool to check if a DTC is detected.



5.



If a DTC has not been detected, replace the main relay.



6.



Inspect the body grounding terminal for a contact failure.



7.



If a problem is discovered, repair the terminal.



8.



Inspect the slow blow fuse.



9.



If a problem is discovered, replace the slow blow fuse.



Note： ・ When the fuse is blown again, repair the cause of slow-blow fuse meltdown. 10. Turn OFF the starter switch. 11. Disconnect the harness connector from the ECM. 12. Inspect the ECM harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 15. Set the injector ID code on the ECM. 16. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0685 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Turn ON the starter switch.



4.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-77



DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High 1.



DTC P0687 Diagnostics 1.



Turn OFF the starter switch.



2.



Remove the main relay.



3.



Turn ON the starter switch.



4.



Use the trouble diagnosis scan tool to see if DTC P0685 is detected.



5.



If the DTC P0685 is not detected, repair the short circuit to the battery power supply of the power supply circuit between the ECM and main relay.



6.



Turn the starter switch OFF for 30 seconds or longer.



7.



Replace the main relay with a glow relay or normal relay.



8.



Turn ON the starter switch.



9.



Use the trouble diagnosis scan tool to check if DTC P0687 has been detected.



10. If the DTC P0687 is not detected, replace the main relay. 2.



DTC P0687 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Turn ON the starter switch.



4.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-78 Engine Control (4HK1)



DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit 1.



DTC P0697 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the DPD differential pressure sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector.



voltage： 5.5 V 5.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the DPD differential pressure sensor 5 V power supply circuit between the ECM and the DPD differential pressure sensor.



6.



If a problem is discovered, repair the DPD differential pressure sensor 5 V power supply circuit.



7.



Inspect to see if there is a short circuit to the battery or ignition power supply with the oil pressure sensor 5 V power supply circuit between the ECM and oil pressure sensor.



8.



If a problem is discovered, repair the oil pressure sensor 5 V power supply circuit.



9.



Inspect to see if there is a short circuit to the battery or ignition power supply with the fuel filter pressure sensor 5 V power supply circuit between the ECM and the fuel filter pressure sensor.



10. If a problem is discovered, repair the fuel filter pressure sensor 5 V power supply circuit. 11. If it is at or below the standard value, measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. voltage： 4.5 V 12. If it is at or above the standard value, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 13. If it is at or below the standard value, turn the starter switch OFF. 14. Disconnect the harness connector from the oil pressure sensor.



15. Turn ON the starter switch. 16. Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. voltage： 4.5 V 17. If it is at or above the standard value, replace the oil pressure sensor. Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure sensor Removal". Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure sensor Installation". 18. If it is at or below the standard value, turn the starter switch OFF. 19. Disconnect the harness connector from the fuel filter pressure sensor. 20. Turn ON the starter switch. 21. Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. voltage： 4.5 V 22. If it is at or above the standard value, replace the fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter pressure sensor Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter pressure sensor Installation". 23. If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the DPD differential pressure sensor 5 V power supply circuit between the ECM and the DPD differential pressure sensor. 24. If a problem is discovered, repair the DPD differential pressure sensor 5 V power supply circuit. 25. Inspect to see if there is a short circuit to the GND with the oil pressure sensor 5 V power supply circuit between the ECM and oil pressure sensor. 26. If a problem is discovered, repair the oil pressure sensor 5 V power supply circuit. 27. Inspect to see if there is a short circuit to the GND with the fuel filter pressure sensor 5 V power supply circuit between the ECM and fuel filter pressure sensor.



Engine Control (4HK1) 1A-79 28. If a problem is discovered, repair the fuel filter pressure sensor 5 V power supply circuit. 29. Replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 30. Set the injector ID code on the ECM. 31. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P0697 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-80 Engine Control (4HK1)



DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low 1.



DTC P1093 Priority DTC DTC P0087 DTC P0091 DTC P0092 DTC P0192 DTC P0193 DTC P0201 DTC P0202



Note： ・ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 12. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. 13. If a problem is discovered, repair the clogging of the fuel system.



DTC P0203



14. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack.



DTC P0204



15. If a problem is discovered, replace the fuel hose.



DTC P2146 DTC P2149 2.



DTC P1093 Diagnostics 1.



Turn OFF the starter switch.



2.



Wait for the specified period of time until the fuel pressure is released from the common rail.



specified time： 2 min 3.



Turn ON the starter switch.



4.



Use the trouble diagnosis scan tool to check if the fuel rail pressure sensor display is within the standard range.



voltage： 0.9 to 1.0 V 5.



If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure.



6.



If a problem is discovered, repair the harness connector.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



Inspect each circuit for high resistance.



10. Repair the circuit if a problem is discovered. 11. If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation".



Note： ・ The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine is running. ・ When the fuel hose is not connected securely, the air can enter. ・ When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P1093 may be detected. 16. Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. 17. If a problem is discovered, replace the clamp. 18. Operate the priming pump until the handle becomes heavy. Note： ・ When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy. 19. Start the engine. 20. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail. Note： ・ The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. ・ The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. ・ Inspect for fuel leaks into the engine oil.



Engine Control (4HK1) 1A-81 21. If fuel leak if found, fix the problem. 22. Turn OFF the starter switch. 23. Remove the fuel hose on the fuel supply pump side from the fuel filter. Note： ・ Use a pan to catch the fuel from the removed fuel hose. ・ Clean the pressure gauge and connection hose before connecting to the fuel pipe. ・ The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose. 24. Connect the pressure gauge between the fuel filter and the removed fuel hose. Note： ・ Confirm that the fuel system is connected securely. 25. Remove the air using the priming pump, and crank the engine for the specified period of time or shorter.



33. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging. 34. If a problem is discovered, repair it. 35. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". 36. If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow. Note： ・ The fuel pipe can be disconnected and clogged with a plug. 37. Start the engine and use the idling control switch to increase the RPM to the highest level. 38. Check the pressure gauge.



specified time： 5 s



specified value： 27.0 kPa { 203 mmHg / 8 inHg }



Note： ・ Repeat this until the engine starts.



Note： ・ When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. ・ Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.



26. Leave the engine idling for the specified period of time or longer. specified time： 1 min 27. While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. specified time： 1 min



39. If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose.



rotational speed： 2500 r/min



40. If a problem is discovered, replace the fuel hose.



28. Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. specified value： 17.0 kPa { 128 mmHg / 5 inHg } Note： ・ Fuel clogging is checked with the negative pressure amount in the fuel system. 29. If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank. 30. If a problem is discovered, repair the fuel system. 31. Inspect the fuel tank bent hose. 32. If a problem is discovered, repair the bent hose.



41. Inspect to see if appropriate clamp is used. 42. If a problem is discovered, replace the clamp with an appropriate one. 43. Turn OFF the starter switch. 44. Inspect the suction control valve harness connector for a contact failure. 45. If a problem is discovered, repair the harness connector. 46. Inspect the ECM harness connector for a contact failure. 47. If a problem is discovered, repair the harness connector. 48. Inspect each circuit for high resistance. 49. Repair the circuit if a problem is discovered.



1A-82 Engine Control (4HK1) 50. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element.



1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Removal".



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter element Installation". Note： ・ When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 51. Perform the unit difference learning of the fuel supply pump to the ECM. 52. If the negative pressure is normal, turn OFF the starter switch. 53. Restore the fuel system. 54. Start the engine. 55. Perform the injector stop test with the trouble diagnosis scan tool. 56. Check to see if any injector does not change the engine RPM when OFF is instructed. 57. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation". 58. When the injector has been replaced, set the injector ID code on the ECM. 59. If the engine RPM changes when OFF is instructed to all injectors, replace the pressure limiter valve. Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Common rail assembly Installation". Note： ・ The pressure limiter valve may be fixed open, or the operation pressure may decrease. ・ Do not replace the pressure limiter valve separately. When a problem is found, replace the common rail assembly. 3.



DTC P1093 Confirm Resolution



Engine Control (4HK1) 1A-83



DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low 1.



DTC P1112 Priority DTC DTC P0651



2.



DTC P1112 Diagnostics 1.



Turn OFF the starter switch.



2.



Remove the harness connector from the boost temperature sensor.



3.



Check the boost temperature sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 4.



If it is at or above the standard value, replace the boost temperature sensor.



Refer to "1.Engine 1F.Induction(4HK1) Boost temperature sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) Boost temperature sensor Installation". 5.



Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and boost temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Inspect the ECM harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P1112 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-84 Engine Control (4HK1)



DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High 1.



GND circuit between the ECM and the boost temperature sensor.



DTC P1113 Priority DTC DTC P0651



2.



Note： ・ The boost temperature sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected.



DTC P1113 Diagnostics 1.



Turn OFF the starter switch.



2.



Remove the harness connector from the boost temperature sensor.



3.



Turn ON the starter switch.



17. If a problem is discovered, repair the GND circuit.



4.



Measure the voltage between the boost temperature sensor signal circuit and a normal GND.



18. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the boost temperature sensor.



voltage： 5.5 V 5.



19. If a problem is discovered, repair the signal circuit.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the boost temperature sensor.



6.



If a problem is discovered, repair the signal circuit.



7.



Connect the test cable with fuse between the boost temperature sensor signal circuit and GND circuit.



8.



Check the boost temperature sensor display with the trouble diagnosis scan tool.



20. Inspect the ECM harness connector for a contact failure. 21. If a problem is discovered, repair the harness connector. 22. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



voltage： 0.1 V 9.



If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the boost temperature sensor.



10. If a problem is discovered, repair the signal circuit. 11. Inspect boost temperature sensor harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the boost temperature sensor. Refer to "1.Engine 1F.Induction(4HK1) Boost temperature sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) Boost temperature sensor Installation". 14. Connect the test cable with fuse between the boost temperature sensor signal circuit and a normal GND. 15. Check the boost temperature sensor display with the trouble diagnosis scan tool. voltage： 0.1 V 16. If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the



23. Set the injector ID code on the ECM. 24. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P1113 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



Note： ・ Run the engine for 3 minutes or longer. 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-85



DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 1.



DTC P1261 Diagnostics 1.



Replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 2.



Set the injector ID code on the ECM.



3.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P1261 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-86 Engine Control (4HK1)



DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 1.



DTC P1262 Diagnostics 1.



Replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 2.



Set the injector ID code on the ECM.



3.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P1262 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-87



DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low 1.



13. If a problem is discovered, repair the signal circuit.



DTC P1293 Priority DTC



14. Inspect the ECM harness connector for a contact failure.



DTC P0697 2.



DTC P1293 Diagnostics 1.



Turn OFF the starter switch.



15. If a problem is discovered, repair the harness connector.



2.



Disconnect the harness connector from the fuel filter pressure sensor.



16. If the harness connector is normal, replace the ECM.



3.



Turn ON the starter switch.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



4.



Measure the voltage between the 5 V power supply circuit of the fuel filter pressure sensor harness connector and normal GND .



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 17. Set the injector ID code on the ECM.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the fuel filter pressure sensor.



Note： ・ The fuel filter pressure sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the fuel filter pressure sensor harness connector.



8.



Check the fuel filter pressure sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the fuel filter pressure sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter pressure sensor Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter pressure sensor Installation". 12. Inspect the signal circuit between the ECM and the fuel filter pressure sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND.



18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P1293 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-88 Engine Control (4HK1)



DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P1294 Priority DTC DTC P0697



2.



14. Set the injector ID code on the ECM.



DTC P1294 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the fuel filter pressure sensor.



3.



Check the fuel filter pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the fuel filter pressure sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the fuel filter pressure sensor.



Note： ・ The fuel filter pressure sensor shares the GND circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 7.



If a problem is discovered, repair the GND circuit.



8.



Inspect to see if there is a contact failure with the fuel filter pressure sensor harness connector.



9.



If a problem is discovered, repair the harness connector.



10. If the harness connector is normal, replace the fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter pressure sensor Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter pressure sensor Installation". 11. Inspect the ECM harness connector for a contact failure. 12. If a problem is discovered, repair the harness connector. 13. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



15. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P1294 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-89



DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance 1.



・There should be no short to EGR position sensor circuit.



DTC P1404 Priority DTC DTC P0404



14. If a problem is discovered, repair the solenoid circuit.



DTC P0409 2.



DTC P1404 Diagnostics 1.



15. If the circuit is normal, replace the EGR valve.



Remove the EGR valve assembly from the engine.



Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal".



Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal". 2.



・There should be nothing to limit flow inside the EGR valve. ・There should be no excessive accumulates inside the EGR valve. ・There should be no bending with the valve shaft or valve itself inside the EGR valve. 3.



Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Installation".



Inspect the EGR valve.



If a problem is discovered, repair or replace the EGR valve.



Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Installation". 4.



Turn OFF the starter switch.



5.



Disconnect the harness connector from the EGR valve.



6.



Inspect the EGR valve harness connector for a contact failure.



7.



If a problem is discovered, repair the harness connector.



8.



Disconnect the harness connector from the ECM.



9.



Inspect the ECM harness connector for a contact failure.



10. If a problem is discovered, repair the harness connector. 11. Inspect the EGR valve circuit between the ECM and the EGR valve for an open circuit and high resistance. 12. If a problem is discovered, repair the EGR valve circuit. 13. Inspect the solenoid circuit between the ECM and EGR valve. ・There should be no short to GND. ・There should be no short to the battery or ignition power supply. ・There should be no short to other circuits.



3.



DTC P1404 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-90 Engine Control (4HK1)



DTC P1455 (Flash Code 132) PM Over Accumulation 1.



DTC P1455 Diagnostics 1.



Check with the operator if the DPD light has blinked before.



2.



If necessary, explain DPD regeneration.



・Check with the operator if the engine operating time was short. ・Ckeck with the operator if the idling time was too long.



12. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. 13. Inspect the mass air flow sensor with the trouble diagnosis scan tool. 14. If a problem is discovered, replace the mass air flow sensor.



・There should be no incorrect piping or disconnection.



15. Use the trouble diagnosis scan tool to check if the boost pressure and atmospheric pressure are operating properly.



4.



If a problem is discovered, repair the hose.



16. Inspect the air cleaner element.



5.



Inspect the DPD differential pressure sensor.



3.



Inspect the DPD differential pressure sensor hose.



・ DPD differential pressure sensor unit should not be damaged. ・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. ・ There should be no detection error or slow response from the DPD differential pressure sensor. 6.



If a problem is discovered, replace the DPD differential pressure sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 7.



When the DPD differential pressure sensor has been replaced, perform the 0-point correction.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 8.



Inspect the exhaust system.



Refer to "1.Engine 1F.Induction(4HK1) Air cleaner element Inspection". 17. If a problem is discovered, replace the air cleaner element. 18. Check the intake duct for a clogging, hole, and leakage. 19. If a problem is discovered, replace the intake duct. 20. Inspect the intake throttle valve for fixing. 21. If a problem is discovered, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation". 22. Inspect the turbocharger assembly. Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Inspection".



・There should be no absence or damage of the exhaust pipe gasket. ・There should be no exhaust gas leak from the exhaust system. ・The exhaust system should not be modified. ・There should be no damage or excessive deposits on the oxidation catalyst.



23. If a problem is discovered, replace the turbocharger assembly.



9.



24. Inspect the quality of fuel.



If a problem is discovered, repair or replace the exhaust system.



10. Inspect the DPD assembly. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 11. If a problem is discovered, replace the DPD assembly.



Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Installation". Note： ・ An appropriate fuel is used. 25. Turn the starter switch ON for 30 seconds. Note： ・ Do not start the engine. ・ This is for the DPD differential pressure sensor to relearn.



Engine Control (4HK1) 1A-91 26. Clear the DTC using the trouble diagnosis scan tool.



43. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load.



27. Perform the DPD regeneration data reset with the trouble diagnosis scan tool. 28. Turn the starter switch OFF for 30 seconds or longer.



Specified value： 150 ℃ { 302 °F }



29. Start the engine. 30. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool.



44. Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value.



31. Confirm that the exhaust temperature is at or below the standard value.



specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi }



Specified value： 130 ℃ { 266 °F }



45. If it is at or above the standard value, perform ash removal.



32. If it is at or above the standard value, idle the engine until it falls to or below the standard value. 33. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value： 150 ℃ { 302 °F } 34. Use the trouble diagnosis scan tool to check if the exhaust differential pressure data display is at or below the standard value. specified value： 7.5 kPa { 0.08 kgf/cm2 / 1.1 psi } 35. If it is at or above the standard value, replace the DPD filter. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Reassembly". 36. If the DPD filter has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. 37. When a DTC has been detected, clear it using the trouble diagnosis scan tool. 38. Turn the starter switch OFF for 30 seconds or longer. 39. Perform the DPD forced slow regeneration with the trouble diagnosis scan tool. Note： ・ After the DPD forced slow regeneration is completed, replace the engine oil. 40. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. 41. Confirm that the exhaust temperature is at or below the standard value. Specified value： 130 ℃ { 266 °F } 42. If it is at or above the standard value, idle the engine until it falls to or below the standard value.



Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 2.



DTC P1455 Confirm Resolution 1.



Turn ON the starter switch.



2.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-92 Engine Control (4HK1)



DTC P1471 (Flash Code 149) DPD Insufficient Regeneration 1.



DTC P1471 Diagnostics



12. Inspect the air intake system.



2.



If a problem is discovered, repair the hose.



・There should be no crush, limited flow, or damage of the duct between the air cleaner and intake manifold. ・The intake system should not be modified. ・There should be no air leak with the intake system.



3.



Inspect the DPD differential pressure sensor.



13. If a problem is discovered, repair the intake system.



1.



Inspect the DPD differential pressure sensor hose.



・There should be no incorrect piping or disconnection.



・ DPD differential pressure sensor unit should not be damaged. ・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. ・ There should be no detection error or slow response from the DPD differential pressure sensor. 4.



If a problem is discovered, replace the DPD differential pressure sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 5.



When the DPD differential pressure sensor has been replaced, perform the 0-point correction.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 6.



14. Use the trouble diagnosis scan tool to inspect the mass air flow sensor. 15. If a problem is discovered, replace the mass air flow sensor. 16. Turn the starter switch ON for 30 seconds. Note： ・ Do not start the engine. ・ This is for the DPD differential pressure sensor to relearn. 17. Start the engine. 18. Use the trouble diagnosis scan tool to check the DPD accumulation status and the DPD time status, and confirm the corresponding area from the DPD status table.



Inspect the exhaust system.



・There should be no absence or damage of the exhaust pipe gasket. ・There should be no exhaust gas leak from the exhaust system. ・The exhaust system should not be modified. 7.



If a problem is discovered, repair or replace the exhaust system.



8.



Inspect the exhaust gas temperature sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Inspection". 9.



If a problem is discovered, replace the exhaust gas temperature sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature sensor Installation". 10. Inspect the air cleaner element. Refer to "1.Engine 1F.Induction(4HK1) Air cleaner element Inspection". 11. If a problem is discovered, replace the air cleaner element.



19. If the situation falls in the area A or B, use the trouble diagnosis scan tool to perform the DPD forced regeneration. Note： ・ When a DTC has been detected, clear it using the trouble diagnosis scan tool. 20. If the situation falls in the area C or D, use the trouble diagnosis scan tool to perform the DPD forced slow regeneration.



Engine Control (4HK1) 1A-93 Note： ・ When a DTC has been detected, clear it using the trouble diagnosis scan tool. ・ After the DPD forced slow regeneration is completed, replace the engine oil. 21. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. 22. Confirm that the exhaust temperature is at or below the standard value. Specified value： 130 ℃ { 266 °F } 23. If it is at or above the standard value, idle the engine until it falls to or below the standard value. 24. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value： 150 ℃ { 302 °F } 25. Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi } 26. If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 2.



DTC P1471 Confirm Resolution 1.



Turn ON the starter switch.



2.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-94 Engine Control (4HK1)



DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance 1.



DTC P1621 Diagnostics 1.



Confirm that the connecting sections of all tools are securely connected.



2.



Confirm that the programming device is operating normally.



3.



Turn the starter switch OFF, and wait for 30 seconds.



4.



Turn ON the starter switch.



5.



Use the trouble diagnosis scan tool to check if a DTC has been detected.



6.



If a DTC has been detected, replace the ECM.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 7.



Set the injector ID code on the ECM.



8.



Perform the unit difference learning of the fuel supply pump to the ECM.



2.



DTC P1621 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-95



DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit 1.



DTC P1655 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the boost sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector.



voltage： 5.5 V 5.



6.



If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the boost sensor 5 V power supply circuit between the ECM and the boost sensor. If a problem is discovered, repair the boost sensor 5 V power supply circuit.



7.



Inspect to see if there is a short circuit to the battery or ignition power supply with the intake throttle position sensor 5 V power supply circuit between the ECM and the intake throttle valve.



8.



If a problem is discovered, repair the intake throttle position sensor 5 V power supply circuit.



9.



Inspect to see if there is a short circuit to the battery or ignition power supply with the EGR valve position sensor 5 V power supply circuit between the ECM and EGR valve.



10. If a problem is discovered, repair the EGR valve position sensor 5 V power supply circuit. 11. If it is at or below the standard value, measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. voltage： 4.5 V 12. If it is at or above the standard value, replace the boost sensor. Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Removal". Refer to "1.Engine 1F.Induction(4HK1) Boost sensor Installation".



16. Measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. voltage： 4.5 V 17. If it is at or above the standard value, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation". 18. If it is at or below the standard value, turn the starter switch OFF. 19. Disconnect the harness connector from the EGR valve. 20. Turn ON the starter switch. 21. Measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. voltage： 4.5 V 22. If it is at or above the standard value, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Installation". 23. If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the boost sensor 5 V power supply circuit between the ECM and the boost sensor. 24. If a problem is discovered, repair the boost sensor 5 V power supply circuit. 25. Inspect to see if there is a short circuit to the GND with the intake throttle position sensor 5 V power supply circuit between the ECM and the intake throttle valve. 26. If a problem is discovered, repair the intake throttle position sensor 5 V power supply circuit.



13. If it is at or below the standard value, turn the starter switch OFF.



27. Inspect to see if there is a short circuit to the GND with the EGR valve position sensor 5 V power supply circuit between the ECM and EGR valve.



14. Remove the harness connector from the intake throttle valve.



28. If a problem is discovered, repair the EGR valve position sensor 5 V power supply circuit.



15. Turn ON the starter switch.



29. Replace the ECM.



1A-96 Engine Control (4HK1) Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 30. Set the injector ID code on the ECM. 31. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC P1655 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-97



DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 1.



22. Set the injector ID code on the ECM.



DTC P1669 Diagnostics 1.



Confirm that the monitor panel operates properly.



2.



Turn OFF the starter switch.



3.



Inspect the fuse.



4.



If a problem is discovered, replace the fuse.



23. Perform the unit difference learning of the fuel supply pump to the ECM. 24. If the DPD light does not turn on, remove the DPD light bulb from the monitor panel. 25. Inspect the DPD light bulb.



Note： ・ When the fuse is blown again, repair the cause of fuse meltdown. 5.



Turn OFF the starter switch.



6.



Disconnect the harness connector from the ECM.



7.



Turn ON the starter switch.



8.



Check to see if the DPD light is off.



9.



If the DPD light is not turned off, repair the short circuit to GND in the DPD light control circuit between the ECM and the monitor panel.



26. Replace the valve if a problem is discovered. 27. Inspect to see if there is an open circuit or high resistance in the ignition power supply circuit between the fuse and the monitor panel. 28. If a problem is discovered, repair the ignition power supply circuit. 29. Inspect to see if there is an open circuit or high resistance in the DPD light control circuit between the ECM and the monitor panel. 30. If a problem is discovered, repair the control circuit. 31. Inspect the monitor panel harness connector for a contact failure.



10. Turn OFF the starter switch. 11. Remove the fuse. 12. Turn ON the starter switch.



32. If a problem is discovered, repair the harness connector.



13. Measure the voltage between the DPD light control circuit and GND of the ECM harness connector.



33. When the harness connector is normal, replace the monitor panel.



voltage： 1.0 V



2.



DTC P1669 Confirm Resolution



14. If it is at or above the standard value, repair the short circuit to the battery or ignition power supply circuit in the DPD light control circuit between the ECM and the monitor panel.



1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Turn the starter switch ON, and wait for 40 seconds.



15. Turn OFF the starter switch.



4.



Start the engine.



16. Install the fuse.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



17. Connect the test cable with fuse between the DPD light control circuit and GND of the ECM harness connector. 18. Turn ON the starter switch. 19. If the DPD light turns on, inspect the ECM harness connector for a contact failure. 20. If a problem is discovered, repair the harness connector. 21. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



1A-98 Engine Control (4HK1)



DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



DTC P2122 Priority DTC DTC P0641



2.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P2122 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the accelerator position sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the 5 V power supply circuit and GND of the accelerator position sensor.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the accelerator position sensor.



6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the 5 V power supply circuit and sensor 1 signal circuit of the accelerator position sensor.



8.



Check the accelerator pedal position sensor 1 (APP1) display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the accelerator position sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the accelerator position sensor. 12. If it is at or below the standard value, inspect the sensor 1 signal circuit between the ECM and accelerator position sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 13. If a problem is discovered, repair the sensor 1 signal circuit. 14. Inspect the ECM harness connector for a contact failure. 15. If a problem is discovered, repair the harness connector. 16. If the harness connector is normal, replace the ECM.



17. Set the injector ID code on the ECM. 18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P2122 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, fully depress the accelerator pedal and then release it while checking the accelerator pedal position sensor 1 (APP1) display with the trouble diagnosis scan tool.



4.



Confirm that the trouble diagnosis scan tool does not show a value at or below the standard value while depressing and then releasing the pedal.



voltage： 0.2 V 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-99



DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input 1.



16. Perform the unit difference learning of the fuel supply pump to the ECM.



DTC P2123 Priority DTC DTC P0641



2.



DTC P2123 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the accelerator position sensor.



3.



DTC P2123 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, fully depress the accelerator pedal and then release it while checking the accelerator pedal position sensor 1 (APP1) display with the trouble diagnosis scan tool.



4.



Confirm that the trouble diagnosis scan tool does not show a value at or above the standard value while depressing and then releasing the pedal.



Check the accelerator pedal position sensor 1 (APP1) display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



3.



If it is at or above the standard value, inspect the sensor 1 signal circuit between the ECM and the accelerator position sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the sensor 1 signal circuit.



6.



Connect the test light between the accelerator position sensor GND circuit and battery power supply.



7.



If the test light comes on, inspect the accelerator position sensor harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the accelerator position sensor.



10. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the accelerator position sensor. 11. If a problem is discovered, repair the GND circuit. 12. Inspect the ECM harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 15. Set the injector ID code on the ECM.



voltage： 4.9 V 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-100 Engine Control (4HK1)



DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



DTC P2127 Priority DTC DTC P0641



2.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P2127 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the accelerator position sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the 5 V power supply circuit and GND of the accelerator position sensor.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the accelerator position sensor.



6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the 5 V power supply circuit and sensor 2 signal circuit of the accelerator position sensor.



8.



Check the accelerator pedal position sensor 2 (APP2) display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the accelerator position sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the accelerator position sensor. 12. If it is at or below the standard value, inspect the sensor 2 signal circuit between the ECM and accelerator position sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 13. If a problem is discovered, repair the sensor 2 signal circuit. 14. Inspect the ECM harness connector for a contact failure. 15. If a problem is discovered, repair the harness connector. 16. If the harness connector is normal, replace the ECM.



17. Set the injector ID code on the ECM. 18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P2127 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, fully depress the accelerator pedal and then release it while checking the accelerator pedal position sensor 2 (APP2) display with the trouble diagnosis scan tool.



4.



Confirm that the trouble diagnosis scan tool does not show a value at or below the standard value while depressing and then releasing the pedal.



voltage： 0.2 V 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-101



DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input 1.



16. Perform the unit difference learning of the fuel supply pump to the ECM.



DTC P2128 Priority DTC DTC P0641



2.



DTC P2128 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the accelerator position sensor.



3.



DTC P2128 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine, fully depress the accelerator pedal and then release it while checking the accelerator pedal position sensor 2 (APP2) display with the trouble diagnosis scan tool.



4.



Confirm that the trouble diagnosis scan tool does not show a value at or above the standard value while depressing and then releasing the pedal.



Check the accelerator pedal position sensor 2 (APP2) display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



3.



If it is at or above the standard value, inspect the sensor 2 signal circuit between the ECM and the accelerator position sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the sensor 2 signal circuit.



6.



Connect the test light between the accelerator position sensor GND circuit and battery power supply.



7.



If the test light comes on, inspect the accelerator position sensor harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the accelerator position sensor.



10. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the accelerator position sensor. 11. If a problem is discovered, repair the GND circuit. 12. Inspect the ECM harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 15. Set the injector ID code on the ECM.



voltage： 4.9 V 5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-102 Engine Control (4HK1)



DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation 1.



19. Set the injector ID code on the ECM.



DTC P2138 Priority DTC



20. Perform the unit difference learning of the fuel supply pump to the ECM.



DTC P0641 DTC P2122 DTC P2123 DTC P2127 DTC P2128 2.



DTC P2138 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the accelerator position sensor.



3.



Inspect the accelerator position sensor harness connector for a contact failure.



4.



If a problem is discovered, repair the harness connector.



5.



Disconnect the harness connector from the ECM.



6.



Inspect the ECM harness connector for a contact failure.



7.



If a problem is discovered, repair the harness connector.



8.



Inspect to see if there is high resistance in the circuit between the ECM and accelerator position sensor.



9.



Repair the circuit if a problem is discovered.



10. Inspect to see if there is a short between circuits in the signal circuit between the ECM and the accelerator position sensor. 11. If a problem is discovered, repair the signal circuit. 12. If the circuit is normal, replace the accelerator position sensor. 13. Restore the actual unit. 14. Clear the DTC using the trouble diagnosis scan tool. 15. Turn the starter switch OFF for 30 seconds or longer. 16. Start the engine. 17. While checking for a DTC with the trouble diagnosis scan tool, fully depress and then release the accelerator pedal. 18. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



3.



DTC P2138 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



While checking the DTC information with the trouble diagnosis scan tool, fully depress and then release the accelerator pedal.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-103



DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 1.



15. Inspect the ECM harness connector for a contact failure.



DTC P2146 Diagnostics 1.



Turn the starter switch OFF.



2.



Disconnect the harness connector from the cylinder head injector harness intermediate connector.



3.



Turn the starter switch ON.



4.



Measure the voltage between the solenoid control circuit and GND.



16. If a problem is discovered, repair the harness connector. 17. Inspect to see if there is an open circuit or high resistance with the charge voltage circuit between the ECM and the injector harness intermediate connector.



Note： ・ Solenoid control circuit and GND of the first cylinder injector ・ Solenoid control circuit and GND of the fourth cylinder injector



18. If a problem is discovered, repair the charge voltage circuit. 19. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head cover Removal".



voltage： 12.0 V 5.



20. Inspect the injector harness tightening nut for looseness.



If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the control circuit between the ECM and injector harness intermediate connector.



6.



If a problem is discovered, repair the control circuit.



7.



Inspect the charge voltage circuit between the ECM and the injector harness intermediate connector.



21. If the injector harness tightening nut is loose, tighten it. 22. Inspect to see if any foreign matter is attached to the injector terminal. 23. If any foreign matter is attached to the injector terminal, remove it.



Note： ・ No short circuit to the battery or ignition power is present. ・ No short circuit to GND is present. 8.



If a problem is discovered, repair the charge voltage circuit.



9.



If the charge voltage circuit between the ECM and the injector harness intermediate connector is normal, replace the ECM.



24. Inspect the injector harness intermediate harness connector for a contact failure. 25. If a problem is discovered, repair the intermediate harness connector. 26. Check if insulation resistance of the first cylinder and fourth cylinder injector is at or above the standard value. resistance： 1.0 Ω 27. If it is at or below the standard value, replace the relevant injector.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation".



10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM.



28. Set the injector ID code on the ECM. 29. If it is at or above the standard value, repair or replace the injector harness.



12. Inspect the injector harness intermediate connector for a contact failure. 13. If a problem is discovered, repair the injector harness intermediate connector. 14. Disconnect the harness connector from the ECM.



2.



DTC P2146 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



1A-104 Engine Control (4HK1) 4.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-105



DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 1.



15. Inspect the ECM harness connector for a contact failure.



DTC P2149 Diagnostics 1.



Turn the starter switch OFF.



2.



Disconnect the harness connector from the cylinder head injector harness intermediate connector.



3.



Turn the starter switch ON.



4.



Measure the voltage between the solenoid control circuit and GND.



16. If a problem is discovered, repair the harness connector. 17. Inspect to see if there is an open circuit or high resistance with the charge voltage circuit between the ECM and the injector harness intermediate connector.



Note： ・ Solenoid control circuit and GND of the second cylinder injector ・ Solenoid control circuit and GND of the third cylinder injector



18. If a problem is discovered, repair the charge voltage circuit. 19. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder head cover Removal".



voltage： 12.0 V 5.



20. Inspect the injector harness tightening nut for looseness.



If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the control circuit between the ECM and injector harness intermediate connector.



6.



If a problem is discovered, repair the control circuit.



7.



Inspect the charge voltage circuit between the ECM and the injector harness intermediate connector.



21. If the injector harness tightening nut is loose, tighten it. 22. Inspect to see if any foreign matter is attached to the injector terminal. 23. If any foreign matter is attached to the injector terminal, remove it.



Note： ・ No short circuit to the battery or ignition power is present. ・ No short circuit to GND is present. 8.



If a problem is discovered, repair the charge voltage circuit.



9.



If the charge voltage circuit between the ECM and the injector harness intermediate connector is normal, replace the ECM.



24. Inspect the injector harness intermediate harness connector for a contact failure. 25. If a problem is discovered, repair the intermediate harness connector. 26. Check if insulation resistance of the first cylinder and fourth cylinder injector is at or above the standard value. resistance： 1.0 MΩ 27. If it is at or below the standard value, replace the relevant injector.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Removal".



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



Refer to "1.Engine 1C.Fuel System(4HK1) Injector Installation".



10. Set the injector ID code on the ECM. 11. Perform the unit difference learning of the fuel supply pump to the ECM.



28. Set the injector ID code on the ECM. 29. If it is at or above the standard value, repair or replace the injector harness.



12. Inspect the injector harness intermediate connector for a contact failure. 13. If a problem is discovered, repair the injector harness intermediate connector. 14. Disconnect the harness connector from the ECM.



2.



DTC P2149 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



1A-106 Engine Control (4HK1) 4.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-107



DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC P2228 Priority DTC DTC P0651



2.



17. Set the injector ID code on the ECM.



DTC P2228 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the atmospheric pressure sensor.



3.



Turn ON the starter switch.



4.



Measure the voltage between the atmospheric pressure sensor 5 V power supply circuit and GND.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the atmospheric pressure sensor.



6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the atmospheric pressure sensor 5 V power supply circuit and the signal circuit.



8.



Check the atmospheric pressure sensor display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



If it is at or above the standard value, inspect to see if there is a contact failure with the atmospheric pressure sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the atmospheric pressure sensor. 12. If it is at or below the standard value, inspect the signal circuit between the ECM and the atmospheric pressure sensor. ・There should be no open circuit or high resistance. ・There should be no short to GND. 13. If a problem is discovered, repair the signal circuit. 14. Inspect the ECM harness connector for a contact failure. 15. If a problem is discovered, repair the harness connector. 16. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



18. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P2228 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-108 Engine Control (4HK1)



DTC P2229 (Flash Code 71) Barometric Pressure Circuit High 1.



16. Perform the unit difference learning of the fuel supply pump to the ECM.



DTC P2229 Priority DTC DTC P0651



2.



DTC P2229 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the atmospheric pressure sensor.



3.



Check the atmospheric pressure sensor display with the trouble diagnosis scan tool.



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the atmospheric pressure sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Connect the test light between the atmospheric pressure sensor GND circuit and battery power supply.



7.



If the test light comes on, inspect the atmospheric pressure sensor harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the atmospheric pressure sensor.



10. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the atmospheric pressure sensor. 11. If a problem is discovered, repair the GND circuit. 12. Inspect the ECM harness connector for a contact failure. 13. If a problem is discovered, repair the harness connector. 14. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 15. Set the injector ID code on the ECM.



3.



DTC P2229 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-109



DTC P242F (Flash Code 131) DPD Restriction 1.



DTC P242F Diagnostics 1.



Check with the operator if the DPD light has blinked before.



2.



If necessary, explain DPD regeneration.



・Check with the operator if the engine operating time was short. ・Ckeck with the operator if the idling time was too long.



12. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. 13. Inspect the mass air flow sensor with the trouble diagnosis scan tool. 14. If a problem is discovered, replace the mass air flow sensor.



・There should be no incorrect piping or disconnection.



15. Use the trouble diagnosis scan tool to check if the boost pressure and atmospheric pressure are operating properly.



4.



If a problem is discovered, repair the hose.



16. Inspect the air cleaner element.



5.



Inspect the DPD differential pressure sensor.



3.



Inspect the DPD differential pressure sensor hose.



・ DPD differential pressure sensor unit should not be damaged. ・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. ・ There should be no detection error or slow response from the DPD differential pressure sensor. 6.



If a problem is discovered, replace the DPD differential pressure sensor.



Refer to "1.Engine 1F.Induction(4HK1) Air cleaner element Inspection". 17. If a problem is discovered, replace the air cleaner element. 18. Inspect the intercooler. Refer to "1.Engine 1F.Induction(4HK1) Intercooler Inspection". 19. If a problem is discovered, replace the intercooler.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal".



20. Check the intake duct for a clogging, hole, and leakage.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation".



21. If a problem is discovered, replace the intake duct.



7.



When the DPD differential pressure sensor has been replaced, perform the 0-point correction.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 8.



Inspect the exhaust system.



・There should be no absence or damage of the exhaust pipe gasket. ・There should be no exhaust gas leak from the exhaust system. ・The exhaust system should not be modified. ・There should be no damage or excessive deposits on the oxidation catalyst. 9.



If a problem is discovered, repair or replace the exhaust system.



10. Inspect the DPD assembly. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 11. If a problem is discovered, replace the DPD assembly.



22. Inspect the intake throttle valve for fixing. 23. If a problem is discovered, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Installation". 24. Inspect the turbocharger assembly. Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Inspection". 25. If a problem is discovered, replace the turbocharger assembly. Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Installation". 26. Inspect the quality of fuel. Note： ・ An appropriate fuel is used. 27. Turn the starter switch ON for 30 seconds.



1A-110 Engine Control (4HK1) Note： ・ Do not start the engine. ・ This is for the DPD differential pressure sensor to relearn.



43. Confirm that the exhaust temperature is at or below the standard value. Specified value： 130 ℃ { 266 °F } 44. If it is at or above the standard value, idle the engine until it falls to or below the standard value.



28. Clear the DTC using the trouble diagnosis scan tool. 29. Perform the DPD regeneration data reset with the trouble diagnosis scan tool.



45. Check the exhaust differential pressure display when the exhaust temperature 1 (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load.



30. Turn the starter switch OFF for 30 seconds or longer. 31. Start the engine.



Specified value： 150 ℃ { 302 °F }



32. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool.



46. Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value.



33. Confirm that the exhaust temperature is at or below the standard value. Specified value： 130 ℃ { 266 °F }



specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi }



34. If it is at or above the standard value, idle the engine until it falls to or below the standard value. 35. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. outside air temperature： 150 ℃ { 302 °F } 36. Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. specified value： 7.5 kPa { 0.08 kgf/cm2 / 1.1 psi } 37. If it is at or above the standard value, replace the DPD filter. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Reassembly". 38. If the DPD filter has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. 39. When a DTC has been detected, clear it using the trouble diagnosis scan tool. 40. Turn the starter switch OFF for 30 seconds or longer. 41. Perform the DPD forced slow regeneration with the trouble diagnosis scan tool. Note： ・ After the DPD forced slow regeneration is completed, replace the engine oil. 42. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool.



47. If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 2.



DTC P242F Confirm Resolution 1.



Turn ON the starter switch.



2.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-111



DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit 1.



DTC P2452 Priority DTC DTC P2456



2.



DTC P2452 Diagnostics 1.



Inspect the DPD differential pressure sensor hose.



・There should be no incorrect piping or disconnection. 2.



If a problem is discovered, repair the hose.



3.



Inspect the DPD differential pressure sensor.



・ DPD differential pressure sensor unit should not be damaged. ・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. ・ There should be no detection error or slow response from the DPD differential pressure sensor. 4.



If a problem is discovered, replace the DPD differential pressure sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 5.



When the DPD differential pressure sensor has been replaced, perform the 0-point correction.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 6.



Inspect the exhaust system.



・There should be no absence or damage of the exhaust pipe gasket. ・There should be no exhaust gas leak from the exhaust system. ・The exhaust system should not be modified.



13. Inspect the DPD differential pressure sensor harness connector for a contact failure. 14. If a problem is discovered, repair the harness connector. 15. Disconnect the harness connector from the ECM. 16. Inspect the ECM harness connector for a contact failure. 17. If a problem is discovered, repair the harness connector. 18. Inspect the signal circuit between the ECM and the DPD differential pressure sensor for a high resistance. 19. If a problem is discovered, repair the signal circuit. 20. If the harness connector and circuit are normal, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 21. When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 22. Restore the actual unit. 23. Turn the starter switch ON for 30 seconds. Note： ・ Do not start the engine. ・ This is for the DPD differential pressure sensor to relearn.



7.



If a problem is discovered, repair or replace the exhaust system.



24. Clear the DTC using the trouble diagnosis scan tool.



8.



Inspect the DPD assembly.



25. Perform the DPD regeneration data reset with the trouble diagnosis scan tool.



Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 9.



If a problem is discovered, replace the DPD assembly.



10. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. 11. Turn OFF the starter switch. 12. Disconnect the harness connector from the DPD differential pressure sensor.



26. Turn the starter switch OFF for 30 seconds or longer. 27. Perform the DPD forced regeneration with the trouble diagnosis scan tool. Note： ・ When the DPD filter is replaced by a new one, do not perform the DPD forced regeneration. 28. Use the trouble diagnosis scan tool to confirm that the exhaust temperature (before the filter) display is at or below the standard value. Specified value： 130 ℃ { 266 °F }



1A-112 Engine Control (4HK1) 29. If it is at or above the standard value, idle the engine until it falls to or below the standard value. 30. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value： 150 ℃ { 302 °F } 31. Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or above the standard value. specified value： 0.5 kPa { 0.01 kgf/cm2 / 0.1 psi } 3.



DTC P2452 Confirm Resolution 1.



Turn ON the starter switch.



2.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-113



DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance 1.



DTC P2453 Priority DTC DTC P2456



2.



DTC P2453 Diagnostics 1.



Inspect the DPD differential pressure sensor hose.



14. If a problem is discovered, repair the harness connector. 15. Inspect the signal circuit between the ECM and the DPD differential pressure sensor for a high resistance.



・There should be no incorrect piping or disconnection.



16. If a problem is discovered, repair the signal circuit.



2.



If a problem is discovered, repair the hose.



3.



Inspect the DPD differential pressure sensor.



17. If the harness connector and signal circuit are normal, replace the DPD assembly.



・ DPD differential pressure sensor unit should not be damaged. ・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. ・ There should be no detection error or slow response from the DPD differential pressure sensor. 4.



If a problem is discovered, replace the DPD differential pressure sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 5.



When the DPD differential pressure sensor has been replaced, perform the 0-point correction.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 6.



Inspect the exhaust system.



・ There should be no missing or damage with the gasket of the exhaust pipe. ・ There should be no exhaust gas leak from the exhaust system. ・ The exhaust system should not be modified. ・ There should be no flow limitation or crush of the exhaust system. 7.



If a problem is discovered, repair or replace the exhaust system.



8.



Turn OFF the starter switch.



9.



Disconnect the harness connector from the DPD differential pressure sensor.



10. Inspect the DPD differential pressure sensor harness connector for a contact failure. 11. If a problem is discovered, repair the harness connector. 12. Disconnect the harness connector from the ECM. 13. Inspect the ECM harness connector for a contact failure.



18. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. 19. Restore the actual unit. 20. Turn the starter switch ON for 30 seconds. Note： ・ Do not start the engine. ・ This is for the DPD differential pressure sensor to relearn. 21. Clear the DTC using the trouble diagnosis scan tool. 22. Perform the DPD regeneration data reset with the trouble diagnosis scan tool. 23. Turn the starter switch OFF for 30 seconds or longer. 24. Perform the DPD forced regeneration with the trouble diagnosis scan tool. 25. Use the trouble diagnosis scan tool to confirm that the exhaust temperature (before the filter) display is at or below the standard value. Specified value： 130 ℃ { 266 °F } 26. If it is at or above the standard value, idle the engine until it falls to or below the standard value. 27. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value： 150 ℃ { 302 °F } 28. Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi } 29. If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection".



1A-114 Engine Control (4HK1) 3.



DTC P2453 Confirm Resolution 1.



Turn ON the starter switch.



2.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-115



DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low 1.



13. If it is at or below the standard value, inspect the signal circuit between the ECM and the DPD differential pressure sensor.



DTC P2454 Priority DTC DTC P0697



2.



DTC P2454 Diagnostics



・There should be no open circuit or high resistance. ・There should be no short to GND.



1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the DPD differential pressure sensor.



3.



Turn ON the starter switch.



15. Inspect the ECM harness connector for a contact failure.



4.



Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND.



16. If a problem is discovered, repair the harness connector.



14. If a problem is discovered, repair the signal circuit.



voltage： 4.5 V 5.



If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the DPD differential pressure sensor.



Note： ・ The DPD differential pressure sensor shares the 5 V power supply circuit with other sensors. ・ The DTC set on a sensor which shares this circuit may be detected. 6.



If a problem is discovered, repair the 5 V power supply circuit.



7.



Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the DPD differential pressure sensor.



8.



Check the exhaust differential pressure display with the trouble diagnosis scan tool.



voltage： 4.5 V 9.



17. If the harness connector is normal, replace the ECM.



If it is at or above the standard value, inspect to see if there is a contact failure with the DPD differential pressure sensor harness connector.



10. If a problem is discovered, repair the harness connector. 11. If the harness connector is normal, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 12. When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection".



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 18. Set the injector ID code on the ECM. 19. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P2454 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-116 Engine Control (4HK1)



DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High 1.



12. If a problem is discovered, repair the GND circuit.



DTC P2455 Priority DTC



13. Inspect the ECM harness connector for a contact failure.



DTC P0697 2.



DTC P2455 Diagnostics 1.



Turn OFF the starter switch.



14. If a problem is discovered, repair the harness connector.



2.



Disconnect the harness connector from the DPD differential pressure sensor.



15. If the harness connector is normal, replace the ECM.



3.



Check the exhaust differential pressure display with the trouble diagnosis scan tool.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



voltage： 0.1 V 4.



If it is at or above the standard value, inspect the signal circuit between the ECM and the DPD differential pressure sensor.



・There should be no short to the battery or ignition power supply. ・There should be no short to the 5 V power supply. 5.



If a problem is discovered, repair the signal circuit.



6.



Connect the test light between the GND circuit and battery power supply of the DPD differential pressure sensor.



7.



If the test light comes on, inspect DPD differential pressure sensor harness connector for a contact failure.



8.



If a problem is discovered, repair the harness connector.



9.



If the harness connector is normal, replace the DPD differential pressure sensor.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 10. When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 11. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the DPD differential pressure sensor. Note： ・ The DPD differential pressure sensor shares the GND circuit with other sensors. ・ The DTC may be detected on a sensor which shares this circuit.



16. Set the injector ID code on the ECM. 17. Perform the unit difference learning of the fuel supply pump to the ECM. 3.



DTC P2455 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-117



DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position 1.



DTC P2456 Priority DTC DTC P2454 DTC P2455



2.



DTC P2456 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the DPD differential pressure sensor.



3.



Inspect the DPD differential pressure sensor harness connector for a contact failure.



4.



If a problem is discovered, repair the harness connector.



5.



Disconnect the harness connector from the ECM.



6.



Inspect the ECM harness connector for a contact failure.



7.



If a problem is discovered, repair the harness connector.



8.



Inspect the circuit between the ECM and DPD differential pressure sensor for an open circuit and high resistance.



9.



Repair the circuit if a problem is discovered.



10. If the circuit is normal, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 11. When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 3.



DTC P2456 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



While checking the DTC information with the trouble diagnosis scan tool, turn the starter switch ON for 30 seconds.



4.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-118 Engine Control (4HK1)



DTC P2458 (Flash Code 139) DPD Regeneration Duration 1.



DTC P2458 Priority DTC DTC P0426 DTC P0427 DTC P0428 DTC P042B DTC P042C DTC P042D



2.



DTC P2458 Diagnostics 1.



Inspect the DPD differential pressure sensor hose.



・There should be no incorrect piping or disconnection. 2.



If a problem is discovered, repair the hose.



3.



Inspect the DPD differential pressure sensor.



・ DPD differential pressure sensor unit should not be damaged. ・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. ・ There should be no detection error or slow response from the DPD differential pressure sensor. 4.



If a problem is discovered, replace the DPD differential pressure sensor.



Refer to "1.Engine 1D.Cooling(4HK1) Cooling fan belt Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Thermostat Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Water pump assembly Inspection". Refer to "1.Engine 1D.Cooling(4HK1) Radiator Inspection". 9.



If a problem is discovered, repair the cooling system.



10. Turn the starter switch ON for 30 seconds. Note： ・ Do not start the engine. ・ This is for the DPD differential pressure sensor to relearn. 11. Turn the starter switch OFF for 30 seconds. 12. Start the engine. 13. Use the trouble diagnosis scan tool to check the DPD accumulation status and the DPD time status, and confirm the corresponding area from the DPD status table.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Installation". 5.



When the DPD differential pressure sensor has been replaced, perform the 0-point correction.



Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust differential pressure sensor Inspection". 6.



Inspect the exhaust system.



・There should be no absence or damage of the exhaust pipe gasket. ・There should be no exhaust gas leak from the exhaust system. ・The exhaust system should not be modified. ・There should be no incorrect detection or slow response from the exhaust gas temperature sensor. 7. 8.



If a problem is discovered, repair or replace the exhaust system. Inspect the engine cooling system for a factor causing overheat.



Refer to "1.Engine 1D.Cooling(4HK1) Coolant Inspection".



14. If the situation falls in the area A or B, use the trouble diagnosis scan tool to perform the DPD forced regeneration. Note： ・ When a DTC has been detected, clear it using the trouble diagnosis scan tool.



Engine Control (4HK1) 1A-119 15. If the situation falls in the area C or D, use the trouble diagnosis scan tool to perform the DPD forced slow regeneration. Note： ・ When a DTC has been detected, clear it using the trouble diagnosis scan tool. ・ After the DPD forced slow regeneration is completed, replace the engine oil. 16. Use the trouble diagnosis scan tool to confirm that the exhaust temperature (before the filter) display is at or below the standard value. Specified value： 130 ℃ { 266 °F } 17. If it is at or above the standard value, idle the engine until it falls to or below the standard value. 18. Check the exhaust differential pressure data display when the exhaust temperature (in front of the filter) data display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value： 150 ℃ { 302 °F } 19. Confirm if the exhaust differential pressure data display is at or below the standard value. specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi } 20. If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Inspection". 3.



DTC P2458 Confirm Resolution 1.



Turn ON the starter switch.



2.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-120 Engine Control (4HK1)



DTC U0001 (Flash Code 84) CAN-Bus Malfunction 1.



DTC U0001 Diagnostics 1.



Turn OFF the starter switch.



2.



Disconnect the harness connector from the ECM.



3.



Measure the resistance between the CAN-High side terminal and CAN-Low side terminal.



Note： ・ Measure the resistance between the terminals of the ECM harness connector. resistance： about 120.0 Ω 4.



If it is outside the standard range, inspect the CANLow circuit and CAN-High circuit between the ECM and the control unit of the actual unit.



・There should be no short to the battery or ignition power supply. ・There should be no open circuit or high resistance. ・There should be no short to GND. 5.



If a problem is discovered, repair the CAN circuit.



6.



If the CAN circuit is normal, replace the control unit of the actual unit.



7.



Connect the harness connector to the ECM.



8.



Disconnect the harness connector from the control unit of the actual unit.



9.



Measure the resistance between the CAN-High side terminal and CAN-Low side terminal.



Note： ・ Measure the resistance between the terminals of the ECM harness connector. resistance： about 120.0 Ω 10. If it is outside the standard range, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 11. Set the injector ID code on the ECM. 12. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC U0001 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-121



DTC U0073 (Flash Code 84) Control Module Communication Bus Off 1.



Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation".



DTC U0073 Diagnostics 1.



Turn OFF the starter switch.



2.



Measure the resistance between the terminals of the termination resistor harness connector.



13. Set the injector ID code on the ECM. 14. Perform the unit difference learning of the fuel supply pump to the ECM.



Note： ・ Make a measurement from the back with the harness connector connected. ・ Confirm that the parallel resistance of the 120 Ω resistor in the termination resistor and that of the 120 Ω resistor in the ECM are both 60Ω.



15. Turn OFF the starter switch. 16. Connect the harness connector to the ECM. 17. Turn ON the starter switch. 18. Measure the voltage between the CAN-High terminal and GND of the termination resistor harness connector.



resistance： 50.0 to 70.0 Ω 3.



Disconnect the harness connector from termination resistor if the resistance value is outside the standard range.



4.



Measure the resistance of the termination resistor.



19. Measure the voltage between the CAN-Low terminal and GND of the termination resistor harness connector. voltage： 1.5 to 3.5 V



resistance： 110.0 to 130.0 Ω 5.



If the resistance value is outside the standard range, replace the termination resistor.



6.



Connect the harness connector to the termination resistor .



7.



Disconnect the harness connector from the control unit of the actual unit.



8.



Measure the resistance between the terminals of the termination resistor harness connector.



20. If the voltage is outside the standard range, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 21. Set the injector ID code on the ECM. 22. Perform the unit difference learning of the fuel supply pump to the ECM.



Note： ・ Make a measurement from the back with the harness connector connected.



23. Turn OFF the starter switch. 24. Connect the harness connector to the control unit of the actual unit.



resistance： 50.0 to 70.0 Ω 9.



25. Turn ON the starter switch.



If the resistance value is within the standard range, replace the control unit of the actual unit.



26. Measure the voltage between the CAN-High terminal and GND of the termination resistor harness connector.



10. Disconnect the harness connector from the ECM. 11. Measure the resistance between the terminals of the termination resistor harness connector.



27. Measure the voltage between the CAN-Low terminal and GND of the termination resistor harness connector.



Note： ・ Make a measurement from the back with the harness connector connected.



voltage： 1.5 to 3.5 V 28. If the voltage is outside the standard range, replace the control unit of the actual unit.



resistance： 110.0 to 130.0 Ω



29. If the voltage is within the standard range, replace the termination resistor.



12. Replace the ECM if the resistance value is within the range of standard value. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal".



2.



DTC U0073 Confirm Resolution 1.



Use the trouble diagnosis scan tool to clear the DTC.



1A-122 Engine Control (4HK1) 2.



Turn the starter switch OFF for 30 seconds.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to check if a DTC has been detected.



Engine Control (4HK1) 1A-123



DTC U0101 (Flash Code 85) Lost Communication with TCM 1.



DTC U0101 Diagnostics 1.



Inspect the CAN-Low circuit and CAN-High circuit between the ECM and the control unit of the actual unit.



・There should be no short to the battery or ignition power supply. ・There should be no open circuit or high resistance. ・There should be no short to GND. 2.



If a problem is discovered, repair the CAN circuit.



3.



If the CAN circuit is normal, connect all harnesses.



4.



Clear the DTC using the trouble diagnosis scan tool.



5.



Turn the starter switch OFF for 30 seconds or longer.



6.



Perform a test-run.



7.



Check the DTC.



8.



If a DTC has been detected, replace the control unit of the actual unit.



9.



Connect all harnesses.



10. Clear the DTC using the trouble diagnosis scan tool. 11. Turn the starter switch OFF for 30 seconds or longer. 12. Perform a test-run. 13. Check the DTC. 14. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 15. Set the injector ID code on the ECM. 16. Perform the unit difference learning of the fuel supply pump to the ECM. 2.



DTC U0101 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



1A-124 Engine Control (4HK1)



DTC U0110 (Flash Code 87) Lost Communication with VNT System 1.



DTC U0110 Priority DTC DTC P0045 DTC U0001



2.



DTC U0110 Diagnostics 1.



Turn OFF the starter switch.



2.



Remove the harness connector from the turbo control unit.



3.



Turn ON the starter switch.



4.



Measure the voltage between the CAN-High circuit and GND of the turbo control unit harness connector.



5.



Measure the voltage between the CAN-High circuit and GND of the turbo control unit harness connector.



voltage： 1.5 to 3.5 V 6.



If it is outside the standard range, inspect to see if there is an open circuit or high resistance with the CAN-High circuit between the turbo control unit and the ECM.



7.



If a problem is discovered, repair the CAN-High circuit.



8.



Inspect to see if there is an open circuit or high resistance with the CAN-Low circuit between the turbo control unit and the ECM.



9.



If a problem is discovered, repair the CAN-Low circuit.



10. Inspect the turbo control unit harness connector for a contact failure. 11. If a problem is discovered, repair the harness connector. 12. Replace the turbo control unit. 3.



DTC U0110 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.



Engine Control (4HK1) 1A-125



DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction 1.



20. Perform the unit difference learning of the fuel supply pump to the ECM.



DTC U0411 Priority DTC DTC P0045 DTC U0001



2.



DTC U0411 Diagnostics 1.



Inspect the CAN circuit between the turbo control unit and the ECM.



・There should be no short to the battery or ignition power supply. ・There should be no open circuit or high resistance. ・There should be no short to GND. 2.



If a problem is discovered, repair the CAN circuit.



3.



Inspect the turbo control unit harness connector for a contact failure.



4.



If a problem is discovered, repair the harness connector.



5.



Connect all harnesses.



6.



Clear the DTC using the trouble diagnosis scan tool.



7.



Turn the starter switch OFF for 30 seconds or longer.



8.



Start the engine.



9.



Perform a test-run.



10. Check the DTC. 11. If a DTC has been detected, replace the turbocharger assembly. Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(4HK1) Turbocharger assembly Installation". 12. Connect all harnesses. 13. Clear the DTC using the trouble diagnosis scan tool. 14. Turn the starter switch OFF for 30 seconds or longer. 15. Start the engine. 16. Perform a test-run. 17. Check the DTC. 18. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(4HK1) ECM Removal". Refer to "1.Engine 1J.Electrical(4HK1) ECM Installation". 19. Set the injector ID code on the ECM.



3.



DTC U0411 Confirm Resolution 1.



Clear the DTC using the trouble diagnosis scan tool.



2.



Turn the starter switch OFF for 30 seconds or longer.



3.



Start the engine.



4.



Perform a test-run.



5.



Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.