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This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
ENGINE 0 Introduction
14A Service Information Guide
15B Maintenance Information
15C Functional Inspection
15D Sympton
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1J Electrical
ETM - 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
1. Repair work Safety Information
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.
Plastic gauge
1. Using the plasti-gauge
Type Measurable range
: 0.025 to 0.076 mm { 0.00098
PG・ (Green)
to 0.00299 in }
: 0.051 to 0.152 mm { 0.00201
PR・ (Red)
to 0.00598 in }
: 0.102 to 0.229 mm { 0.00402
PB・ (Blue)
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 Method for measuring the gap between the crank bearing
is at the specified torque. and crank journal
Caution: Clean the installation surfaces of the cylinder block and
crankcase bearing, and assemble them on the cylinder
・ Never move the connecting rod when the block and crankcase. Gently place the crankshaft on the
plastic gauge is in use. cylinder block, and lock it into place by turning it
Gently remove the cap and connecting rod and use a scale approximately 30 degrees. Cut the plastic gauge to the
printed on the packaging of the plastic gauge to measure width of the crank journal and lay it parallel avoiding the
the flattened plastic gauge. 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)
Manufacturer
Type Product name Area used (reference)
name
Silicon type ThreeBond 1207B ThreeBond Engine oil seal retainer
(room temperature ThreeBond 1207C ThreeBond engine oil pan
vulcanization ThreeBond 1215 ThreeBond timing gear case
process) ThreeBond 1216 ThreeBond cylinder head cover
Water–soluble ThreeBond 1141 ThreeBond fuel pump
ThreeBond 1104 ThreeBond water pump
Solvent type etc.
ThreeBond 1194 ThreeBond
Loctite 515 Loctite
Engine oil seal retainer
Loctite 518 Loctite
water pump
Anaerobic FMD127 Loctite
plug
(Loctite 5127) Loctite
etc.
Loctite 271 Loctite
Caution: Caution:
・ Make sure to use a liquid gasket with the ・ Be careful to apply a proper amount of the
above product name or equivalent. liquid gasket to avoid an excess or lack in
・ Use an appropriate amount of liquid gasket. application.
・ Follow the handling precautions for the ・ Be sure to overlap the beginning and ending of
product. the liquid gasket application.
・ Do not use Loctite 515/518 or FMD 127 ・ Be careful not to misalign the applied part with
(Loctite 5127), as they are anaerobic, and do the mating part when assembling.
not provide sufficient effect when there is a Note:
gap larger than 0.25 mm {0.0098 in} between
・ When there is a misalignment, apply again.
the contact surfaces of metals.
・ Use the same size studs as a guide when
Whenever disassembling, completely remove old liquid using with a section which has no positioning
gasket using a scraper, and clean by removing any oil, such as a knock pin.
moisture, filth, etc. from the locations of parts and the
mating parts where liquid gasket was used by using a rag, Caution:
etc. After cleaning, apply the specified liquid gasket to ・ After applying the liquid gasket, assemble
each location and assemble them. within 15 minutes.
Note: Note:
・ It is better to start the removal operation ・ When more than 15 minutes have passed after
approximately 10 minutes after applying when applying liquid gasket, remove the liquid
using gasket remover to make the operation gasket and apply it again.
easier while cleaning.
Caution:
Caution: ・ Wait at least 30 minutes before starting the
・ Do not apply gasket remover to plastic parts engine after assembling each part.
and painted parts.
Apply liquid gasket of the specified bead width to one
side of the contact surface thoroughly.
Service Information Guide (All) 14A-7
Caution:
・ If the workshop manual specifies an
application method, follow that method.
14A-8 Service Information Guide (All)
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 Description
A/D Analog/Digital
ABDC After bottom dead center
AC Alternating current
ACC Accessory
ACG Alternating current generator
ACT Actuator
API American Petroleum Industry
ASM Assembly
ATDC After top dead center
ATF Automatic transmission fluid
B+ Battery + terminal
BAT Battery
BBDC Before bottom dead center
BKT Bracket
BRG Bearing
BTDC Before the top dead center
C/B Circuit breaker
C/U Control unit
CAN A control unit communication method (Control area network)
CKP Crankshaft position
CMP Camshaft position
CO Carbon monoxide
CPU CPU (Central processing unit)
DC Direct current
DI Direct injection type
DLC Data link connector
DPD Diesel particulate diffuser
DTC Self-diagnosis code
DMM Digital multi–meter
ECM Engine control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable/programmable ROM
EGR EGR (Exhaust gas recirculation)
EMI Electromagnetic interference
EVRV Electric vacuum regulating valve
EXH Exhaust
F/B Feedback
F/C Fuel cut
F/L Fusible link
FLW Fusible link wire
FRT Front
FT Fuel temperature
FWD Front
14A-12 Service Information Guide (All)
GEN Generator
GND Ground
HC Hydrocarbon
HO2S Superheat O2 sensor
IAC Idle air control
IAT Intake air temperature
IC Integrated circuit
ID Plate ID plate (Name plate)
IDSS ISUZU Diagnostic Service System
IMT Intake manifold temperature
INL Intake
INJ Injection
ISO International Organization for Standardization
ISP Intake shutter position
ITP Intake throttle position
J/C Joint connector
JIS Japan Industrial Standard
KW A communication method (Keyword)
LH Left side
LLC Long life coolant
M/V Electromagnetic valve
MAF Mass air flow
MAP Manifold air pressure
Max Maximum
MIL Warning light (Diagnostic light)
Min Minimum
MPU Micro processing unit
NC Normally closed
NC Normally closed
NO Normally open
NOx Nitrogen oxide
N–TDC Top dead center revolution speed
O2S O2 sensor
OBD On–board diagnosis
OEM Original equipment manufacturer
OPT Option
OT Oil temperature
P/L Pilot light
PCV Pump control valve/Positive crankcase ventilation
P–I Proportion–integration
PM Particle material
PTO Power take–off
PWM Pulse width modulation wave
QOS QOS (Quick on start system)
QWS QWS (Quick warming up system)
Service Information Guide (All) 14A-13
RH Right side
R/L Relay
RAM RAM (Random access memory)
REF Reference
ROM ROM (Read only memory)
RP Rail pressure
Rr Rear
Rr Rear
RWD Rear
SAE Society of Automotive Engineers
SBF Slow blow fuse
SCV Suction control valve
SIG Signal
SLD Shield
ST Starter/start
STD Standards
SW Switch
TDC Top dead center
TEMP Temperature
TP Throttle position
VB Battery voltage
VGS Turbo Variable geometry system turbo, VGS turbo
W/H Wire/harness
W/L Warning light (Warning light)
W/S Weld splice
WOT 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 4.8
7T
category 4T
Bolt head
Hex bolt Flange bolt Hex bolt Flange bolt
shape
: 3.9 to 7.8 N・m { 0.4 to : 4.6 to 8.5 N・m { 0.5 to : 4.9 to 9.8 N・m { 0.5 to : 5.7 to 10.6 N・m { 0.6
M6 x 1 0.8 kgf・m / 35 to 69 lb・ 0.9 kgf・m / 41 to 75 lb・ 1.0 kgf・m / 43 to 87 lb・ to 1.1 kgf・m / 50 to 94
in } in } in } lb・in }
: 7.8 to 17.7 N・m { 0.8 : 10.5 to 19.6 N・m { 1.1 : 11.8 to 22.6 N・m { 1.2 : 13.5 to 25.0 N・m { 1.4
M8 x 1.25 to 1.8 kgf・m / 69 to 157 to 2.0 kgf・m / 93 to 173 to 2.3 kgf・m / 9 to 17 lb・ to 2.5 kgf・m / 10 to 18
lb・in } lb・in } ft } lb・ft }
: 20.6 to 34.3 N・m { 2.1 : 23.1 to 38.5 N・m { 2.4 : 27.5 to 46.1 N・m { 2.8 : 31.0 to 51.7 N・m { 3.2
M10 x 1.25 to 3.5 kgf・m / 15 to 25 to 3.9 kgf・m / 17 to 28 to 4.7 kgf・m / 20 to 34 to 5.3 kgf・m / 23 to 38
lb・ft } lb・ft } lb・ft } lb・ft }
: 19.6 to 33.3 N・m { 2.0 : 22.3 to 37.2 N・m { 2.3 : 27.5 to 45.1 N・m { 2.8 : 30.3 to 50.4 N・m { 3.1
*M10 x 1.5 to 3.4 kgf・m / 14 to 25 to 3.8 kgf・m / 16 to 27 to 4.6 kgf・m / 20 to 33 to 5.1 kgf・m / 22 to 37
lb・ft } lb・ft } lb・ft } lb・ft }
: 49.0 to 73.5 N・m { 5.0 : 54.9 to 82.3 N・m { 5.6 : 60.8 to 91.2 N・m { 6.2 : 68.1 to 102.1 N・m
M12 x 1.25 to 7.5 kgf・m / 36 to 54 to 8.4 kgf・m / 40 to 61 to 9.3 kgf・m / 45 to 67 { 6.9 to 10.4 kgf・m / 50
lb・ft } lb・ft } lb・ft } to 75 lb・ft }
: 45.1 to 68.6 N・m { 4.6 : 51.0 to 76.5 N・m { 5.2 : 56.9 to 84.3 N・m { 5.8 : 62.7 to 94.0 N・m { 6.4
*M12 x 1.75 to 7.0 kgf・m / 33 to 51 to 7.8 kgf・m / 38 to 56 to 8.6 kgf・m / 42 to 62 to 9.6 kgf・m / 46 to 69
lb・ft } lb・ft } lb・ft } lb・ft }
: 76.5 to 114.7 N・m : 83.0 to 124.5 N・m : 93.2 to 139.3 N・m : 100.8 to 151.1 N・m
M14 x 1.5 { 7.8 to 11.7 kgf・m / 56 { 8.5 to 12.7 kgf・m / 61 { 9.5 to 14.2 kgf・m / 69 { 10.3 to 15.4 kgf・m / 74
to 85 lb・ft } to 92 lb・ft } to 103 lb・ft } to 111 lb・ft }
: 71.6 to 106.9 N・m : 77.2 to 115.8 N・m : 88.3 to 131.4 N・m : 94.9 to 142.3 N・m
*M14 x 2 { 7.3 to 10.9 kgf・m / 53 { 7.9 to 11.8 kgf・m / 57 { 9.0 to 13.4 kgf・m / 65 { 9.7 to 14.5 kgf・m / 70
to 79 lb・ft } to 85 lb・ft } to 97 lb・ft } to 105 lb・ft }
: 104.0 to 157.0 N・m : 115.6 to 173.3 N・m : 135.3 to 204.0 N・m : 150.1 to 225.2 N・m
M16 x 1.5 { 10.6 to 16.0 kgf・m / 77 { 11.8 to 17.7 kgf・m / 85 { 13.8 to 20.8 kgf・m / { 15.3 to 23.0 kgf・m /
to 116 lb・ft } to 128 lb・ft } 100 to 150 lb・ft } 111 to 166 lb・ft }
: 100.0 to 149.1 N・m : 109.4 to 164.2 N・m : 129.4 to 194.2 N・m : 142.5 to 213.8 N・m
*M16 x 2 { 10.2 to 15.2 kgf・m / 74 { 11.2 to 16.7 kgf・m / 81 { 13.2 to 19.8 kgf・m / 95 { 14.5 to 21.8 kgf・m /
to 110 lb・ft } to 121 lb・ft } to 143 lb・ft } 105 to 158 lb・ft }
: 151.0 to 225.6 N・m : 195.2 to 293.2 N・m
M18 x 1.5 { 15.4 to 23.0 kgf・m / - { 19.9 to 29.9 kgf・m / -
111 to 166 lb・ft } 144 to 216 lb・ft }
: 151.0 to 225.6 N・m : 196.1 to 294.2 N・m
*M18 x 2.5 { 15.4 to 23.0 kgf・m / - { 20.0 to 30.0 kgf・m / -
111 to 166 lb・ft } 145 to 217 lb・ft }
: 206.0 to 310.0 N・m : 269.7 to 405.0 N・m
M20 x 1.5 { 21.0 to 31.6 kgf・m / - { 27.5 to 41.3 kgf・m / -
152 to 229 lb・ft } 199 to 299 lb・ft }
: 190.2 to 286.4 N・m : 249.1 to 374.6 N・m
*M20 x 2.5 { 19.4 to 29.2 kgf・m / - { 25.4 to 38.2 kgf・m / -
140 to 211 lb・ft } 184 to 276 lb・ft }
: 251.1 to 413.8 N・m : 362.8 to 544.3 N・m
M22 x 1.5 { 25.6 to 42.2 kgf・m / - { 37.0 to 55.5 kgf・m / -
185 to 305 lb・ft } 268 to 401 lb・ft }
: 217.7 to 327.5 N・m : 338.3 to 507.0 N・m
*M22 x 2.5 { 22.2 to 33.4 kgf・m / - { 34.5 to 51.7 kgf・m / -
161 to 242 lb・ft } 250 to 374 lb・ft }
14A-16 Service Information Guide (All)
Strength 9.8
8.8
category 9T
Bolt head
Hex bolt Flange bolt Hex bolt Flange bolt
shape
: 5.6 to 11.2 N・m { 0.6 : 6.6 to 12.2 N・m { 0.7
M6 x 1 to 1.1 kgf・m / 50 to 99 to 1.2 kgf・m / 58 to 108 - -
lb・in } lb・in }
: 13.4 to 25.7 N・m { 1.4 : 15.3 to 28.4 N・m { 1.6 : 16.7 to 30.4 N・m { 1.7 : 18.1 to 33.6 N・m { 1.8
M8 x 1.25 to 2.6 kgf・m / 10 to 19 to 2.9 kgf・m / 11 to 21 to 3.1 kgf・m / 12 to 22 to 3.4 kgf・m / 13 to 25
lb・ft } lb・ft } lb・ft } lb・ft }
: 31.3 to 52.5 N・m { 3.2 : 35.4 to 58.9 N・m { 3.6 : 37.3 to 62.8 N・m { 3.8 : 42.3 to 70.5 N・m { 4.3
M10 x 1.25 to 5.4 kgf・m / 23 to 39 to 6.0 kgf・m / 26 to 43 to 6.4 kgf・m / 28 to 46 to 7.2 kgf・m / 31 to 52
lb・ft } lb・ft } lb・ft } lb・ft }
: 31.3 to 51.4 N・m { 3.2 : 34.5 to 57.5 N・m { 3.5 : 36.3 to 59.8 N・m { 3.7 : 40.1 to 66.9 N・m { 4.1
*M10 x 1.5 to 5.2 kgf・m / 23 to 38 to 5.9 kgf・m / 25 to 42 to 6.1 kgf・m / 27 to 44 to 6.8 kgf・m / 30 to 49
lb・ft } lb・ft } lb・ft } lb・ft }
: 69.3 to 104.0 N・m : 77.7 to 116.5 N・m : 75.5 to 113.8 N・m : 85.0 to 127.5 N・m
M12 x 1.25 { 7.1 to 10.6 kgf・m / 51 { 7.9 to 11.9 kgf・m / 57 { 7.7 to 11.6 kgf・m / 56 { 8.7 to 13.0 kgf・m / 63
to 77 lb・ft } to 86 lb・ft } to 84 lb・ft } to 94 lb・ft }
: 64.8 to 96.1 N・m { 6.6 : 71.4 to 107.2 N・m : 71.6 to 106.9 N・m : 79.5 to 119.2 N・m
*M12 x 1.75 to 9.8 kgf・m / 48 to 71 { 7.3 to 10.9 kgf・m / 53 { 7.3 to 10.9 kgf・m / 53 { 8.1 to 12.2 kgf・m / 59
lb・ft } to 79 lb・ft } to 79 lb・ft } to 88 lb・ft }
: 106.2 to 158.8 N・m : 114.9 to 172.3 N・m : 113.8 to 170.6 N・m : 123.4 to 185.1 N・m
M14 x 1.5 { 10.8 to 16.2 kgf・m / 78 { 11.7 to 17.6 kgf・m / 85 { 11.6 to 17.4 kgf・m / 84 { 12.6 to 18.9 kgf・m / 91
to 117 lb・ft } to 127 lb・ft } to 126 lb・ft } to 137 lb・ft }
: 100.6 to 149.8 N・m : 108.2 to 162.2 N・m : 106.9 to 160.0 N・m : 115.5 to 173.3 N・m
*M14 x 2 { 10.3 to 15.3 kgf・m / 74 { 11.0 to 16.5 kgf・m / 80 { 10.9 to 16.3 kgf・m / 79 { 11.8 to 17.7 kgf・m / 85
to 110 lb・ft } to 120 lb・ft } to 118 lb・ft } to 128 lb・ft }
: 154.3 to 232.5 N・m : 171.1 to 256.7 N・m : 160.0 to 240.3 N・m : 176.9 to 265.3 N・m
M16 x 1.5 { 15.7 to 23.7 kgf・m / { 17.4 to 26.2 kgf・m / { 16.3 to 24.5 kgf・m / { 18.0 to 27.1 kgf・m /
114 to 171 lb・ft } 126 to 189 lb・ft } 118 to 177 lb・ft } 130 to 196 lb・ft }
: 147.6 to 221.4 N・m : 162.5 to 243.8 N・m : 153.0 to 229.5 N・m : 168.5 to 252.7 N・m
*M16 x 2 { 15.1 to 22.6 kgf・m / { 16.6 to 24.9 kgf・m / { 15.6 to 23.4 kgf・m / { 17.2 to 25.8 kgf・m /
109 to 163 lb・ft } 120 to 180 lb・ft } 113 to 169 lb・ft } 124 to 186 lb・ft }
: 222.5 to 334.3 N・m : 229.5 to 345.2 N・m
M18 x 1.5 { 22.7 to 34.1 kgf・m / - { 23.4 to 35.2 kgf・m / -
164 to 247 lb・ft } 169 to 255 lb・ft }
: 223.6 to 335.4 N・m : 230.5 to 346.2 N・m
*M18 x 2.5 { 22.8 to 34.2 kgf・m / - { 23.5 to 35.3 kgf・m / -
165 to 247 lb・ft } 170 to 255 lb・ft }
: 307.4 to 461.7 N・m : 293.2 to 440.3 N・m
M20 x 1.5 { 31.3 to 47.1 kgf・m / - { 29.9 to 44.9 kgf・m / -
227 to 341 lb・ft } 216 to 325 lb・ft }
: 284.0 to 472.1 N・m : 293.2 to 440.3 N・m
*M20 x 2.5 { 29.0 to 48.1 kgf・m / - { 29.9 to 44.9 kgf・m / -
209 to 348 lb・ft } 216 to 325 lb・ft }
: 413.6 to 620.5 N・m : 424.6 to 636.5 N・m
M22 x 1.5 { 42.2 to 63.3 kgf・m / - { 43.3 to 64.9 kgf・m / -
305 to 458 lb・ft } 313 to 469 lb・ft }
: 385.7 to 578.0 N・m : 394.2 to 592.3 N・m
*M22 x 2.5 { 39.3 to 58.9 kgf・m / - { 40.2 to 60.4 kgf・m / -
284 to 426 lb・ft } 291 to 437 lb・ft }
14A-18 Service Information Guide (All)
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) 1/2 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: Note:
・ The tightening torque of the tapered thread for ・ Tighten the elbow connector until it is aligned
products other than connectors and brass with the right angle after tightening according
products is only applied when the opposite to the minimum torque indicated above.
side is not made of aluminum. ・ 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 Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
: 85.0 ℃ { 185 °F } With jiggle valve
Open valve temperatur
: 82.0 ℃ { 180 °F } Without jiggle valve
: 100.0 ℃ { 212 °F } With jiggle valve
Full-open temperature
: 95.0 ℃ { 203 °F } Without jiggle valve
Electrical system main specifications
generator
Item Specifications
Isuzu parts number 8980921161
Nominal output 24 V/50 A
Rated rotation count 5,000 r/min
Regulator type IC type
Regulated voltage 28.5 V±1
weight : 9.5 kg { 20.9 lb }
starter
Type (Manufacturer) Nikko
Rating voltage 24V
Output 5 KW
Time 30 sec
Number of pinion teeth 13
Rotational direction (facing the pinion) Right
Weight (Approx.) : 8.0 kg { 17.6 lb }
Current/voltage 85 A or less/24 V
No-load characteristics
Revolution speed 3,300 r/min or more
Current/voltage 400 A/18.5 V
Load characteristics Torque 28.4N・m{2.9kgf・m} or more
Revolution speed 1,250 r/min or more
Current/voltage 1,400 A or less/9 V
Locking characteristics
Torque 88.2N・m{9.0kgf・m} or more
glow plug
Item Type
Preheat device model glow plug
Glow plug rated voltage/current 23 V/3.5 A
Maintenance Information (4HK1) 15B-5
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.
Maintenance Information (4HK1) 15B-11
1. ID plate
2. Terminal stud
3. Injector drive section
4. Injector assembly
5. Gasket
6. O-ring
7. Leak-off pipe installation section
Fuel filter
1. Union
2. Gauze filter
3. Supply pump
4. Strainer
5. Joint bolt
Injector
1. Priming pump
2. Plug
3. Case
4. Drain plug
4. 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)
Water pump The water pump is a centrifugal impeller type pump and
is driven by the engine fan belt.
Maintenance Information (4HK1) 15B-13
7. Exhaust system
15B-18 Maintenance Information (4HK1)
8. Emission control device The EGR operates when the engine RPM, engine coolant
temperature, intake temperature, and atmospheric
EGR
pressure satisfy certain criteria. Thereafter, the valve
The EGR system recirculates a part of the exhaust gas to
opening angle is calculated according to the engine RPM
the intake manifold, and the generation of NOx is
and the desired fuel injection amount. The calculated
suppressed. By controlling the EGR system, high
valve opening angle is used to determine the motor drive
operability and exhaust gas reduction are both achieved.
duty and the valve is driven accordingly. The intake
The control current from the ECM activate the solenoid
throttle valve closes when the EGR operates to ensure an
to control the EGR valve lift amount. The EGR position
appropriate internal pressure of the intake manifold.
sensor detects the actual valve lift amount and the data is
used for precise control of the EGR amount.
Maintenance Information (4HK1) 15B-19
1. Rectifier 7. Rotor
2. Field coil 8. Rear bracket
3. Stator 9. Regulator
4. Bearing 10. Bearing
5. Pulley
6. Front bracket
Starter system When the starter switch is turned ON, the plunger is
The starter is 5 kW and uses a reduction type. drawn in, the contact point of the magnetic switch closes
Gear housing and armature end bearing housing are made and the armature rotates. At the same time, the pinion is
of aluminum. Brush assembly is an replaceable type. pushed to the front via the shift lever to mesh with the
Starter circuit is started using a battery. ring gear. When the ring gear rotates, the crankshaft is
The battery cable is connected to a large terminal on the turned to start the engine. After the engine is started, the
starter. plunger returns, the pinion separates from the ring gear,
The wiring is connected from the terminal to the engine and the armature stops rotating when the starter switch is
control switch and the starter relay. turned OFF. When the engine rotation becomes faster
than the pinion, the pinion is caused to turn in reverse,
Starter
but the pinion just idles due to the one-way clutch
The starter is an outer gearing mesh method reduction
function, so the armature is not driven.
starter adopting the
magnetic shift type.
Maintenance Information (4HK1) 15B-21
Injection pressure control the second injection is performed when ignition is made.
The injection pressure is controlled by regulating the fuel This control for injection timing and injection amount is
pressure inside the common rail. The proper pressure performed through regulating the injector.
inside the common rail is controlled by calculating from
Maximum fuel injection amount
the engine RPM, fuel injection amount, etc., and the
The maximum fuel injection amount is the amount of fuel
appropriate amount of the fuel is discharged by regulating
injection calculated by adjustment of initial injection
the supply pump to be force-fed to the common rail.
amount under certain water temperature, limitation of
Injection timing control maximum injection amount for the boost pressure, and
This control is performed by calculating the proper fuel control of injection amount for the high altitude due to
injection timing mainly from the engine RPM or injection the atmospheric pressure.
amount in substitution for the timer function to regulate
Inter-cylinder correction
the injector.
It is not used for this engine.
Injection rate control
System schematic
To improve combustion inside the cylinder, only a small
amount of the fuel is injected first to be ignited, and then
15B-26 Maintenance Information (4HK1)
Removing air from fuel system Wait for approx. 1 minute, and then loosen the plug to
Place an appropriate pan under the air removal plug. remove the air in the fuel filter. This should be repeated
Turn the starter switch ON, and activate the at least 3 times until no air comes out from the plug.
electromagnetic pump. Securely tighten each plug, and wipe off the fuel spilled
Loose the air removal plug of the fuel filter sufficiently, around. Operate the priming pump 10 - 15 times until the
and operate the priming pump 20 times or more until the fuel permeates and then is fed to the engine.
fuel comes out from near the plug.
Tighten the plug, and operate the priming pump 10 times
or more until the fuel permeates.
Maintenance Information (4HK1) 15B-29
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 nozzle vane operates the nozzle control rod through the
The actuator is activated based on the signal from the operation plate.
turbo control unit to move the nozzle control rod. The
15B-32 Maintenance Information (4HK1)
CAN communication
When CAN controller does not exist on the actual unit
side
Outer switch
Operation mode Control
MAP0 MAP1 MAP2
H OFF OFF OFF Basic operations
OFF ON ON
ON ON ON
S ON OFF OFF Maximum rotation count control #1
L OFF ON OFF Maximum rotation count control #2
I OFF OFF ON Constant rotation operation #1
B ON ON OFF Maximum rotation count control #3
LM ON OFF ON Constant rotation operation #2
I, LM and H modes
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
Accelerator position switch, with APS learning control automatically set to the optimum value in accordance
If the APS learning control is available, for example, with the engine coolant temperature.
when the ignition cycle ends with the accelerator position
Note:
as 2 V (1), the accelerator position learning causes the 2
V status to be recognized as the opening angle 0 % and ・ The specifications vary depending on the
the control range is set to 2 V to 4 V (2). 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 Control during starter switch OFF state
adjusted. There are 2 types of controls provided when the starter
switch is turned OFF after the idling control switch is
Note:
operated, and either one of them is performed depending
・ As for the installation positions of the idling on the specification.
control change switch and idling control switch, The engine RPM adjusted by the idling control switch is
refer to the manual of the actual unit. recorded in the ECM, and the next operation is performed
The engine RPM upper limit varies depending with the engine RPM at the time when the starter switch
on the engine model, actual unit specifications is turned OFF.
and engine warming-up condition. The engine RPM adjusted by the idling control switch is
Up not recorded in the ECM, and the next operation is
While the Up side of the switch is pressed, the engine performed with the default engine RPM.
RPM is increased and the idling RPM can be raised. As for confirmation and questions regarding the
specifications, contact an Isuzu service related person.
Down
While the Down side of the switches is pressed, the Idle manual control
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 engine RPM based on the engine RPM pulse sent from
The ECM outputs the engine rpm pulse to the tachometer the ECM.
as a tachometer output. The tachometer displays the
Maintenance Information (4HK1) 15B-37
Preheat control switch is turned ON, the ECM detects the temperature of
QOS system the engine coolant based on the signal sent from the water
The ECM determines the glow time according to the temperature sensor to
engine coolant temperature, and activates the glow relay change the glow time, so the engine can be always started
and the QOC indicator light.. The QOS system is a under the optimum conditions. Also, the after-glow
system to facilitate engine start in a low temperature as function can stabilize the idling immediately after engine
well as reducing the amount of white smoke and noise start.
generated immediately after engine start. When the starter
1. Engine 7. Silencer
2. MAF sensor 8. Filter
3. Air cleaner 9. Oxidation catalyst
4. Various sensors 10. Exhaust gas temperature sensor
5. ECM 11. DPD differential pressure sensor
6. DPD switch
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.
Maintenance Information (4HK1) 15B-41
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 signal sent from the sensor, and uses it to control the fuel
are installed on the common rail. injection, etc.
1. Pressure limiter
Water temperature sensor
Fuel pressure sensor Water temperature sensor is installed on the engine block,
The fuel pressure sensor is installed on the common rail, and the thermistor changes the resistance value according
and detects the fuel pressure inside the common rail to to the temperature change. The resistance value becomes
convert into the voltage signal and sends it to the ECM. smaller when the engine coolant temperature is high, and
The voltage becomes higher when the pressure is higher, the value becomes larger when the engine coolant
and it becomes lower when the pressure is lower. The temperature is low. The ECM applies 5 V to the water
ECM calculates the actual fuel pressure from the voltage 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.
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 Intake air temparture and mass air flow sensors
The boost temperature sensor is installed to the EGR Intake air temperature sensor
valve upstream side of the intake manifold. The sensor is The intake air temperature sensor is installed on the duct
the thermistor type, and the resistance value inside the between the air cleaner and turbocharger. The intake air
sensor changes in accordance with the change in the temperature sensor is variable resistance inside the mass
temperature. 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.
IMT sensor
Maintenance Information (4HK1) 15B-47
The IMT sensor is a variable resistance installed on the the engine load, etc., and the turbo control unit performs
intake manifold to measure the intake temperature of the control by operating the motor built into the the turbo
intake manifold. When the sensor is cold, the sensor actuator. Also, it receives the signal from the position
resistance is high. When the intake temperature rises, the sensor built into the turbo actuator, and provides the
sensor resistance decreases. For low sensor resistance, the ECM with feedback on the turbocharger operation
ECM detects a low voltage of the signal circuit. amount through communication with the ECM.
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: 1. Starter switch
・ As for the installation position and shape of the 2. Engine stop switch
diagnostic switch, refer to the manual of the 3. Fuel meter
actual unit. 4. Memory clear switch
5. Mode switch
Memory clear switch
6. Water temperature gauge
This is used when clearing the recorded DTCs in the
7. Oil temperature gauge
ECM by operating the diagnostic switch and the memory
8. Hour meter
clear switch.
Note: ECM power distribution diagram Some sensors may not
be connected to the ECM depending on the specifications
・ As for the installation position of the memory
of the actual unit.
clear switch, refer to the manual of the actual
Since some sensors may perform input/output with the
unit.
ECM depending on the CAN communication, confirm
Mode change switch (0, 1, 2) the specifications of the actual unit.
The operation can be performed at the engine RPM
specified for each mode by switching the mode change
switch.
Maintenance Information (4HK1) 15B-49
15B-50 Maintenance Information (4HK1)
60 pin connector
15B-52 Maintenance Information (4HK1)
44 - -
45 IA-SCVLO SCV-LO drive
46 OS-INJ3 Injector 3, Fourth cylinder
47 - -
48 OS-INJ2 Injector 2, Third cylinder
49 OM-IDM1 Intake throttle motor, +
50 OM-IDM2 Intake throttle motor, -
51 - -
52 IS-EBMPOS1 EGR position sensor signal U
53 IS-EBMPOS2 EGR position sensor signal V
54 IS-EBMPOS3 EGR position sensor signal W
55 SG-5VRT8 IMT sensor GND
56 IF-CAM Camshaft position sensor signal
57 IF-CRANK Crankshaft position sensor signal
58 SG-SLD8 Fuel pressure sensor shield
59 - -
60 IA-SCVLO SCV-LO drive
94 pin connector
15B-54 Maintenance Information (4HK1)
Maintenance precautions
1. Maintenance precautions Important precautions for handling this engine
The holes and gaps in the fuel system including inside the
1. Precautions on maintenance
injector where the fuel passes through are manufactured
To prevent the engine from being damaged and to ensure with high precision. Therefore, these are extremely
the reliability of engine performance, be careful of the sensitive to any foreign matter, and may be severely
following points when performing maintenance works. damaged due to foreign matter accidentally intruded. For
When placing the engine on the ground, make sure that this reason, extreme care must be taken to prevent any
the bearing surface of the oil pan does not directly contact foreign matter from entering.
the ground. When performing maintenance on the fuel system, take
Use an appropriate wood frame, etc. to support the engine extreme care to prevent any foreign matter from entering
at the engine foot portion and the flywheel housing the system.
portion.
・Before starting maintenance, clean the fuel line and its
There is only a small gap between the oil pan and oil
surroundings.
pump strainer, so be careful not to damage the oil pan and
oil strainer. ・Be sure to wash your hands before starting
maintenance. Do not put on cotton work gloves.
・While the air duct or air cleaner is removed, cover the
open section of the intake to prevent foreign matters from ・When the fuel hose or fuel pipe is removed, cover the
entering the cylinder. opening with a plastic bag and fix it with a piece of tape.
If a foreign matter enters the cylinder, it may seriously
・When the high-pressure piping of the fuel system is
damage the cylinder when the engine starts.
removed, be sure to replace it with a new one. If it is
・When maintaining the engine, be sure to disconnect the reused, the sealing surface may be damaged to cause fuel
negative battery cable. Failure to do this may cause the leakage.
harness or electrical components to be damaged.
・When replacing the fuel hose and/or fuel pipe, do not
If energizing is required for inspection, be careful not to
unpack new components before starting installation.
cause a short.
・When the fuel pipe, injection pipe, fuel injector, fuel
・Before assembly, apply the engine oil to the slide
supply pump, and/or common rail are removed, seal each
contact surface of the engine.
opening immediately.
This work ensures appropriate lubrication when first
starting the engine. ・Store the eyebolt and gasket in a clean parts box with a
cover so that foreign matter does not attach to them.
・When the valve train component, piston, piston ring,
connecting rod, connecting rod bearing, and/or crankshaft ・Fuel leakage may cause a fire. Therefore, be sure to
journal bearing are removed, line them up in the correct wipe spilled fuel after completing the maintenance work
order so that their original positions are clear. and confirm that there is no fuel leakage before starting
the engine.
・When installing, install it in the same position as when
it was removed. 2. Cautions on electronic system
・When assembling the engine, replace the gasket, oil Using circuit test tools
seal, and O-ring with new ones. Unless specifically instructed in the diagnostic procedure,
do not use a test light when diagnosing the powertrain
・For a component with the liquid gasket applied,
electronic system. When a probe connector is required in
carefully remove the old liquid gasket and clean the
the diagnostic procedure, use the connector test adapter
component so that no oil, water, and/or dust remain.
kit.
Thereafter, apply the specified liquid gasket to each
component before assembly.
・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
SST: 5-8840-2835-0 - connector test adapter kit
installation.
Commercial electronic equipment
15B-58 Maintenance Information (4HK1)
Commercial electronic equipment refers to commercially ・ To prevent damage due to electrostatic
available electronic equipment attached to the unit after it discharge, do not open the packaging of a
has been shipped from the factory. Be careful, as such replacement part until installation preparation
accessories are not taken into particular consideration at for the replacement part is completed.
the machine design stage.
・ To prevent damage due to electrostatic
Commercial electronic equipment may cause
discharge, connect the part packaging to a
malfunctions in the electronic control system, even if the
properly working ground connection of the
equipment is properly attached. This includes equipment
actual unit before removing the part from its
not connected to the electronic system of the machine,
packaging.
such as mobile telephones and radios. Therefore, when
diagnosing power train problems, confirm whether such ・ To prevent damage due to electrostatic
commercial electronic equipment is attached first and discharge, when handling a part while sliding
then remove them from the machine if such equipment is across the seat, sitting down from a standing
attached. If the problem has not been resolved after position, or walking a certain distance, touch a
removing the equipment, perform the diagnosis using the properly working ground connection before
regular procedure. attaching the part.
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)
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)
Careful visual inspection is required for several symptom Fuel system abnormalities such as fuel running out, fuel
procedures. This can lead to fixing a problem without freezing, mixture of air into the fuel piping, filter
further inspections, and can save valuable time. The abnormalities, piping abnormalities, fuel quality, fuel
inspection includes the following. Whether there is grime tank, etc.
or clogging of the fuel filter. Whether there is an Air intake system abnormalities such as filter clogging,
improper connection of connectors. Particularly for the air intake piping abnormalities, etc.
crankshaft position sensor and camshaft position sensor. Use of low-viscosity fuel such as kerosene causes wear
Whether the battery terminal voltage has dropped. Proper on the supply pump plunger and may result in the
wiring connections, tightening, and disconnection discharge abnormalities and cause start failure. In such
Whether the power of any commercial accessories is cases, replacement of the supply pump is required. When
being taken divergingly from the ECM power. Whether a start failure has occurred, check with the customer
the ECM ground is free of dirt, etc. and securely installed about the fuel used. If low-viscosity fuel such as kerosene
in the correct location Proper connections, cracks, and has been used, instruct the customer not to use low-
twists in the pipes and hoses related to fuel, air, and oil. viscosity fuel because the malfunction recurs even after
Extensively check for any leaks or blockage. Whether the replacing the supply pump. A mixed oil biofuel
layout of the fuel filter, pre-filter, and electromagnetic containing long-term storage fuel and organic substances
pump has a structure in which air accumulates easily. is easily oxidizable. An oxidized fuel causes wear on the
camshaft related parts in the supply pump and may result
Check whether they are arranged to prevent air in start failure due to discharge abnormalities. In such
accumulation as Isuzu genuine pre-filters do not have any cases, replacement of the supply pump is required. Since
plugs for air removal. Also check whether the inlet and the replacement of the supply pump due to the use of
outlet of the electromagnetic pump have an appropriate mixed oil biofuel containing long-term storage fuel and
layout. Fix layouts which have the electromagnetic pump organic substances is at the customer’s expense, instruct
inlet on the upper side or have an outlet toward the the customer not to use mixed oil biofuel containing
motion direction of the actual unit. Whether there are any long-term storage fuel and organic substances. When
fuel leaks, pipe damage, or dents in the fuel system. using fuel with a high water content, add the larger
Abnormalities of the air intake system parts sedimenter to the pre-fuel filter to prevent water from
Abnormalities of the exhaust system parts 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
Symptom (4HK1) 15D-5
with non-pressure fuel supply due to the supply pump Engine body abnormalities such as seizure, insufficient
abnormalities. compression pressure, and other mechanical failures, etc.
ACG failure
Note:
Failure related to the actual unit equipment such as the oil
・ Since the crankshaft position sensor pressure pump, etc.
abnormalities will not be diagnosed unless Effect of the post-installed accessories such as wireless
cranking is performed 14 revolutions or more, devices and lights, etc.
crank for more than 14 seconds at 60 r/min or ECM failure
more. For crankshaft position sensor errors at Inspect the connector for connection failures and the
low engine revolution speed, the crankshaft harness for abnormalities such as abrasions, bending, etc.
position sensor DTC may not be detected. For Inspect to see if the wires inside the harness are separate
intermittent failure, increase the engine and have not caused a short circuit with other circuits.
revolution speed to No Load Max and check if Perform inspections for functional diagnosis, and confirm
the crankshaft position sensor related DTC is the operation, control of each part, etc. Repair if
detected. abnormalities are found.
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 ・ Diagnostic aids
sensor related DTC is detected. The scan tool data is
Fuel system abnormalities such as fuel running out, fuel
within the normal operating range. Check the condition of
freezing, mixture of air into the fuel piping, filter
the actual unit, and locate the appropriate symptom.
abnormalities, piping abnormalities, fuel quality, fuel
Check with the customers whether they are using the
tank, etc.
specified engine oil and fuel. Check whether fuel is
Air intake system abnormalities such as filter clogging
contained.
and air intake piping abnormalities, etc.
・ Visual inspection Abnormalities of the supply pump, non-pressure fuel
Careful visual inspection is required for several symptom supply
procedures. This can lead to fixing a problem without The ECM determination of the supply pump non-pressure
further inspections, and can save valuable time. The fuel supply DTC will not be detected unless a condition
inspection includes the following. Whether there is an continues for 3 seconds or more in which the engine
improper connection of connectors. Particularly for the revolution speed is 900 r/min and the absolute pressure is
crankshaft position sensor and camshaft position sensor. below 15 MPa {153 kgf/cm2 / 2175 psi}. Therefore, the
Proper wiring connections, tightening, and disconnection DTC will not be detected when the engine does not start
Whether the power of any commercial accessories is with non-pressure fuel supply due to supply pump
being taken divergingly from the ECM power. Whether abnormalities.
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
Symptom (4HK1) 15D-7
Careful visual inspection is required for several symptom Fuel system abnormalities such as fuel running out, fuel
procedures. This can lead to fixing a problem without freezing, mixture of air into the fuel piping, filter
further inspections, and can save valuable time. The abnormalities, piping abnormalities, fuel quality, fuel
inspection includes the following. Whether there is an tank, etc.
improper connection of connectors. Whether the battery Air intake system abnormalities such as filter clogging,
terminal voltage has dropped. Proper wiring connections, air intake piping abnormalities, etc.
tightening, and disconnection Abnormalities of the supply pump, non-pressure fuel
Whether the power of any commercial accessories is supply
being taken divergingly from the ECM power. Whether Switch input circuit system abnormalities Abnormalities
the ECM ground is free of dirt, etc. and securely installed of the sensor input circuit system such as the accelerator
in the correct location. Proper connections, cracks, and position sensor, harness, and water temperature sensor
twists in the pipes and hoses related to fuel, air, and oil. Accelerator position sensor system abnormalities Engine
Extensively check for any leaks or blockage. Whether body abnormalities such as seizure, insufficient
there are any fuel leaks, pipe damage, or dents in the fuel compression pressure, and other mechanical failures, etc.
system. Whether the layout of the fuel filter, pre-filter, Failure related to the actual unit equipment such as the oil
and electromagnetic pump has a structure in which air pressure pump, etc. Effect of the post-installed
accumulates easily. accessories such as wireless devices and lights, etc.
Inspect the connector for connection failures and the
Check whether they are arranged to prevent air harness for abnormalities such as abrasions, bending, etc.
accumulation as Isuzu genuine pre-filters do not have any Inspect that the wires inside the harness are separate and
plugs for air removal. Also check whether the inlet and have not caused a short circuit with other circuits.
outlet of the electromagnetic pump have an appropriate Perform inspections for functional diagnosis, and confirm
layout. Fix layouts which have the electromagnetic pump the operation, control of each part, etc. Repair if
inlet on the upper side or have an outlet toward the abnormalities are found.
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
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)
Description Engine
DTC Information
(4HK1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
Position Correlation.......................................................15E-3 .....................................................................................15E-24
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
Solenoid Circuit.............................................................15E-4 .....................................................................................15E-25
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
Too Low........................................................................15E-5 .....................................................................................15E-26
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - DTC P0217 (Flash Code 542) Engine Coolant Over
Too High........................................................................15E-6 Temperature Condition................................................15E-27
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Performance...................................................................15E-7 .....................................................................................15E-28
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit Low.......................................................15E-8 Condition.....................................................................15E-29
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor
Control Circuit High......................................................15E-9 Circuit Low..................................................................15E-30
DTC P0093 (Flash Code 227) Fuel System Leak Detected DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor
.....................................................................................15E-10 Circuit High.................................................................15E-31
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Input.............................................................................15E-11 Circuit..........................................................................15E-32
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High DTC P0336 (Flash Code 15) Crankshaft Position Sensor
Input.............................................................................15E-12 Circuit Range/Performance.........................................15E-33
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit Low..................................................................15E-13 Circuit..........................................................................15E-34
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0404 (Flash Code 45) Exhaust Gas Recirculation
Circuit High.................................................................15E-14 Control Circuit Range/Performance............................15E-35
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0409 (Flash Code 44) Exhaust Gas Recirculation
Sensor Circuit Low......................................................15E-15 Sensor Circuit..............................................................15E-36
DTC P0118 (Flash Code 23) Engine Coolant Temperature DTC P041C (Flash Code 27) Intake Manifold Temperature
Sensor Circuit High.....................................................15E-16 Sensor Circuit High.....................................................15E-37
DTC P0122 (Flash Code 43) Throttle Position Sensor DTC P041D (Flash Code 27) Intake Manifold Temperature
Circuit Low..................................................................15E-17 Sensor Circuit Low......................................................15E-38
DTC P0123 (Flash Code 43) Throttle Position Sensor DTC P0426 (Flash Code 143) Catalyst Temperature Sensor
Circuit High.................................................................15E-18 Circuit Range/Performance Sensor 1..........................15E-39
DTC P0182 (Flash Code 211) Fuel Temperature Sensor DTC P0427 (Flash Code 48) Catalyst Temperature Sensor
Circuit Low..................................................................15E-19 Circuit Low Sensor 1...................................................15E-40
DTC P0183 (Flash Code 211) Fuel Temperature Sensor DTC P0428 (Flash Code 48) Catalyst Temperature Sensor
Circuit High.................................................................15E-20 Circuit High Sensor 1..................................................15E-41
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor DTC P042B (Flash Code 145) Catalyst Temperature Sensor
Circuit Low..................................................................15E-21 Circuit Range/Performance Sensor 2..........................15E-42
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor DTC P042C (Flash Code 49) Catalyst Temperature Sensor
Circuit High.................................................................15E-22 Circuit Low Sensor 2...................................................15E-43
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
.....................................................................................15E-23
15E-2 DTC Information (4HK1)
DTC P042D (Flash Code 49) Catalyst Temperature Sensor DTC P1621 (Flash Code 54) Control Module Long Term
Circuit High Sensor 2..................................................15E-44 Memory Performance..................................................15E-71
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit DTC P1655 (Flash Code 57) Sensor Reference Voltage
Low..............................................................................15E-45 Circuit..........................................................................15E-72
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
High.............................................................................15E-46 .....................................................................................15E-73
DTC P0560 (Flash Code 155) System Voltage...........15E-47 DTC P2122 (Flash Code 121) Pedal Position Sensor 1
DTC P0563 (Flash Code 35) System Voltage High....15E-48 Circuit Low Input........................................................15E-74
DTC P0601 (Flash Code 53) Internal Control Module DTC P2123 (Flash Code 121) Pedal Position Sensor 1
Memory Check Sum Error..........................................15E-49 Circuit High Input........................................................15E-75
DTC P0602 (Flash Code 154) Control Module DTC P2127 (Flash Code 122) Pedal Position Sensor 2
Programming Error......................................................15E-50 Circuit Low Input........................................................15E-76
DTC P0604 (Flash Code 153) Internal Control Module DTC P2128 (Flash Code 122) Pedal Position Sensor 2
Random Access Memory (RAM) Error......................15E-51 Circuit High Input........................................................15E-77
DTC P0606 (Flash Code 51) ECM/PCM Processor. . .15E-52 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Voltage Correlation.....................................................15E-78
DTC P060B (Flash Code 36) Internal Control Module A/D
Processing Performance..............................................15E-53 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
Voltage Circuit............................................................15E-79
DTC P0638 (Flash Code 61) Throttle Actuator Control
Range/Performance.....................................................15E-54 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply
Voltage Circuit............................................................15E-80
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1
Circuit..........................................................................15E-55 DTC P2228 (Flash Code 71) Barometric Pressure Circuit
Low..............................................................................15E-81
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp
(MIL) Control Circuit..................................................15E-56 DTC P2229 (Flash Code 71) Barometric Pressure Circuit
High.............................................................................15E-82
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2
Circuit..........................................................................15E-57 DTC P242F (Flash Code 131) DPD Restriction.........15E-83
DTC P0685 (Flash Code 416) ECM/PCM Power Relay DTC P2452 (Flash Code 142) DPD Differential Pressure
Control Circuit/Open...................................................15E-58 Sensor Circuit..............................................................15E-84
DTC P0687 (Flash Code 416) ECM/PCM Power Relay DTC P2453 (Flash Code 141) DPD Differential Pressure
Control Circuit High....................................................15E-59 Sensor Circuit Range/Performance.............................15E-85
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 DTC P2454 (Flash Code 47) DPD Differential Pressure
Circuit..........................................................................15E-60 Sensor Circuit Low......................................................15E-86
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too DTC P2455 (Flash Code 47) DPD Differential Pressure
Low..............................................................................15E-61 Sensor Circuit High.....................................................15E-87
DTC P1112 (Flash Code 295) Boost Temperature Sensor DTC P2456 (Flash Code 47) DPD Differential Pressure
Circuit Low..................................................................15E-62 Sensor Learned Position..............................................15E-88
DTC P1113 (Flash Code 295) Boost Temperature Sensor DTC P2458 (Flash Code 139) DPD Regeneration Duration
Circuit High.................................................................15E-63 .....................................................................................15E-89
DTC P1261 (Flash Code 34) Injector Positive Voltage DTC U0001 (Flash Code 84) CAN-Bus Malfunction.15E-90
Control Circuit Group 1...............................................15E-64 DTC U0073 (Flash Code 84) Control Module
DTC P1262 (Flash Code 34) Injector Positive Voltage Communication Bus Off..............................................15E-91
Control Circuit Group 2...............................................15E-65 DTC U0101 (Flash Code 85) Lost Communication with
DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit TCM.............................................................................15E-92
Low..............................................................................15E-66 DTC U0110 (Flash Code 87) Lost Communication with
DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit VNT System................................................................15E-93
High.............................................................................15E-67 DTC U0411 (Flash code 87) Turbo Charger Control Module
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation Signal Malfunction......................................................15E-94
(EGR) Closed Position Performance...........................15E-68 DTC mapping table.....................................................15E-95
DTC P1455 (Flash Code 132) PM Over Accumulation
.....................................................................................15E-69
DTC P1471 (Flash Code 149) DPD Insufficient
Regeneration................................................................15E-70
DTC Information (4HK1) 15E-3
SPN-FMI P code
636-7 P0016 Crankshaft Position - Camshaft Position Correlation
10023-12 P0045 Turbocharger Boost Control Solenoid Circuit
633-7 P0087 Fuel Rail/System Pressure - Too Low
157-16
P0088 Fuel Rail/System Pressure - Too High
157-0
157-15 P0089 Fuel Pressure Regulator Performance
1347-4 P0091 Fuel Pressure Regulator Control Circuit Low
1347-3 P0092 Fuel Pressure Regulator Control Circuit High
1239-1 P0093 Fuel System Leak Detected
132-4 P0102 Mass Air Flow Circuit Low Input
132-3 P0103 Mass Air Flow Circuit High Input
172-4 P0112 Intake Air Temperature Sensor Circuit Low
172-3 P0113 Intake Air Temperature Sensor Circuit High
110-4 P0117 Engine Coolant Temperature Sensor Circuit Low
110-3 P0118 Engine Coolant Temperature Sensor Circuit High
10022-4 P0122 Throttle Position Sensor Circuit Low
10022-3 P0123 Throttle Position Sensor Circuit High
174-4 P0182 Fuel Temperature Sensor Circuit Low
174-3 P0183 Fuel Temperature Sensor Circuit High
157-4 P0192 Fuel Rail Pressure Sensor Circuit Low
157-3 P0193 Fuel Rail Pressure Sensor Circuit High
651-5 P0201 Injector Circuit - Cylinder 1
652-5 P0202 Injector Circuit - Cylinder 2
653-5 P0203 Injector Circuit - Cylinder 3
654-5 P0204 Injector Circuit - Cylinder 4
110-0 P0217 Engine Coolant Over Temperature Condition
190-0 P0219 Engine Overspeed Condition
102-0 P0234 Turbocharger Overboost Condition
102-4 P0237 Turbocharger Boost Sensor Circuit Low Input
102-3 P0238 Turbocharger Boost Sensor Circuit High Input
723-2 P0335 Crankshaft Position Sensor Circuit
723-2 P0336 Crankshaft Position Sensor Circuit Range/Performance
636-2 P0340 Camshaft Position Sensor Circuit
10002-2 P0404 Exhaust Gas Recirculation Control 1 Circuit Range/Performance
10001-2 P0409 Exhaust Gas Recirculation 1 Sensor Circuit
1131-3 P041C Manifold Air Temperature Circuit High Input
1131-4 P041D Manifold Air Temperature Circuit Low Input
173-0 P0426 Catalyst Temperature 1 Too High
173-4 P0427 Catalyst Temperature Sensor Circuit Low Sensor 1
173-3 P0428 Catalyst Temperature Sensor Circuit High Sensor 1
10028-0 P042B Catalyst Temperature 2 Too High
10024-4 P042C Catalyst Temperature Sensor Circuit Low Sensor 2
10024-3 P042D Catalyst Temperature Sensor Circuit High Sensor 2
100-4 P0522 Oil Pressure Sensor Circuit Low Input
DTC Information (4HK1) 15E-97
Engine Control
Engine Control
(4HK1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
Position Correlation........................................................1A-3 .......................................................................................1A-33
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
Solenoid Circuit..............................................................1A-4 .......................................................................................1A-35
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
Too Low..........................................................................1A-6 .......................................................................................1A-37
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - DTC P0217 (Flash Code 542) Engine Coolant Over
Too High.........................................................................1A-9 Temperature Condition.................................................1A-39
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Performance..................................................................1A-12 .......................................................................................1A-40
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit Low......................................................1A-14 Condition.......................................................................1A-41
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor
Control Circuit High.....................................................1A-15 Circuit Low...................................................................1A-42
DTC P0093 (Flash Code 227) Fuel System Leak Detected DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor
.......................................................................................1A-16 Circuit High...................................................................1A-43
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Input..............................................................................1A-19 Circuit............................................................................1A-44
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High DTC P0336 (Flash Code 15) Crankshaft Position Sensor
Input..............................................................................1A-20 Circuit Range/Performance...........................................1A-46
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit Low...................................................................1A-21 Circuit............................................................................1A-47
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0404 (Flash Code 45) Exhaust Gas Recirculation
Circuit High...................................................................1A-22 Control Circuit Range/Performance..............................1A-49
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0409 (Flash Code 44) Exhaust Gas Recirculation
Sensor Circuit Low.......................................................1A-23 Sensor Circuit................................................................1A-50
DTC P0118 (Flash Code 23) Engine Coolant Temperature DTC P041C (Flash Code 27) Intake Manifold Temperature
Sensor Circuit High.......................................................1A-24 Sensor Circuit High.......................................................1A-52
DTC P0122 (Flash Code 43) Throttle Position Sensor DTC P041D (Flash Code 27) Intake Manifold Temperature
Circuit Low...................................................................1A-25 Sensor Circuit Low.......................................................1A-53
DTC P0123 (Flash Code 43) Throttle Position Sensor DTC P0426 (Flash Code 143) Catalyst Temperature Sensor
Circuit High...................................................................1A-26 Circuit Range/Performance Sensor 1............................1A-54
DTC P0182 (Flash Code 211) Fuel Temperature Sensor DTC P0427 (Flash Code 48) Catalyst Temperature Sensor
Circuit Low...................................................................1A-27 Circuit Low Sensor 1....................................................1A-55
DTC P0183 (Flash Code 211) Fuel Temperature Sensor DTC P0428 (Flash Code 48) Catalyst Temperature Sensor
Circuit High...................................................................1A-28 Circuit High Sensor 1....................................................1A-56
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor DTC P042B (Flash Code 145) Catalyst Temperature Sensor
Circuit Low...................................................................1A-29 Circuit Range/Performance Sensor 2............................1A-57
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor DTC P042C (Flash Code 49) Catalyst Temperature Sensor
Circuit High...................................................................1A-30 Circuit Low Sensor 2....................................................1A-58
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
.......................................................................................1A-31
1A-2 Engine Control (4HK1)
DTC P042D (Flash Code 49) Catalyst Temperature Sensor DTC P1621 (Flash Code 54) Control Module Long Term
Circuit High Sensor 2....................................................1A-59 Memory Performance....................................................1A-94
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit DTC P1655 (Flash Code 57) Sensor Reference Voltage
Low...............................................................................1A-61 Circuit............................................................................1A-95
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
High...............................................................................1A-62 .......................................................................................1A-97
DTC P0560 (Flash Code 155) System Voltage............1A-63 DTC P2122 (Flash Code 121) Pedal Position Sensor 1
DTC P0563 (Flash Code 35) System Voltage High.....1A-64 Circuit Low Input..........................................................1A-98
DTC P0601 (Flash Code 53) Internal Control Module DTC P2123 (Flash Code 121) Pedal Position Sensor 1
Memory Check Sum Error............................................1A-65 Circuit High Input.........................................................1A-99
DTC P0602 (Flash Code 154) Control Module DTC P2127 (Flash Code 122) Pedal Position Sensor 2
Programming Error.......................................................1A-66 Circuit Low Input........................................................1A-100
DTC P0604 (Flash Code 153) Internal Control Module DTC P2128 (Flash Code 122) Pedal Position Sensor 2
Random Access Memory (RAM) Error........................1A-67 Circuit High Input.......................................................1A-101
DTC P0606 (Flash Code 51) ECM/PCM Processor.....1A-68 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Voltage Correlation.....................................................1A-102
DTC P060B (Flash Code 36) Internal Control Module A/D
Processing Performance................................................1A-69 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
Voltage Circuit............................................................1A-103
DTC P0638 (Flash Code 61) Throttle Actuator Control
Range/Performance.......................................................1A-70 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply
Voltage Circuit............................................................1A-105
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1
Circuit............................................................................1A-72 DTC P2228 (Flash Code 71) Barometric Pressure Circuit
Low.............................................................................1A-107
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp
(MIL) Control Circuit...................................................1A-74 DTC P2229 (Flash Code 71) Barometric Pressure Circuit
High.............................................................................1A-108
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2
Circuit............................................................................1A-75 DTC P242F (Flash Code 131) DPD Restriction.........1A-109
DTC P0685 (Flash Code 416) ECM/PCM Power Relay DTC P2452 (Flash Code 142) DPD Differential Pressure
Control Circuit/Open.....................................................1A-76 Sensor Circuit..............................................................1A-111
DTC P0687 (Flash Code 416) ECM/PCM Power Relay DTC P2453 (Flash Code 141) DPD Differential Pressure
Control Circuit High.....................................................1A-77 Sensor Circuit Range/Performance.............................1A-113
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 DTC P2454 (Flash Code 47) DPD Differential Pressure
Circuit............................................................................1A-78 Sensor Circuit Low.....................................................1A-115
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too DTC P2455 (Flash Code 47) DPD Differential Pressure
Low...............................................................................1A-80 Sensor Circuit High.....................................................1A-116
DTC P1112 (Flash Code 295) Boost Temperature Sensor DTC P2456 (Flash Code 47) DPD Differential Pressure
Circuit Low...................................................................1A-83 Sensor Learned Position..............................................1A-117
DTC P1113 (Flash Code 295) Boost Temperature Sensor DTC P2458 (Flash Code 139) DPD Regeneration Duration
Circuit High...................................................................1A-84 .....................................................................................1A-118
DTC P1261 (Flash Code 34) Injector Positive Voltage DTC U0001 (Flash Code 84) CAN-Bus Malfunction 1A-120
Control Circuit Group 1................................................1A-85 DTC U0073 (Flash Code 84) Control Module
DTC P1262 (Flash Code 34) Injector Positive Voltage Communication Bus Off.............................................1A-121
Control Circuit Group 2................................................1A-86 DTC U0101 (Flash Code 85) Lost Communication with
DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit TCM............................................................................1A-123
Low...............................................................................1A-87 DTC U0110 (Flash Code 87) Lost Communication with
DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit VNT System................................................................1A-124
High...............................................................................1A-88 DTC U0411 (Flash code 87) Turbo Charger Control Module
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation Signal Malfunction......................................................1A-125
(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
Engine Control (4HK1) 1A-3
26. If a problem is discovered, replace the clamp. 36. While keeping the engine rotating at the specified
engine RPM for the specified period of time, check
27. Operate the priming pump until the handle becomes the pressure gauge.
heavy.
specified time: 1 min
Note:
rotational speed: 2500 r/min
・ When a leak exists in the fuel system between
the priming pump and the fuel supply pump, 37. Check if the pressure gauge shows a negative
the pressing weight of the priming pump does pressure value at or above the standard value during
not become heavy. 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 Note:
check for fuel leak between the fuel supply pump ・ Fuel clogging is checked with the negative
and common rail. pressure amount in the fuel system.
Note: 38. If the negative pressure is at or above the standard
・ The fuel may leak to the bottom section of the value, inspect to see if there is damage or twisting
cylinder head cover from the high pressure with the fuel system between the fuel supply pump
hose inlet. and the fuel tank.
・ The engine oil level increases when the fuel 39. If a problem is discovered, repair the fuel system.
leaks to the bottom portion of the cylinder head
cover. 40. Inspect the fuel tank bent hose.
・ Inspect for fuel leaks into the engine oil. 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
31. Turn OFF the starter switch. clogging.
32. Remove the fuel hose on the fuel supply pump side 43. If a problem is discovered, repair it.
from the fuel filter.
44. Replace the fuel filter element.
Note:
・ Use a pan to catch the fuel from the removed Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
fuel hose. element Removal".
・ Clean the pressure gauge and connection Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
hose before connecting to the fuel pipe. element Installation".
・ The fuel supply pump may be damaged due to 45. If the negative pressure is at or below the standard
foreign matter that has entered in the value, pinch the fuel hose at a position as close as
connection hose. possible to the fuel tank, so that the fuel does not
33. Connect the pressure gauge between the fuel filter flow.
and the removed fuel hose.
1A-8 Engine Control (4HK1)
Note: Note:
・ The fuel pipe can be disconnected and ・ When replacing the fuel supply pump, it is
clogged with a plug. required to also replace the fuel filter element
at the same time.
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.
3. DTC P0087 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 2. Turn the starter switch OFF for 30 seconds or longer.
value exceeding the standard value during 3. Start the engine.
inspection, release the fuel being blocked.
4. Perform a test-run.
・ Air mixture is checked with the negative
pressure amount while the fuel flow is being 5. Use the trouble diagnosis scan tool to confirm that a
blocked. DTC has not been detected.
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".
Engine Control (4HK1) 1A-9
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter Refer to "1.Engine 1C.Fuel System(4HK1)
element Removal". Injector Installation".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter 20. When the injector has been replaced, set the injector
element Installation". ID code on the ECM.
5. Turn OFF the starter switch. 21. Inspect to see if there is clogging with the fuel
system between the fuel tank and the fuel supply
6. Wait for the specified period of time until the fuel pump.
pressure is released from the common rail.
22. If a problem is discovered, repair the clogging of the
specified time: 2 min fuel system.
7. Turn ON the starter switch. 23. Inspect the fuel hose between the fuel tank and the
8. Check the fuel rail pressure sensor display with the fuel supply pump for a cut and crack.
trouble diagnosis scan tool. 24. If a problem is discovered, replace the fuel hose.
voltage: 0.9 to 1.0 V Note:
9. If the fuel rail pressure sensor display is outside the ・ The fuel hose between the fuel tank and the
standard range, inspect the fuel pressure sensor fuel supply pump becomes negative pressure
harness connector for a contact failure. state when the engine is running.
1A-10 Engine Control (4HK1)
27. Operate the priming pump until the handle becomes specified time: 1 min
heavy. rotational speed: 2500 r/min
Note: 37. Check if the pressure gauge shows a negative
・ When a leak exists in the fuel system between pressure value at or above the standard value during
the priming pump and the fuel supply pump, inspection.
the pressing weight of the priming pump does specified value: 17.0 kPa { 128 mmHg / 5 inHg }
not become heavy.
Note:
28. Start the engine.
・ Fuel clogging is checked with the negative
29. Inspect the high-pressure side of the fuel system and pressure amount in the fuel system.
check for fuel leak between the fuel supply pump
and common rail. 38. If the negative pressure is at or above the standard
value, inspect to see if there is damage or twisting
Note: with the fuel system between the fuel supply pump
・ The fuel may leak to the bottom section of the and the fuel tank.
cylinder head cover from the high pressure 39. If a problem is discovered, repair the fuel system.
hose inlet.
・ The engine oil level increases when the fuel 40. Inspect the fuel tank bent hose.
leaks to the bottom portion of the cylinder head 41. If a problem is discovered, repair the bent hose.
cover.
42. Check to see if there is any foreign matter in the fuel
・ Inspect for fuel leaks into the engine oil. tank or any foreign matter which can cause fuel
30. If fuel leak if found, fix the problem. 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 44. Replace the fuel filter element.
from the fuel filter. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
Note: element Removal".
・ Use a pan to catch the fuel from the removed Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
fuel hose. element Installation".
・ Clean the pressure gauge and connection 45. If the negative pressure is at or below the standard
hose before connecting to the fuel pipe. value, pinch the fuel hose at a position as close as
・ The fuel supply pump may be damaged due to possible to the fuel tank, so that the fuel does not
foreign matter that has entered in the flow.
connection hose.
Note:
33. Connect the pressure gauge between the fuel filter ・ The fuel pipe can be disconnected and
and the removed fuel hose. clogged with a plug.
Note: 46. Start the engine and use the idling control switch to
・ Confirm that the fuel system is connected increase the RPM to the highest level.
securely.
47. Check the pressure gauge.
34. Remove the air using the priming pump, and crank
the engine for the specified period of time or shorter. specified value: 27.0 kPa { 203 mmHg / 8 inHg }
Engine Control (4HK1) 1A-11
Note: 3. Start the engine.
・ When the pressure gauge is likely to indicate a 4. Perform a test-run.
value exceeding the standard value during
inspection, release the fuel being blocked. 5. Use the trouble diagnosis scan tool to confirm that a
DTC has not been detected.
・ 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.
1A-12 Engine Control (4HK1)
3. If a problem is discovered, repair the High side 21. If the harness connector is normal, replace the
circuit. suction control valve.
4. If it is within the standard range, inspect to see if Refer to "1.Engine 1C.Fuel System(4HK1) Suction
there is a short circuit to the GND with the Low side control valve Removal".
circuit between the ECM and the suction control Refer to "1.Engine 1C.Fuel System(4HK1) Suction
valve. control valve Installation".
Note: 22. Inspect the ECM harness connector for a contact
・ When the Low side circuit is shorted to GND, failure.
DTC P0091 may not be detected.
23. If a problem is discovered, repair the harness
・ When the Low side circuit is shorted to GND, connector.
the engine stalls and does not start.
24. If the harness connector is normal, replace the ECM.
5. If a problem is discovered, repair the Low side
circuit. Refer to "1.Engine 1J.Electrical(4HK1)
ECM Removal".
6. Turn the starter switch OFF for 30 seconds or longer.
Refer to "1.Engine 1J.Electrical(4HK1)
7. Disconnect the harness connector from the suction ECM Installation".
control valve.
25. Set the injector ID code on the ECM.
8. Connect the test light between the suction control
valve High side circuit and a normal GND. 26. Perform the unit difference learning of the fuel
supply pump to the ECM.
9. Turn ON the starter switch.
2. DTC P0091 Confirm Resolution
10. Check if the test light comes on and then goes off.
1. Clear the DTC using the trouble diagnosis scan tool.
11. If it does not turn off, inspect the High side circuit
between the ECM and the suction control valve. 2. Turn the starter switch OFF for 30 seconds or longer.
3. If a problem is discovered, repair the High side 21. If the harness connector is normal, replace the
circuit. suction control valve.
4. If it is within the standard range, inspect to see if Refer to "1.Engine 1C.Fuel System(4HK1) Suction
there is a short circuit to the GND with the Low side control valve Removal".
circuit between the ECM and the suction control Refer to "1.Engine 1C.Fuel System(4HK1) Suction
valve. control valve Installation".
Note: 22. Inspect the ECM harness connector for a contact
・ When the Low side circuit is shorted to GND, failure.
DTC P0092 may not be detected.
23. If a problem is discovered, repair the harness
・ When the Low side circuit is shorted to GND, connector.
the engine stalls and does not start.
24. If the harness connector is normal, replace the ECM.
5. If a problem is discovered, repair the Low side
circuit. Refer to "1.Engine 1J.Electrical(4HK1)
ECM Removal".
6. Turn the starter switch OFF for 30 seconds or longer.
Refer to "1.Engine 1J.Electrical(4HK1)
7. Disconnect the harness connector from the suction ECM Installation".
control valve.
25. Set the injector ID code on the ECM.
8. Connect the test light between the suction control
valve High side circuit and a normal GND. 26. Perform the unit difference learning of the fuel
supply pump to the ECM.
9. Turn ON the starter switch.
2. DTC P0092 Confirm Resolution
10. Check if the test light comes on and then goes off.
1. Clear the DTC using the trouble diagnosis scan tool.
11. If it does not turn off, inspect the High side circuit
between the ECM and the suction control valve. 2. Turn the starter switch OFF for 30 seconds or longer.
1. Inspect for fuel leaks on the high-pressure side 8. Turn OFF the starter switch.
between the fuel supply pump and injector. 9. Wait for the specified period of time until the fuel
・There should be no fuel leakage from the fuel supply pressure is released from the common rail.
pump. specified time: 2 min
・There should be no fuel leakage from the common rail.
10. Turn ON the starter switch.
・There should be no fuel leakage from the pressure
limiter valve. 11. Check the fuel rail pressure sensor display with the
・There should be no fuel leakage from the fuel pressure trouble diagnosis scan tool.
sensor.
voltage: 0.9 to 1.0 V
・There should be no fuel leakage from the fuel pipe
between the fuel supply pump and common rail. 12. If the fuel rail pressure sensor display is outside the
・There should be no fuel leakage from the fuel pipe standard range, inspect the fuel pressure sensor
between the common rail and injector. harness connector for a contact failure.
・There should be no fuel leakage from the sleeve nut of
13. If a problem is discovered, repair the harness
the fuel pipe.
connector.
2. If fuel leak if found, fix the problem.
14. Inspect the ECM harness connector for a contact
Note: failure.
・ The fuel may leak to the bottom section of the 15. If a problem is discovered, repair the harness
cylinder head cover from the high pressure connector.
pipe inlet.
16. Inspect each circuit for high resistance.
・ The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder head 17. Repair the circuit if a problem is discovered.
cover. 18. If the harness connector and each circuit are normal,
・ Inspect for fuel leaks into the engine oil. replace the fuel pressure sensor.
・ Remove and inspect the high pressure pipe Refer to "1.Engine 1C.Fuel System(4HK1) Common
joint connected to the injector for a fuel rail assembly Removal".
leakage from the sleeve nut.
・ When foreign matter has been attached, Refer to "1.Engine 1C.Fuel System(4HK1) Common
replace the injector and the high pressure rail assembly Installation".
pipe.
Engine Control (4HK1) 1A-17
Note: 31. Start the engine.
・ Do not replace the fuel pressure sensor 32. Inspect the high-pressure side of the fuel system and
separately. When a problem is found, replace check for fuel leak between the fuel supply pump
the common rail assembly. and common rail.
19. If the fuel rail pressure sensor display is within the Note:
standard range, start the engine.
・ The fuel may leak to the bottom section of the
20. Perform the injector stop test with the trouble cylinder head cover from the high pressure
diagnosis scan tool. hose inlet.
21. Command each injector OFF, and confirm that the ・ The engine oil level increases when the fuel
engine RPM changes on each injector. leaks to the bottom portion of the cylinder head
cover.
22. If any injector does not change the engine RPM
・ Inspect for fuel leaks into the engine oil.
when OFF is instructed, replace the relevant injector.
33. If fuel leak if found, fix the problem.
Refer to "1.Engine 1C.Fuel System(4HK1)
Injector Removal". 34. Turn OFF the starter switch.
Refer to "1.Engine 1C.Fuel System(4HK1) 35. Remove the fuel hose on the fuel supply pump side
Injector Installation". from the fuel filter.
23. When the injector has been replaced, set the injector Note:
ID code on the ECM. ・ Use a pan to catch the fuel from the removed
24. Inspect to see if there is clogging with the fuel fuel hose.
system between the fuel tank and the fuel supply ・ Clean the pressure gauge and connection
pump. hose before connecting to the fuel pipe.
25. If a problem is discovered, repair clogging. ・ The fuel supply pump may be damaged due to
foreign matter that has entered in the
26. Inspect to see if there is cut or crack with the fuel connection hose.
hose in the fuel system between the fuel tank and the
fuel supply pump. 36. Connect the pressure gauge between the fuel filter
and the removed fuel hose.
27. If a problem is discovered, replace the fuel hose.
Note:
Note:
・ Confirm that the fuel system is connected
・ The fuel hose between the fuel tank and the securely.
supply pump becomes negative pressure state
when the engine is running. 37. Remove the air using the priming pump, and crank
the engine for the specified period of time or shorter.
・ When the fuel hose is not connected securely,
the air can enter. specified time: 5 s
・ When the engine RPM or the engine load Note:
increases while the air has intruded in the fuel
・ Repeat this until the engine starts.
system, fluctuation in the common rail
pressure is caused, and DTC P0093 may be 38. Leave the engine idling for the specified period of
detected. time or longer.
28. Check that an appropriate clamp is used between the specified time: 1 min
fuel tank and the fuel supply pump. 39. While keeping the engine rotating at the specified
29. If a problem is discovered, replace the clamp with an engine RPM for the specified period of time, check
appropriate one. the pressure gauge.
30. Operate the priming pump until the handle becomes specified time: 1 min
heavy. rotational speed: 2500 r/min
Note: 40. Check if the pressure gauge shows a negative
・ When a leak exists in the fuel system between pressure value at or above the standard value during
the priming pump and the fuel supply pump, inspection.
the pressing weight of the priming pump does
not become heavy. specified value: 17.0 kPa { 128 mmHg / 5 inHg }
1A-18 Engine Control (4HK1)
Note: 56. Inspect the suction control valve harness connector
・ Fuel clogging is checked with the negative for a contact failure.
pressure amount in the fuel system. 57. If a problem is discovered, repair the harness
41. If the negative pressure is at or above the standard connector.
value, inspect to see if there is damage or twisting 58. Inspect the ECM harness connector for a contact
with the fuel system between the fuel supply pump failure.
and the fuel tank.
59. If a problem is discovered, repair the harness
42. If a problem is discovered, repair the fuel system. 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 62. If the suction control valve harness connector and the
tank or any foreign matter which can cause fuel ECM harness connector are normal and there is no
clogging. high resistance in each circuit, replace the fuel
46. If a problem is discovered, repair it. supply pump and the fuel filter element.
47. Replace 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 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 Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
possible to the fuel tank, so that the fuel does not element Installation".
flow. Note:
Note: ・ When replacing the fuel supply pump, it is
・ The fuel pipe can be disconnected and required to also replace the fuel filter element
clogged with a plug. at the same time.
49. Start the engine and use the idling control switch to 63. Perform the unit difference learning of the fuel
increase the RPM to the highest level. supply pump to the ECM.
specified value: 27.0 kPa { 203 mmHg / 8 inHg } 1. Clear the DTC using the trouble diagnosis scan tool.
14. If the harness connector is normal, replace the fuel 4. Perform a test-run.
pressure sensor. 5. Use the trouble diagnosis scan tool to confirm that a
Refer to "1.Engine 1C.Fuel System(4HK1) Common DTC has not been detected.
rail assembly Removal".
Refer to "1.Engine 1C.Fuel System(4HK1) Common
rail assembly Installation".
Engine Control (4HK1) 1A-31
7. Measure the voltage between the EGR position 17. If there is a data display which does not display ON,
sensor 5 V power supply circuit and a normal GND. inspect the EGR position sensor circuit which does
not display ON.
voltage: 4.5 V
・There should be no open circuit or high resistance
8. If it is at or below the standard value, inspect to see between ECM and EGR position sensor.
if there is an open circuit or high resistance with the ・There should be no short to GND between ECM and
5 V power supply circuit between the ECM and the EGR position sensor.
EGR position sensor.
18. If a problem is discovered, repair the EGR position
Note: sensor circuit.
・ The EGR position sensor shares the 5 V 19. Inspect the EGR valve harness connector for a
power supply circuit with other sensors. contact failure.
・ The DTC set on a sensor which shares this
circuit may be detected. 20. If a problem is discovered, repair the harness
connector.
9. If a problem is discovered, repair the 5 V power
supply circuit. 21. In the EGR solenoid circuit between the ECM and
EGR valve, inspect to see if there is a short circuit
10. Measure the voltage between the EGR position with the EGR position sensor.
sensor 5 V power supply circuit and the GND circuit.
22. If a problem is discovered, repair the EGR solenoid
voltage: 4.5 V circuit.
11. If it is at or below the standard value, inspect to see 23. If the EGR solenoid circuit is normal, replace the
if there is an open circuit or high resistance with the EGR valve.
GND circuit between the ECM and EGR position
sensor. Refer to "1.Engine 1H.Aux. Emission Control
Devices(4HK1) EGR valve Removal".
Note:
Refer to "1.Engine 1H.Aux. Emission Control
・ The EGR position sensor shares the GND Devices(4HK1) EGR valve Installation".
circuit with other sensors.
・ The DTC set on a sensor which shares this 24. Inspect the ECM harness connector for a contact
circuit may be detected. 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)
5. Disconnect the harness connector from the intake 23. If a DTC has been detected, replace the ECM.
throttle valve. Refer to "1.Engine 1J.Electrical(4HK1)
6. Inspect the intake throttle valve harness connector ECM Removal".
for a contact failure. Refer to "1.Engine 1J.Electrical(4HK1)
7. If a problem is discovered, repair the harness ECM Installation".
connector. 24. Set the injector ID code on the ECM.
8. Disconnect the harness connector from the ECM. 25. Perform the unit difference learning of the fuel
9. Inspect the ECM harness connector for a contact supply pump to the ECM.
failure. 3. DTC P0638 Confirm Resolution
10. If a problem is discovered, repair the harness 1. Turn ON the starter switch.
connector.
2. Turn the starter switch OFF for 30 seconds or longer.
11. Inspect the intake throttle valve circuit for high
resistance. Note:
・ The starter switch must be once turned ON
12. Repair the circuit if a problem is discovered.
and then turned OFF before clearing the DTC.
13. Inspect the solenoid circuit between the ECM and
3. Clear the DTC using the trouble diagnosis scan tool.
the intake throttle valve.
4. Turn the starter switch OFF for 30 seconds or longer.
・There should be no short to GND.
・There should be no short to the battery or ignition 5. Start the engine.
power supply. 6. Perform a test-run with the intake throttle solenoid
・There should be no short between the solenoid circuits. 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)
12. If it is at or above the standard value, replace the 25. Inspect to see if there is a short circuit to the GND
accelerator pedal assembly. with the crankshaft position sensor 5 V power supply
circuit between the ECM and the crankshaft position
13. If it is at or below the standard value, turn the starter sensor.
switch OFF.
26. If a problem is discovered, repair the crankshaft
14. Disconnect the harness connector from the position sensor 5 V power supply circuit.
crankshaft position sensor.
27. Inspect to see if there is a short circuit to the GND
15. Turn ON the starter switch. with the fuel pressure sensor 5 V power supply
16. Measure the voltage between the accelerator position circuit between the ECM and the fuel pressure
sensor 5 V power supply circuit and GND of the sensor.
accelerator position sensor harness connector.
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)
5. If the fuel rail pressure sensor display is outside the 18. Operate the priming pump until the handle becomes
standard range, inspect the fuel pressure sensor heavy.
harness connector for a contact failure. Note:
6. If a problem is discovered, repair the harness ・ When a leak exists in the fuel system between
connector. the priming pump and the fuel supply pump,
the pressing weight of the priming pump does
7. Inspect the ECM harness connector for a contact
not become heavy.
failure.
19. Start the engine.
8. If a problem is discovered, repair the harness
connector. 20. Inspect the high-pressure side of the fuel system and
check for fuel leak between the fuel supply pump
9. Inspect each circuit for high resistance.
and common rail.
10. Repair the circuit if a problem is discovered.
Note:
11. If the harness connector and each circuit are normal, ・ The fuel may leak to the bottom section of the
replace the fuel pressure sensor. cylinder head cover from the high pressure
Refer to "1.Engine 1C.Fuel System(4HK1) Common hose inlet.
rail assembly Removal". ・ The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder head
Refer to "1.Engine 1C.Fuel System(4HK1) Common
cover.
rail assembly Installation".
・ Inspect for fuel leaks into the engine oil.
Engine Control (4HK1) 1A-81
21. If fuel leak if found, fix the problem. 33. Check to see if there is any foreign matter in the fuel
tank or any foreign matter which can cause fuel
22. Turn OFF the starter switch.
clogging.
23. Remove the fuel hose on the fuel supply pump side
34. If a problem is discovered, repair it.
from the fuel filter.
35. Replace the fuel filter element.
Note:
・ Use a pan to catch the fuel from the removed Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
fuel hose. element Removal".
・ Clean the pressure gauge and connection Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
hose before connecting to the fuel pipe. element Installation".
・ The fuel supply pump may be damaged due to 36. If the negative pressure is at or below the standard
foreign matter that has entered in the value, pinch the fuel hose at a position as close as
connection hose. possible to the fuel tank, so that the fuel does not
24. Connect the pressure gauge between the fuel filter flow.
and the removed fuel hose. Note:
Note: ・ The fuel pipe can be disconnected and
・ Confirm that the fuel system is connected clogged with a plug.
securely. 37. Start the engine and use the idling control switch to
25. Remove the air using the priming pump, and crank increase the RPM to the highest level.
the engine for the specified period of time or shorter. 38. Check the pressure gauge.
specified time: 5 s specified value: 27.0 kPa { 203 mmHg / 8 inHg }
Note: Note:
・ Repeat this until the engine starts. ・ When the pressure gauge is likely to indicate a
26. Leave the engine idling for the specified period of value exceeding the standard value during
time or longer. inspection, release the fuel being blocked.
・ Air mixture is checked with the negative
specified time: 1 min
pressure amount while the fuel flow is being
27. While keeping the engine rotating at the specified blocked.
engine RPM for the specified period of time, check
39. If the standard negative pressure cannot be
the pressure gauge.
generated, inspect to see if there is a cut or crack
specified time: 1 min 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 41. Inspect to see if appropriate clamp is used.
pressure value at or above the standard value during
42. If a problem is discovered, replace the clamp with an
inspection.
appropriate one.
specified value: 17.0 kPa { 128 mmHg / 5 inHg }
43. Turn OFF the starter switch.
Note:
44. Inspect the suction control valve harness connector
・ Fuel clogging is checked with the negative for a contact failure.
pressure amount in the fuel system.
45. If a problem is discovered, repair the harness
29. If the negative pressure is at or above the standard connector.
value, inspect to see if there is damage or twisting
with the fuel system between the fuel supply pump 46. Inspect the ECM harness connector for a contact
and the fuel tank. failure.
30. If a problem is discovered, repair the fuel system. 47. If a problem is discovered, repair the harness
connector.
31. Inspect the fuel tank bent hose.
48. Inspect each circuit for high resistance.
32. If a problem is discovered, repair the bent hose.
49. Repair the circuit if a problem is discovered.
1A-82 Engine Control (4HK1)
50. If the suction control valve harness connector and the 1. Clear the DTC using the trouble diagnosis scan tool.
ECM harness connector are normal and there is no
2. Turn the starter switch OFF for 30 seconds or longer.
high resistance in each circuit, replace the fuel
supply pump and the fuel filter element. 3. Start the engine.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply 4. Perform a test-run.
pump Removal".
5. Use the trouble diagnosis scan tool to confirm that a
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply DTC has not been detected.
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
11. Turn OFF the starter switch. 28. Use the trouble diagnosis scan tool to confirm that
the exhaust temperature (before the filter) display is
12. Disconnect the harness connector from the DPD at or below the standard value.
differential pressure sensor.
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
1. Inspect the DPD differential pressure sensor hose. 10. Turn the starter switch ON for 30 seconds.