4hk1 - Engine Manual - TM PDF

65722_Maegaki 10.12.
16 6:15 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section 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.
9. When handling volatile materials, be extremely

careful to not let them catch fire.
Also make sure to wipe away any oil that sticks to
rubber parts, as it can cause deterioration.
2. Replacement parts and parts number Safety
Information
1. Whenever disassembly is performed, make sure to
replace the packing, oil seals, O-rings, crimping lock
nuts, bending lock plate, and split pins, etc., with
new ones.
2. Since the part numbers indicated in this manual may
differ from the supply system and are subject to
change, make sure to check the supply system and
part numbers in the parts catalog.
4. Do not leave the engine running for an extended
period of time or perform painting in a poorly
ventilated working environment.
5. Make sure to use only the special tools if the
procedure requires them for the work. Performing
the procedure using other tools may cause damage to
parts or personal injury.
6. Inspect the tools, instruments, and special tools
regularly, and prepare them before working. Do not
use tools such as a wrench that has lost its edges, a
hammer with frayed edges, or a chipped chisel.
7. When performing work using a device such as a
grinder, crane or welder, make sure to pay sufficient
attention to the handling precautions.
Wear work clothes and safety equipments in the
other operations as well.
8. Be sure to check that there is no fuel leaks when
performing maintenance on fuel systems.
Service Information Guide (All) 14A-1
Description General Information

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

1. Contents included in service information Precautions
Includes the content-specific maintenance precautions.
Removal Includes the removal procedure for repairing
parts and devices, etc. Disconnection
Includes the disconnection method for wirings and
Installation
pipings.
Includes the installation procedure for repairing parts and
devices, etc. Connection
Includes the connection method for wirings and pipings.
Disassembly
Includes the disassembly procedure for performing an Setting
overhaul of a unit or assembly part, etc. Includes the setting method if necessary when replacing
the ECM, etc.
Assembly
Includes the assembly procedure for performing an Replacement Includes the replacement method for parts,
overhaul of a unit or assembly part, etc. oil, grease, etc.
Inspection DTC priority Includes the DTC priority according to each
Includes the inspection items for the parts that code.
particularly require inspection to ensure the performance
Diagnosis
of parts or devices, etc. Includes the standard values, set
Includes the diagnostic procedure for checking the cause
values, and limits for use of parts if they have these
of the symptom. DTCs are listed in order of priority.
specifications set.
Checking to see if the symptom has been resolved
Cleaning Includes the cleaning procedure for parts and
Includes the diagnostic procedure for when it is necessary
devices, etc.
to check whether the symptom is resolved by a method
Preparation other than checking if the DTC has been cleared (such as
Includes the necessary preparations before removing checking numerical values, etc.).
parts and devices, etc.
Description of the function Includes detailed information
Adjustment Includes the adjustment method when on functions for function inspection.
adjustments to set values or standard values have to be
Description of the symptom
made when performing assembly or installation.
Includes detailed information on symptoms for diagnosis
Measurement Includes the measuring method when according to symptoms.
checking if parts are installed at the proper locations, etc.
DTC description　Includes circuit description for DTC.
Discharge
Setting condition
Includes the discharging method for oil, grease, etc.
Includes information for DTC setting conditions.
Supply
Action taken when DTC is set
Includes the adding method for oil, grease, etc.
Includes information on the controlling operation taken
Air removal by ECU, etc. when DTC is set.
Includes the air removal method if necessary when
Contents regarding ETM
replacing oil, grease, etc.
Contents regarding ETM is included in “Using the wiring
Inscription diagram”.
Includes the inscription method if necessary when
2. Arrows and symbols
replacing the ECM or supply pump.
1. Vehicle front 9. Gas or warm air

2. Upper 10. Mixing of outside air and gas, or cold air and
3. Operating section or operating direction warm air
4. Detail on a section 11. Rotation direction
5. Detailed view from the direction of A 12. Oil feeding
6. Arrow indicates measurement 13. Lubrication
7. Arrow indicates cross-section 14. Application area of liquid gasket
8. Outside air or cold air
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.
Recommended liquid gasket

1. Using the thread liquid gasket
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.
Caution：
・ If the workshop manual specifies an
application method, follow that method.
Thread locking adhesive agent

1. Using the thread locking adhesive agent
Type Color
Loctite 242 Blue
Loctite 262 Red
Loctite 271 Red
Caution：
・ Remove grime, fluid, oil, and grease off
thoroughly from the bolts, bolt holes, and
screw thread section of nuts to which thread
locking adhesive agent will be applied.
Note：
・ Check if the cleaned sections are dry.
Caution：
・ After tightening, do not apply excessive torque
or vibrations for at least an hour until the
thread locking adhesive agent hardens.
Apply thread locking adhesive agent to the end 1/3 of the
screw and tighten at the specified torque.
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.
Abbreviations
1. Abbreviations
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
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)
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
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.
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 }
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 }
*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
： 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 }
： 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 }
*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
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 }
*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 }
： 358.9 to 539.4 N・m ： 430.5 to 711.0 N・m

M24 x 2 { 36.6 to 55.0 kgf・m / - { 43.9 to 72.5 kgf・m / -
265 to 398 lb・ft } 318 to 524 lb・ft }
： 338.3 to 507.0 N・m ： 406.0 to 608.0 N・m
*M24 x 3 { 34.5 to 51.7 kgf・m / - { 41.4 to 62.0 kgf・m / -
250 to 374 lb・ft } 299 to 448 lb・ft }
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 }
： 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 }
*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
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 }
*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 }
： 490.8 to 810.5 N・m ： 554.1 to 830.6 N・m

M24 x 2 { 50.0 to 82.6 kgf・m / - { 56.5 to 84.7 kgf・m / -
362 to 598 lb・ft } 409 to 613 lb・ft }
： 462.8 to 693.1 N・m ： 520.7 to 781.6 N・m
*M24 x 3 { 47.2 to 70.7 kgf・m / - { 53.1 to 79.7 kgf・m / -
341 to 511 lb・ft } 384 to 576 lb・ft }
Note：・ Refer to the following diagram regarding the
・ Those indicated with an asterisk ( * ) are used marking on the top of standard bolts.
for the female threaded portion of soft
materials such as castings.
1. Hex bolt, 4.8, 4 T 10. Hex bolt, non-thermal refining 8.8

2. Hex bolt, 4.8, 4 T 11. Flange bolt 8.8
3. Flange bolt, 4.8, 4 T 12. Flange bolt 8.8
4. Flange bolt, 4.8, 4 T 13. Hex bolt, 9.8, 9 T
5. Hex bolt, 7 T 14. Hex bolt, 9.8, 9 T
6. Flange bolt, 7 T 15. Flange bolt, 9.8, 9 T
7. Hex bolt, thermal refining 8.8 16. Flange bolt, 9.8, 9 T
8. Hex bolt, thermal refining 8.8
9. Hex bolt, non-thermal refining 8.8
Tightening torque for large/medium sizeFlare nut width across flat

Pipe diameter
vehicles Previous New
： 12.8 to 18.6 N・m { 1.3 to 1.9 kgf・： 14 mm ： 14 mm
： 4.6 mm { 0.181 in }
m / 9 to 14 lb・ft } { 0.55 in } { 0.55 in }
： 23.5 to 49.0 N・m { 2.4 to 5.0 kgf・： 17 mm ： 17 mm
： 6.35 mm { 0.25 in }
m / 17 to 36 lb・ft } { 0.67 in } { 0.67 in }
： 23.5 to 49.0 N・m { 2.4 to 5.0 kgf・： 19 mm ： 17 mm
Tightening torque of ： 8.0 mm { 0.31 in } m / 17 to 36 lb・ft } { 0.75 in } { 0.67 in }
the flare nut
Service standard value ： 10.0 mm { 0.39 in } ： 44.1 to 93.2 N・m { 4.5 to 9.5 kgf・： 22 mm ： 19 mm
m / 33 to 69 lb・ft } { 0.87 in } { 0.75 in }
： 58.8 to 137.3 N・m { 6.0 to 14.0 kgf・： 27 mm ： 24 mm
： 12.0 mm { 0.47 in }
m / 43 to 101 lb・ft } { 1.06 in } { 0.94 in }
： 78.5 to 156.9 N・m { 8.0 to 16.0 kgf・： 30 mm ： 30 mm
： 15.0 mm { 0.59 in }
m / 58 to 116 lb・ft } { 1.18 in } { 1.18 in }
Tapered thread for connectors and brass products

Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12
- { 0.20 to 1.50 kgf・m / { 0.5 to 1.6 kgf・m / 43 { 1.0 to 1.7 kgf・m / 87 { 1.0 to 1.8 kgf・m / 87
18 to 130 lb・in } to 139 lb・in } to 148 lb・in } to 157 lb・in }
Tapered thread for products other than connectors and brass products
Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 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
Item Engine model 4HK1

Type Diesel/ 4-cycle /water cooling, inline 4 cylinder OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm {4.53 in} × 125 mm {4.92 in}
Displacement 5.193 L ｛316.88 cu・in｝
Compression ratio 17.5
： 3.23 MPa { 32.9 kgf/cm2 / 468 psi } 3.23 MPa {32.9 kgf/cm2 /
Compression pressure
468 psi}
Idling rotation speed 800 r/min
Intake ： 0.4 mm { 0.016 in } While cool
valve clearance
Exhaust ： 0.4 mm { 0.016 in } While cool
Ignition method Compression ignition
Injection order 1,3,4,2
Lubricant system
Lubricating type Pressure type
Oil pump type Gear type
Lubrication oil amount ： 20 to 27 L { 5.2 to 7.1 US gal }
Oil filter type Full-flow / partial-flow united filter (cartridge type)
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax type unit
： 82.0 ℃ { 180 °F } Without jiggle valve
Open valve temperature of the thermostat valve
： 85.0 ℃ { 185 °F } With jiggle valve
Coolant container ： 14.5 L { 3.8 US gal }
fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
7 holes, inner diameterφ0.14mm {0.0055 in}
Charging system
Generator type AC type
Output 24 V/50 A
Regulator type IC
Starting system
Starter type Reduction type
Output 24 V/5.0 kW
Preheat system type glow plug
Glow plug standard voltage/current 23 V/3.5 A
Cleaning system main specifications
Item Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
Open valve temperatur
Full-open temperature
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
Function, Structure, Operation

1. Engine number
1. Engine number stamping
2. Function, Structure, Operation 1. Engine structural diagram

2. Description of functions and operations Crankshaft

The tufftrided steel is being used, and the grade of each
Engine electronic control
journal diameter is engraved on the No. 1 balance weight.
The control provided by the control unit applies to the
range from injection to air intake and exhaust including EGR system
fuel injection amount, injection timing, air intake The EGR system is controlled by the engine control
restriction, EGR and idling speed. module (ECM) according to various data including the
water temperature, engine RPM, and engine load to
Cylinder block
recirculate the exhaust gas for purification.
The cylinder block is made of cast iron, and it has the
The primary components are the EGR valve, EGR cooler,
equal center distance for each bore and a high rigidity,
and various sensors.
and the center of the crankshaft matches the center of the
block. The bearing cap has the ladder frame structure, and Connecting rod cap bolt
is tightened using the plastic region rotational angle The angle tightening method has been adopted to the
tightening method. connecting rod cap bolt to further improve its reliability
and durability.
Cylinder liner
The cylinder liner is selected in accordance with the inner Common rail type electronic control injection system
diameter of the cylinder block bore, and its identification The common rail type electronic control injection system
number is stamped on the left side of the cylinder. consists of the supply pump that sets the target pressure
of high-pressure fuel to supply the fuel, the common rail
Piston
that measures the high-pressure fuel and the fuel injector
The piston is a strut cast autothermatic piston made of
that injects the fuel in the form of a fine mist. Each of
aluminum alloy, and the combustion chamber is the
these are controlled by the ECM based on various signals
round re-entrant type.
to control the injection timing and injection amount in
Cylinder head accordance with the driving condition.
The cylinder head is made of cast iron, and has four
Fuel injector
valves per each cylinder. The angle tightening method
The fuel injector has adopted the 7-hole nozzle, and
has been adopted to the cylinder head bolt to further
adjusts the fuel injection amount and injection timing by
improve its reliability and durability.
opening or closing the electromagnetic valve on the activated when the engine coolant temperature is low to
injector head portion. help engine start.
The ECM corrects variation in the fuel injection amount
Lubricating system
from fuel injector to fuel injector in accordance with the
It uses and oil filter with a full-flow bypass, and cools
ID code data in the memory. When adjusting the fuel
down the pistons using the water-cooled oil cooler and
injector, the ID code date must be recorded in the ECM.
the oil jet.
Fuel filter with sedimenter
DPD
The fuel filter with sedimenter removes the water by
An integrated DPD oxidation catalyst is installed for
using the difference in the relative density between diesel
reducing exhaust gas.
oil and water, and notifies the operator through the
indicator when it becomes full of water. 3. Fuel system
Preheat system Fuel system diagram
The preheat system consists of the ECM, glow relay,
glow plug and glow indicator light. The preheat system is
1. Electromagnetic pump 6. Fuel tank

2. Fuel filter 7. Fuel return pipe
3. Common rail 8. Pre-fuel filter
4. Fuel injector
5. Supply pump
Caution： Common rail

・ Since the high-precision fuel system has been
adopted, take care to prevent any foreign
matter from entering the fuel system.
1. Pressure sensor 2. Pressure limiter
Fuel supply pump

1. Fuel temperature sensor 5. Camshaft nut

2. Suction control valve 6. Union
3. High pressure pipe 7. Joint bolt
4. Camshaft key
Caution：
・ There is a gauze filter assembled inside the
union of the fuel supply pump, but the union
should not be removed to prevent any foreign
matter from entering.
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.
1. Water jacket 10. Radiator reserve tank

2. Drain plug 11. Air removal plug
3. Oil cooler 12. Water outlet pipe
4. Water pump 13. Thermostat, 2 units
5. Drain cock 14. Water temperature sensor
6. Radiator 15. Bypass route
7. Cooling fan 16. Turbocharger
8. Radiator cap 17. EGR cooler
9. Heater core
Water pump The water pump is a centrifugal impeller type pump and
is driven by the engine fan belt.
1. Fan guide 4. Seal unit

2. Bearing
3. Impeller
Thermostat temperature is 85ºC {185 °F}. The structure allows the

The thermostat is the wax pellet type, and consists of 2 water temperature to be fine adjusted, and it is assembled
units. One unit is the bottom bypass type and its initial inside the thermostat housing unit.
open valve temperature is 82ºC {185 °F}, and the other
unit is the inline type and its initial open valve
1. Jiggle valve 4. Gasket

2. Stamp mark (initial open valve temperature) 5. Piston
3. Valve
5. Lubrication system A full-flow bypass integrated filter element, water

cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.
Oil pump structural diagram

1. Driven gear assembly 6. Drive gear assembly

2. Oil pump body 7. Driven gear assembly
3. Drive gear assembly 8. Oil pump drive gear
4. Oil pump drive gear
5. Oil pump body
6. Induction system Turbocharger structural diagram

1. Connector 6. Coolant inlet

2. Rod 7. Coolant outlet
3. Oil inlet 8. Oil outlet
4. Turbine housing 9. Compressor housing
5. Exhaust adapter
7. Exhaust system
1. DPD assembly 4. DPD differential pressure sensor

2. Exhaust temperature sensor 1
3. Exhaust temperature sensor 2
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.
9. Electrical system 3 out of the 6 main diodes are referred to as positive

diode, and the rest is referred to as negative diode.
Charging system
In addition, 3 small diodes that are referred to as trio-
The main components of the charging system are the
diode are used to supply the field current.
battery, generator, and battery discharge indicator light
This generator has 3 terminals of B terminal (direct
circuit.
current output terminal), L terminal and R terminal.
Generator is a self-rectifier type with a regulator built in.
Since the L terminal is connected to the field coil, it
Generator works as an input terminal together with the R terminal
The generator is the brushless type. until the generator starts generating power.
The main components are the rotor, stator, rectifier Also, it functions as an output terminal. (current capacity
assembly, front bracket, rear bracket, IC regulator, is 1 A) When the L terminal voltage reaches the battery
bearing, pulley, etc. voltage, the charge light turns off.
The moving parts are the rotor and pulley. The field coil Since the both bearings are sealed, periodic lubrications
is fixed to the rear bracket. are not required.
6 main diodes and 2 additional diodes are used to change The IC regulator cannot be disassembled, so it should be
the three-phase alternating current generated in the stator handled as an assembly.
coil to a direct current.
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.
1. Lever assembly 6. Internal gear

2. Magnetic switch assembly 7. Clutch
3. Yoke 8. Pinion
4. Armature
5. Brush holder
Preheat system consists of the electronic control fuel injection system,

The preheat system has adopted the QOS system glow EGR, and idling control.
plug type. Also, the energization control is performed by Also, besides controlling the engine, the engine control
the ECM. system has the QOS system, engine RPM signal output,
self-diagnosing function, and CAN communication SAE
10. Engine control system
J1939/21 and SAE J1939/11 system control functions.
Engine control system overview and implementation
System control schematic
The engine control system is an electronic control system
The specifications vary depending on the actual unit, so
that controls the engine to be always in the optimal
refer to the manual of the actual unit.
combustion state according to the driving condition, and
Fuel injection correction

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

ECM calculates the current altitude using signals from If the ECM is equipped with an emergency stop function
the atmospheric pressure sensor. by a high engine coolant temperature, it stops the engine
According to the conditions such as the current altitude, when the temperature has reached 105 ℃ {221 °F}.
the fuel amount is corrected properly.
Engine emergency stop function

Control during overheat The ECM is designed to make an emergency engine stop
To protect the engine, restriction on fuel flow is started when an input from the engine stop switch, decrease in
when the engine coolant temperature exceeds 100 ℃ the engine oil pressure, increase in the engine coolant
{212 °F}. When the engine coolant temperature increases temperature or overrun occurs.
further, the fuel flow is also restricted further. As for emergency stop made due to decrease in the
When the temperature reaches 110 ℃ {230 °F}, a failure engine oil pressure, increase in the engine coolant
is recorded in the ECM. When the temperature is near temperature or overrun, the control is performed when the
120 ℃ {248 °F}, the fuel flow is restricted to a certain corresponding function is added to the calibration of the
level. The setting varies depending on the actual unit ECM.
manufacturer.
Input from engine stop switch
The actual unit is designed to issue an alarm from 105 ℃
The engine stops when the battery voltage is applied to
{221 °F}. By reducing the load applied to the actual unit
the ECM terminal No. 121.
upon alarm issuance, it is possible to avoid the operation
condition with fuel flow restriction.
Decrease in engine oil pressure

When the engine oil pressure drops to 100 kPa {1.02 kgf/ Overrun
cm2 / 14 psi} or lower, an alarm for engine oil pressure When the engine RPM reaches to the specified value, an
decrease is issued and the engine is stopped. alarm for overrun is issued and the engine is stopped.
It varies depending on the actual unit manufacturer.
Increase in engine coolant temperature
When the engine coolant temperature increases to 105ºC I/O Table
{221 °F} or higher, an alarm for engine coolant
temperature increase is issued and the engine is stopped.
Electronic control fuel injection system Injection amount control

This is the system in which the ECM obtains information To make the injection amount optimal, the fuel injection
such as the engine RPM and engine load and sends the amount is controlled by regulating the injector based on
electrical signals based on the information to the supply mainly the signals from the engine RPM and accelerator
pump, injectors, etc. to properly control the fuel injection opening angle or the instructed rotation from the control
amount and injection timing for each cylinder. unit in the actual unit.
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
Fuel system supplied to the common rail is controlled by regulating

The fuel is supplied to the supply pump from the fuel the suction control valve based on the signal from the
tank, and then it is boosted by the pump before supplied ECM.
to the common rail. At this time, the fuel amount to be
1. Electromagnetic pump 6. Fuel tank

2. Fuel filter 7. Fuel return pipe
3. Common rail 8. Pre-fuel filter
4. Fuel injector
5. Supply pump
Fuel filter clog warning function and engine RPM
restriction function
When the clogged fuel filter is kept used, the ECM
detects DTC P0093, and the output restriction is
implemented.
The first stage
In order to notify a filter clogging before DTC P0093 is
detected, the first stage alarm is issued when the output
value from the fuel filter pressure sensor falls below the
specified threshold value.
The alarm stops when the output value exceeds the
threshold value.
The second stage
The second stage alarm is issued when the output value
from the fuel filter pressure sensor falls below the
threshold value even after the first stage alarm occurs.
The second stage alarm remains as issued until the starter
switch is turned OFF. 1. Supply pump
At the same time as the second stage alarm is issued, the 2. Warning light
target engine RPM is reduced gradually at a constant rate. 3. Monitor
When the output value from the sensor exceeds the 4. Monitor, CAN communication
specified threshold value, reduction of the restricted 5. Fuel tank
engine RPM is stopped, and the regulation is continued 6. Pre-filter
maintaining the restricted engine RPM at that time. When 7. Electromagnetic pump
the output value from the sensor falls below the threshold 8. Fuel filter pressure sensor
value again, the restricted engine RPM is reduced further. 9. Main filter
When the starter switch is turned OFF and then turned
back ON, the restriction is once cancelled.
1. First stage 2. Second stage
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.
EGR Darker portions in the diagram represent large valve lift

The EGR system recirculates a part of the exhaust gas to amounts and the darkest portion represents the lift
the intake manifold, and by mixing in inert gas to the amount of nearly 100 %.
intake air, the combustion temperature is lowered and the
generation of NOx is suppressed.
The EGR amount is controlled by opening and closing
the EGR valve provided between the exhaust manifold
and intake manifold. The EGR amount is determined
from the engine RPM and engine load ratio and the EGR
valve is operated to control the EGR amount.
By installing the EGR cooler on the path of the EGR gas,
high-temperature gas is cooled by the EGR cooler and
then mixed with fresh air to further lower the burning
temperature in order to reduce NOx amount.
Further, the EGR system is also equipped with a check
valve to prevent the EGR from flowing in the opposite
direction to increase the EGR amount.
EGR control
The ECM controls the EGR valve lift amount by
operating the motor according to the engine status such as
the engine RPM and engine load. The valve lift amount is
detected by the EGR position sensor. EGR system schematic diagram
EGR and turbine noise

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

There are the following 4 types of operation control
instructions, and the selection varies depending on each
specification.
Voltage input by APS, 1 - 4 V
Accelerator opening angle instruction given through
CAN communication control, 0 - 100 %, RPM instruction
RPM instruction given through mode map switch control,
RPM instruction and change instruction given by APS
Increase and decrease instruction for each rotation given
by the idle switch
Mode map switch
The mode map switch has 6 rotation control mode types
of H, S, L, B, I and LM.
The rotation settings are H > S > L > B, I > LM.
For H, S, L and B, the rotation speed can be decreased by
the APS, but any change cannot be made from the APS
for I and LM.
When the regulation mode switch input is present in
addition to the mode map switch, the following 2 types of
control methods are available.
Meaning of mode map switch and each mode
In the APS, a change toward the engine RPM decrease
direction can be made from each mode point.
The specified engine RPM for H, S, L and B are
determined depending on the calibration of the ECM.
CAN communication
When CAN controller does not exist on the actual unit
side
H, S, L and B of the mode map switch change as follows

depending on the APS input.
When CAN controller exists on the actual unit side

Mode map switch control
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
H, S, L, and B modes (irrigation pump)

H, S, L, and B modes
Accelerator position switch Regulation mode switch

By operating the accelerator position switch, the output When an input from the regulation mode switch is
voltage changes between 1 V and 4 V. present, the engine RPM changes as follows.
Voltages between 0.2 V and 1.05 V are recognized as 1
V. When the voltage is lowered below 0.2 V or raised
above 1.05 V, an error is detected.
In addition, if the ECM terminals 85 and 86 are not at the
same potential, DTC P2138 is detected.
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
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
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
DPD the optimum value, the ECM detects the exhaust

DPD uses the oxidation catalyst to clean NOx and HC, temperature using the the exhaust temperature sensor and
and uses a dedicated filter to collect PM emitted from the control fuel injection to raise the temperature to burn the
engine. When PM has accumulated on the filter, the filter accumulated PM. When regeneration has started, it must
regeneration is performed. The ECM detects the complete within a certain period of time. After
accumulation status of PM from the DPD differential regeneration has completed, the purification status of the
pressure sensor or mileage. When the accumulated filter can be determined by checking the exhaust
amount of PM or mileage has reached a certain value, differential pressure. When excessive amount of
automatic regeneration of the filter is performed. During accumulated PM has been detected, regeneration is not
regeneration, the filter is heated up to burn the performed because burning cannot be controlled, but the
accumulated PM. To adjust the burning temperature to check engine warning light is turned ON instead.
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
ECM output circuit by controlling the ground or power supply

About ECM function circuit via one of the devices.
The ECM constantly monitors the information sent from
Note：
various sensors, and controls the each system of the
powertrain. The ECM performs the diagnostic functions ・ As for the ECM installation position, refer to
of the system, detects operational problems of the system, the manual of the actual unit.
warns the operator via the diagnostic light, and records
the DTC. The DTC identifies the area where the problem
has occurred to assist the repair operation performed by
the technician.
The ECM outputs voltages (e.g., 5 V) to supply power to
various sensors and switches. The ECM controls the
Notes on ECM maintenance
The ECM has been designed to withstand the regular
current consumption associated with the actual unit
operation. Make sure that the circuit does not overload.
When performing tests for an open circuit or short circuit,
do not ground or apply voltage to the circuit of the ECM,
unless otherwise instructed. When performing these
circuit tests, make sure to use the digital multimeter
5-8840-2691-0.
Note：
・ Use the ECM which has the part No.
corresponding to the actual unit.
When performing welding work on the actual
unit, start the work after disconnecting the
negative terminal of the battery.
Turning OFF of the ECM power supply
In approximately 10 seconds after turning the starter
ECM and components switch to OFF, the internal power supply of the ECM is
The ECM is designed to maintain regulation levels of not turned to OFF. When it is necessary to turn OFF the
exhaust gases while obtaining excellent fuel efficiency. ECM power supply, e.g., when clearing the memory, it is
The ECM monitors various engine functions via the required to wait for 10 seconds or longer after turning the
sensors such as the crankshaft position sensor. starter switch OFF.
ECM voltage
The ECM applies the standard voltage to various
switches and sensors. The ECM is able to apply voltage
in such a way because the ECM resistance value is very
high. The voltage that is actually applied to the circuit is
low. Therefore, the test light may not illuminate even if it
is connected to the circuit. The voltmeter that is normally
used at maintenance factories may not display a correct
reading because its input impedance is too low. An
accurate voltage reading can be obtained by using a
digital multimeter with an input impedance of 10MΩ (for
example, 5-8840-2691-0).
Electrically Erasable Programmable Read Only Memory,
EEPROM
EEPROM contains various programs and calibration
information necessary for the ECM to control the power
train operations.
If abnormalities are found with the EEPROM, replace the Engine components location diagram
ECM. Locations, shapes and existence or nonexistence of
The program and calibration information for the ECM components vary depending on the specifications of the
power train control includes the engine type, engine actual unit.
number, ECM part number, DTC, inter-cylinder
correction learning value, QR, Q tune, and EGR
correction learning value.
1. Overheat switch 9. Suction control valve

2. Water temperature sensor 10. Oil pressure sensor
3. Glow plug 11. Fuel pressure sensor
4. Injector 12. EGR valve
5. Boost sensor 13. CMP sensor
6. IMT sensor 14. Oil level switch
7. Boost temperature sensor 15. CKP sensor
8. Fuel temperature sensor
Supply pump
The supply pump highly pressurizes the fuel using the
engine torque, and force-feeds the fuel to the common
rail. Also, the suction control valve, fuel temperature
sensor, feed pump, etc, are installed on the supply pump.
1. Suction control valve Fuel temperature sensor

2. Fuel temperature sensor The fuel temperature sensor is installed on the supply
3. Feed pump pump, and the thermistor changes the resistance value
according to the temperature change. The resistance value
Suction control valve becomes lower when the fuel temperature is high, and it
The suction control valve is installed on the supply pump becomes higher when the fuel temperature is low. The
portion, and controls the fuel force-feed to the common ECM applies 5 V to the fuel temperature sensor through
rail. The ECM controls the fuel discharge amount by the pull-up resistor, and it calculates the fuel temperature
regulating the energizing time to the suction control from changes in the voltage and uses it for controlling the
valve. supply pump, etc. The voltage becomes lower when the
resistance is lower, and it becomes higher when the
resistance is higher.
Note：
・ Do not replace the fuel temperature sensor.
When an abnormality is found, replace the
supply pump assembly.
1. Suction control valve
Common rail
The common rail receives the fuel from the supply pump,
retains the fuel pressure and distributes the fuel to each
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 1. Fuel pressure sensor

2. Fuel pressure sensor
3. Common rail Injector
The injector is installed on the cylinder head portion, and
Pressure limiter is controlled by the ECM to perform fuel injection. The
The pressure limiter is activated when the pressure in the ECM internally boosts the voltage for driving the injector
common rail becomes abnormally high to release the to apply it to the injector, and uses it for fuel injection
pressure inside the common rail. amount control and injection timing control by regulating
the energizing time of the injector.
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
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.
Camshaft position sensor

The camshaft position sensor is installed behind the
cylinder head, and generates a CMP signal when the
camshaft cam passes by it. The ECM determines the
cylinder and specifies the crank angle using the CMP
Overheat switch
signal input from the camshaft position sensor, and uses
The overheat switch is installed on the water outlet pipe,
the information for the fuel injection control and
and is turned ON when the engine coolant temperature
calculation of the engine RPM. While this control is
exceeds 105ºC {221 °F}.
usually performed using the CKP signal, the CMP signal
is used instead when the crankshaft position sensor is
faulty.
Crankshaft position sensor

The crankshaft position sensor is installed on the
flywheel housing and the CKP signal is generated every
1. Camshaft gear
time when the protruding section of the flywheel passes
2. Rotational direction
the sensor. The ECM determines the cylinder and
3. CMP sensor
specifies the crank angle using the CMP signal input
from the camshaft position sensor, and uses the Oil pressure sensor
information for the fuel injection control and calculation The oil pressure sensor is installed near the starter motor
of the engine RPM. of the cylinder block, and it detects the pressure of the
While this control is usually performed using the CKP engine oil to convert into the voltage signal and send it to
signal, the CMP signal is used instead when the the ECM.
crankshaft position sensor is faulty.
The voltage becomes higher when the pressure is higher,
and it becomes lower when the pressure is lower.
EGR position sensor

This sensor is installed inside the EGR valve to detect the
EGR valve lift amount.
Accelerator position sensor
The accelerator position sensor is installed on the console Note：
panel of the actual unit to supply the voltage signal which ・ Do not disassemble the EGR position sensor.
varies in accordance with the accelerator volume angle to When an abnormality is found, replace the
the ECM. The ECM calculates the accelerator pedal EGR valve assembly.
position from the voltage signal, and uses it for fuel
injection control and many other controls.
Note：
・ As for the installation position of the
accelerator position sensor, refer to the
manual of the actual unit.
Atmospheric pressure sensor
The atmospheric pressure sensor is installed on the actual
unit side, and it replaces the atmospheric pressure with
the voltage signal. The ECM calculates the atmospheric
pressure from the voltage signal, and uses the
atmospheric pressure to correct the fuel injection amount.
Note：
・ As for the installation position of the
atmospheric pressure sensor, refer to the
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.
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.
Fuel filter pressure sensor

The fuel filter pressure sensor is installed on the fuel
filter, and converts the negative pressure in the fuel filter
into the voltage signal. The ECM calculates the negative
pressure in the fuel filter based on the voltage signal to
determine clogging in the fuel filter.
Intake throttle valve
The intake throttle valve is installed on the inlet of the
inlet manifold. The ECM controls the opening angle of
the intake throttle valve according to the condition of
engine operation. The motor inside the intake throttle
valve is controlled based on the duty ratio signals sent
from the ECM. The opening angle of the intake throttle
valve is adjusted when the duty ratio is changing from 0
% to the appropriate ratio. The valve closes when the
duty signal increases, and the valve opens when the duty
signal decreases. The opening angle of the intake throttle
valve is detected by the position sensor. The position
sensor outputs the signal representing the intake throttle
valve opening angle.
The ECM detects a low signal voltage when the opening
angle is small or the valve is at the closed position. Also,
the ECM detects a high signal voltage when the opening
angle is large.
Exhaust gas temperature sensor
The exhaust gas temperature sensors are the variable
resistors that are installed at 2 locations on the DPD
housing, and one is installed in front of the DPD
oxidation catalyst, and the other is installed in front of the
filter. The exhaust gas temperature sensor 1 that is
located in front of the filter measures the temperature of
the exhaust gas before entering the DPD filter, and the
exhaust gas temperature sensor 2 that is located in front
of the oxidation catalyst measures the temperature of the
exhaust gas before entering the oxidation catalyst. When
the exhaust gas temperature sensor is cold, the resistance
of the sensor is high. When the exhaust temperature rises,
the resistance of the sensor decreases. The ECM detects a
high voltage in the signal circuit when the sensor
resistance is high. Also, the ECM detects a low voltage in
the signal circuit when the sensor resistance is low. The
ECM uses this voltage signal for temperature control
during the DPD regeneration.
DPD differential pressure sensor
The DPD differential pressure sensor is installed near
DPD. DPD differential pressure sensor varies the signal
voltage according to changes of the exhaust gas
differential pressure between in front and rear of DPD
filter. The ECM detects a lower signal voltage when the
differential pressure is small due to a small amount of
accumulated PM. The ECM detects a higher signal
voltage when the differential pressure is large due to a
large amount of accumulated PM.
The ECM uses this voltage signal for controlling DPD
regeneration and determining purification after
regeneration.
It also uses the signal voltage to detect filter failures such
as a too low differential pressure.
IMT sensor
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.
Turbo actuator Diagnostic light

The turbo actuator is installed on the turbocharger. The By turning ON the diagnostic switch, the DTC is
ECM communicates with the turbo control unit based on indicated by blinking.
the engine load, etc., and the turbo control unit controls
Note：
the turbo actuator.
The nozzle control of the turbocharger is activated by the ・ As for the installation position of the diagnostic
operation of the motor built into to the turbo actuator to light, refer to the manual of the actual unit.
control the variable nozzle. The ECM performs control DLC
that changes the boost pressure by adjusting the variable DLC is the connector for communication and connection
nozzle opening angle in accordance with the load between the trouble diagnosis scanning tool and various
requirement for the engine. controllers.
Note：
・ As for the DLC installation position, refer to the
Turbo control unit

The turbo control unit is installed on the actual unit. The
ECM communicates with the turbo control unit based on
Note：
・ As for the installation position of the mode
change switch, refer to the manual of the
actual unit.
Diagnostic switch
The diagnostic switch shorts the DLC terminal No. 1 and
No. 4 or No.5 and flashes the diagnostic light to indicate
the DTC.
Note： 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.
ECM pin assignment

60 pin connector
Pin No. Pin name Connection

1 OP-COM1A Injector power supply 1, First cylinder
2 OP-COM1B Injector power supply 1, Fourth cylinder
3 - -
4 - -
5 OM-EBM3 EGR valve DC servomotor power input W
6 SP-5V4 Boost sensor power supply
7 SP-5V8 -
8 IA-MAT IMT sensor signal
9 IA-THL Fuel temperature sensor signal
10 IA-THBST Boost temperature sensor signal
11 IA-PFUEL Fuel pressure sensor signal
12 IA-OILPRESS Oil pressure sensor signal
13 IA-MAP Boost sensor signal
14 IA-IDMPOS Intake throttle position sensor signal
15 OP-SCVHI SCV-HI drive
16 OP-COM2A Injector power supply 2, Third cylinder
17 OP-COM2B Injector power supply 2, Second cylinder
18 - -
19 - -
20 OM-EBM2 EGR valve DC servomotor power input V
21 SP-5V5 Crankshaft position sensor, fuel pressure sensor power supply
22 SP-5V6 Camshaft position sensor power supply
23 SP-5V7 Oil pressure sensor power supply
24 - -
25 IA-THW Water temperature sensor signal
Boost sensor, EGR position sensor, intake throttle position sensor, fuel
26 SG-5VRT4
temperature sensor GND
27 - -
28 SG-SLD5 Crankshaft position sensor shield
29 IA-OPLO -
30 OP-SCVHI SCV-HI drive
31 OS-INJ1 Injector 1, First cylinder
32 - -
33 OS-INJ4 Injector 4, Second cylinder
34 - -
35 OM-EBM1 EGR valve DC servomotor power input U
36 - -
37 - -
38 - -
39 - -
40 SG-5VRT7 Oil pressure sensor, water temperature sensor GND
Intake air temperature sensor, crankshaft position sensor, fuel pressure sensor
41 SG-5VRT5
GND
42 SG-5VRT6 Camshaft position sensor, boost temperature sensor GND
43 SG-SLD6 Camshaft position sensor GND
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
Pin No. Pin name Connection

61 PG-POWER GND
62 PG-POWER GND
63 PG-POWER GND
64 PG-POWER GND
65 PG-POWER GND
66 PG-POWER GND
67 PS-+B Power supply
68 SP-5V1 Accelerator position sensor power supply
69 SP-5V2 Atmospheric pressure sensor power supply
70 SP-5V3 DPD differential pressure sensor, fuel filter pressure sensor power supply
71 - -
72 CC-KW2000 Data link connector
73 (CC-BOOTRX) -
74 - -
75 - -
76 - -
77 - -
78 - -
79 IA-THE1 Exhaust gas temperature sensor 1 signal
80 IA-THE2 Exhaust gas temperature sensor 2 signal
81 IA-IAT Intake air temperature sensor signal
82 IA-MAF Mass air flow sensor signal
83 IA-FIPRESS Fuel filter pressure sensor signal
84 IA-EXHP DPD differential pressure sensor signal
85 IA-ACCEL1 Accelerator pedal position sensor 1 signal
86 IA-ACCEL2 Accelerator pedal position sensor 2 signal
87 IA-BARO Atmospheric pressure sensor signal
88 CC-ISOCAN-L ISO CAN-Low
90 SG-5VRT1 Accelerator position sensor GND
91 - -
92 - -
93 - -
94 - -
95 (CC-BOOTTX) -
96 (MOD1) -
97 PG-SIGN GND
98 - -
99 IS-SCVSW SCV switch signal
100 IS-START Starter switch start signal
101 IS-LOAD Load advance switch signal
102 IS-REG Regulation mode switch signal
103 IS-SWLO1 -
104 IS-IDLMNL Idling control change selector switch signal
105 IS-MDMAP0 Mode map switch 0 signal

106 IS-IDLUP Idling control switch Up signal
109 IS-IDLDWN Idling control switch Down signal
110 CC-ISOCAN-H ISO CAN-High
DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas
112 SG-5VRT3
temperature sensor 1, exhaust gas temperature sensor 2 GND
113 SG-12VRT Mass air flow sensor GND
114 OS-MAINR ECM main relay
115 SG-SLD1 Accelerator position sensor shield
116 - -
117 SP-12V Mass air flow sensor power supply
118 - -
119 PG-SIGN GND
120 - -
121 IS-ENGSTP Engine stop switch signal
122 IS-DPDREG DPD switch
123 OS-OVRL Engine overrun light
124 OS-OILPL Engine oil pressure light
125 OS-BOOSTL Boost temperature sensor pilot light
126 OS-OVHL Overheat light
127 OS-OPL1 -
128 OF-TACHO Tachometer
129 OS-DPDREG DPD regeneration light
130 OS-DIAGL Diagnosis light
131 OS-EGRTL -
132 CC-CAN-L CAN-Low
134 IS-IGKEY Starter switch ON signal
135 SG-5VRT2 Atmospheric pressure sensor GND
136 OS-MAINR ECM main relay signal
137 PG-CASE GND
138 - -
139 PS-MAFBAT dropping resistor
140 IS-SWHI1 -
141 IS-DIAG Diagnostic switch signal
142 IS-MEMCL Memory clear switch signal
143 IS-DGSEL Diagnostic switch signal
144 IS-SWHI2 -
145 OS-GLOWL Glow light
146 OS-OPL2 -
147 OS-FIPRESSL Fuel filter clogging light
148 OS-THLL Fuel temperature light
149 OS-DPDSL DPD light
150 OS-HOUR Hour meter relay

151 - -
152 OS-STARTR Starter cut relay
153 OS-GLOWR glow relay
154 CC-CAN-H CAN-High
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
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.
Caution： Fuel injection system

Fuel piping
・ Make sure that commercial electronic
The high pressure pipe and injector pipe in the fuel
equipment is connected to a circuit that is not
system should not be reused. When it is once removed,
involved with the circuits of the electronic
make sure to replace it with new one.
control system for both power and ground.
The pressure limiter or fuel pressure sensor should not be
Welding operation for the actual unit replaced individually. When a failure is found, the
When performing welding to the actual unit, make sure to common rail assembly and all fuel pipes should be
disconnect the battery in prior to the operation. replaced.
Current that occurred during welding may lead to failure
and/or damage to the electronic control system.
Damage caused by electrostatic discharge
As the electronic components used in the electronic
control system are designed to operate at extremely low
voltages, they can be easily damaged by electrostatic
discharge, and some types of electronic components can
be damaged by static electricity of 100 V or less, which
cannot be felt by a person. Note that a voltage of 4000 V
is required for a person to be able to detect electrostatic
discharge.
There are various ways a person can build up an
electrostatic charge. The most common way to build up
an electrostatic charge is through methods based on
friction or induction.
An example of when a person builds an electrostatic
charge by friction is when he/she slides across the seat of
the machine.
A person wearing insulated shoes can build an 1. Injector pipe
electrostatic charge by induction if he/she momentarily 2. Fuel pressure sensor
touches the ground while standing near a highly charged 3. Pressure limiter
object. A charge of the same polarity flows out, and with 4. Common rail
a highly opposing polarity, that person becomes charged.
As static electricity causes damage, be cautious when 3. Programming
handling or testing electronic components. Programming guideline
Caution： When the ECM or injector has been replaced, use the
trouble diagnosis scan tool to write each data into the
・ To prevent damage due to electrostatic
ECM.
discharge, do not touch the connector pins of
As for the programming method, refer to the instruction
the ECM or the electronic components
manual of the trouble diagnosis scan tool.
soldered onto the circuit board of the ECM.
Prior confirmation item for programming
When performing programming, check the ECM part No.
as necessary.
When performing programming, check the engine type as
necessary.
When performing programming, check the engine No. as
necessary.
When performing programming, check the injector ID
code as necessary.
Items require programming
When the ECM has been replaced, perform
programming.
When the engine has been replaced, perform
programming.
When the injector has been replaced, perform
programming.
Introduction to the trouble diagnosis

1. Introduction to the trouble diagnosis The customer complaint is clear, but the failure
conditions are unclear.
1. About trouble diagnosis
Therefore, the person performing the diagnosis can
The following trouble diagnosis procedure is
reproduce the failure by understanding its conditions.
extremely important to resolve problems of all
Intermittent failures, intermittent
electric/electronic systems.
Neglecting to implement these steps may result in Stage where failure is realistic
requiring unnecessary repairs. Read and understand The occurrence of the failure is set, and the customer
the procedure carefully and proceed with the trouble complaint is real and clear.
diagnosis. Therefore, the person performing the diagnosis can
Also, use available functions and the trouble reproduce the failure. However, there may sometimes be
diagnosis scan tool to perform the trouble diagnosis more than 2 causes for the failure.
and system check. Current malfunction, Current failures
2. Trouble diagnosis procedure 3. Diagnosis
Checking complaints from customer Fully understand the description given by the
・Use the check sheet to organize the trouble customer using the Engine Control System Check
situation. Sheet.
Performing preliminary inspection Note：
・Perform overall visual inspection. ・ When questioning, do not ask randomly but
・Check the past maintenance history. focus on the system that is inferred to be
・Detect any abnormality such as abnormal noise, smell, defective based on the malfunction
etc. phenomenon.
・Collect the failure trouble DTC information to provide
effective repair. Determine failure information accurately.
・Inspect for an abnormality by comparing to the standard Have concrete understanding based on 5W1H.
value. Low air temperature, at start or on a steady basis, near the
engine parts, metallic sound, etc.
Inspect the service information
・Check the market service bulletin. Check points
・Failure symptoms
Perform inspection for the displayed code. ・Month and Date, Time, Frequency of occurrence
・Inspect the item shown by DTC. ・Road conditions
Perform an inspection for problems according to ・Driving conditions, Operation conditions, Weather
symptoms ・Feeling of symptom
・Check the item that is not displayed in the DTC. Engine control system check sheet
NOTE When receiving the actual unit from the customer at the
System trouble diagnosis type service factory, the failure symptoms and the data on
The system diagnosis method is a standardized method occurrence of failure must be confirmed with the
applied for repairing all electric/electronic systems. customer based on the engine control check sheet.
Failures in electric/electronic systems often occur in the ・Failure symptoms may not be able to be reproduced at
following steps unlike common actual unit failures. the service factory.
Initial stage of failure ・The customer's complaint may not always be a
The failure occurs sporadically and for a short time, often malfunction.
times the driver does not notice it. At this stage, the ・Notification of incorrect malfunction conditions to the
customer's complaint is unclear, and the malfunction person in charge of repairs may result in unnecessary
cannot be reproduced. However, the ECM may have man-hours for repairs.
recorded the failure. ・ The check sheet assists actual unit diagnosis, repair,
Past malfunction, past failures and repair confirmation at the vehicle servicing station.
Middle stage of failure

The failure occurs sporadically and for a short time, but
may occur repeatedly at intervals, and occurs under
specific conditions.
1. Failure symptoms
2. Failure frequency・failure conditions
4. Preparatory check When implementing the diagnostic procedures,

Visual inspection of engine room carefully make a visual inspection of the engine
room. This inspection can often lead to solving a understanding of hand tools, such as the
problem without taking extra steps. trouble diagnosis scan tools, is required to
・Visually inspect all air hoses for punched holes, cuts, utilize the service manual effectively.
disconnections, and appropriate piping. About the diagnostic test performed on the actual unit
・Visually inspect the hoses that are difficult to see Past failures
behind other components. ・The diagnostic tests of the previous ignition cycle have
・For every harness in the engine room, visually inspect been completed.
that all harnesses are properly connected. Inspect that ・The diagnostic tests of the current ignition cycle have
there are no burned or worn areas, that the harnesses are passed.
properly fastened and that they are not in contact with ・Problems identified in the diagnostic tests currently do
sharp edges or the hot exhaust manifold or pipes. not exist.
Checking the machine maintenance status Current failures
if the actual unit is not maintained properly, the ・The diagnostic tests of the previous ignition cycle have
diagnostic light is turned on. been completed.
Restricted oil filters, fuel filters, and crankcase deposits ・Problems identified in the diagnostic tests currently
due to lack of oil changes or improper oil viscosity can exist.
trigger actual unit faults that were not previously ・Problems exist in the current ignition cycle.
monitored prior to OBD.
Poor vehicle maintenance cannot be classified as a non- Glossary DTC
machine failure, but since the sensitivity of OBD system Every time the starter switch is turned ON, the ECM
checks is high, actual unit maintenance schedules must be performs the self-test on most of the wiring and
further closely followed. components, records any detected system failure in the
memory of the ECM, and performs the backup control,
Non-OEM parts depending on the DTC.
All the OBD system checks are adjusted to operate with Also, as for an abnormality that can affect driving, the
the genuine parts. Therefore, when a commercially sold diagnostic light is turned on to inform the operator.
sensor or switch, etc. is installed, a wrong diagnosis is
made, and the diagnostic light comes on. Ignition cycle
Commercial electronics, such as mobile phones, stereos, Because the actual unit activates with a method to satisfy
and anti-theft devices, may emit EMI into the control a predetermined diagnosis standard, an ignition cycle is
system when they are improperly installed. As the result, defined as turning the starter switch ON, running, then
false sensor information is generated causing the turning the starter switch OFF.
diagnostic light to come on. When conducting a trouble Diagnostic light
diagnoses, either turn OFF the power for all Basically, the diagnostic light is turned on when a DTC is
commercially sold parts or remove them, and then check detected due to a failure occurred in the electronic control
the failure again. system such as ECM.
NOTE DLC
Related system failure The equipment for communicating with the control unit is
Many OBD system checks go into the backup operation the Data Link Connector (DLC). The DLC is also
mode based on the instruction from the ECM which is provided to establish a connection with the scan tool.
given when the ECM detects a failure in the related Identification of recorded
systems or components. When the backup operation DTC Reading the serial data
mode is activated, the output is reduced to protect the
actual unit. Note：
・ The installation position of the DLC and
5. Trouble diagnosis
existence or nonexistence of the DLC vary
Basic knowledge of tools required
depending on the actual unit, so refer to the
Note： manual of the actual unit.
・ When performing the diagnostic procedure, ECM OFF
lack of basic knowledge regarding this Turn the ECM off starter switch off and the ECM power
powertrain could result in an incorrect supply completely tops in approximately 10 seconds to
diagnosis or damage to the powertrain disable the ECM.
components. Do not attempt to diagnose a
problem related to the powertrain without General diagnostic operations of the components monitor
having the basic knowledge. A basic To run the engine normally, a general diagnosis of the
components is required.
Input components ・Turn the starter switch ON, but the engine off.
Inspect the input components to see whether an open in ・Connect the diagnostic switch. For an actual unit
the circuit or outside range value exists. with no diagnostic switch, short the DLC No. 1 and
Crankshaft position sensor No. 4 or No. 5.
Camshaft position sensor ・Read the blinking count of the diagnostic light.
Water temperature sensor ・The DTC determines the failure contents from the
Boost sensor diagnostic trouble code list.
Fuel pressure sensor If the trouble diagnostic scan tool is connected, the
Accelerator position sensor diagnostic codes can be read by operating the trouble
diagnostic scan tool.
Output components The output components are inspected
to diagnose whether responses to commands from the Note：
control unit are appropriate. Inspect whether the circuits ・ As for the installation position of the diagnostic
have disconnections and whether their values are within light, refer to the manual of the actual unit.
the range.
Suction control valve Display code when no DTC is recorded
Light, Relay control Code 1 (indicating the start of code display) continues to
Magnetic valve be displayed.
Diagnostic light Display when a DTC is recorded
6. DTC reading procedure The recorded trouble codes are displayed 3 times. If more
Reading DTC with diagnostic light than 2 or more trouble codes have been recorded, the
Current and past DTCs recorded in the ECM can be DTCs will be output in ascending order with each DTC
displayed by connecting the diagnostic switch and being displayed three times. After displaying all codes,
blinking the diagnostic light. the codes will be displayed again starting with the
・Turn the starter switch ON and check that the smallest code number. This display continues while the
diagnostic light turns on. diagnosis connector is connected.
DTC indicated by diagnostic light blinking display Note：

The current and past DTCs are both displayed while the ・ For the work procedure, refer to the manual of
engine is being stopped. the trouble diagnosis scan tool.
While the engine is in operation, the light is turned on
only when a current DTC exists. When the DTC is recorded
Perform repairs accurately according to the specified
Using the trouble display monitor to read the DTC DTC chart.
When a DTC occurs, the DTC can be displayed on the
trouble display monitor of the actual unit. If no DTC is available
Select the symptom from "Diagnosis By Symptom".
Using the scan tool to read the DTC Complete the repair according to the diagnostic
The DTC can be read using the trouble diagnosis scan
tool.
procedure. It is also possible to perform the inspection by confirmation test performed on the actual unit or other
referring to the functional diagnosis. methods to confirm that the complaint has been resolved.
Confirm by testing under the conditions given by the
When the appropriate symptom is not found;
customer.
Investigate the complaint in detail.
When a DTC is diagnosed, confirm that the failure has
Create a diagnosis plan.
been repaired by reproducing the condition that appeared
Utilize the schematics and operation principles.
when the DTC was set while checking the scan tool data.
When repair history for similar cases are available,
request technical assistance. Combine technical 7. Check after repair
knowledge and effective utilization of available service Check repair on actual unit
information. When an repair has been performed for the electronic
control system, it is necessary to check that the repair
Intermittent
is accurate after repairing the actual unit. If this
A failure condition that does not necessarily always
check is not adequate, the diagnostic light may light
appear is referred to as intermittent.
again while returning the actual unit to the customer,
Check the DTC information and the data display.
or drivability problems may occur. Especially for
Verify the symptoms and conditions reported by the
an intermittent failure, it is necessary to perform the
customer.
check by reproducing the conditions of the customer
Use a check sheet or other method to check the circuit or
complaint.
electronic system components.
About confirmation of the actual unit repairs
When no trouble is detected
It is effective to use the OBD system check for
This status indicates that the actual unit is determined as
confirming actual unit repairs.
operating properly. The condition reported by the
After the repair is completed, the person who have
customer may be normal. Check the customer complaint
performed the actual unit diagnosis shall review either the
by comparing to other actual unit that is operating
DTC that was diagnosed or scan tool data, or both, and
properly. However, depending on the condition, it may be
record it.
an intermittent. Before returning the actual unit, check the
Clear the DTC.
complaint under the conditions given by the customer.
Run the actual unit based on the scan tool data.
Investigate the complaint again.
Check the DTC status information of the specified DTC
If the complaint cannot be adequately detected or
that was diagnosed until the diagnosis test related to that
confirmed , it is necessary to perform the diagnosis again
DTC is implemented by the control unit.
to verify the complaint. As stated above in "Intermittent",
The implementation of these steps is extremely important
the complaint may be an intermittent or normal condition.
when checking the repair status with the OBD system
Repair and confirm.
check. Neglecting to implement these steps may result in
Perform the repair when the cause has been confirmed.
unnecessary repairs.
Confirm that the operation is performed properly, and
that the symptom has been corrected. This includes the 8. Final check item list
Item Item Objective Method

Clear the previous DTCs. Keep the engine idling
Confirm the DTC display after to warm up, then perform a racing run to
1 DTC check
the repair increase the engine rpm to No Load Max to
secure the test conditions.
Check whether the idling rotation speed is
constant under the no load condition after
Idling speed check after To check whether the idling
2 engine is warmed up. If a problem is detected,
warming up the engine control is operating normally.
refer to Idling Unstable in Diagnosis by
Symptom.
Check the engine control,
Monitor the scan tool data list, and check the
Confirm the scan tool communication status error and
3 values using a typical value sheet. Confirm the
data list abnormality under the standard
typical values of the scan tool data list.
condition.
After warming up the engine, confirm that the
To check whether the starting cranking time is 5 seconds or less when
4 Re-startability check
control is normal. restarting the vehicle, and that the engine
revolution is stable after starting.
Check whether turning the electromagnetic
When electromagnetic
transmitter such as a transceiver ON and OFF
Check powerful transmitters such as a transceiver
causes the idling engine rpm to change. If a
5 electromagnetic have been added to the vehicle,
problem is found, let the customer know that the
transmitters confirm that no interfering waves
installation position and output of the
are being emitted.
electromagnetic transmitter need to be changed.
Supplementary information regarding the check for Clearing DTC
powerful electromagnetic transmitters If an error occurs in the system and the DTC is
If you discover a problem in this item, convey it to the recorded in the ECU, that DTC is not deleted from
customer as necessary. the memory even when the malfunctioning part is
・Install the antenna to the a place distant from the repaired, so use the following measures to execute a
electronic control system of the actual unit such as the forced deletion.
control units and sensors.
Using the scan tool to delete the DTC
・Install the antenna cord at least 20 cm away from the
If the trouble diagnosis scan tool is connected, you can
electronic systems of the actual unit, such as the control
delete codes by performing turning off of the trouble
units and sensors.
diagnosis scan tool.
・Do not wire other cables together with antenna.
Also, locate the antenna cord as far away from other Clearing method with use of harness for memory clear
wiring as possible. HITACHI Construction Machinery Company
・Make sure to attach retrofitted equipment in accordance 1, Connect the harness for memory clear to the data link
with their respective installation manuals. connector.
・Do not install high-output mobile communication
devices.
Caution：
・ Follow the steps when performing the OBD
system checks to confirm the repair. Failure to
follow these steps may result in performing
unnecessary repair works.
・ Review the scan tool data relating to the DTC
that was diagnosed and make a record.
・ Clear the DTC.
・ Operate the actual unit while checking the
related scan tool data.
9. DTC clearing method
The ECM is reflashed by automatically searching for the
ECM part number compatible with the part number
currently reflashed.
Forced reflash
The ECM is reflashed by specifying an arbitrary ECM
part number.
In this case, a password dedicated for forced reflash is
necessary.
Campaign reflash The ECM is reflashed by selecting the
part number during a campaign carried out by the
manufacturer.
Rewriting injector QR code
The injector QR code that is required when replacing the
injector can be rewritten. This allows fuel compensation
to be performed on each injector to optimize the engine
condition.
Engine replacement mode
2. Turn the starter switch ON. This should be used when changing back to the old ECM
3. Connect the Memory Clear terminal to the Ground for part number which requires hardware changes such as
one second or longer. addition of actual unit wiring is performed along with
4. Turn the starter switch OFF. engine replacement, etc.
When the starter switch is turned OFF, the memory is
ECM replacement
cleared.
When replacing the ECM within the same model, the data
5. Disconnect the Diagnostic switch terminal.
can be updated from the current ECM to a trouble
Erasure by ECM diagnosis scan tool and then downloaded it from the
A DTC recorded in the ECM is erased if the same DTC trouble diagnosis scan tool to the new ECM after
has not been satisfied for 40 consecutive ignition cycles. replacement.
About trouble diagnosis scan tool Factory shipment settings
This tool is effective for diagnosing electrical failures in Based on the engine serial number, data such as ECM
engine control units and performing system checks. injector QR code can be downloaded to ECM.
If you connect the SAE 16/19 adapter to the DLC
Actuator test
installed in the unit, it performs communication with the
The injector test, fuel injection test, rail pressure test,
control units of the machine, and enables various
glow plug test, and EGR control test are performed to
diagnoses and tests to be performed.
inspect the operation and function of each target
Functions of the trouble diagnosis scan tool. component.
Data display Caution：
Snapshot ・ When conditions such as the running state of
the actual unit or the engine, water
Programming temperature, switches and gear position are
Actuator test not met, or when a DTC has been detected,
each test may possibly not operate.
Caution：
Links with the HTML manual display
・ When conditions such as the running state of
DTC to display the manual along with the failure
the actual unit or the engine, water
diagnosis procedure.
temperature, switches and gear position are
not met, or when a DTC has been detected, Reading saved data
each test may possibly not operate. Read in the saved snapshot data to display reproduction.
ECM reflash Caution：
The ECM can be updated by overwriting its control ・ When using the trouble diagnosis scan tool,
program using the most recent control data issued every 3 refer to the separate instruction manual for the
months. trouble diagnosis scan tool.
Normal reflash
10. Reference data value
HITACHI Construction Machinery Company whether the vehicle data is temporarily or always
The purpose of data list is for checking the status of the different from the reference values. This display menu is
actual unit and equipment. subject to change without notice.
This data is used in trouble diagnosis by comparing the
Non-operational P rotation
each unit data with standard values, and checking
Non operation P rotation reference value

Data display items Units It varies depending on the actual machine
condition
Battery voltage V 28.3 - 28.5
Target engine rpm RPM 500
Engine rpm RPM 1,797 - 1,801
Accelerator pedal position sensor 1 (APP1) V 0..0
Accelerator pedal position (APP) ％ 0
Fuel rail pressure sensor V 2.0 - 2.1
Fuel rail pressure feedback Feedback mode
Coolant temperature sensor V 0.4 - 0.5
Coolant temperature ℃ 80 - 83
Intake temperature sensor V 2.4
Intake air temperature ℃ 27
Fuel temperature sensor V 1.3
Fuel temperature ℃ 44
barometric pressure sensor V 1.9
Atmospheric pressure kPa 100
Boost temperature sensor voltage V 4.4
Boost pressure sensor kPa 118 - 119
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode Fuel mode
EGR valve 1 drive duty ％ 0
Reverse the polarity of either 1, 2, or 3
EGR position 1 ON/OFF
(Example: 1=ON, 2=ON, 3=OFF, etc)
Ignition switch ON/OFF ON
starter switch ON/OFF OFF
OFF
glow relay ON/OFF
ON immediately after the starter switch ON
Q adjustment compensation data 1 - This differs depending on the actual unit.
Two pump relief
Two Pump Relief reference value

Data display items Units
varies according to actual unit conditions
Battery voltage V 28.4 - 28.5
Target engine rpm RPM 500
Engine rpm RPM 1,898 - 1,901
Accelerator pedal position (APP) ％ 0
Fuel rail pressure difference
MPa -
(actual – target)
Fuel rail pressure sensor V 3.3 - 3.5
Fuel rail pressure feedback Feedback mode
Coolant temperature sensor V 0.4
Coolant temperature ℃ 83 - 85
Intake temperature sensor V 2.2
Intake air temperature ℃ 27
Fuel temperature sensor V 1.3
Fuel temperature ℃ 43 - 44
barometric pressure sensor V 1.9
Atmospheric pressure kPa Approx. 100
Boost temperature sensor voltage V 4.3
Boost pressure sensor kPa 203 - 210
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode Fuel mode
EGR valve 1 drive duty ％ 19
Ignition switch ON/OFF ON
starter switch ON/OFF OFF
OFF
glow relay ON/OFF
ON immediately after the starter switch ON
Functional Inspection (4HK1) 15C-1
Description Engine
Functional Inspection
(4HK1)
Table of Contents
Starting system check....................................................15C-2
Fuel system check.........................................................15C-3
Air intake system check................................................15C-4
Exhaust system check....................................................15C-5
EGR control system check............................................15C-6
Glow control system check...........................................15C-7
DPD control system check............................................15C-8
OBD system check......................................................15C-11
Inspection of the diagnostic light warning light illumination
circuit system...............................................................15C-12
Inspection of the diagnostic light warning light blinking
circuit system...............................................................15C-13
Inspection of the starter circuit system........................15C-14
Engine compression pressure inspection.....................15C-15
Lubrication system check............................................15C-17
15C-2 Functional Inspection (4HK1)
Starting system check

1. Starting system check Description of Function 10. Inspect the engine coolant temperature sensor.
This diagnosis chart is an organized approach to 11. Inspect the fuel pressure sensor.
identifying a condition that causes the status for when an
12. Inspect the EGR position sensor.
engine does not start. The appropriate system diagnosis
can be performed with this diagnostic chart. 13. Inspect the injector.
･ The battery should be fully charged when performing 14. Inspect the engine mechanical timing.
this diagnosis. 15. Inspect the installation status of the flywheel.
･ The battery cable should be securely connected when
performing this diagnosis. 16. Inspect the air intake system.
･ The rotation speed during cranking should be normal 17. Inspect the exhaust piping for collapsing, damage,
when performing this diagnosis. and exhaust leakage.
･ The appropriate fuel should be sufficiently supplied
when performing this diagnosis. 18. Repair or replace the part found to have a problem.
･ No fuel leaks should be found when performing this
diagnosis.
･ No air should be mixed into the fuel when performing
this diagnosis.
･ The air cleaner element should be clean when
performing this diagnosis.
･ The fuel filter should be clean when performing this
diagnosis.
2. Starting system check Inspection
Inspection when the starter operates and cranks but the
engine does not start
1. Turn the emergency stop switch to OFF.
Note：
・ If the actual unit does not have an emergency
stop switch setting, do not perform this
operation.
2. Inspect the overheat switch circuit.
Note：
・ If the actual unit does not have a overheat
switch setting, do not perform this operation.
3. Repair the circuit if a problem is discovered.
4. Check the DTC.
Note：
・ If the DTC is detected, inspect the
corresponding DTC.
5. Check the SCV F/B display using a trouble diagnosis
scan tool while cranking the engine.
standard： 900 mA
6. Repair the SCVLO drive circuit if it is below the
standard value.
7. Remove the harness connector from the SCV.
8. Crank the engine.
Note：
・ If the engine starts, diagnose the DTC P0090.
9. Inspect the fuel system if the engine does not start.
Fuel system check

1. Fuel system check Description of Function
The fuel system is composed of the fuel filter, supply
pump, common rail, and injector, and each of them
connects with the fuel pipe.
2. Fuel system check Inspection
Inspection when there is a possibility that there is an
abnormality in the fuel system
1. Inspect the quality of fuel.
Appropriate fuel should be used.
2. Check the amount of fuel.
Sufficient amount should be supplied.
3. Perform the fuel discharge inspection for the supply
pump.
Fuel discharge inspection
The fuel discharge should be normal and no air should be
mixed.
4. Confirm that the genuine fuel filter, pre filter, and
filters other than for the electromagnetic pump are
added to the fuel piping of the actual unit.
Note：
・ A problem such as the detection of the DTC
P0093 may occur as the resistance of fuel
increases due to the added filter.
5. Remove it if the filter is added.
6. Inspect the main fuel filter, pre-fuel filter, and
electromagnetic pump filter.
･ No excessive contamination or clogging should be
found.
･ No air should be mixed in.
7. Clean or replace if a problem is discovered.

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

1. Air intake system check Description of Function
Caution：
・ If the air intake system part is installed by the
actual unit manufacturer, refer to the manual of
the actual unit.
The air intake system is comprised of the air cleaner, air
intake piping, turbocharger, etc. The intake air is supplied
to the engine through the air cleaner and intake manifold.
2. Air intake system check Inspection
abnormality in the air intake system
1. Inspect the air cleaner.
･ No excessive contamination or clogging should be
found.
2. Clean or replace if a problem is discovered.
3. Inspect the air intake piping.
･ No collapsing, damage, or air leakage should be found.
･ There are no distorted or improper piping arrangements
which may lead to an increase in the air intake resistance.
･ The lead valve should have no damage.
5. Inspect the turbocharger.
･ The turbine axis should have no abnormal looseness.
･ There are no oil leaks.
Exhaust system check

1. Exhaust system check Description of Function
The exhaust system is comprised of the exhaust pipe, tail
pipe, etc.
2. Exhaust system check Inspection
abnormality in the exhaust system
1. Inspect the exhaust pipe and tail pipe.
･ No collapsing, damage, or exhaust leakage should be
found.
3. Repair the actual unit.
EGR control system check

1. EGR control system check Description of Function
The ECM controls the EGR valve based on the engine
revolution speed, engine coolant temperature, intake air
temperature, fuel injection amount, and atmospheric
pressure. The EGR valve is driven by the EGR motor,
and the EGR valve opening is detected by the EGR
position sensor.
2. EGR control system check Inspection
abnormality in the locations relating to the EGR.
1. Check the DTC.
Note：
・ If the DTC is detected, inspect the
corresponding DTC.
2. Start the engine and warm it up until the coolant
temperature exceeds the standard value.
Specified value： 70 ℃ { 158 °F }
3. Check the EGR position display using a trouble
Specified value： -3 to 3 %
4. Perform the actuator test EGR control using a trouble
diagnosis scan tool if the EGR position display is
outside the standard value.
5. Execute an Up and Down command to the EGR
valve and check the EGR position display.
6. Inspect the EGR piping if the EGR position display
is outside the standard value.
No damage or gas leaks should be found.
8. Start the engine and warm it up until the coolant
9. Check the EGR position display using a trouble
10. Replace the EGR valve if the EGR position display
is outside the standard value.
EGR valve Removal
EGR valve Installation
11. When replacing the EGR valve, perform EGR
learning to the ECM.
Glow control system check

1. Glow control system check Description of Function standard： 6 Ω At room temperature
Caution： Note：
・ The starter ECM control specification and ・ If it is outside the standard value, inspect the
safety relay specification are the same for the corresponding glow plug.
QOS circuit.
11. Replace the glow plug if a problem is discovered.
The QOS system is comprised of the ECM, glow relay,
12. Connect the DMM to the glow plug connector and
glow plug, and QOS indicator light. When the starter
GND.
switch is turned to ON under low engine coolant
temperature, the ECM determines the glow time 13. Turn ON the starter switch.
according to the engine coolant temperature, and starts 14. Perform the actuator test glow plug relay using a
the glow relay and QOS indicator light. The ECM will trouble diagnosis scan tool.
turn to OFF the glow relay and QOS indicator light after
a certain period of time. Note：
2. Glow control system check Inspection ・ Turn the command to OFF and check the
voltage value of the DMM.
abnormality in the locations relating to the QOS system standard： 0 V
control 15. Inspect the circuit if it is outside the standard value.
1. Perform the OBD system check. Note：
2. Check the DTC. ・ No short circuit to battery or ignition power
supply should be found between the glow relay
Note： and glow plug.
・ If the DTC P0117, P0118, P0380, or P0381 is
detected, inspect the corresponding DTC. 16. Repair or replace the circuit if a problem is
discovered.
3. Turn ON the starter switch.
17. Perform the actuator test glow plug relay using a
4. Check the operation of the QOS indicator light. trouble diagnosis scan tool.
Note： Note：
・ If the QOS does not operate, the QOS ・ Turn the command to ON and check the
indicator light will illuminate when the starter voltage value of the DMM.
switch is turned to ON by the light check
function. standard： 18 V
・ The QOS indicator light turns off within 10 18. Inspect the circuit if it is below the standard value.
seconds.
･ No fuse should be blown.
5. Inspect the circuit if the QOS indicator light does not ･ No open circuit should be found between the fuse and
illuminate or turn off. glow relay.
･ No fuse should be blown. ･ No open circuit should be found between the glow relay
and glow plug.
･ No open circuit should be found between the fuse and
･ No open circuit should be found between the glow relay
QOS indicator light.
･ No open circuit or short circuit should be found and ECM.
between the QOS indicator light and ECM. 19. Repair or replace the circuit if a problem is
･ The QOS indicator light should not have a burned-out discovered.
bulb.
20. Replace the ECM.
6. Repair or replace the circuit if a problem is
discovered. Removal of ECM
7. Inspect the glow relay. Installation of ECM
8. Replace the relay if a problem is discovered. 21. After replacing the ECM, perform EGR learning.
9. Remove all glow plugs.
10. Measure the resistance between the glow plug
terminal and GND using the DMM.
DPD control system check

1. DPD control system check Description of Function 6. Connect the trouble diagnosis scan tool to the DTC.
The ECM detects the condition of PM accumulations 7. Start the engine.
from the DPD differential pressure sensor. The DPD
8. Display the scan tool data DPD regeneration switch
differential pressure sensor changes the signal voltage in
using a trouble diagnosis scan tool.
accordance with changes in the exhaust gas pressure
difference between the front and the rear of the DPD 9. Check if the data displayed on the DPD regeneration
filter. When the DPD differential pressure sensor reaches switch of the trouble diagnosis scan tool is turned to
to a certain amount of PM accumulation, or a certain ON or OFF when changing each switch.
period of operating hours, DPD automatic regeneration
Note：
starts. If the automatic regeneration cannot be completed
due to driving, the DPD manual regeneration indicator ・ If the ON or OFF operation does not link,
light in the monitor panel blinks to prompt the driver to inspect the DPD switch and harness.
perform manual regeneration. When regeneration has 10. Inspect the installation condition of the DPD
once started, it must be completed within a certain period differential pressure sensor.
of time. After completion of DPD regeneration,
purification status of the filter is determined based on the 11. Inspect the exhaust differential pressure sensor.
exhaust differential pressure. When the ECM detects ･ Damage on the DPD differential pressure sensor
excessive amount of PM accumulation, it becomes so hot ･ Foreign matter or contamination which interferes with
that it is eroded during regeneration process and cannot the DPD differential pressure sensor inlet
control combustion; therefore, DPD regeneration is not ･ Wrong detection or slow response for the DPD
allowed to start. differential pressure sensor
2. DPD control system check Inspection 12. Inspect the exhaust system.
Inspection for determining the failure location in the DPD 13. Inspect the air intake system.
system
14. Start the engine and maintain idling for 30 seconds.
1. Perform the inspection of the engine control system.
15. Confirm that the DPD manual regeneration indicator
2. Turn the starter switch ON for 30 seconds. light blinks.
3. Check that the monitor panel functions normally. Note：
･ DPD automatic regeneration indicator light illuminates ・ If it is not blinking, use the trouble diagnosis
in green scan tool to confirm DPD accumulation status
･ DPD manual regeneration indicator light illuminates in and DPD time status and applicable area
based on the DPD status table.
orange
Note：・Compare DPD accumulation status and DPD time
status and use the DPD status table to determine DPD
・ If it dose not illuminate, inspect the circuit of
regeneration process status.
the DPD indicator light.
・To use the DPD status table, confirm the data display
・ Not all are displayed depending on actual unit values on the trouble diagnosis scan tool and readings in
manufacturers. the DPD status table.
4. Turn the starter switch OFF for 30 seconds.
5. Inspect the amount of engine oil.
Note：・ If no error message has been displayed,

・ The area where 2 status values meets will inspect for a problem in the fuel system.
point to either A, B, C, or D.
19. Confirm that the data display of exhaust temperature
16. Operate the trouble diagnosis scan tool. 1 is below the standard value using a trouble
diagnosis scan tool if the regeneration completed.
Note：
・ Use a trouble diagnosis scan tool to reset the Specified value： 130 ℃ { 266 °F }
DPD status. Note：
･ If it is range A or B, perform the DPD forced ・ If it is the standard value or greater, idle the
regeneration test with the trouble diagnosis scan tool. engine until it reaches the standard value or
･ If it is range C or D, perform the DPD forced slow lower.
regeneration test with the trouble diagnosis scan tool.
20. Accelerate the engine revolution to maximum
Note： revolution speed without load.
・ After the DPD forced slow regeneration is 21. Check the data display of the exhaust differential
completed, replace the engine oil. pressure when the data display of exhaust
17. Check the DTC detection with the trouble diagnosis temperature 1 reaches the standard value.
scan tool if the regeneration does not start. Specified value： 150 ℃ { 302 °F }
Note： 22. Check the exhaust differential pressure data display
・ If no DTC is detected, confirm data display using a trouble diagnosis scan tool.
related to DPD regeneration control.
specified pressure： 0.5 to 1.8 kPa { 0.01 to 0.02 kgf/
18. Inspect the corresponding DTC if the regeneration is cm2 / 0.07 to 0.26 psi }
not completed and the scan tool displays an error
Note：
message.
・ If it is the standard value or lower, perform ash
Note： removal.
・ If no error message has been displayed, ・ If it is the standard value or greater, inspect for
inspect the DPD filter for damage, cracks, or the abnormalities in the DPD differential
melting. pressure sensor system.
・ If no error message has been displayed,
23. Replace the ECM if any problem can be seen
inspect the oxidation catalyst for degradation,
through the inspections above.
damage, cracks, melting, or excessive
sediment. ECM Removal
・ If no error message has been displayed, ECM Installation
inspect for the cause of overheating.
24. Set the injector ID code on the ECM.
25. Perform the unit difference learning of the fuel
supply pump to the ECM.
OBD system check

1. OBD system check Description of Function 5. Use the trouble diagnosis scan tool to confirm the
DTCs of the ECU that has communication
The OBD system check is a systematic method for
established.
checking problems caused by functional failures in the
Loss of communication with the trouble diagnosis
engine control system, and is also the starting point for all
scan tool occurs due to the abnormalities in the
diagnoses for driveability complaints. By correctly using
communication circuit of ECM and the trouble
this diagnostic step, it is possible to reduce the time for
diagnosis and prevent the replacement of parts that are
not defective. 6. Start the engine.
Note： Note：
・ Points to remember regarding the OBD system ・ If the starter does not operate, inspect the
check starter circuit system.
･ If there are no complaints on driveability, do not ・ If the engine does not start, check the DTC.
perform these diagnostic steps unless otherwise ・ If the DTC is detected, inspect the
instructed in other sections. corresponding DTC.
･ Check the service technical report before starting the ・ If no DTC has been detected, inspect the
diagnosis. starting system.
･ Do not delete the DTCs unless it is instructed in a
diagnostic step. 7. Check the engine stalling for problems.
･ If a malfunction is found in the engine starting system, 8. Check the engine hunching and rough idling for
inspect the starting system. problems.
･ The battery should be fully charged.
･ The battery cable should be normal and securely 9. Check if there are problems with insufficient engine
connected. output, blowup failure, or engine hesitation.
･ The GND of the ECM should be securely connected in 10. Check for problems with sudden stopping.
the correct position.
･ The harness connector of the ECM should be clean and 11. Check for problems with sudden change.
correctly connected. 12. Check for problems with insufficient output or
blowup failure.
2. OBD system check Inspection
13. Check for problems with engine hesitation or
Inspection for determining the failure location in the acceleration failure.
OBD system
14. Check for problems with dark smoke.
15. Check for problems with white smoke.
2. Check if the diagnostic light is illuminated.
16. Check for problems with the idling revolution speed
Note： maladjustment.
・ If the actual unit does not have a diagnostic 17. Check for problems with the idling revolution speed
light setting, do not perform this operation. not decreasing.
・ If the diagnostic light is not illuminated, inspect
the diagnostic light illumination circuit system. 18. Check for problems with frequent DPD regeneration
by the manual regeneration.
3. Short the DTC.
19. Check for problems with long DPD regeneration
Note： time.
・ Short the No.4 terminal and No.12 terminal.
・ If the actual unit does not have a diagnostic
light setting, do not perform this operation.
4. Check if the diagnostic light is blinking.
Note：
・ If the actual unit does not have a diagnostic
light setting, do not perform this operation.
・ If the diagnostic light is not blinking, inspect
the diagnostic light blinking circuit system.
Inspection of the diagnostic light warning light illumination circuit system

1. Inspection of the diagnostic light warning light
illumination circuit system Description of Function
The diagnostic light supplies power voltage via the starter
switch and is lit by a signal from the ECM. The ECM
lights the diagnostic light at the light check and at the
time the DTC is set when the starter switch is turned to
ON. It also blinks the diagnostic light depending on the
detected DTC when the body ground terminal and
diagnostic switch terminal of the DLC are shorted. A
monitor circuit is incorporated inside the ECM and
monitors operation of the light.
illumination circuit system Inspection
Inspection when the diagnostic light is not illuminated
when the starter switch is turned to ON
1. Perform the OBD system check.
2. Inspect the diagnostic light bulb.
3. Replace the valve if a problem is discovered.
4. Inspect the diagnostic light circuit.
･ No open circuit or high resistance should be found
between the fuse and diagnostic light.
･ No open circuit or high resistance should be found
between the diagnostic light and ECM.
6. Replace the ECM.
Removal of ECM
Installation of ECM
7. After replacing the ECM, perform EGR learning.
Inspection of the diagnostic light warning light blinking circuit system

1. Inspection of the diagnostic light warning light Removal of ECM
blinking circuit system Description of Function
Installation of ECM
The diagnostic light supplies power voltage via the starter
14. After replacing the ECM, perform EGR learning.
switch and is lit by a signal from the ECM. The ECM
lights the diagnostic light at the light check and at the 15. Turn ON the starter switch.
time the DTC is set when the starter switch is turned to
16. Short the body ground terminal and diagnostic
ON. It also blinks the diagnostic light depending on the
switch terminal of the DLC.
detected DTC when the body ground terminal and
diagnostic switch terminal of the DLC are shorted. A 17. Check if the diagnostic light is blinking.
monitor circuit is incorporated inside the ECM and 18. Perform the OBD system check.
monitors operation of the warning light.
blinking circuit system Inspection
Inspection when the diagnostic light does not blink but
continues to light when the diagnostic switch is turned to
ON
1. Perform the OBD system check.
2. Turn OFF the starter switch.
3. Connect the DMM between the DLC diagnostic
switch terminal and GND.
5. Confirm that the voltage displayed on the DMM
exceeds the standard value.
standard： 18 V
6. Inspect the diagnostic switch circuit between the
ECM and DLC using the DMM if it is under the
standard value.
･ No open circuit or high resistance should be found.
Standard value: 100Ω or less
･ No short circuit with GND should be found.
Standard value: 10MΩ or more
7. Repair if a problem is discovered.
9. Confirm that there is continuity between the DLC
body ground and GND.
11. Short the DTC.
Note：
・ Short the No.4 terminal and No.12 terminal.
12. Check if the diagnostic light is blinking.
Note：
・ If it does not blink, inspect the diagnostic light
blinking circuit system.
Inspection of the starter circuit system

1. Inspection of the starter circuit system Description of ･ No open circuit should be found between the
Function starter relay and starter.
The starter relay on the ECM is turned to ON when the 13. Repair the circuit if a problem is discovered.
starter switch moves to the START position. When the
14. Inspect the starter.
starter relay is turned to ON, the starter operates to start
the engine. Inspection of the starter
2. Inspection of the starter circuit system Inspection 15. Replace the starter if a problem is discovered.
Inspection when the starter does not operate 16. Replace the ECM.
1. Turn the emergency stop switch to OFF. Removal of ECM
Note： Installation of ECM
・ If the actual unit does not have an emergency 17. After replacing the ECM, perform EGR learning.
stop switch setting, do not perform this
operation.
2. Check the DTC.
Note：
・ If the DTC P0117, P0340, P0341, P0615,
P0651, or P1625 is detected, inspect the
corresponding DTC.
4. Remove the starter cut relay.
5. Inspect the starter cut relay.
･ Check the continuity between the switch side terminals.
6. Replace the relay if a problem is discovered.
7. Remove the starter relay.
8. Inspect the starter relay.
･ Connect the battery between the coil side terminals and
check the continuity between the switch side terminals.
9. Replace the relay if a problem is discovered.
10. Inspect the starter switch start signal circuit.
･ No open circuits or high resistance should be found
between the starter switch and ECM. Standard value:
100Ω or less
･ No short circuits with the GND should be found
between the starter switch and ECM. Standard value:
10MΩ or more
12. Inspect the starter circuit.
･ No open circuit should be found between the starter
switch and starter cut relay.
･ No open circuit should be found between the starter cut
relay and starter relay.
･ No open circuit should be found between the starter
relay and GND.
Engine compression pressure inspection

1. Engine compression pressure inspection Inspection SST: 5-8840-2675-0（5-8531-7002-0） - compression
gauge
Note：
・ Warm-up the engine.
1. Remove the glow plug from the cylinder head
assembly.
Note：
・ Remove all glow plugs.
2. Remove the injector harness connector from the
lower cover.
1. Injector harness connector 1. Compression gauge

2. Compression gauge adapter
3. Install the special tool to the cylinder head assembly.
Note：
Note：
・ Measure the compression pressure.
・ Insert the compression gauge adapter into the
installation hole of the glow plug to install the ・ Rotate the starter, and read the indication of
compression gauge. the compression pressure when the
compression gauge needle stabilizes at
approximately 200 rpm.
・ Measure the compression pressure of all
cylinders.
specified value： 2840.0 to 3240.0 kPa { 28.96 to 33.04
kgf/cm2 / 412 to 470 psi }
limit： 1960.0 kPa { 19.99 kgf/cm2 / 284 psi }
SST: 5-8840-2815-0 - compression gauge adapter
difference between each cylinder： 294.0 kPa { 3.00 kgf/
cm2 / 43 psi }
Caution：
・ Note that air will burst out through the glow
plug hole during rotation.
Note：
・ When the starter switch is turned to ON with
the injector harness connector removed, the
ECM determines a malfunction and records a
DTC, so make sure the DTC has been cleared
after the inspection is completed.
Lubrication system check

1. Lubrication system check Inspection
Note：
・ Oil pressure inspection
1. Inspect whether the engine oil is dirty, or contains
water, etc.
Note：
・ If oil is dirty or contains water, change the oil
after investigating the causes and taking
appropriate measures.
2. Inspect the engine oil level.
Note：
・ When the oil level is low, replenish it.
3. Remove the oil pressure switch.
4. Install the oil pressure gauge.
SST: 5-8840-2843-0 - oil pressure gauge

5. Start the engine.
Note：
・ Warm-up the engine.
6. Measure and confirm that the oil pressure is 550 kPa
(5.6 kg/cm2 / 80 psi) or higher at 2000 r/min.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
Note：
・ Check for oil leakage.
・ Check for engine oil leakage
Inspect for oil leaks from the cylinder head cover and oil
pan, etc. while the vehicle is lifted up.
Symptom (4HK1) 15D-1
Description Engine
Symptom
(4HK1)
Table of Contents
DPD system manual regeneration frequently...............15D-2
DPD system regeneration long time.............................15D-3
Engine start failure........................................................15D-4
Engine stalling...............................................................15D-6
Engine hunching, rough idling......................................15D-8
Excessive white smoke in the exhaust gas....................15D-9
Excessive black smoke in the exhaust gas..................15D-10
Abnormal noise...........................................................15D-11
Large fuel consumption...............................................15D-12
Large oil consumption.................................................15D-14
Insufficient engine output...........................................15D-15
15D-2 Symptom (4HK1)
DPD system manual regeneration frequently

1. DPD system manual regeneration frequently installation. Inspect the DPD differential pressure sensor
Description of Symptom for damage. Inspect the DPD differential pressure sensor
for contamination and foreign materials which interfere
The manual regeneration is frequently requested by
with its inlet. Check the DPD differential pressure sensor
blinking the DPD manual regeneration lamp or indicating
for abnormalities and operation delay with the scan tool
Press DPD switch. Or, it is requested more frequently
data display exhaust differential pressure. Check the
than before.
exhaust temperature sensor at various temperatures, and
{Automatic regeneration cannot be performed
inspect for the possibility of sensor abnormalities. Check
frequently}
the mass air flow sensor for abnormalities and operation
Note： delay with the scan tool data display MAF. Check the
・ Depending on the manufacturer of the actual boost pressure and atmospheric pressure when the starter
unit, the indication may not be shown. switch is ON and the engine is not started. It is normal if
both data displays are within 7.0kPa {0.07 kgf/cm2 / 1.0
2. DPD system manual regeneration frequently psi}.
Diagnostics
･ Inspection of the air intake system
･ Preliminary inspection
Inspect the air cleaner and air intake duct for clogging,
Inspect the fuel quality. holes, and leakage. Inspect whether a condition exists
Inspect the engine oil level and quality. where the flow in the turbocharger inlet duct is restricted.
Inspect whether the odometer operates correctly. Inspect the intake throttle valve for anchoring. Inspect the
If excessive amount of black smoke is observed, inspect inside of the intake manifold for clogging or air leaks.
the black smoke. Inspect the air intake system for modification. Inspect the
Inspect the inside of the DPD filter for excessive ash mass air flow sensor for contamination and damage.
deposits. Inspect the turbocharger turbine wheel, shaft, or
Check the scan tool data list. compressor wheel for wear and damage.
Check the service technical report.
Confirm the ECM carry part number. ･ Inspection of the exhaust system
Check the operator's operating habits and conditions. Inspect for any condition that restricts the flow of the
Recommend the owner to voluntarily carry out exhaust system.
regeneration as necessary. Inspect for absence or damage of the exhaust system
Check whether the idling time is too long under the gasket.
normal operation conditions. Inspect for exhaust gas leakage from the exhaust pipe,
Check whether operation is frequently performed at low gasket, DPD, exhaust temperature sensor, and DPD
speed under the normal operation conditions. differential pressure sensor's hose and pipe.
Check whether long downhill driving is performed under Inspect the exhaust system for modification.
the normal operation conditions. Inspect the inside of the DPD filter for excessive ash
Check whether the idling time is too long in DPD deposits.
regeneration. Inspect the DPD filter for damages, cracks, melt and
Check whether operation is frequently performed at low excessive deposits.
speed in DPD regeneration. Inspect the oxidation catalyst for damages, cracks, melt
Check whether PTO is activated frequently and for long and excessive deposits.
period of time in DPD regeneration. If any excessive white smoke is observed in the
Check whether the engine operating time is short in DPD regeneration process, the oxidation catalyst may be
regeneration. deteriorated or damaged.
Check whether accelerator is switched frequently
between ON and OFF in DPD regeneration.
･ Inspection of the sensor
Inspect the hose and pipe of the DPD differential pressure
sensor for incorrect piping or if they came off. {The hose
of the DPD differential pressure sensor has a specified
installation direction}
　Inspect the hose and pipe of the DPD differential
pressure sensor for clogging, collapsing, or twisting.
Inspect the DPD differential pressure sensor for incorrect
DPD system regeneration long time

1. DPD system regeneration long time Description of Inspect the air cleaner, air intake duct, and intercooler for
Symptom clogging, holes, or leakage. Inspect whether a condition
exists where the flow in the turbocharger inlet duct is
The regeneration requires more time than expected. Or, it
restricted. Inspect the intake throttle valve for anchoring.
takes longer than before.
Inspect the inside of the intake manifold for clogging or
2. DPD system regeneration long time Diagnostics air leaks. Inspect the air intake system for modification.
Inspect the mass air flow sensor for contamination and
damage. Inspect the turbocharger turbine wheel, shaft, or
Inspect the fuel quality. compressor wheel for wear and damage.
Check the scan tool data list.
･ Inspection of the exhaust system
Check the service technical report.
Check whether DPD regeneration and engine warm up Inspect for any condition that restricts the flow of the
control are mixed up. exhaust system.
Check the operator's operating habits and conditions. Inspect for absence or damage of the exhaust system
Check whether the manual regeneration is started when gasket.
the engine is cold in DPD regeneration. Inspect for exhaust gas leakage from the exhaust pipe,
Check whether the idling time is too long in DPD gasket, DPD, exhaust gas temperature sensor, and DPD
regeneration. differential pressure sensor's hose and pipe.
Check whether operation is frequently performed at low Inspect the exhaust system for modification.
speed in DPD regeneration. Inspect the inside of the DPD filter for excessive ash
Check whether the engine operating time is short in DPD deposits.
regeneration. Inspect the DPD filter for damages, cracks, melt and
Check whether accelerator is switched frequently excessive deposits.
between ON and OFF in DPD regeneration. Inspect the oxidation catalyst for damages, cracks, melt
Check whether the temperature in the work environment and excessive deposits.
is excessively high in DPD regeneration. If any excessive white smoke is observed in the
regeneration process, the oxidation catalyst may be
･ Inspection of the sensor
deteriorated or damaged.
Inspect the hose and pipe of the DPD differential pressure
･ Other inspections
sensor for incorrect piping or if they came off. {The hose
of the DPD differential pressure sensor has a specified Inspect for possible factors of overheat.
installation direction} Inspect the hose and pipe of the
DPD differential pressure sensor for clogging, collapsing,
or twisting. Inspect the DPD differential pressure sensor
for incorrect installation. Inspect the DPD differential
pressure sensor for damage. Inspect the DPD differential
pressure sensor for contamination and foreign materials
which interfere with its inlet. Check the DPD differential
pressure sensor for abnormalities and operation delay
with the scan tool data display exhaust differential
pressure. Check the exhaust gas temperature sensor at
various temperatures, and inspect for the possibility of
sensor abnormalities.
･ Inspection of the cooling system
Inspect the engine coolant level. Inspect the engine
coolant leakage. Inspect the cooling fan belt slip. Inspect
the operation of the cooling fan clutch. Inspect the
operation of the thermostat. Inspect the operation of the
water pump. Inspect the radiator for clogging. Inspect
whether the cooling amount of the cooling system is not
low due to modification.
･ Inspection of the air intake system
Engine start failure

1. Engine start failure Description of Symptom
The cranking revolution is low. The cranking revolution
is normal, but the engine does not start. The engine starts
but cannot maintain its revolution stably or does not
reach normal revolution speeds.
2. Engine start failure Diagnostics
Before using this section, perform the functional
inspection and OBD system check to check all of the
following. Check whether the actual unit has a significant
load. The ECM and diagnostic light are operating
correctly. DTC check. The scan tool data is within the
normal operating range. Check the condition of the actual
unit, and locate the appropriate symptom. Check with the
customers whether they are using the specified engine oil
and fuel.
･ Visual inspection ･ Diagnostic aids
Careful visual inspection is required for several symptom 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
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.
Abnormalities of the common rail such as the flow

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

damper, operation of the pressure limiter, or inside
sealing degradation
System down due to failure
Engine body abnormalities such as seizure, insufficient
compression pressure, and other mechanical failures, etc.
ACG failure
pressure pump, etc.
Effect of the post-installed accessories such as wireless
devices and lights, etc.
ECM failure
Inspect the connector for connection failures and the
harness for abnormalities such as abrasions, bending, etc.
Inspect to see if the wires inside the harness are separate
and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm
the operation, control of each part, etc. Repair if
abnormalities are found.
Engine hunching, rough idling

1. Engine hunching, rough idling Description of
Symptom
The engine has variable engine idling, or has change in
idling revolution speed. In a severe case, the engine or the
actual unit may vibrate. In either case, the engine stall
may occur if the symptom gets worse.
2. Engine hunching, rough idling Diagnostics
following. The ECM and diagnostic light are operating
and fuel.
･ Visual inspection ･ Diagnostic aids
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
Excessive white smoke in the exhaust gas

1. Excessive white smoke in the exhaust gas Description
of Symptom
Excessive white smoke when driving.
2. Excessive white smoke in the exhaust gas Diagnostics
and fuel.
･ Visual inspection
Careful visual inspection is required for several symptom
procedures. This can lead to fixing a problem without
further inspections, and can save valuable time. The
inspection includes the following. Whether there is an
improper connection of injector connectors. Proper
wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is
being taken divergingly from the ECM power. Whether
system. Abnormalities of the air intake system parts
･ Diagnostic aids
Fuel quality when using a product with a low cetane
number or a product other than those specified
Use of low-viscosity fuel such as kerosene may result in
abnormal wear on the seat area of the injector and cause
abnormal spray and white smoke. In such cases,
replacement of the injector is required. Since the
replacement of the injector due to the use of low-viscosity
fuel such as kerosene is at the customer's expense,
instruct the customer not to use low-viscosity fuel such as
kerosene. Idling for a long time
Failure of the water temperature sensor, fuel temperature
sensor, intake air temperature sensor, boost sensor failure,
or air pressure sensor
Engine body failure such as insufficient compression
pressure, piston related failure, turbocharger failure, and
raised oil or sucked down oil, etc.
ECM failure
Excessive black smoke in the exhaust gas

1. Excessive black smoke in the exhaust gas Description
of Symptom
Excessive black smoke when driving.
2. Excessive black smoke in the exhaust gas Diagnostics
Note：
・ Preliminary inspection
and fuel.
Note：
・ Visual inspection
inspection includes the following. Whether there is grime
or clogging in the air cleaner element. Proper wiring
connections, tightening, and disconnection
Note：
・ Diagnostic aids
Fuel quality when using a product other than those
specified, etc.
Air intake system abnormalities such as filter clogging,
air intake piping abnormalities, etc.
Abnormalities of the EGR control system Abnormalities
of the exhaust system such as exhaust pipe abnormalities,
etc.
Water temperature sensor malfunction
Boost sensor failure
Engine body failure such as insufficient compression
pressure, piston related failure, turbocharger failure, and
raised oil, etc.
Abnormal noise
1. Abnormal noise Description of Symptom
Engine combustion noise is abnormal.
2. Abnormal noise Diagnostics
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.
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
･ 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.
Engine body abnormalities such as seizure, insufficient
compression pressure, and other mechanical failures, etc.
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.
Large fuel consumption

1. Large fuel consumption Description of Symptom connections, tightening, and disconnection Whether the
ECM ground is free of dirt, etc. and securely installed in
Fuel consumption is significantly larger than indicated in
the correct location. Proper connections, cracks, and
the actual unit manual.
2. Large fuel consumption Diagnostics Extensively check for any leaks or blockage. Whether
Before using this section, perform the functional Abnormalities of the exhaust system parts
･ Diagnostic aids
following. Since the fuel consumption varies widely
depending on the handling of the actual unit, check the Fuel system abnormalities such as fuel running out, fuel
reference fuel consumption (A) of the actual unit freezing, mixture of air into the fuel piping, filter
manufacturer. Reference fuel consumption (L {qts}/hour) abnormalities, piping abnormalities, fuel quality, fuel
Check the actual fuel consumption (B). Actual fuel tank, etc.
consumption (L {qts}/hour) Air intake system abnormalities such as EGR valve
If B is greater than A, refer to the actual unit manual and abnormalities, etc.
check the setting of the unit. Check whether the actual Abnormalities of the injector such as excessive fuel
unit does not have a significant load. Refer to the injection
inspections and maintenance list in the operation manual Engine body abnormalities such as seizure, insufficient
and perform the inspection based on the operation time of compression pressure, and other mechanical failures, etc.
the actual unit. Refer to the actual unit manual to inspect Failure related to the actual unit equipment such as the oil
an actual unit whose operation time exceeds 3,000 hours. pressure pump, etc.
The ECM and diagnostic light are operating correctly. ECM failure Inspect the connector for connection failures
DTC check. Check the condition of the actual unit, and and the harness for abnormalities such as abrasions,
locate the appropriate symptom. Check with the bending, etc. Inspect that the wires inside the harness are
customers whether they are using the specified engine oil separate and have not caused a short circuit with other
and fuel. Check whether engine oil change or periodical circuits. Perform inspections for functional diagnosis, and
maintenance for the air cleaner filter or fuel filter, etc. has confirm the operation, control of each part, etc. Repair if
been performed. abnormalities are found.
･ Visual inspection For the inspection locations of the engine air intake and
exhaust system Inspect the air intake and exhaust system
for abnormalities such as clogging, collapsing and
damage. Other than the inspection locations of the engine
body, inspect the air cleaner, intercooler, and muffler.
inspection includes the following. Proper wiring
1. EGR valve 5. Exhaust pipe

2. From the intercooler 6. EGR cooler
3. From the air cleaner
4. To the intercooler
Large oil consumption

1. Large oil consumption Description of Symptom
The oil consumption amount described in the manual of
the actual unit is significantly exceeded.
2. Large oil consumption Diagnostics
following. Since the oil consumption varies widely by
handling of the actual unit, check the reference oil
consumption (A) of the actual unit manufacturer.
Reference oil consumption/hour
Reference oil consumption per engine: 4L {4.2 qts}/100
hours Check the actual oil consumption (B). Actual oil
consumption/hour Refer to the inspections and
maintenance list in the operation manual and perform the
inspection based on the operation time of the actual unit.
Refer to the actual unit manual to inspect an actual unit
whose operation time exceeds 3,000 hours. The ECM and
diagnostic light are operating correctly. DTC check.
Check the condition of the actual unit, and locate the
appropriate symptom. Check with the customers whether
they are using the specified engine oil and fuel.
inspection includes the following. Whether bluish white
smoke continuously comes out. Whether blow-by gas
comes out excessively. Whether oil is mixed into the
coolant. Proper connections, cracks, and twists in the
pipes and hoses related to oil. Extensively check for any
leaks or blockage. Whether there is any fuel leak, pipe
damage, or dents in the lubricant system. Abnormalities
of the air intake system parts such as the turbocharger
inspection
･ Diagnostic aids
Air intake system abnormalities such as sucked down oil
or raised oil and excessive blow-by gas
Engine body abnormalities such as oil combustion and
excessive blow-by gas Perform inspections for functional
diagnosis, and confirm the operation, control of each part,
etc. Repair if abnormalities are found.
Insufficient engine output

1. Insufficient engine output Description of Symptom Exhaust system abnormalities such as exhaust pipe
abnormality
The engine output is lower than expected, the output does
Abnormalities of the sensor input circuit system
not change when the accelerator lever (throttle lever) is
including the accelerator position sensor and the harness
lifted up, the operation is not effective.
Abnormalities of the switch input circuit system
2. Insufficient engine output Diagnostics Engine unit abnormalities including other mechanical
failures such as compression pressure, valve clearance,
turbocharger, supply pump, injector, and common rail
Before using this section, perform the functional Failures related to actual unit side equipment such as
inspection, OBD system check to confirm the following hydraulic pump
all items. Influence of the post-mounted electrical components such
The ECM and the diagnostic light are operating properly. as wireless devices and lights
DTC check. Inspect for connector improper connections, harness
The scan tool data is within the normal operating range. abnormalities such as abrasions and bends, and short
Check the actual unit condition, and locate the circuits with other circuits due to wire split inside
corresponding symptom. harness. Also, perform inspections for functional
Check with the customer if the customer is using the diagnosis, and check the operation and control of each
specified engine oil and fuel. part. Make repairs if any abnormality is found.
For insufficient output, various causes can be suspected, Output reduction due to fuel flow restriction imposed
so thoroughly investigate the relationship between the upon overheat
engine and the actual unit side. Insufficient output due to fuel flow restriction during
Check what kind of operations cause insufficient output. operation at high altitude
If hesitation or lug-down is included in the symptoms of
･ Control when overheating
insufficient output, it is related to the control on the actual
unit side, so contact the manufacturer of the actual unit. To protect the engine, restriction on fuel flow is started
If a trouble diagnosis scan tool is available, the engine when the engine coolant temperature exceeds 100 ºC
output at the rated point can be easily verified by (212 ºF). When the engine coolant temperature increases
checking the boost at the rated point. further, the fuel flow is also restricted further.
When the temperature is near 120 ºC (248 ºF), the fuel
flow is restricted to a certain level. The setting varies
Careful visual inspection is required for several symptom depending on the actual unit manufacturer.
procedures. This can lead to fixing a problem without The actual unit is designed to issue an alarm from 105 ºC
further inspections, and can save valuable time. The (221 ºF). By reducing the load applied to the actual unit
inspection includes the following. Whether there is grime upon alarm issuance, it is possible to avoid the operation
or clogging in the air cleaner element. Proper wiring condition with fuel flow restriction.
connections, tightening, and disconnection
system. Increased resistance due to grime, clogging, or air
intake piping collapsing particularly in the air cleaner
element among the air intake system parts Abnormalities
of the exhaust system parts
･ Diagnostic aids
Fuel system abnormalities such as running out of fuel,
fuel freezing, air intrusion in the fuel pipe, filter
abnormality, pipe abnormality, fuel quality, and fuel tank
Air intake system abnormalities such as filter clogging
and air intake pipe abnormality
･ High altitude correction
The ECM calculates the current altitude in accordance
with the signal from the atmospheric pressure sensor.
Depending on the conditions of altitude, etc. at this time,
the SCV opening and closing timing and injector
energizing time are controlled and the fuel flow is
corrected to be optimum.
DTC Information (4HK1) 15E-1
Description Engine
DTC Information
(4HK1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft 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
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
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
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
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 P0016 (Flash Code 16)

Crankshaft Position - Camshaft Position Correlation
1. DTC P0016 Description of DTC
The crankshaft position sensor is installed on the upper
position of the flywheel housing. The sensor rotor is fixed
to the flywheel. There are 56 notches arranged at 6 degree
intervals and an opening of 30 degrees. This opening
allows detecting the top dead center of the cylinder No.1.
cylinder head. The camshaft position sensor detects 5
protrusions per 1 rotation of the engine. The camshaft
gear has 4 protrusions arranged at 90 degree intervals and
1 reference protrusion. By detecting the opening section
from the crankshaft position sensor and a single reference
protrusion from the camshaft position sensor, the ECM
can determine the compression top dead center of the
cylinder No.1 and confirm that they are related to each
other. When the ECM has detected that both signals are
out of synchronization, it sets DTC.
2. DTC P0016 Condition for setting the DTC
DTC P0335, P0336, P0340, and P0341 have not been
detected
The starter switch has been ON
The crankshaft position sensor signal pulse has been
detected
The camshaft position sensor signal pulse has been
detected
When the ECM has detected that the crankshaft position
sensor signal and camshaft position sensor signal have
been out of synchronization, while the engine has been
running
3. DTC P0016 Action taken when the DTC sets
Failure is indicated in the monitor on the actual unit, or
the diagnostic light is turned on.
Note：
・ Depending on the manufacturer of the actual
unit, the failure indication may not be shown.

Turbocharger Boost Control Solenoid Circuit
The opening angle of the variable nozzle on the
turbocharger is controlled by the turbo control unit
through operating the motor built into the actuator to
activate the control rod in accordance with the signal
received from the ECM. The ECM controls the variable
nozzle based on the boost pressure, and detects the
operation amount of the variable nozzle with the position
sensor built into the turbo actuator. When the engine is
not under load, the variable nozzle is in the open
condition, or the boost pressure is not present. When the
engine is under load, the turbo actuator is controlled to
close the variable nozzle. As the result, the boost pressure
increases. The ECM performs control that changes the
boost pressure in accordance with the load requirements
for the engine. The ECM communicates with the turbo
control unit through CAN communication to perform
control. The DTC is set when the ECM detects an open
circuit or short circuit in the circuit between the turbo
actuator and turbo control unit or an abnormality in
communication with the turbo control unit.
The battery voltage is between 20 and 32 V
The starter switch is ON
Any of the following conditions is satisfied
When the turbo control unit has detected 34V or higher
for longer than 60 seconds
When the turbo control unit detects that no change has
been made in the position sensor signal or that all signals
have remained in the Low or High state without any
change
When the turbo control unit has detected an open circuit
or short circuit in the motor circuit for longer than 3
seconds
Note：

Fuel Rail/System Pressure - Too Low
The general common rail system is comprised of the
following two fuel pressure sections. The suction side
between the fuel tank and the supply pump and the high-
pressure side between the supply pump and the fuel
injectors. The fuel is drawn from the fuel tank and
supplied to the common rail by the two plungers located
inside the supply pump. The common rail pressure is
adjusted by the ECM through controlling the suction
control valve based on the signal from the common rail
pressure sensor. When the common rail pressure becomes
in excess, the common rail pressure limiter valve opens to
release the excessive pressure and return the fuel back to
the fuel tank. The ECM sets the DTC when the common
rail pressure increases more than necessary and then
drops drastically. This DTC detects that the pressure
limiter valve has been activated.
DTC P0192 and P0193 are not detected
When the ECM has detected that the pressure limiter
valve operated due to an excessive pressure of 180 MPa
{1835 kgf/cm2 / 26100 psi} or higher inside the common
rail　for longer than 1 second
Note：
Restrict the fuel injection amount.
Restrict the fuel flow.
Stop the EGR control.
Stop the DPD regeneration.

Fuel Rail/System Pressure - Too High
following 2 fuel pressure sections. The suction side
supplied to the common rail by the 3 plungers located
pressure sensor.
As for the first stage, this DTC is set when the ECM
detects an abnormally high fuel pressure for a certain
period of time.
Also, as for the second stage, the check engine warning
light turns on when the ECM from the first stage, a period
of time even if it detects a high fuel pressure. When the
check engine warning light turns on, this DTC sets a
DTC if the fuel pressure becomes abnormally high
because the pressure limiter valve is not operated or is not
operated immediately.
DTC P0091, P0092, P0192, and P0193 have not been
detected
The starter switch the ignition switch has been ON
While the engine has been running
First Stage
When the ECM has detected that the common rail
pressure has been 185 MPa {1886 kgf/cm2 / 26825 psi}
or higher for 5 seconds or longer
Second Stage
pressure has been 190 MPa {1937 kgf/cm2 / 27550 psi}
or higher for 5 seconds or longer
Note：

Fuel Pressure Regulator Performance
pressure sensor. This DTC is set when the ECM detects
that the fuel pressure is higher than the target fuel
pressure.
DTC P0091, P0092, P0192, P0193, P060B, P0651,
P0201-P0204, P1261, P1262, P2146, and P2149 have not
been detected
The battery voltage has been between 18 and 32 V
Starter switch the ignition switch has been ON
While the engine has been running
pressure has been higher than the target fuel pressure for
40 MPa {408 kgf/cm2 / 5800 psi} or more for 5 seconds
or longer
Note：

Fuel Pressure Regulator Control Circuit Low
The suction control valve is installed on the supply pump,
and controls the fuel amount to be taken into the common
rail. The suction control valve is normally fully open, and
the opening of the regulator becomes smaller when the
drive current becomes larger. The ECM calculates the
common rail target pressure and fuel flow, and determine
the opening angle of the suction control valve by
comparing the calculated common rail pressure with the
actual pressure value. When the actual common rail
pressure is higher than the target pressure, the suction
control valve closes to reduce the fuel flow. The DTC is
set when the ECM detects that the feedback current of the
suction control valve is abnormally low.
When the ECM has detected that the feedback current has
been 50 mA or below for longer than 2 seconds or has
fallen below the target current by 1000 mA or more
Note：

Fuel Pressure Regulator Control Circuit High
The suction control valve is installed on the supply pump,
and controls the fuel amount to be taken into the common
rail. The suction control valve is normally fully open, and
the opening of the regulator becomes smaller when the
drive current becomes larger. The ECM calculates the
common rail target pressure and fuel flow, and determine
the opening angle of the suction control valve by
comparing the calculated common rail pressure with the
actual pressure value. When the actual common rail
pressure is higher than the target pressure, the suction
control valve closes to reduce the fuel flow. The DTC is
set when the ECM detects that the feedback current of the
suction control valve is abnormally high.
When the ECM has detected that the feedback current has
been 2400 mA or above for longer than 2 seconds or has
exceeded the target current by 1000 mA or more
Note：

Fuel System Leak Detected
pressure sensor. The DTC is set when the ECM detects
that the common rail pressure is low compared to the
engine RPM.
DTC P0087, P0091, P0092, P0192, P0193, P0201,
P0202, P0203, P0204, P060B, P0651, P1261, P1262,
P2146, and P2149 have not been detected
Starter switch the ignition switch has been ON
The engine RPM has been 900 r/min or more
When the ECM has detected that the actual common rail
pressure has been 15 MPa {153 kgf/cm2 / 2175 psi} or
lower for 3 seconds or longer (this may not be a
prerequisite depending on the device manufacturer)
Note：

Mass Air Flow Circuit Low Input
The mass air flow sensor is an air flow meter to measure
the amount of air taken into the engine. It is installed
between the air cleaner and turbocharger. A small amount
of air taken into the engine indicates deceleration or idle
RPM. A large amount of air indicates acceleration or high
load. The sensor has the following circuits
12 V voltage circuit
GND circuit
Mass air flow sensor signal circuit
The ECM monitors the voltage of the mass air flow
sensor signal. The scan tool displays the air flow as g/cyl
for each voltage and cylinder from this output voltage.
When the ECM has detected that the signal voltage is
absolutely low, it sets DTC.
P060B has not been detected
The starter switch the ignition switch is ON
While the engine is rotating
When the ECM has detected that the mass air flow sensor
signal voltage has been 0.1 V or lower for 3 seconds
Note：
Substitute the default value for the MAF sensor.
Limit the fuel injection amount.

Mass Air Flow Circuit High Input
The mass air flow sensor is an air flow meter to measure
the amount of air taken into the engine. It is installed
between the air cleaner and turbocharger. A small amount
of air taken into the engine indicates deceleration or idle
RPM. A large amount of air indicates acceleration or high
load. The sensor has the following circuits
12 V voltage circuit
GND circuit
Mass air flow sensor signal circuit
The ECM monitors the voltage of the mass air flow
sensor signal. The scan tool displays the air flow as g/cyl
for each voltage and cylinder from this output voltage.
When the ECM has detected that the signal voltage is
absolutely low, it sets DTC.
P060B has not been detected
The starter switch the ignition switch is ON
While the engine is rotating
When the ECM has detected that the mass air flow sensor
signal voltage has been 4.9 V or lower for 3 seconds
Note：
Substitute the default value for the MAF sensor.

Intake Air Temperature Sensor Circuit Low
The intake air temperature sensor is a thermistor type
sensor to measure the temperature of air taken into the
engine. This sensor has a signal circuit and GND circuit.
The ECM supplies 5 V to the signal circuit, and the GND
circuit connects to GND. When the intake air temperature
sensor is cold, the resistance of the sensor is high. When
the air temperature rises, the resistance of the sensor
becomes low. The ECM detects the high voltage when
the sensor resistance is high. The ECM detects the low
voltage when the sensor resistance is low. When the
ECM has detected that the DPD differential pressure is
abnormally low, it sets DTC.
DTC P060B is not set
When the ECM has detected that the intake air
temperature sensor signal voltage has been 0.1 V or lower
for 4 seconds
Note：
Substitute the default value for intake air temperature
sensor.

Intake Air Temperature Sensor Circuit High
The intake air temperature sensor is a thermistor type
sensor to measure the temperature of air taken into the
engine. This sensor has a signal circuit and GND circuit.
The ECM supplies 5 V to the signal circuit, and the GND
circuit connects to the GND. When the intake air
temparture sensor is cold, the resistance of the sensor is
high. When the air temperature rises, the resistance of the
sensor becomes low. The ECM detects the high voltage
when the sensor resistance is high. The ECM detects the
low voltage when the sensor resistance is low. When the
ECM has detected that the DPD differential pressure is
abnormally high, it sets DTC.
The engine is running for 3 minutes or longer
When the ECM has detected that the signal voltage of the
intake air temperature sensor has been 4.85 V or higher
for 4 seconds
Note：
Substitute the default value for intake air temperature
sensor.

Engine Coolant Temperature Sensor Circuit Low
The water temperature sensor is installed in the
thermostat housing. The water temperature sensor is a
thermistor type sensor, and measures the temperature of
the engine coolant. This sensor has a signal circuit and
GND circuit. The ECM supplies 5 V to the signal circuit,
and the GND circuit connects to GND. When the water
temperature sensor is cold, the resistance of the sensor is
high. When the engine coolant temperature rises, the
resistance of the sensor becomes low. The ECM detects
the high voltage when the sensor resistance is high. The
ECM detects the low voltage when the sensor resistance
is low. The DTC is set when the ECM detects an
abnormally low signal voltage.
water temperature sensor has been 0.1 V or lower for 4
seconds
Note：
Substitute the default value of water temperature.
Prohibit the DPD regeneration.

Engine Coolant Temperature Sensor Circuit High
thermistor type sensor, and measures the temperature of
the engine coolant. This sensor has a signal circuit and
and the GND circuit connects to GND. When the water
high. When the engine coolant temperature rises, the
resistance of the sensor becomes low. The ECM detects
the high voltage when the sensor resistance is high. The
ECM detects the low voltage when the sensor resistance
is low. The DTC is set when the ECM detects an
abnormally high signal voltage.
water temperature sensor has been 4.85 V or higher for 4
seconds
Note：
Substitute the default value of water temperature.

Throttle Position Sensor Circuit Low
The intake throttle position sensor is installed on the
intake throttle valve body together with the solenoid. The
intake throttle position sensor changes the signal voltage
in accordance with the opening angle of the intake
throttle valve. The sensor has the following circuits.
5 V power supply circuit
GND circuit
Intake throttle position sensor signal circuit
The intake throttle position sensor sends the change
signal of the intake throttle valve opening angle to the
ECM.The DTC is set when the ECM detects an
When the ECM has detected that the intake throttle
position sensor signal voltage has been 0.3 V or lower for
3 seconds
Note：

Throttle Position Sensor Circuit High
The intake throttle position sensor is installed on the
intake throttle valve body together with the solenoid. The
intake throttle position sensor changes the signal voltage
in accordance with the opening angle of the intake
throttle valve. The sensor has the following circuits.
GND circuit
Intake throttle position sensor signal circuit
The intake throttle position sensor sends the change
signal of the intake throttle valve opening angle to the
ECM.
The DTC is set when the ECM detects an abnormally
high signal voltage.
When the ECM has detected that the intake throttle
position sensor signal voltage has been 4.9 V or higher
for 3 seconds
Note：

Fuel Temperature Sensor Circuit Low
The fuel temperature sensor is installed on the supply
pump. The fuel temperature sensor is a thermistor type
sensor, and measures the temperature of the fuel entering
the supply pump. This sensor has a signal circuit and
and the GND circuit connects to GND. When the fuel
high. When the fuel temperature rises, the resistance of
the sensor decreases. The ECM detects a high voltage
when the sensor resistance is high. The ECM detects a
low voltage when the sensor resistance is low. The DTC
is set when the ECM detects an abnormally low signal
voltage.
fuel temperature sensor has been 0.1 V or lower for 4
seconds
Note：
Substitute the default value of fuel temperature sensor.

Fuel Temperature Sensor Circuit High
The fuel temperature sensor is installed on the supply
pump. The fuel temperature sensor is a variable resistor,
and measures the temperature of the fuel entering the
supply pump. This sensor has a signal circuit and GND
circuit. The ECM supplies 5 V to the signal circuit, and
the GND circuit connects to GND. When the fuel
high. When the fuel temperature rises, the resistance of
the sensor decreases. The ECM detects a high voltage
when the sensor resistance is high. The ECM detects a
low voltage when the sensor resistance is low. The DTC
is set when the ECM detects an abnormally high signal
voltage.
fuel temperature sensor has been 4.85 V or higher for 4
seconds
Note：
Substitute the default value of fuel temperature sensor.

Fuel Rail Pressure Sensor Circuit Low
Common rail pressure sensor is installed on the common
rail, and it detects the fuel pressure in the common rail to
covert into the voltage signal. The sensor has the
following circuits.
GND circuit
Common rail pressure sensor signal circuit
The ECM monitors the voltage of the common rail
pressure sensor signal. The signal voltage becomes higher
when the pressure of the common rail is higher, and it
becomes lower when the pressure is lower. The ECM
calculates the actual common rail pressure from the
voltage signal, and uses the result for various controls
such as the fuel injection control. The DTC is set when
the ECM detects an abnormally low signal voltage.
pressure sensor signal voltage has been 0.7 V or lower for
longer than 0.16 seconds
Note：
Substitute the default value of common rail pressure.
Limit the fuel flow.

Fuel Rail Pressure Sensor Circuit High
pressure in the common rail to covert into the voltage
signal. The sensor has the following circuits.
GND circuit
Common rail pressure sensor signal circuit
The ECM monitors the voltage of the common rail
pressure sensor signal. The signal voltage becomes higher
when the pressure of the common rail is higher, and it
becomes lower when the pressure is lower. The ECM
calculates the actual common rail pressure from the
voltage signal, and uses the result for controls such as the
fuel injection control. The DTC is set when the ECM
detects an abnormally high signal voltage.
pressure sensor signal voltage has been 4.8 V or higher
for longer than 1 second
Note：
Substitute the default value of common rail pressure.

Injector Circuit - Cylinder 1
The ECM calculates the optimum fuel injection ON time
using data transmitted from the sensor. The injector
power circuit supplies the high voltage while the ECM
grounds the injector solenoid control circuit as well as
drives the injector of each cylinder. The ECM sets a DTC
when an abnormality is detected in the first cylinder
injector circuit.
DTC P1261 and P2146 are not set
While the engine is running
When the ECM has detected an open circuit with the
injector solenoid
When the ECM has detected that a short of the injector
solenoid control circuit to the voltage circuit or charge
voltage circuit has occurred
Note：
Stop the injection of the first cylinder.

using the data transmitted from the sensor. The injector
power supply circuit supplies the high voltage while the
ECM grounds the injector solenoid control circuit as well
as drives the injector of each cylinder. The ECM sets a
DTC when an abnormality is detected in the second
cylinder injector circuit.
injector solenoid
Note：
Stop the injection of the second cylinder.

DTC when an abnormality is detected in the third
injector solenoid
Note：
Stop the injection of the third cylinder.

DTC when an abnormality is detected in the fourth
injector solenoid
Note：
Stop the injection of the fourth cylinder.

Engine Coolant Over Temperature Condition
thermistor type, and measures the temperature of the
engine coolant.
high temperature in the coolant.
When the ECM has detected that the engine coolant
temperature has been 110 ℃ (230 ℉) or higher for 5
seconds
When the ECM has detected that the engine coolant
temperature has been 110 ℃ (230 ℉) or higher for 5
seconds during DPD regeneration

Engine Overspeed Condition
position of the flywheel housing. The ECM calculates the
engine RPM and the correct position of the crankshaft
using the signal pulses from the crankshaft position
sensor. When the ECM has detected that the engine has
overrun, it sets DTC.
When the ECM detects that the engine RPM is 2500 r/
min or above for longer than 3 seconds
When it has been detected for 2 consecutive times, the
failure is displayed on the monitor of the main device or
the Diagnostic light illuminates.
Note：

Turbocharger Overboost Condition
The boost sensor is located in the air intake pipe. This
sensor changes the signal voltage in accordance with the
change in the air pressure inside the air intake pipe. The
ECM monitors the boost sensor signal. The DTC is set
when the ECM detects an abnormally high sensor signal.
This indicates that the boost pressure is abnormally high.
DTC P0045, P0237, P0238, U0001,U0110, and U0411
are not set
When the ECM has detected that the boost pressure has
been 270 kPa {3 kgf/cm2 / 39 psi} or higher for 5
seconds or longer
Note：
The highest engine RPM is restricted to 1200 r/min.

Turbo Charger Boost Sensor Circuit Low
boost sensor has the following circuits.
GND circuit Boost sensor circuit
The boost sensor sends the change signal of the pressure
inside the air intake pipe to the ECM. The ECM detects
an high voltage signal when the air pressure is high due
to the high load applied to the engine, etc.
The DTC is set when the ECM detects an abnormally low
signal voltage.
When the ECM has detected that the boost sensor signal
voltage has been 0.1 V or lower for 3 seconds
Note：
Substitute the default value of boost pressure.

Turbo Charger Boost Sensor Circuit High
boost sensor has the following circuits.
GND circuit Boost sensor circuit
The boost sensor sends the change signal of the pressure
inside the air intake pipe to the ECM. The ECM detects
an high voltage signal when the air pressure is high due
to the high load applied to the engine, etc.
high signal voltage.
When the ECM has detected that the boost sensor signal
voltage has been 4.9 V or lower for 3 seconds
Note：
Substitute the default value of boost pressure.

Crankshaft Position Sensor Circuit
The crankshaft position sensor is installed on the
flywheel housing. The sensor rotor is fixed to the
flywheel. There are 56 notches arranged at 6 degree
The crankshaft position sensor generates the pulse signal.
The sensor has following circuits.
GND circuit
Crankshaft position sensor signal circuit.
The ECM monitors the signal pulses from the crankshaft
position sensor and camshaft position sensor to confirm
that they are related to each other. While no crankshaft
position sensor signal pulse is detected, the ECM sets
DTC when it has received a certain amount of camshaft
position sensor signal pulses.
DTC P0016, P0336, P0340, and P0341 are not set
The CMP sensor signal pulse is detected
When the ECM has detected that the CKP sensor signal
pulse has not been generated, while the engine has been
running
Note：

Crankshaft Position Sensor Circuit Range/Performance
position of the flywheel housing. The sensor rotor is fixed
to the flywheel. There are 56 notches arranged at 6 degree
position sensor and camshaft position sensor, and
confirms that they are related to each other. When the
ECM has received excessive or insufficient crankshaft
position sensor signal pulses, it sets DTC.
The CKP sensor signal pulse is detected
When the ECM has detected excessive or insufficient of
CKP sensor signal pulse, while the engine has been
running
Note：

Camshaft Position Sensor Circuit
cylinder head with the camshaft gear. The camshaft
position sensor detects 5 protrusions per 1 revolution of
the engine. The camshaft gear has 4 protrusions arranged
at 90 degree intervals and 1 reference protrusion. The
crankshaft position sensor generates the pulse signal. The
sensor has following circuits.
GND circuit
Crankshaft position sensor signal circuit
position sensor and camshaft position sensor to confirm
that they are related to each other. While no crankshaft
position sensor signal pulse is detected, the ECM sets
DTC when it has received a certain amount of camshaft
position sensor signal pulses.
The CKP sensor signal pulse is detected
When the ECM has detected that the CMP sensor signal
pulse has not been generated, while the engine has been
running
Note：

Exhaust Gas Recirculation Control Circuit Range/Performance
The ECM controls the EGR valve opening and closing
based on the engine running condition and by controlling
the EGR solenoid. The EGR valve lift amount is detected
by the position sensor and transmitted to the ECM. If the
ECM has detected a variance between the actual EGR
valve position and desired EGR valve position for a
certain period of time while the EGR valve is
commanded ON, it sets DTC.
DTC P0409 is not set
The ON instruction is issued for EGR control
When the ECM has detected that the difference between
the actual and desired EGR valve positions has been 20
% or more for 10 seconds or longer
Note：

Exhaust Gas Recirculation Sensor Circuit
The EGR position sensor is provided on the EGR valve
together with the control solenoid. The sensor consists of
three individual sensors within one housing. The EGR
position sensor 1, EGR position sensor 2, and EGR
position sensor 3 are hall IC type sensors with the
following circuits.
GND circuit Signal circuit
The EGR position sensor transmits
The high/low status of the signals related to changes of
the EGR valve position.
When the ECM has detected that the signals are not
related to each other (e.g., all signals are high or low), it
sets DTC.
When the ECM has detected that the signal from the EGR
valve position sensor has been kept low or high for longer
than 3 seconds
Note：
DTC P041C (Flash Code 27)

Intake Manifold Temperature Sensor Circuit High
1. DTC P041C Description of DTC
The IMT sensor is installed on the intake manifold. The
IMT sensor is a thermistor type sensor to measure the
temperature of intake air mixed with EGR gas. This
sensor has a signal circuit and GND circuit. The ECM
supplies 5 V to the signal circuit, and the GND circuit
connects to GND. When the IMT sensor is cold, the
resistance of the sensor is high. When the EGR gas
amount increases, the intake air temperature rises and the
sensor resistance decreases. The ECM detects the high
voltage when the sensor resistance is high. The ECM
detects the low voltage when the sensor resistance is low.
When the ECM has detected that the DPD differential
pressure is abnormally high, it sets DTC.
2. DTC P041C Condition for setting the DTC
DTC P060B is not detected
IMT sensor has been 4.94 V or higher for 4 seconds
3. DTC P041C Action taken when the DTC sets
Note：
Substitute the default value for the IMT sensor.
DTC P041D (Flash Code 27)

Intake Manifold Temperature Sensor Circuit Low
1. DTC P041D Description of DTC
The IMT sensor is installed on the intake manifold. The
IMT sensor is a thermistor type sensor to measure the
temperature of intake air mixed with EGR gas. This
sensor has a signal circuit and GND circuit. The ECM
supplies 5 V to the signal circuit, and the GND circuit
connects to GND. When the IMT sensor is cold, the
resistance of the sensor is high. When the EGR gas
amount increases, the intake air temperature rises and the
sensor resistance decreases. The ECM detects the high
voltage when the sensor resistance is high. The ECM
detects the low voltage when the sensor resistance is low.
pressure is abnormally low, it sets DTC.
2. DTC P041D Condition for setting the DTC
DTC P060B has not been detected
IMT sensor has been 0.1 V or lower for 4 seconds or
longer
3. DTC P041D Action taken when the DTC sets
Note：
Substitute the default value for the IMT sensor.

Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
The exhaust gas temperature sensor 1 is installed on the
DPD housing. The exhaust gas temperature sensor 1 is a
variable resistor, and measures the temperature of the
exhaust gas before entering the DPD filter. The DTC is
set when the ECM detects an abnormally high exhaust
temperature.
When the ECM has detected that the measure value of the
exhaust gas temperature sensor 1 has been 880 ℃ {1616
°F} or more for 5 seconds
Note：
Restricts the fuel injection amount.

Catalyst Temperature Sensor Circuit Low Sensor 1
The exhaust temperature sensor 1 is installed on the DPD
housing. The exhaust gas temperature sensor 1 is a
exhaust gas before entering the DPD filter. This sensor
has a signal circuit and GND circuit. The ECM supplies 5
V to the signal circuit, and the GND circuit connects to
GND. When the DPD exhaust temperature sensor 1 is
cold, the resistance of the sensor is high. When the
exhaust temperature rises, the resistance of the sensor
decreases. The ECM detects a high voltage when the
sensor resistance is high. The ECM detects a low voltage
when the sensor resistance is low.
signal voltage.
exhaust temperature sensor 1 has been 0.2 V or lower for
3 seconds
Note：

Catalyst Temperature Sensor Circuit High Sensor 1
housing. The exhaust gas temperature sensor 1 is a
exhaust gas before entering the DPD filter. This sensor
has a signal circuit and GND circuit. The ECM supplies 5
V to the signal circuit, and the GND circuit connects to
GND. When the DPD exhaust temperature sensor 1 is
cold, the resistance of the sensor is high. When the
exhaust temperature rises, the resistance of the sensor
decreases. The ECM detects a high voltage when the
sensor resistance is high. The ECM detects a low voltage
when the sensor resistance is low.
signal voltage.
DTC P0112, P0113, P0117, P0118, P060B, P2228, and
P2229 are not set
The engine coolant temperature is 70 ℃ (158 ℉) or
higher
The fuel injection amount is a certain value or more
The engine operating time is 0.5 - 10 minutes or longer
exhaust temperature sensor 1 has been 4.85 V or higher
for 5 seconds
Note：
DTC P042B (Flash Code 145)

1. DTC P042B Description of DTC
housing. The exhaust temperature sensor 2 is a variable
resistor, and measures the temperature of the exhaust gas
before entering the oxidation catalyst. The DTC is set
when the ECM detects an abnormally high exhaust
temperature.
2. DTC P042B Condition for setting the DTC
DTC P042C and P042D are not set
When the ECM has detected that the exhaust temperature
2 has been 870 ℃ (1600 ℉) or higher for 5 seconds
3. DTC P042B Action taken when the DTC sets
Note：

1. DTC P042C Description of DTC
before entering the oxidation catalyst. This sensor has a
signal circuit and GND circuit. The ECM supplies 5 V to
the signal circuit, and the GND circuit connects to GND.
When the exhaust temperature sensor 2 is cold, the
resistance of the sensor is high. When the exhaust
temperature rises, the resistance of the sensor decreases.
The ECM detects a high voltage when the sensor
resistance is high. The ECM detects a low voltage when
the sensor resistance is low. The DTC is set when the
ECM detects an abnormally low signal voltage.
2. DTC P042C Condition for setting the DTC
DTC P060B7 is not set
exhaust temperature sensor 2 signal voltage has been 0.2
V or lower for 3 seconds
3. DTC P042C Action taken when the DTC sets
Note：

1. DTC P042D Description of DTC
before entering the oxidation catalyst. This sensor has a
signal circuit and GND circuit. The ECM supplies 5 V to
the signal circuit, and the GND circuit connects to GND.
When the exhaust temperature sensor 2 is cold, the
resistance of the sensor is high. When the exhaust
temperature rises, the resistance of the sensor decreases.
The ECM detects a high voltage when the sensor
resistance is high. The ECM detects a low voltage when
the sensor resistance is low. The DTC is set when the
ECM detects an abnormally low signal voltage.
2. DTC P042D Condition for setting the DTC
DTC P0112, P0113, P0117, P0118, P060B, P2228, and
P2229 are not set
The engine coolant temperature is 70 ℃ (158 ℉) or
higher
The fuel injection amount is a certain value or more
The engine operating time is 0.5 - 10 minutes or longer
exhaust temperature sensor 2 has been 4.85 V or higher
for 5 seconds
3. DTC P042D Action taken when the DTC sets
Note：

Oil Pressure Sensor Circuit Low
The oil pressure sensor detects the engine oil pressure.
The oil pressure sensor is installed near the starter motor
of the cylinder block. The internal resistance of the oil
pressure sensor changes in accordance with the change in
the pressure. The resistance value is low when the
pressure is high, and the resistance value is high when the
pressure is low. The ECM is connected to the oil pressure
sensor through the power supply circuit, signal circuit
and GND circuit, and applies +5 V power to the power
supply circuit.
The ECM detects the change in the signal voltage that is
occurred according to the resistance change based on the
pressure of the oil pressure sensor as a signal.
oil pressure sensor has been 0.1 V or lower for 4 seconds
Note：
Substitute the default value of the oil pressure sensor.

Oil Pressure Sensor Circuit High
The oil pressure sensor detects the engine oil pressure.
The oil pressure sensor is installed near the starter motor
of the cylinder block. The internal resistance of the oil
pressure sensor changes in accordance with the change in
the pressure. The resistance value is low when the
pressure is high, and the resistance value is high when the
pressure is low. The ECM is connected to the oil pressure
sensor through the power supply circuit, signal circuit
and GND circuit, and applies +5 V power to the power
supply circuit.
The ECM detects the change in the signal voltage that is
occurred according to the resistance change based on the
pressure of the oil pressure sensor as a signal.
oil pressure switch has been 4.85 V or higher for 4
seconds
Note：
Substitute the default value of the oil pressure sensor.

System Voltage
The ECM supplies 12 V power to the mass air flow
sensor. The battery power is supplied to the ECM via the
dropping register and converted into 12 V. The ECM
monitors the 12 V power supply circuit voltage.
When the ECM has detected that the voltage is
abnormally low or high, it sets DTC.
P060B is not set
When the ECM has detected that 12 V power supply
circuit voltage has been 7 V or lower for longer than 1.2
seconds
circuit voltage has been 19 V or higher for longer than
1.2 seconds
Note：

System Voltage High
The ECM monitors ignition voltage of the ignition feed
terminal and makes sure that the voltage stays within the
appropriate range.
When the ECM has detected that the ignition power
voltage is abnormally high, it sets DTC.
When the ECM has detected that ignition power supply
circuit voltage has been 32 V or higher for 5 seconds
Note：

Internal Control Module Memory Check Sum Error
This diagnosis applies to the microprocessor inside the
ECM.
When ECM detects that the calculated checksum does not
correspond with the checksum that is registered into
ROM.
Note：
Stop the engine.

Control Module Programming Error
The EEPROM inside the ECM records the injector ID
code information. When the ECM has detected that the
injector ID code is not programmed in the EEPROM or
found an error in the programmed injector ID code, it sets
DTC.
When the ECM has detected that the injector ID code has
not been programmed
When the ECM has detected an error of the programmed
injector ID code
Note：

Internal Control Module Random Access Memory (RAM) Error
ECM.
The battery voltage is 16 V or above
When the ECM detects an abnormality in the internal
RAM
Note：
Stop the engine.

ECM/PCM Processor
ECM.
The battery voltage is 16 V or higher
When the internal sub CPU has detected an abnormality
in the main CPU
Note：
Upon returning to CPU, it limits the fuel injection
amount.
Limit the maximum engine RPM to 1700 r/min.
Stop EGR control.
Stop DPD regeneration.

Internal Control Module A/D Processing Performance
1. DTC P060B Description of DTC
ECM.
2. DTC P060B Condition for setting the DTC
When the ECM has detected an abnormality of the
internal A/D converter
3. DTC P060B Action taken when the DTC sets
Note：

Throttle Actuator Control Range/Performance
The ECM controls the intake throttle solenoid to open
and close the intake throttle valve according to the engine
operating status. The intake throttle valve opening angle
is detected by the position sensor and transmitted to the
ECM. While the ON command to the intake throttle
solenoid is being executed, if the ECM has detected a
difference between the actual opening angle and desired
opening angle of the intake throttle, it sets DTC.
DTC P0122, P0123 are not set
The desired opening angle of the intake throttle is
constant
The ON instruction has been issued for the intake throttle
solenoid
When the ECM has detected that the difference between
the actual and desired opening angles of the intake
throttle has been 40 % or more for 5 seconds or longer
Note：

Sensor Reference Voltage 1 Circuit
The ECM supplies 5 V power to the following sensors
via the power supply circuit 1.
Accelerator position sensor
The ECM also supplies 5 V power to the following
sensors via the power supply circuit 5.
Intake air temperature sensor
Crankshaft position sensor
Fuel pressure sensor
The 5 V power supply circuits 1 and 5 are independent of
each other outside the ECM, but they share the bus inside
the ECM. Therefore, when one of the sensor 5 V power
supply circuits is shorted, the entire 5 V power supply
circuits 1 and 5 may be affected. The ECM monitors the
voltage of the 5 V power supply circuits 1 and 5, and sets
DTC when the ECM has detected that the voltage is
abnormally low or high.
When the ECM has detected that voltages of the 5 V
power supply circuits 1 and 5 have been 4.5 V or lower or
5.5 V or higher for longer than 0.4 seconds
Note：

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

via the 5 V power supply circuit 2.
Atmospheric pressure sensor
sensors via the 5 V power supply circuit 6.
Camshaft position sensor
Boost temperature sensor
each other outside the ECM, but they share a bus inside
power supply circuit 2 or 6 has been 4.5 V or lower or 5.5
V or higher for longer than 0.4 seconds
Note：

ECM/PCM Power Relay Control Circuit/Open
When the ECM has received the starter switch ON signal,
power is applied to the ECM main relay and the battery
power is supplied to the ECM via the relay switch side.
When the starter switch was turned to OFF, power
applied to the ECM main relay is discontinued after a
certain period of time.
If the ECM has detected a low voltage with the relay
voltage supply circuit when the ON command has been
executed for the ECM main relay, it sets DTC.
When the ECM has detected the voltage condition in the
ECM main relay voltage supply circuit has been 1V or
lower for 3 seconds while the ON command is being
executed to the relay
Note：

ECM/PCM Power Relay Control Circuit High
When the ECM has received the starter switch ON signal,
power is applied to the ECM main relay and the battery
power is supplied to the ECM via the relay switch side.
When the starter switch was turned to OFF, power
applied to the ECM main relay is discontinued after a
certain period of time.
If the ECM has detected that the ECM is ON when the
OFF command has been executed for the ECM main
relay, it sets DTC.
When the ECM has detected that the ECM has been ON
for 5 seconds when the OFF command to the relay
Note：

DPD differential pressure sensor
Exhaust gas temperature sensors １ and ２
Fuel filter pressure sensor
Oil pressure sensor
ECT sensor
Water temperature sensor
power supply circuit 3 or 7 has been 4.5 V or lower or 5.5
V or higher for longer than 0.4 seconds
Note：

Fuel Rail Pressure (FRP) Too Low
between the fuel tank and the fuel supply pump and the
high-pressure side between the fuel supply pump and the
injectors. The fuel is drawn from the fuel tank through the
fuel supply pump and supplied to the common rail by the
two plungers located inside the fuel supply pump. The
common rail pressure is regulated by the ECM through
controlling the suction control valve based on the signal
from the common rail pressure sensor.
This DTC is set when the ECM detects that the actual
fuel pressure is lower than the target fuel pressure.
DTC P0087, P0091, P0092, P0192, P0193, P0201-P0204,
P1261, P1262, P2146, and P2149 are not set
The suction control valve instructs a certain fuel flow
amount or more
pressure has been lower than the target fuel pressure for
50 MPa (7250 psi) or more for 5 seconds or longer
Note：

Boost Temperature Sensor Circuit Low
The boost temperature sensor is installed on the intake
manifold. The resistance value of the boost temperature
sensor changes depending on the temperature inside the
intake manifold. The resistance value becomes lower
when the intake air temperature is high, and higher when
the intake air temperature is low. The ECM applies 5 V to
the boost temperature sensor through the pull-up resistor,
and calculates the boost temperature from the change in
the voltage to use it for various controls such as the fuel
injection control. The voltage becomes lower when the
resistance is small (the temperature is high), and higher
when the resistance is large (the temperature is low).
When the ECM has detected that the boost temperature
sensor voltage has been 0.1 V or lower for 4 seconds or
longer
Note：
Substitute the default value of boost temperature sensor.

Boost Temperature Sensor Circuit High
The boost temperature sensor is installed on the intake
manifold. The resistance value of the boost temperature
sensor changes depending on the temperature inside the
intake manifold. The resistance value becomes lower
when the intake air temperature is high, and higher when
the intake air temperature is low. The ECM applies 5 V to
the boost temperature sensor through the pull-up resistor,
and calculates the boost temperature from the change in
the voltage to use it for various controls such as the fuel
injection control. The voltage becomes lower when the
resistance is small (the temperature is high), and higher
when the resistance is large (the temperature is low).
The water temperature is 50 ℃ {122 °F} or higher
The engine has been running for 3 minutes or longer
When the ECM has detected that the boost temperature
sensor voltage has been 4.94 V or higher for 4 seconds or
longer
Note：
Substitute the default value of boost temperature sensor.

Injector Positive Voltage Control Circuit Group 1
The charge voltage circuit inside the ECM increases the
voltage applied to the injector. The charge voltage circuit
is divided into 2 banks; the common power supply 1 and
common power supply 2. The common power supply 1
supplies power to the injectors of the No. 1 and No. 4
cylinders while the common power supply 2 supplies
power to the injectors of the No. 2 and No. 3 cylinders.
When the injector charge voltage circuit of the common
power supply 1 or 2 of the ECM has been opened, the
ECM sets DTC.
When the ECM has been detected an open or short circuit
in the ECM internal common power 1 injector charge
voltage circuit for longer than 1.3 seconds
Note：
Stop EGR control.
Stop the fuel injection for the No. 1 and No. 4 cylinders.

The charge voltage circuit inside the ECM increases the
voltage applied to the injector. The charge voltage circuit
is divided into 2 banks; the common power supply 1 and
common power supply 2. The common power supply 1
power supply 1 or 2 of the ECM has been opened, the
ECM sets DTC.
When the ECM has been detected an open or short circuit
in the ECM internal common power 2 injector charge
voltage circuit for longer than 1.3 seconds
Note：
Stop EGR control.

Fuel Pressure Sensor Circuit Low
The fuel filter pressure sensor detects the negative
pressure in the fuel filter. The fuel filter pressure sensor is
installed on the fuel filter. The output voltage becomes
lower when the negative pressure in the fuel filter is
smaller and becomes higher when the negative pressure is
larger. The output voltage of the fuel filter pressure
sensor changes as the negative pressure in the fuel filter
changes. The ECM reads this change in the output
voltage to convert into the fuel negative pressure, and
uses it for control.
When the ECM has detected that the fuel filter pressure
sensor voltage has been 0.1 V or lower for 4 seconds
Note：
Substitute the default value of fuel filter pressure sensor.

Fuel Pressure Sensor Circuit High
The fuel filter pressure sensor detects the negative
pressure in the fuel filter. The fuel filter pressure sensor is
installed on the fuel filter. The output voltage becomes
lower when the negative pressure in the fuel filter is
smaller and becomes higher when the negative pressure is
larger. The output voltage of the fuel filter pressure
sensor changes as the negative pressure in the fuel filter
changes. The ECM reads this change in the output
voltage to convert into the fuel negative pressure, and
uses it for control.
When the ECM has detected that the fuel filter pressure
sensor voltage has been 4.9 V or higher for 4 seconds
Note：
Substitute the default value of fuel filter pressure sensor.

Exhaust Gas Recirculation (EGR) Closed Position Performance
The ECM controls the EGR valve opening and closing
based on the engine running condition and by controlling
the EGR solenoid. The EGR opening angle is detected by
the position sensor and transmitted to the ECM. For the
closed position error DTC, when the ECM has detected
that the actual EGR valve opening angle is greater than a
certain value, it sets this DTC.
For the learned position error DTC, when the ECM has
detected a difference between the learned closed position
and the actual closed position, it sets DTC.
When the ECM has detected that the EGR-learned closed
position is not within the specific range when the starter
switch was turned to OFF
Note：

PM Over Accumulation
The ECM detects PM accumulation failures from the
DPD differential pressure sensor installed near the DPD
itself. When it is reached to a certain amount of PM
accumulations or a certain length of operating time, the
automatic regeneration of the DPD starts. If the automatic
regeneration cannot be completed by some reason, the
manual regeneration is requested to the operator by
displaying a message requesting for pressing the DPD
switch on the display.
When DPD regeneration continues for longer than the
specified period of time, it sets DTC.
The operation time from the last DPD regeneration has
been 8 hours or longer
Note：

DPD Insufficient Regeneration
blinking the orange DPD indicator light on the display.
After DPD regeneration is finished, the DPD differential
pressure sensor monitors a purification of the filter.
When purification determination after the DPD
regeneration has failed for 2 consecutive times, the ECM
sets DTC.
DPD regeneration has been completed
The ECM detects that purification determination after the
DPD regeneration has failed for 2 consecutive times
Note：

Control Module Long Term Memory Performance
ECM.
When the ECM has detected that the calculated checksum
has not matched the check sum internally registered in the
EEPROM
Note：

Sensor Reference Voltage Circuit
Boost sensor EGR position sensor
Intake throttle position sensor
Fuel temperature sensor
IMT sensor
circuit 4 or 8 voltage has been 4.5 V or lower or 5.5 V or
higher for longer than 0.4 seconds
Note：

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

Pedal Position Sensor 1 Circuit Low Input
The accelerator position sensor consists of 2 sensors
installed within a single housing. The ECM uses the
accelerator position sensor to calculate the desired
acceleration and deceleration amounts. The accelerator
position sensor 1 has the following circuits
GND circuit
Accelerator position sensor 1 signal circuit
The accelerator position sensor 1 transmits the signal
related to changes of the accelerator pedal angle position
to the ECM via the signal circuit. When the ECM has
detected that the signal voltage is abnormally low, it sets
DTC.
When the ECM has detected that the accelerator pedal
position sensor 1 signal voltage has been 0.2 V or lower
for longer than 0.3 seconds
When the accelerator position sensors 1 and 2 are faulty,
the accelerator opening angle is limited to 0 %.

Pedal Position Sensor 1 Circuit High Input
position sensor 1 has the following circuits.
GND circuit
detected that the signal voltage is abnormally high, it sets
DTC.
DTC P060B and P0641 are not set
position sensor 1 signal voltage has been 4.9 V or higher

GND circuit
detected that the signal voltage is abnormally low, it sets
DTC.
DTC P060B and P0651 are not set
position sensor 2 signal voltage has been 0.2 V or lower

GND circuit Accelerator position sensor 2 signal circuit
detected that the signal voltage is abnormally high, it sets
DTC.
position sensor 2 signal voltage has been 4.9 V or higher

Pedal Position Sensor 1 - 2 Voltage Correlation
installed within a single housing. The accelerator position
sensor 1 and accelerator position sensor 2 are hall IC type
sensors and each has the following circuits.
GND circuit
Signal circuit
The ECM supplies 5 V to the accelerator position sensor
via the 5 V power supply circuit and the GND circuit
connects to the GND. The accelerator position sensor
transmits the signal related to changes of the accelerator
pedal angle position to the ECM via the signal circuit.
The signal voltage of the accelerator position sensor 1 is
kept low first, and then increases as the pedal is
depressed. The signal voltage of the accelerator position
sensor 2 is kept high first, and then decreases as the pedal
is depressed. When the ECM has detected that the
accelerator position sensor 1 signal and accelerator
position sensor 2 signal voltages are not related to each
other, it sets DTC.
DTC P060B, P2122, P2123, P2127, and P2128 are not
set
When the ECM has detected that both the accelerator
pedal position sensors 1 and 2 have been outside the
specified range for 45 % or more for longer than 2.6
seconds

Fuel Injector Group 1 Supply Voltage Circuit
using the data transmitted from the various sensors. The
injector charge voltage circuits of the common power
supplies 1 and 2 supply the high voltage while the ECM
grounds the injector solenoid control circuit as well as
drives the injector of each cylinder. The common power
supply 1 supplies power to the injectors of the No. 1 and
No. 4 cylinders while the common power supply 2
cylinders.
power supply 1 or 2 has been opened or shorted to the
GND or voltage circuit, the faulty injector common
power supply circuit sets DTC.
Also when the injector solenoid control circuit has been
shorted to the GND, the ECM sets DTC.
When the ECM has detected that an open circuit with the
injector charge voltage circuit of the common power
supply 1, a short to GND or voltage circuit, or a short of
the injector solenoid coil control circuit of the cylinder
No. 1 or No. 4 to GND has occurred for longer than 2.6
seconds
Note：
Stop EGR control.

charge voltage circuits of the common power supplies 1
and 2 supply the high voltage while the ECM grounds the
injector solenoid control circuit as well as drives the
injector of each cylinder. The common power supply 1
power supply 1 or 2 has been opened or shorted to the
GND or voltage circuit, the faulty injector common
power supply circuit detects DTC P2149.
When the injector solenoid control circuit has been
shorted to the GND, the ECM also sets DTC.
When the ECM has detected that an open circuit with the
injector charge voltage circuit of the common power
supply 2, a short to GND or voltage circuit, or a short of
the injector solenoid coil control circuit of the cylinder
No. 2 or No. 3 to GND has occurred for longer than 2.6
seconds
Note：
Stop EGR control.

Barometric Pressure Circuit Low
The atmospheric pressure sensor changes the signal
voltage in accordance with the change in the atmospheric
pressure. The sensor has the following circuits.
GND circuit
Atmospheric pressure sensor signal circuit Atmospheric
pressure sensor sends to ECM the signal with regard to
the change in the atmospheric pressure. The ECM detects
a low signal voltage when the altitude is high and the
atmospheric pressure is low. The ECM detects a high
signal voltage when the atmospheric pressure is high. The
ECM uses the voltage signal to adjust the amount and
timing of fuel injection, and performs the altitude
correction. The DTC is set when the ECM detects an
atmospheric sensor has been 0.5 V or lower for 5 seconds
Note：
Substitute the default value of atmospheric pressure.

Barometric Pressure Circuit High
The atmospheric pressure sensor changes the signal
voltage in accordance with the change in the atmospheric
pressure. The sensor has the following circuits.
GND circuit
Atmospheric pressure sensor signal circuit Atmospheric
pressure sensor sends to ECM the signal with regard to
the change in the atmospheric pressure. The ECM detects
a low signal voltage when the altitude is high and the
atmospheric pressure is low. The ECM detects a high
signal voltage when the atmospheric pressure is high. The
ECM uses the voltage signal to adjust the amount and
timing of fuel injection, and performs the altitude
correction. The DTC is set when the ECM detects an
abnormally high signal voltage.
atmospheric sensor has been 4.0 V or higher for 5
seconds
Note：
Substitute the default value of atmospheric pressure.
DTC P242F (Flash Code 131)

DPD Restriction
1. DTC P242F Description of DTC
If the ECM detects that learned exhaust differential
pressure is not within a predetermined range, it sets DTC.
2. DTC P242F Condition for setting the DTC
The DPD differential pressure has been above the
calculated range for 30 seconds or longer
3. DTC P242F Action taken when the DTC sets
Note：

DPD Differential Pressure Sensor Circuit
DPD itself. DPD differential pressure sensor varies the
signal voltage according to changes of the exhaust gas
filter.
If the ECM detects that the DPD differential pressure is
certain pressure low under certain conditions, it sets
DTC.
The engine RPM is 2200 r/min or more
pressure has been 0.5 kPa {0.01 kgf/cm2 / 0.1 psi} or
lower for longer than 13 seconds
Note：

DPD Differential Pressure Sensor Circuit Range/Performance
filter.
pressure is abnormally high, it sets DTC.
pressure has been 60 kPa {0.61 kgf/cm2 / 8.7 psi} or
higher for longer than 2.4 seconds
Note：

DPD Differential Pressure Sensor Circuit Low
filter. The sensor has the following circuits.
GND circuit
DPD differential pressure sensor signal circuit
The DPD differential pressure sensor transmits signals
concerning changes of the DPD differential pressure to
the ECM via the signal circuit. The ECM detects a lower
signal voltage when the differential pressure is small due
to a small amount of accumulated PM. The ECM also
uses this voltage signal for controlling DPD regeneration.
pressure sensor signal voltage has been 0.18 V or lower
Note：
Substitute the default value of DPD differential pressure
sensor.

DPD Differential Pressure Sensor Circuit High
filter. The sensor has the following circuits.
GND circuit
DPD differential pressure sensor signal circuit
The DPD differential pressure sensor transmits signals
concerning changes of the DPD differential pressure to
the ECM via the signal circuit. The ECM detects a lower
signal voltage when the differential pressure is small due
to a small amount of accumulated PM. The ECM also
uses this voltage signal for controlling DPD regeneration.
pressure sensor signal voltage has been 4.9 V or higher
Note：
sensor.

DPD Differential Pressure Sensor Learned Position
DPD itself of the actual unit. DPD differential pressure
sensor varies the signal voltage according to changes of
the exhaust gas differential pressure between in front and
rear of DPD filter.
The ECM learns a variance of the exhaust differential
pressure sensor signal at every ignition cycle after the
starter switch has been ON with the engine OFF for 30
seconds.
If the ECM detects that learned exhaust differential
pressure is not within a predetermined range, it sets DTC.
The engine is stopped
When the ECM has detected that the learned absolute
value of　differential pressure has been 4.5 kPa {0.05
kgf/cm2 / 0.7 psi} or higher
Note：
sensor.

DPD Regeneration Duration
Once the DPD filter regeneration starts, it must be
finished within a certain time.
When DPD regeneration continues for longer than the
specified period of time, it sets DTC.
The DPD filter regeneration has been completed
When the ECM detected that the DPD filter regeneration
process took time longer than a certain period of time for
3 consecutive times
Note：
DTC U0001 (Flash Code 84)

CAN-Bus Malfunction
1. DTC U0001 Description of DTC
The ECM communicates with the turbo control unit and
the actual unit control unit via the CAN communication
circuit. The ECM outputs data via the CAN-High circuit
and input data from other ECUs from the CAN-Low
circuit. CAN communication is continuously performed
at a constant rate and the data output count and input
count are always identical. The ECM sets DTC when it
has detected a CAN communication failure.
2. DTC U0001 Condition for setting the DTC
When the ECM has detected an abnormality in the CAN
communication circuit
3. DTC U0001 Action taken when the DTC sets
Note：
Stop EGR control.

Control Module Communication Bus Off
The ECM communicates with the actual unit control unit
via the CAN communication circuit. The ECM outputs
data via the CAN-High circuit and input data from other
ECUs from the CAN-Low circuit. CAN communication
is continuously performed at a constant rate and the data
output count and input count are always identical. The
ECM sets DTC when it has detected a CAN
communication failure.
When the ECM detects an abnormality in the CAN
communication circuit
Note：

Lost Communication with TCM
The ECM communicates with the actual unit control unit
via the CAN communication circuit. The ECM outputs
data via the CAN-High circuit and input data from other
ECUs from the CAN-Low circuit. CAN communication
is continuously performed at a constant rate and the data
output count and input count are always identical. ECM
sets DTC when it has lost CAN communication with the
actual unit control unit.
When the ECM has detected that CAN data reception for
5 seconds or longer has not been satisfied
Note：
Stop EGR control.
Limit the engine RPM to the idle RPM.

Lost Communication with VNT System
The ECM and turbo control unit communicate the control
and diagnostic information via CAN communication. The
ECM outputs data via the CAN-High circuit and input
data from other ECUs from the CAN-Low circuit. CAN
communication is continuously performed at a constant
rate and the data output count and input count are always
identical. ECM sets DTC when it has lost CAN
communication with the turbo control unit.
When the ECM has detected that No CAN Bus message
has been received from the turbocharger controller unit
for longer than 5 seconds
Note：
The highest engine RPM is restricted to 1200 r/min.
DTC U0411 (Flash code 87)

Turbo Charger Control Module Signal Malfunction
The ECM and turbo control unit communicate the control
and diagnostic information via CAN communication. The
ECM outputs data via the CAN-High circuit and input
data from other ECUs from the CAN-Low circuit. CAN
communication is continuously performed at a constant
rate and the data output count and input count are always
identical. ECM sets DTC when it has received a CAN
communication failure message from the turbo control
unit.
When ECM has received the error message from the
turbo control unit
Note：
Stop EGR control.
DTC mapping table

1. DTC mapping table
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
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
100-3 P0523 Oil Pressure Sensor Circuit High Input

10012-2 P0560 System Voltage
158-3 P0563 System Voltage High
628-2 P0601 Internal Control Module Memory Check Sum Error
10032-2 P0602 Control Module Programming Error
10033-2 P0604 Internal Control Module Random Access Memory (RAM)
1077-2
P0606 ECM/PCM Processor
10007-2
10008-2 P060B Internal Control Module A/D Processing Performance
10022-2 P0638 Throttle Actuator Control Range/Performance
1079-2 P0641 Sensor Reference Voltage 1 Circuit
987-5 P0650 Malfunction Indicator Lamp (MIL) Control Circuit
1485-5 P0685 ECM/PCM Power Relay Control Circuit /Open
1485-6 P0687 ECM/PCM Power Relay Control Circuit High
1239-17 P1093 Fuel Rail Pressure (FRP) Too Low
105-4 P1112 Boost Temperature Sensor Circuit Low Input
105-3 P1113 Boost Temperature Sensor Circuit High Input
10005-1 P1261 Fuel Injector Group 1 Supply Voltage Circuit
1381-4 P1293 Fuel Intake Pressure Sensor Circuit Low Input
1381-3 P1294 Fuel Intake Pressure Sensor Circuit High Input
10001-13 P1404 Exhaust Gas Recirculation (EGR) 1 Closed Position Performance
10026-0 P1455 PM Over Accumulation
10027-0 P1471 DPD Insufficient Regeneration
10013-2 P1621 Control Module Long Term Memory Performance
10025-5 P1669 DPD Lamp Control Circuit
91-4 P2122 Pedal Position Sensor 1 Circuit Low Input
91-3 P2123 Pedal Position Sensor 1 Circuit High Input
91-4 P2127 Pedal Position Sensor 2 Circuit Low Input
91-3 P2128 Pedal Position Sensor 2 Circuit High Input
91-2 P2138 Pedal Position Sensor 1 - 2 Voltage Correlation
108-4 P2228 Barometric Pressure Circuit Low
108-3 P2229 Barometric Pressure Circuit High
10026-15 P242F DPD Restriction
81-1 P2452 DPD Differential Pressure Sensor Circuit
81-0 P2453 DPD Differential Pressure Sensor Circuit Range/Performance
81-4 P2454 DPD Differential Pressure Sensor Circuit Low
81-3 P2455 DPD Differential Pressure Sensor Circuit High
81-2 P2456 DPD Differential Pressure Sensor Learned Position
10029-0 P2458 DPD Regeneration Duration
10040-19 U0001 CAN Bus Error (ISO-CAN)

CAN Bus Error (J1939)
639-19 U0073
639-2 U0101 Lost Communication With Transmission Control Module
10023-2 U0110 Lost Communication With VNT System
10023-19 U0411 VNT Communication
Engine Control (4HK1) 1A-1
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
Circuit Low...................................................................1A-27 Circuit Low Sensor 1....................................................1A-55
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
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
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
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
Circuit............................................................................1A-75 DTC P242F (Flash Code 131) DPD Restriction.........1A-109
Control Circuit/Open.....................................................1A-76 Sensor Circuit..............................................................1A-111
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

Crankshaft Position - Camshaft Position Correlation
1. DTC P0016 Priority DTC 5. Use the trouble diagnosis scan tool to confirm that a
DTC has not been detected.
DTC P0335
DTC P0336
DTC P0340
2. DTC P0016 Diagnostics
1. Inspect the CKP sensor.
Refer to "1.Engine 1B.Mechanical(4HK1) CKP
sensor Inspection".
2. If a problem is discovered, replace the crankshaft
position sensor.
sensor Removal".
sensor Installation".
3. Inspect the CMP sensor.
Refer to "1.Engine 1B.Mechanical(4HK1) CMP
sensor Inspection".
4. If a problem is discovered, replace the camshaft
position sensor.
sensor Removal".
5. Inspect the flywheel.
・The sensor rotor should not be damaged.
・The ring gear should be installed correctly.
6. If a problem is discovered, repair the flywheel.
7. Inspect the camshaft gear.
・The camshaft gear should not be damaged
・The camshaft gear should be installed correctly.
8. If a problem is discovered, repair the camshaft gear.
3. DTC P0016 Confirm Resolution
1. Clear the DTC using the trouble diagnosis scan tool.
2. Turn the starter switch OFF for 30 seconds or longer.
Note：
・ When the engine does not start, crank the
engine for 10 seconds.
4. Perform a test-run.

Turbocharger Boost Control Solenoid Circuit
1. DTC P0045 Priority DTC 13. Measure the voltage between the position sensor
power supply terminal and GND of the turbo
DTC P0563
actuator harness connector.
voltage： 8.0 to 11.0 V
14. If the voltage is outside the standard range, inspect
2. Inspect the turbocharger assembly. the position sensor power supply circuit between the
turbo actuator and the turbo control unit.
Refer to "1.Engine 1F.Induction(4HK1) Turbocharger
assembly Inspection". ・There should be no open circuit or high resistance.
・There should be no short to the battery power supply or
3. If a problem is discovered, replace the turbocharger
ignition power supply circuit.
assembly.
・There should be no short to GND.
15. If a problem is discovered, repair the position sensor
assembly Removal".
power supply circuit.
16. If the circuit is normal, inspect to the turbo control
assembly Installation".
unit harness connector for a contact failure.
4. Disconnect the harness connector from the turbo
17. If a problem is discovered, repair the harness
actuator.
connector.
5. Connect the test light between the motor operation
18. If the harness connector is normal, replace the turbo
terminal and GND of the turbo actuator harness
control unit.
connector.
19. If the voltage is within the standard range, measure
the voltage between the position sensor signal
7. Check if the test light does not come on or remains terminal of the turbo actuator harness connector and
on. GND.
Note： Note：
・ The inspection with a test light should be ・ Measurement of voltage value should be taken
performed on each terminal. on each terminal.
・ When it is normal, the test light comes on after voltage： 4.0 to 6.0 V
the key switch is turned ON, and then goes out
after a few seconds. 20. If the voltage is outside the standard range, inspect
the position sensor signal circuit between the turbo
8. If the test light does not come on or remains on, actuator and the turbo control unit.
inspect the motor operation circuit between the turbo
actuator and turbo control unit. ・There should be no open circuit or high resistance.
・There should be no open circuit or high resistance. ignition power supply circuit.
・There should be no short to the battery power supply or ・There should be no short to GND.
・There should be no short to GND. 21. If a problem is discovered, repair the position sensor
signal circuit.
9. If a problem is discovered, repair the motor
operation circuit. 22. If the circuit is normal, inspect to the turbo control
10. If the test light operates properly, inspect to see if a
short with other circuit exists in the motor operation 23. If a problem is discovered, repair the harness
circuit between the turbo actuator and turbo control connector.
unit. 24. If the harness connector is normal, replace the turbo
11. If a problem is discovered, repair the motor control unit.
operation circuit. 25. If the voltage is within the standard range, inspect to
12. Turn ON the starter switch. see if there is a short circuit with the position sensor
signal circuit between the turbo actuator and turbo
control unit.
signal circuit.
28. Measure the voltage between the position sensor
power supply terminal and position sensor GND
terminal of the turbo actuator harness connector.
29. If the voltage is outside the standard range, inspect
the position sensor GND circuit between the turbo
actuator and the turbo control unit.
・There should be no open circuit or high resistance.
GND circuit.
31. If the circuit is normal, inspect to the turbo control
connector.
33. If the harness connector is normal, replace the turbo
control unit.
34. If the voltage is within the standard range, inspect to
see if there is a contact failure with the turbo actuator
harness connector.
connector.
36. If the harness connector is normal, replace the
turbocharger.
assembly Removal".
5. Use the trouble diagnosis scan tool to confirm that a

Fuel Rail/System Pressure - Too Low
1. DTC P0087 Priority DTC 10. If a problem is discovered, repair the harness
connector.
DTC P0088
11. Inspect the ECM harness connector for a contact
DTC P0089
failure.
DTC P0091
DTC P0092 connector.
DTC P0192 13. Inspect each circuit for high resistance.
DTC P0193 14. Repair the circuit if a problem is discovered.
DTC P0201 15. If the harness connector and each circuit are normal,
replace the fuel pressure sensor.
DTC P0202
Refer to "1.Engine 1C.Fuel System(4HK1) Common
DTC P0203
rail assembly Removal".
DTC P0204
DTC P2146 rail assembly Installation".
DTC P2149 Note：
2. DTC P0087 Diagnostics ・ Do not replace the fuel pressure sensor
separately. When a problem is found, replace
1. Start the engine. the common rail assembly.
2. Rev the engine a few times in neutral while checking 16. If the fuel rail pressure sensor display is within the
for a DTC with the trouble diagnosis scan tool. standard range, start the engine.
3. Check to see if the DTC P0087 is detected. 17. Perform the injector stop test with the trouble
4. If the DTC P0087 is not detected, replace the fuel diagnosis scan tool.
filter element. 18. Command each injector OFF, and confirm that the
Note： engine RPM changes on each injector.
・ An intermittent problem due to foreign matter 19. If any injector does not change the engine RPM
in the fuel is suspected. when OFF is instructed, replace the relevant injector.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter Refer to "1.Engine 1C.Fuel System(4HK1)
element Removal". Injector Removal".
element Installation". Injector Installation".
5. Turn OFF the starter switch. 20. When the injector has been replaced, set the injector
6. Wait for the specified period of time until the fuel ID code on the ECM.
pressure is released from the common rail. 21. Inspect to see if there is clogging with the fuel
specified time： 2 min system between the fuel tank and the fuel supply
pump.
22. If a problem is discovered, repair the clogging of the
8. Check the fuel rail pressure sensor display with the fuel system.
trouble diagnosis scan tool.
23. Inspect the fuel hose between the fuel tank and the
voltage： 0.9 to 1.0 V fuel supply pump for a cut and crack.
9. If the fuel rail pressure sensor display is outside the 24. If a problem is discovered, replace the fuel hose.
standard range, inspect the fuel pressure sensor
harness connector for a contact failure.
Note： Note：
・ The fuel hose between the fuel tank and the ・ Confirm that the fuel system is connected
fuel supply pump becomes negative pressure securely.
state when the engine is running.
34. Remove the air using the priming pump, and crank
・ When the fuel hose is not connected securely, the engine for the specified period of time or shorter.
the air can enter.
specified time： 5 s
・ When the engine RPM or the engine load
increases while the air has intruded in the fuel Note：
system, fluctuation in the common rail ・ Repeat this until the engine starts.
pressure is caused, and DTC P0087 may be
detected. 35. Leave the engine idling for the specified period of
time or longer.
25. Check that an appropriate clamp is used between the
fuel tank and the fuel supply pump. specified time： 1 min
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.
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
47. Check the pressure gauge.
specified value： 27.0 kPa { 203 mmHg / 8 inHg }
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.
・ 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.
53. Inspect the suction control valve harness connector
for a contact failure.
connector.
failure.
connector.
57. Inspect each circuit for high resistance.
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".
pump Installation".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
element Removal".
element Installation".

Fuel Rail/System Pressure - Too High
connector.
DTC P0089
DTC P0091
failure.
DTC P0092
DTC P0192 connector.
DTC P0193 13. Inspect each circuit for high resistance.
DTC P0201 14. If a problem is discovered, repair the circuit.
DTC P0202 15. If the harness connector and each circuit are normal,
replace the fuel pressure sensor.
DTC P0203
DTC P0204
DTC P2146
DTC P2149 rail assembly Installation".
2. DTC P0088 Diagnostics Note：
1. Start the engine. ・ Do not replace the fuel pressure sensor
2. Rev the engine a few times in neutral while checking the common rail assembly.
the actual fuel rail pressure display with the trouble
diagnosis scan tool. 16. Start the engine.
3. Check the actual fuel rail pressure display with the 17. Perform the injector stop test with the trouble
trouble diagnosis scan tool. diagnosis scan tool.
Standard value ：(-5) - 5 MPa 18. Command each injector OFF, and confirm that the
engine RPM changes on each injector.
4. If it is at or below the standard value, replace the fuel
filter element. 19. If any injector does not change the engine RPM
when OFF is instructed, replace the relevant injector.
Note：
・ An intermittent problem due to foreign matter Refer to "1.Engine 1C.Fuel System(4HK1)
in the fuel is suspected. Injector Removal".
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.
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.
・ When the fuel hose is not connected securely, specified time： 5 s

the air can enter. Note：
・ When the engine RPM or the engine load ・ Repeat this until the engine starts.
increases while the air has intruded in the fuel
system, fluctuation in the common rail 35. Leave the engine idling for the specified period of
pressure is caused, and DTC P0088 may be time or longer.
detected. specified time： 1 min
25. Check that an appropriate clamp is used between the 36. While keeping the engine rotating at the specified
fuel tank and the fuel supply pump. engine RPM for the specified period of time, check
26. If a problem is discovered, replace the clamp. the pressure gauge.
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：
・ 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".
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 }
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
pressure amount while the fuel flow is being
blocked.
with the fuel hose.
appropriate one.
connector.
failure.
connector.
59. If the suction control valve harness connector and the
supply pump and the fuel filter element.
pump Removal".
pump Installation".
element Removal".
Note：
・ When replacing the fuel supply pump, it is
required to also replace the fuel filter element
at the same time.

Fuel Pressure Regulator Performance
1. DTC P0089 Priority DTC 10. Inspect the suction control valve harness connector
DTC P0091
DTC P0092
connector.
DTC P0192
DTC P0193 failure.
DTC P0201 13. If a problem is discovered, repair the harness
connector.
DTC P0202
DTC P0203
DTC P0204
DTC P2146
DTC P2149
18. Rev the engine a few times in neutral while checking
the actual fuel rail pressure display with the trouble
1. Wait for the specified period of time until the fuel diagnosis scan tool.
pressure is released from the common rail.
19. Use the trouble diagnosis scan tool to check if the
specified time： 2 min actual fuel rail pressure display shows a value within
2. Check the fuel rail pressure sensor display with the the standard range at a sufficient rate.
trouble diagnosis scan tool. Standard values: (-5) - 5MPa
voltage： 0.9 to 1.0 V Note：
3. If the fuel rail pressure sensor display is outside the ・ If possible, compare with other actual unit
standard range, inspect the fuel pressure sensor equipped with the same model engine.
harness connector for a contact failure. 20. If it is within the standard range, replace the fuel
4. If a problem is discovered, repair the harness filter element.
connector. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
5. Inspect the ECM harness connector for a contact element Removal".
failure. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
6. If a problem is discovered, repair the harness element Installation".
connector. 21. If it is outside the standard range, replace the fuel
7. Inspect each circuit for high resistance. supply pump and the fuel filter element.
8. Repair the circuit if a problem is discovered. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
pump Removal".
9. If the harness connector and each circuit are normal,
replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
pump Installation".
rail assembly Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
element Removal".
rail assembly Installation". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
Note：
・・Do not replace the fuel pressure sensor Note：
separately. When a problem is found, replace ・ When replacing the fuel supply pump, it is
the common rail assembly. required to also replace the fuel filter element
at the same time.

Fuel Pressure Regulator Control Circuit Low
1. DTC P0091 Diagnostics 17. If it does not turn off, inspect the Low side circuit
between the ECM and suction control valve.
1. Check the rail pressure regulator feedback current
display with the trouble diagnosis scan tool. ・There should be no open circuit or high resistance.
・There should be no short to the battery or ignition
current： 300 to 900 mA
power supply.
2. If it is at or above the standard value, inspect to see if
18. If a problem is discovered, repair the Low side
there is a short circuit to the battery or ignition power
circuit.
supply with the High side circuit between the ECM
and the suction control valve. 19. Inspect the suction control valve harness connector
Note：
・ When the High side circuit is shorted to the 20. If a problem is discovered, repair the harness
voltage, the engine stalls and does not start. connector.
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.
・ 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.
circuit. Refer to "1.Engine 1J.Electrical(4HK1)
ECM Removal".
Refer to "1.Engine 1J.Electrical(4HK1)
7. Disconnect the harness connector from the suction ECM Installation".
control valve.
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
10. Check if the test light comes on and then goes off.
11. If it does not turn off, inspect the High side circuit
between the ECM and the suction control valve. 2. Turn the starter switch OFF for 30 seconds or longer.
・There should be no open circuit or high resistance. 3. Start the engine.

・There should be no short to GND. 4. Perform a test-run.
・There should be no short to the LOW side circuit.
12. If a problem is discovered, repair the High side DTC has not been detected.
circuit.
valve Low side circuit and battery power supply.

Fuel Pressure Regulator Control Circuit High
1. DTC P0092 Diagnostics 17. If it does not turn off, inspect the Low side circuit
between the ECM and suction control valve.
1. Check the rail pressure regulator feedback current
display with the trouble diagnosis scan tool. ・There should be no open circuit or high resistance.
current： 300 to 900 mA
power supply.
circuit.
supply with the High side circuit between the ECM
and the suction control valve. 19. Inspect the suction control valve harness connector
Note：
・ When the High side circuit is shorted to the 20. If a problem is discovered, repair the harness
voltage, the engine stalls and does not start. connector.
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.
・ When the Low side circuit is shorted to GND, connector.
the engine stalls and does not start.
circuit. Refer to "1.Engine 1J.Electrical(4HK1)
ECM Removal".
7. Disconnect the harness connector from the suction ECM Installation".
control valve.
valve High side circuit and a normal GND. 26. Perform the unit difference learning of the fuel
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.
・There should be no open circuit or high resistance. 3. Start the engine.

・There should be no short to GND. 4. Perform a test-run.
・There should be no short to the LOW side circuit.
12. If a problem is discovered, repair the High side DTC has not been detected.
circuit.
valve Low side circuit and battery power supply.

Fuel System Leak Detected
1. DTC P0093 Priority DTC 3. Remove each glow plug from the cylinder head
assembly.
DTC P0087
Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder
DTC P0091
head assembly Removal".
DTC P0092
4. Inspect for fuel leaks into the combustion chamber
DTC P0192
5. Inspect to see if there is a cylinder from which fuel
DTC P0193 leaks into the combustion chamber.
DTC P0201 6. If fuel leak is found, replace the corresponding
injector.
DTC P0202
Refer to "1.Engine 1C.Fuel System(4HK1)
DTC P0203
Injector Removal".
DTC P0204
DTC P2146 Injector Installation".
DTC P2149 7. When the injector has been replaced, set the injector
2. DTC P0093 Diagnostics ID code on the ECM.
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.
・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.
・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
the fuel pipe.
connector.
2. If fuel leak if found, fix the problem.
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.
・ 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.
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.
33. If fuel leak if found, fix the problem.
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.
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：
・ 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 }
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.
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".
element Removal". Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
pump Installation".
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.
50. Check the pressure gauge. 3. DTC P0093 Confirm Resolution
specified value： 27.0 kPa { 203 mmHg / 8 inHg } 1. Clear the DTC using the trouble diagnosis scan tool.
Note： 2. Turn the starter switch OFF for 30 seconds or longer.

・ When the pressure gauge is likely to indicate a 3. Start the engine.
value exceeding the standard value during
inspection, release the fuel being blocked.
・ Air mixture is checked with the negative 5. Use the trouble diagnosis scan tool to confirm that a
pressure amount while the fuel flow is being DTC has not been detected.
blocked.
with the fuel hose.
appropriate one.

Mass Air Flow Circuit Low Input
1. DTC P0102 Priority DTC 1. Clear the DTC using the trouble diagnosis scan tool.
DTC P0560 2. Turn the starter switch OFF for 30 seconds or longer.
2. DTC P0102 Diagnostics 3. Start the engine.
1. Turn OFF the starter switch. 4. Perform a test-run.
2. Disconnect the harness connector from the mass air 5. Use the trouble diagnosis scan tool to confirm that a
flow sensor. DTC has not been detected.
3. Inspect to see if there is an open circuit or high
resistance in the 12 V power supply circuit between
the ECM and the mass air flow sensor.
4. If a problem is discovered, repair the 12 V power
supply circuit.
5. Connect the test cable with fuse between the 12 V
power supply circuit and the signal circuit of the
mass air flow sensor harness connector.
6. Check the mass air flow sensor display with the
voltage： 4.9 V
there is a contact failure with the mass air flow
sensor harness connector.
connector.
9. If the harness connector is normal, replace the mass
air flow sensor.
10. Inspect the signal circuit between the ECM and the
mass air flow sensor.
11. If a problem is discovered, repair the signal circuit.
failure.
connector.
ECM Removal".
ECM Installation".

Mass Air Flow Circuit High Input
1. DTC P0103 Priority DTC 2. Turn the starter switch OFF for 30 seconds or longer.
DTC P0560 3. Start the engine.
2. DTC P0103 Diagnostics 4. Perform a test-run.
1. Turn OFF the starter switch. 5. Use the trouble diagnosis scan tool to confirm that a
2. Disconnect the harness connector from the mass air
flow sensor.
3. Check the mass air flow sensor display with the
voltage： 0.1 V
4. If it is at or above the standard value, inspect the
signal circuit between the ECM and the mass air
flow sensor.
power supply.
・There should be no short to the 12 V or 5 V power
supply.
resistance in the GND circuit between the ECM and
the mass air flow sensor.
7. If a problem is discovered, repair the GND circuit.
8. Inspect the mass air flow sensor harness connector
connector.
10. If the harness connector is normal, replace the mass
air flow sensor.
failure.
connector.
ECM Removal".
ECM Installation".

Intake Air Temperature Sensor Circuit Low
1. DTC P0112 Priority DTC
DTC P0641
2. Disconnect the harness connector from the intake air
temperature sensor.
3. Check the intake air temperature sensor display with
the trouble diagnosis scan tool.
voltage： 4.5 V
4. If it is at or above the standard value, replace the
intake air temperature sensor.
5. Inspect to see if there is a short circuit to the GND
with the signal circuit between the ECM and the
intake air temperature sensor.
8. Disconnect the harness connector from the ECM.
failure.
connector.
ECM Removal".
ECM Installation".

Intake Air Temperature Sensor Circuit High
1. DTC P0113 Priority DTC GND circuit between the ECM and the intake air
temperature sensor.
DTC P0641
Note：
・ The intake air temperature sensor shares the
1. Turn OFF the starter switch. GND circuit with other sensors.
2. Disconnect the harness connector from the intake air ・ The DTC set on a sensor which shares this
temperature sensor. circuit may be detected.
3. Turn ON the starter switch. 17. If a problem is discovered, repair the GND circuit.
4. Measure the voltage between the intake air 18. Inspect to see if there is an open circuit or high
temperature sensor signal circuit and a normal GND. resistance in the signal circuit between the ECM and
the intake air temperature sensor.
voltage： 5.5 V
signal circuit between the ECM and the intake air 20. Inspect the ECM harness connector for a contact
temperature sensor. failure.
・There should be no short to the battery or ignition 21. If a problem is discovered, repair the harness
power supply connector.
・There should be no short to the 12 V power supply.
7. Connect the test cable with fuse between the intake ECM Removal".
air temperature sensor signal circuit and the GND
circuit.
ECM Installation".
voltage： 0.1 V
9. If it is at or below the standard value, inspect to see
if there is a short circuit to the 5 V power supply
circuit with the signal circuit between the ECM and 1. Clear the DTC using the trouble diagnosis scan tool.
the intake air temperature sensor.
11. Inspect the intake air temperature sensor harness
connector for a contact failure.
connector.
13. If the harness connector is normal, replace the intake
air temperature sensor.
14. Connect the test cable with fuse between the intake
air temperature sensor signal circuit and a normal
GND.
voltage： 0.1 V
if there is an open circuit or high resistance with the

Engine Coolant Temperature Sensor Circuit Low
DTC P0697
2. Disconnect the harness connector from the water
temperature sensor.
3. Check the coolant temperature sensor display with
voltage： 4.5 V
water temperature sensor.
Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant
temperature sensor Removal".
temperature sensor Installation".
with the signal circuit between the ECM and water
temperature sensor.
failure.
connector.
ECM Removal".
ECM Installation".

Engine Coolant Temperature Sensor Circuit High
1. DTC P0118 Priority DTC 16. If it is at or below the standard value, inspect to see
DTC P0697
water temperature sensor GND circuit.
Note：
1. Turn OFF the starter switch. ・ The water temperature sensor shares the
2. Disconnect the harness connector from the water GND circuit with other sensors.
temperature sensor. ・ The DTC set on a sensor which shares this
3. Turn ON the starter switch. circuit may be detected.
4. Measure the voltage between the water temperature
sensor signal circuit and normal GND. 18. Inspect to see if there is a breakage or high resistance
in the signal circuit of the water temperature sensor.
voltage： 5.5 V
there is a short circuit to the battery or ignition power 20. Inspect the ECM harness connector for a contact
supply with the signal circuit between the ECM and failure.
the water temperature sensor.
6. If a problem is discovered, repair the signal circuit. connector.
7. Connect the test cable with fuse between the water 22. If the harness connector is normal, replace the ECM.
temperature sensor signal circuit and GND circuit.
8. Check the coolant temperature sensor display with ECM Removal".
voltage： 0.1 V ECM Installation".
9. If it is at or below the standard value, inspect to see 23. Set the injector ID code on the ECM.
circuit with the signal circuit between the ECM and
the water temperature sensor.
11. Inspect to see if there is a contact failure with the
water temperature sensor harness connector. 2. Turn the starter switch OFF for 30 seconds or longer.
12. If a problem is discovered, repair the harness 3. Start the engine.
connector.
13. If the harness connector is normal, replace the water
temperature sensor.
14. Connect the test cable with fuse between the water
temperature sensor signal circuit and normal GND.
15. Check the coolant temperature sensor display with
voltage： 0.1 V

Throttle Position Sensor Circuit Low
1. DTC P0122 Priority DTC 13. If a problem is discovered, repair the signal circuit.
DTC P1655 14. Inspect the ECM harness connector for a contact
failure.
connector.
2. Disconnect the harness connector from the intake
throttle valve.
ECM Removal".
4. Measure the voltage between the intake throttle
position sensor 5 V power supply circuit and a
ECM Installation".
normal GND.
voltage： 4.9 V
5 V power supply circuit between the ECM and the 3. DTC P0122 Confirm Resolution
intake throttle position sensor.
Note：
・ The intake throttle position sensor shares the 5
V power supply circuit with other sensors. 3. Start the engine.
・ The DTC set on a sensor which shares this 4. Perform a test-run.
circuit may be detected. 5. Use the trouble diagnosis scan tool to confirm that a
6. If a problem is discovered, repair the 5 V power DTC has not been detected.
supply circuit.
7. Connect the test cable with fuse between the intake
throttle position sensor 5 V power supply circuit and
the signal circuit.
8. Check the intake throttle position sensor display with
voltage： 4.9 V
there is a contact failure with the intake throttle valve
harness connector.
connector.
throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake
throttle valve Removal".
throttle valve Installation".
12. Inspect the signal circuit between the ECM and
intake throttle position sensor.

Throttle Position Sensor Circuit High
1. DTC P0123 Priority DTC Refer to "1.Engine 1J.Electrical(4HK1)
ECM Installation".
DTC P1655
2. Disconnect the harness connector from the intake
throttle valve.
3. Check the intake throttle position sensor display with
the trouble diagnosis scan tool. 2. Turn the starter switch OFF for 30 seconds or longer.
voltage： 0.1 V 3. Start the engine.
4. If it is at or above the standard value, inspect the 4. Perform a test-run.
signal circuit between the ECM and the intake
throttle position sensor.
power supply.
6. Inspect the intake throttle valve harness connector
connector.
throttle valve.
the intake throttle position sensor.
Note：
・ The intake throttle position sensor shares the
GND circuit with other sensors.
・ The DTC set on a sensor which shares this
circuit may be detected.
11. Check the ECM harness connector for a contact
failure.
connector.
ECM Removal".

Fuel Temperature Sensor Circuit Low
DTC P1655
2. Disconnect the harness connector from the fuel
temperature sensor.
3. Check the fuel temperature sensor display with the
voltage： 4.5 V
4. If it is at or above the standard value, replace the fuel
temperature sensor.
pump Removal".
pump Installation".
Note：
・ Do not replace the fuel temperature sensor
separately. If a problem is found, replace the
fuel supply pump.
with the signal circuit between the ECM and fuel
temperature sensor.
failure.
connector.
ECM Removal".
ECM Installation".

Fuel Temperature Sensor Circuit High
1. DTC P0183 Priority DTC 15. Check the fuel temperature sensor display with the
DTC P1655
voltage： 0.1 V
2. Disconnect the harness connector from the fuel GND circuit between the ECM and fuel temperature
temperature sensor. sensor.
3. Turn ON the starter switch. Note：
4. Measure the voltage between the fuel temperature ・ The fuel temperature sensor shares the GND
sensor signal circuit and normal GND. circuit with other sensors.
voltage： 5.5 V ・ The DTC set on a sensor which shares this
supply with the signal circuit between the ECM and 18. Inspect to see if there is an open circuit or high
the fuel temperature sensor. resistance in the signal circuit between the ECM and
the fuel temperature sensor.
7. Connect the test cable with fuse between the fuel
temperature sensor signal circuit and GND circuit. 20. Inspect the ECM harness connector for a contact
failure.
8. Check the fuel temperature sensor display with the
trouble diagnosis scan tool. 21. If a problem is discovered, repair the harness
connector.
voltage： 0.1 V
if there is a short circuit to the 5 V power supply Refer to "1.Engine 1J.Electrical(4HK1)
circuit with the signal circuit between the ECM and ECM Removal".
the fuel temperature sensor.
10. If a problem is discovered, repair the signal circuit. ECM Installation".
11. Inspect to see if there is a contact failure with the 23. Set the injector ID code on the ECM.
fuel temperature sensor harness connector.
12. If a problem is discovered, repair the harness supply pump to the ECM.
connector.
13. If the harness connector is normal, replace the fuel
temperature sensor.
pump Removal". 3. Start the engine.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply 4. Perform a test-run.
pump Installation".
Note：
Note：・ Run the engine for 3 minutes or longer.
・ Do not replace the fuel temperature sensor
separately. If a problem is found, replace the
fuel supply pump.
14. Connect the test cable with fuse between the fuel
temperature sensor signal circuit and normal GND.

Fuel Rail Pressure Sensor Circuit Low
1. DTC P0192 Priority DTC 12. Inspect the ECM harness connector for a contact
failure.
DTC P0641
connector.
pressure sensor.
ECM Removal".
3. Check the fuel rail pressure sensor display with the
ECM Installation".
voltage： 4.5 V
if there is a short circuit to the GND with the signal
circuit between the ECM and the fuel pressure
sensor. 3. DTC P0192 Confirm Resolution
5. If a problem is discovered, repair the signal circuit. 1. Clear the DTC using the trouble diagnosis scan tool.
6. Measure the voltage between the fuel pressure sensor 2. Turn the starter switch OFF for 30 seconds or longer.
5 V power supply circuit and normal GND.
voltage： 4.5 V
there is a contact failure with the fuel pressure sensor
harness connector.
connector.
pressure sensor.
rail assembly Installation".
Note：
・ Do not replace the fuel pressure sensor
the common rail assembly.
resistance with the 5 V power supply circuit between
the ECM and fuel pressure sensor.
Note：
・ The fuel pressure sensor shares the 5 V power
supply circuit with other sensors.
supply circuit.

Fuel Rail Pressure Sensor Circuit High
1. DTC P0193 Priority DTC Note：
DTC P0641 ・ Do not replace the fuel pressure sensor
2. DTC P0193 Diagnostics the common rail assembly.
1. Turn OFF the starter switch. 15. Inspect to see if there is an open circuit or high
2. Disconnect the harness connector from the fuel resistance in the GND circuit between the ECM and
pressure sensor. the fuel pressure sensor.
3. Turn ON the starter switch. Note：
4. Measure the voltage between the fuel pressure sensor ・ The fuel pressure sensor shares the GND
signal circuit and normal GND. circuit with other sensors.
voltage： 5.5 V circuit may be detected.
5. If it is at or above the standard value, inspect to see if 16. If a problem is discovered, repair the GND circuit.
supply with the signal circuit between the ECM and 17. Inspect to see if there is an open circuit or high
the fuel pressure sensor. resistance in the signal circuit between the ECM and
the fuel pressure sensor.
7. Measure the voltage between the fuel pressure sensor
signal circuit and normal GND. 19. Inspect the ECM harness connector for a contact
failure.
voltage： 4.5 V
8. If it is at or above the standard value, inspect to see if connector.
there is a short circuit to the 5 V power supply circuit
with the signal circuit between the ECM and the fuel 21. If the harness connector is normal, replace the ECM.
pressure sensor. Refer to "1.Engine 1J.Electrical(4HK1)
9. If a problem is discovered, repair the signal circuit. ECM Removal".
10. Connect the test cable with fuse between the fuel Refer to "1.Engine 1J.Electrical(4HK1)
pressure sensor signal circuit and GND circuit. ECM Installation".
11. Check the fuel rail pressure sensor display with the 22. Set the injector ID code on the ECM.
trouble diagnosis scan tool. 23. Perform the unit difference learning of the fuel
voltage： 0.1 V supply pump to the ECM.
12. If it is at or below the standard value, inspect to see 3. DTC P0193 Confirm Resolution
if there is a contact failure with the fuel pressure 1. Clear the DTC using the trouble diagnosis scan tool.
connector. 3. Start the engine.
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.

1. DTC P0201 Diagnostics 18. Inspect to see if any foreign matter is attached to the
injector terminal.
19. If any foreign matter is attached to the injector
2. Disconnect the harness connector from the cylinder
terminal, remove it.
head injector intermediate harness connector.
20. Inspect the injector harness intermediate harness
4. Measure the voltage between the first cylinder
21. If a problem is discovered, repair the intermediate
injector charge voltage circuit and normal GND.
harness connector.
voltage： 1.0 V
22. Inspect the first cylinder injector circuit between the
5. If it is at or above the standard value, inspect to see if injector and injector harness intermediate connector.
there is a short circuit to the common power supply 1
charge voltage circuit with the control circuit
・There should be no short between the circuits.
between the ECM and the injector harness
intermediate connector. 23. If a problem is discovered, repair the injector circuit.
6. If a problem is discovered, repair the control circuit. 24. If the first cylinder injector circuit between the
injector and the injector intermediate connector is
7. Measure the voltage between the solenoid control
normal, replace the first cylinder injector.
circuit of the first cylinder injector and normal GND.
voltage： 16.0 V
Injector Removal".
Injector Installation".
supply with the control circuit between the ECM and
the injector harness intermediate connector. 25. When the injector has been replaced, set the injector
ID code on the ECM.
9. If a problem is discovered, repair the control circuit.
circuit of the first cylinder injector and normal GND. 27. Inspect the ECM harness connector for a contact
failure.
voltage： 12.0 V
connector.
control circuit between the ECM and injector harness 29. If the harness connector is normal, replace the ECM.
intermediate connector.
12. If a problem is discovered, repair the control circuit. ECM Removal".
13. Inspect the injector harness intermediate connector Refer to "1.Engine 1J.Electrical(4HK1)
for a contact failure. ECM Installation".
14. If a problem is discovered, repair the injector harness 30. Set the injector ID code on the ECM.
15. Remove the cylinder head cover. supply pump to the ECM.
Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder 2. DTC P0201 Confirm Resolution
head cover Removal".
16. Inspect the injector harness tightening nut for
looseness.
17. If the injector harness tightening nut is loose, tighten
it. 4. Perform a test-run.

injector terminal.
4. Measure the voltage between the second cylinder
harness connector.
voltage： 1.0 V
22. Inspect the second cylinder injector circuit between
5. If it is at or above the standard value, inspect to see if the injector and injector harness intermediate
there is a short circuit to the common power supply 2 connector.
23. If a problem is discovered, repair the injector circuit.
24. If the second cylinder injector circuit between the
circuit of the second cylinder injector and normal
normal, replace the second cylinder injector.
GND.
voltage： 16.0 V
Injector Removal".
ID code on the ECM.
circuit of the second cylinder injector and normal 27. Inspect the ECM harness connector for a contact
GND. failure.
voltage： 12.0 V 28. If a problem is discovered, repair the harness
connector.
if there is an open circuit or high resistance with the 29. If the harness connector is normal, replace the ECM.
control circuit between the ECM and injector harness
ECM Removal".
13. Inspect the injector harness intermediate connector ECM Installation".
14. If a problem is discovered, repair the injector harness
15. Remove the cylinder head cover.
looseness. 3. Start the engine.
17. If the injector harness tightening nut is loose, tighten 4. Perform a test-run.
it.

injector terminal.
4. Measure the voltage between the third cylinder
harness connector.
voltage： 1.0 V
22. Inspect the third cylinder injector circuit between the
5. If it is at or above the standard value, inspect to see if injector and injector harness intermediate connector.
there is a short circuit to the common power supply 2
intermediate connector. 23. If a problem is discovered, repair the injector circuit.
6. If a problem is discovered, repair the control circuit. 24. If the third cylinder injector circuit between the
normal, replace the third cylinder injector.
circuit of the third cylinder injector and normal
GND. Refer to "1.Engine 1C.Fuel System(4HK1)
Injector Removal".
voltage： 16.0 V
supply with the control circuit between the ECM and 25. When the injector has been replaced, set the injector
the injector harness intermediate connector. ID code on the ECM.
9. If a problem is discovered, repair the control circuit. 26. Disconnect the harness connector from the ECM.
10. Measure the voltage between the solenoid control 27. Inspect the ECM harness connector for a contact
circuit of the third cylinder injector and normal failure.
GND.
voltage： 12.0 V connector.
11. If it is at or below the standard value, inspect to see 29. If the harness connector is normal, replace the ECM.
ECM Removal".
ECM Installation".
13. Inspect the injector harness intermediate connector
head cover Removal". 2. Turn the starter switch OFF for 30 seconds or longer.
16. Inspect the injector harness tightening nut for 3. Start the engine.
looseness.
it.

injector terminal.
4. Measure the voltage between the fourth cylinder
harness connector.
voltage： 1.0 V
22. Inspect the fourth cylinder injector circuit between
5. If it is at or above the standard value, inspect to see if the injector and injector harness intermediate
there is a short circuit to the common power supply 1 connector.
23. If a problem is discovered, repair the injector circuit.
24. If the fourth cylinder injector circuit between the
circuit of the fourth cylinder injector and normal
normal, replace the fourth cylinder injector.
GND.
voltage： 16.0 V
Injector Removal".
ID code on the ECM.
circuit of the third cylinder injector and normal 27. Inspect the ECM harness connector for a contact
GND. failure.
voltage： 12.0 V 28. If a problem is discovered, repair the harness
connector.
if there is an open circuit or high resistance with the 29. If the harness connector is normal, replace the ECM.
ECM Removal".
13. Inspect the injector harness intermediate connector ECM Installation".
looseness. 3. Start the engine.
17. If the injector harness tightening nut is loose, tighten 4. Perform a test-run.
it.

Engine Coolant Over Temperature Condition
1. DTC P0217 Priority DTC 4. Confirm that the coolant temperature display does
not show a value at or above the standard value.
DTC P0117
1. Inspect the engine cooling system.
Refer to "1.Engine 1D.Cooling(4HK1)
Coolant Inspection".
Refer to "1.Engine 1D.Cooling(4HK1) Cooling fan
belt Inspection".
Thermostat Inspection".
Refer to "1.Engine 1D.Cooling(4HK1) Water pump
assembly Inspection".
Radiator Inspection".
2. While checking the coolant temperature display with
the trouble diagnosis scan tool, start the engine.
3. Wait until the engine has been completely warmed
up.
coolant temperature display is at or above the
standard value.
5. If it is at or below the standard value, check with the
driver if the overheat occurred due to a cause such as
low engine coolant level.
6. Make sure to inspect the engine if it has experienced
engine overheat in the past.
7. Inspect the engine coolant temperature sensor.
temperature sensor Inspection".
8. If any abnormality is found in the inspection results,
replace the water temperature sensor.
3. While checking the coolant temperature display with
the trouble diagnosis scan tool, start the engine and
wait until it is completely warmed up.

Engine Overspeed Condition
DTC P0335
DTC P0336
3. Check the engine RPM display with the trouble
4. Increase the engine RPM, as needed.
5. Check the engine RPM display with the trouble
rotational speed： 2500 RPM
6. When the standard value has not been exceeded,
check with the operator if an operation failure has
occurred due to the overrun.
7. Make sure to inspect the engine if it has experienced
engine overrun in the past.
sensor Inspection".
9. If any abnormality is found in the inspection results,
replace the crankshaft position sensor.
sensor Removal".
3. Start the engine, and rev the engine a few times in
neutral between the idling speed and the maximum
revolution speed without load while checking the
engine rpm display with the trouble diagnosis scan
tool.
4. Confirm that the engine RPM display does not
exceed the standard value.
rotational speed： 2500 RPM

Turbocharger Overboost Condition
DTC P0045 ・ The atmospheric pressure in the trouble
diagnosis scan tool normally indicates a value
DTC P0237 close to the surrounding atmospheric
DTC P0238 pressure.
DTC P0638 13. If the atmospheric pressure display is within the
standard range, inspect the boost sensor system.
DTC P2228
Refer to "1.Engine 1F.Induction(4HK1) Boost
DTC P2229 sensor Inspection".
2. DTC P0234 Diagnostics 14. If the inspection result of the boost sensor has a
1. Turn ON the starter switch. problem, replace the boost sensor.
2. Check the difference between the boost pressure Refer to "1.Engine 1F.Induction(4HK1) Boost
display and the atmospheric pressure display with sensor Removal".
the trouble diagnosis scan tool. Refer to "1.Engine 1F.Induction(4HK1) Boost
specified value： 10.0 kPa { 1.5 psi } sensor Installation".
Note： 15. If the atmospheric pressure display is outside the
・ The value is normal if the boost pressure standard range, inspect the atmospheric pressure
indicated by the trouble diagnosis scan tool is sensor system.
close to the atmospheric pressure when the 16. If the inspection result of the atmospheric pressure
starter switch is ON and the engine is stopped. sensor has a problem, replace the atmospheric
3. If it is at or below the standard value, inspect to see pressure sensor.
if there is a failure with the actuator which controls 17. Inspect the ECM harness connector for a contact
the turbocharger nozzle. failure.
4. If a problem is discovered, repair the actuator. 18. If a problem is discovered, repair the harness
5. Perform the intake throttle test with the trouble connector.
diagnosis scan tool to check the intake throttle valve 3. DTC P0234 Confirm Resolution
for fixing.
6. If a problem is discovered, repair the intake throttle
valve.
7. Check to see if there is oil mixing in the air intake
piping. 4. Perform a test-run.
8. If oil is attached inside the pipe, the intercooler, or 5. Use the trouble diagnosis scan tool to confirm that a
the turbocharger, wipe it off. DTC has not been detected.
9. Use the trouble diagnosis scan tool to confirm that
the boost sensor signal is normal.
10. Compare the sensor values under various load
conditions to check for an abnormally high value.
11. If it is at or above the standard value, compare the
value of the atmospheric pressure with the
surrounding atmospheric pressure.
atmospheric pressure display is within the standard
range.

Turbo Charger Boost Sensor Circuit Low
failure.
connector.
2. Disconnect the harness connector from the boost
sensor.
ECM Removal".
4. Measure the voltage between the 5 V power supply
circuit of the boost sensor harness connector and a
ECM Installation".
normal GND.
voltage： 4.5 V
boost sensor.
Note：
・ The boost sensor shares the 5 V power supply
circuit with other sensors. 3. Start the engine.
supply circuit.
power supply circuit and the signal circuit of the
boost sensor harness connector.
8. Check the boost pressure sensor display with the
voltage： 4.5 V
there is a contact failure with the boost sensor
harness connector.
connector.
11. If the harness connector is normal, replace the boost
sensor.
sensor Removal".
boost sensor.

Turbo Charger Boost Sensor Circuit High
ECM Installation".
DTC P1655
sensor.
3. Check the boost pressure sensor display with the
trouble diagnosis scan tool. 2. Turn the starter switch OFF for 30 seconds or longer.
signal circuit between the ECM and the boost sensor.
・There should be no short to the battery or ignition DTC has not been detected.
power supply.
the boost sensor.
Note：
・ The boost sensor shares the GND circuit with
other sensors.
8. Inspect the boost sensor harness connector for a
contact failure.
connector.
sensor.
sensor Removal".
failure.
connector.
ECM Removal".

Crankshaft Position Sensor Circuit
1. DTC P0335 Priority DTC 13. Connect the test light between the signal circuit and
normal GND of the crankshaft position sensor
DTC P0340
harness connector.
DTC P0641
14. Measure the voltage between the probe of the test
2. DTC P0335 Diagnostics light and a normal GND.
1. Turn OFF the starter switch. voltage： 4.5 V
2. Disconnect the harness connector from the 15. If it is at or above the standard value, inspect to see if
crankshaft position sensor. there is a short circuit to the 5 V power supply circuit
crankshaft position sensor.
circuit and normal GND of the crankshaft position
sensor harness connector. 17. Measure the voltage between the 5 V power supply
circuit and GND circuit of the crankshaft position
voltage： 4.5 V
voltage： 4.50 V
5 V power supply circuit between the ECM and the 18. If it is at or above the standard value, inspect to see if
crankshaft position sensor. there is a contact failure with the crankshaft position
Note：
・ The crankshaft position sensor shares the 5 V 19. If a problem is discovered, repair the harness
power supply circuit with other sensors. connector.
・ The DTC set on a sensor which shares this 20. If the harness connector is normal, inspect the
circuit may be detected. crankshaft position sensor.
6. If a problem is discovered, repair the 5 V power Refer to "1.Engine 1B.Mechanical(4HK1) CKP
supply circuit. sensor Inspection".
7. Measure the voltage between the signal circuit and 21. If a problem is discovered, replace the crankshaft
normal GND of the crankshaft position sensor position sensor.
harness connector.
voltage： 5.5 V sensor Removal".
8. If it is at or above the standard value, inspect to see if Refer to "1.Engine 1B.Mechanical(4HK1) CKP
there is a short circuit to the battery or ignition power sensor Installation".
supply with the signal circuit between the ECM and
22. Inspect the GND circuit between the ECM and the
the crankshaft position sensor.
crankshaft position sensor for an open circuit and
9. If a problem is discovered, repair the signal circuit. high resistance.
10. Measure the voltage between the signal circuit of the Note：
crankshaft position sensor harness connector and a ・ The crankshaft position sensor shares the
normal GND again. GND circuit with other sensors.
voltage： 4.5 V ・ The DTC set on a sensor which shares this
11. If it is at or below the standard value, inspect the circuit may be detected.
signal circuit between the ECM and the crankshaft 23. If a problem is discovered, repair the GND circuit.
position sensor.
・There should be no open circuit or high resistance. failure.
ECM Removal".
ECM Installation".

Crankshaft Position Sensor Circuit Range/Performance
DTC P0335
DTC P0340
DTC P0641
1. Inspect the crankshaft position sensor circuit.
・There should be enough clearing from the wiring or
component of the fuel injection unit.
・There should be enough clearing from additionally
installed electronic components.
・There should be enough clearing from the solenoids and
relays.
2. If a problem is discovered, repair the crankshaft
position sensor circuit.
failure.
connector.
7. Disconnect the harness connector from the
8. Inspect the crankshaft position sensor harness
connector.
sensor Inspection".
11. If a problem is discovered, replace the crankshaft
position sensor.
sensor Removal".

Camshaft Position Sensor Circuit
1. DTC P0340 Priority DTC voltage： 4.5 V
DTC P0601 15. If it is at or above the standard value, inspect to see if
there is a short circuit to the 5 V power supply circuit
DTC P0651
2. DTC P0340 Diagnostics camshaft position sensor.
1. Turn OFF the starter switch. 16. If a problem is discovered, repair the signal circuit.
2. Disconnect the harness connector from the camshaft 17. Measure the voltage between the 5 V power supply
position sensor. circuit and GND circuit of the camshaft position
voltage： 4.5 V
circuit and normal GND of the camshaft position 18. If it is at or above the standard value, inspect to see if
sensor harness connector. there is a contact failure with the camshaft position
voltage： 4.5 V
connector.
5 V power supply circuit between the ECM and the 20. If the harness connector is normal, inspect the
camshaft position sensor. camshaft position sensor.
6. If a problem is discovered, repair the 5 V power Refer to "1.Engine 1B.Mechanical(4HK1) CMP
supply circuit. sensor Inspection".
7. Measure the voltage between the signal circuit and 21. If a problem is discovered, replace the camshaft
normal GND of the camshaft position sensor harness position sensor.
connector.
voltage： 5.5 V sensor Removal".
8. If it is at or above the standard value, inspect to see if Refer to "1.Engine 1B.Mechanical(4HK1) CMP
there is a short circuit to the battery or ignition power sensor Installation".
22. Inspect the camshaft gear.
the camshaft position sensor.
・The camshaft gear should not be damaged
・The camshaft gear should be installed correctly.
10. Measure the voltage between the signal circuit of the
23. If a problem is discovered, repair the camshaft gear.
camshaft position sensor harness connector and a
normal GND again. 24. Inspect the GND circuit between the ECM and the
camshaft position sensor for an open circuit and high
voltage： 4.5 V
resistance.
11. If it is at or below the standard value, inspect the
Note：
signal circuit between the ECM and the camshaft
position sensor. ・ The camshaft position sensor shares the GND
circuit with other sensors.
13. Connect the test light between the signal circuit and
normal GND of the camshaft position sensor harness
failure.
connector.
14. Measure the voltage between the probe of the test
connector.
light and a normal GND.
ECM Removal".
ECM Installation".

Exhaust Gas Recirculation Control Circuit Range/Performance
1. DTC P0404 Priority DTC Refer to "1.Engine 1H.Aux. Emission Control
Devices(4HK1) EGR valve Installation".
DTC P0409
15. Restore the actual unit.
1. Remove the EGR valve assembly from the engine.
Refer to "1.Engine 1H.Aux. Emission Control
Devices(4HK1) EGR valve Removal". 18. Turn the starter switch OFF for 30 seconds or longer.
2. Inspect the EGR valve. 19. Start the engine.
・There should be nothing to limit flow inside the EGR 20. Perform a test-run.
valve.
21. Check the DTC using the trouble diagnosis scan tool.
・There should be no excessive accumulates inside the
EGR valve. 22. If the DTC P0404 has been detected, replace the
・There should be no bending with the valve shaft or ECM.
valve itself inside the EGR valve.
3. Turn OFF the starter switch. ECM Removal".
4. Disconnect the harness connector from the EGR Refer to "1.Engine 1J.Electrical(4HK1)
valve. ECM Installation".
5. Inspect the EGR valve harness connector for a 23. Set the injector ID code on the ECM.
contact failure.
6. If a problem is discovered, repair the harness supply pump to the ECM.
connector.
failure.
connector. 4. Perform a test-run.
10. Inspect to see if there is an open circuit or high 5. Use the trouble diagnosis scan tool to confirm that a
resistance in the EGR control circuit. DTC has not been detected.
11. If a problem is discovered, repair the EGR control
circuit.
12. Inspect the EGR solenoid circuit between the ECM
and EGR valve.
power supply circuit.
・There should be no short to EGR position sensor
circuit.
13. If a problem is discovered, repair the EGR solenoid
circuit.
14. If the EGR solenoid circuit is normal, replace the
EGR valve.
Devices(4HK1) EGR valve Removal".

Exhaust Gas Recirculation Sensor Circuit
1. DTC P0409 Priority DTC 12. If a problem is discovered, repair the GND circuit.
DTC P1655 13. While momentarily disconnecting the test cable with
fuse from the EGR position sensor 1 signal circuit
and 5 V power supply circuit, check the EGR
1. Turn OFF the starter switch. position 1 display with the trouble diagnosis scan
tool.
2. Disconnect the harness connector from the EGR
valve. 14. While momentarily disconnecting the test cable with
fuse from the EGR position sensor 2 signal circuit
and 5 V power supply circuit, check the EGR
4. Use the trouble diagnosis scan tool to check if any of position 2 display with the trouble diagnosis scan
the EGR position 1, EGR position 2, and EGR tool.
position 3 shows ON.
15. While momentarily disconnecting the test cable with
5. If there is a data display showing ON, inspect the fuse from the EGR position sensor 3 signal circuit
signal circuit between the ECM and EGR valve of and 5 V power supply circuit, check the EGR
the EGR showing ON. position 3 display with the trouble diagnosis scan
・There should be no short to the battery or ignition tool.
power supply. 16. Check to see if there is a data display which does not
・There should be no short to the 5 V power supply. display ON when the EGR position sensor signal
6. If a problem is discovered, repair the signal circuit. circuit and 5 V power supply circuit are shorted.
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.
circuit may be detected. 20. If a problem is discovered, repair the harness
connector.
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
Note：
・ The EGR position sensor shares the GND Devices(4HK1) EGR valve Installation".
・ The DTC set on a sensor which shares this 24. Inspect the ECM harness connector for a contact
circuit may be detected. failure.
connector.
ECM Removal".
ECM Installation".

Intake Manifold Temperature Sensor Circuit High
1. DTC P041C Priority DTC 16. If it is at or below the standard value, inspect to see
DTC P1655
GND circuit between the ECM and IMT sensor.
2. DTC P041C Diagnostics
Note：
1. Turn OFF the starter switch. ・ The IMT sensor shares the GND circuit with
2. Disconnect the harness connector from the IMT other sensors.
sensor. ・ The DTC set on a sensor which shares this
3. Turn ON the starter switch. circuit may be detected.
4. Measure the voltage between the IMT sensor signal
circuit and a normal GND. 18. Inspect to see if there is an open circuit or high
resistance in the signal circuit between the ECM and
voltage： 5.5 V
the IMT sensor.
supply with the signal circuit between the ECM and 20. Inspect the ECM harness connector for a contact
the IMT sensor. failure.
6. If a problem is discovered, repair the signal circuit. 21. If a problem is discovered, repair the harness
connector.
7. Connect the test cable with fuse between the IMT
sensor signal circuit and the GND circuit. 22. If the harness connector is normal, replace the ECM.
8. Check the intake manifold temperature sensor Refer to "1.Engine 1J.Electrical(4HK1)
display with the trouble diagnosis scan tool. ECM Removal".
voltage： 0.1 V Refer to "1.Engine 1J.Electrical(4HK1)
ECM Installation".
if there is a short circuit to the 5 V power supply 23. Set the injector ID code on the ECM.
IMT sensor.
3. DTC P041C Confirm Resolution
11. Inspect the IMT sensor harness connector for a
contact failure.
connector. 3. Start the engine.
13. If the harness connector is normal, replace the IMT 4. Perform a test-run.
sensor.
Note：
Refer to "1.Engine 1F.Induction(4HK1) IMT ・ Run the engine for 3 minutes or longer.
sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1) IMT DTC has not been detected.
14. Connect the test cable with fuse between the IMT
sensor signal circuit and a normal GND.
15. Check the intake manifold temperature sensor
display with the trouble diagnosis scan tool.
voltage： 0.1 V

Intake Manifold Temperature Sensor Circuit Low
1. DTC P041D Priority DTC
DTC P1655
2. DTC P041D Diagnostics
2. Disconnect the harness connector from the IMT
sensor.
3. Check the intake manifold temperature sensor
voltage： 4.5 V
IMT sensor.
Refer to "1.Engine 1F.Induction(4HK1) IMT
sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1) IMT
IMT sensor.
failure.
connector.
ECM Removal".
ECM Installation".
3. DTC P041D Confirm Resolution

DTC P0093
DTC P0427
DTC P1093
1. Inspect the exhaust gas temperature sensor 1.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas
2. If a problem is discovered, replace the exhaust gas
temperature sensor 1.
3. Inspect the DPD filter for a damage.
Refer to "1.Engine 1G.Exhaust(4HK1) DPD
4. If a problem is discovered, replace the DPD filter.
assembly Disassembly".
assembly Reassembly".
5. Perform the DPD regeneration data reset with the

DTC P0697
2. Disconnect the harness connector from the exhaust
gas temperature sensor 1.
3. Check the exhaust temperature sensor (before the
filter) display with the trouble diagnosis scan tool.
voltage： 4.5 V
exhaust gas temperature sensor 1.
failure.
connector.
ECM Removal".
ECM Installation".

1. DTC P0428 Priority DTC 16. If it is at or above the standard value, inspect to see if
there is an open circuit or high resistance with the
DTC P0697
signal circuit between the ECM and the exhaust gas
2. DTC P0428 Diagnostics temperature sensor 1.
1. Turn OFF the starter switch. 17. If a problem is discovered, repair the signal circuit.
2. Disconnect the harness connector from the exhaust 18. Inspect to see if there is an open circuit or high
gas temperature sensor 1. resistance in the GND circuit between the ECM and
the exhaust gas temperature sensor 1.
4. Measure the voltage between the exhaust gas Note：
temperature sensor 1 signal circuit and normal GND. ・ The exhaust gas temperature sensor 1 shares
the GND circuit with other sensors.
voltage： 5.5 V
・ The DTC may be detected on a sensor which
5. If it is at or above the standard value, inspect to see if shares this circuit.
the exhaust gas temperature sensor 1. 20. Inspect the ECM harness connector for a contact
failure.
7. Connect the test cable with fuse between the exhaust
connector.
gas temperature sensor 1 signal circuit and GND
circuit. 22. If the harness connector is normal, replace the ECM.
8. Check the exhaust temperature sensor (before the Refer to "1.Engine 1J.Electrical(4HK1)
filter) display with the trouble diagnosis scan tool. ECM Removal".
voltage： 0.1 V Refer to "1.Engine 1J.Electrical(4HK1)
ECM Installation".
if there is a short circuit to the 5 V power supply 23. Set the injector ID code on the ECM.
exhaust gas temperature sensor 1 harness connector.
connector. 3. Start the engine and warm it up until the coolant
exhaust gas temperature sensor 1. Specified value： 70 ℃ { 158 °F }
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas 4. Repeatedly rev the engine in neutral to increase the
temperature sensor Removal". engine rpm while checking the exhaust temperature
sensor (in front of the filter) display with the trouble
the exhaust temperature sensor (before the filter)
gas temperature sensor 1 signal circuit and normal
display does not exceed the standard value.
GND.
voltage： 4.8 V
filter) display with the trouble diagnosis scan tool. 6. Use the trouble diagnosis scan tool to confirm that a
voltage： 0.1 V

1. DTC P042B Priority DTC
DTC P0093
DTC P042C
DTC P1093
2. DTC P042B Diagnostics
1. Inspect the exhaust gas temperature sensor 2.
temperature sensor 2.
3. Inspect the DPD filter for a damage.
4. If a problem is discovered, replace the DPD filter.
3. DTC P042B Confirm Resolution

1. DTC P042C Priority DTC
DTC P0697
2. DTC P042C Diagnostics
2. Disconnect the harness connector from the exhaust
oxidation catalyst) display with the trouble diagnosis
scan tool.
voltage： 4.5 V
failure.
connector.
ECM Removal".
ECM Installation".
3. DTC P042C Confirm Resolution

1. DTC P042D Priority DTC voltage： 0.1 V
DTC P0697 16. If it is at or above the standard value, inspect to see if
2. DTC P042D Diagnostics
signal circuit between the ECM and the exhaust gas
1. Turn OFF the starter switch. temperature sensor 2.
2. Disconnect the harness connector from the exhaust 17. If a problem is discovered, repair the signal circuit.
3. Turn ON the starter switch. resistance in the GND circuit between the ECM and
4. Measure the voltage between the exhaust gas
temperature sensor 2 signal circuit and normal GND. Note：
voltage： 5.5 V ・ The exhaust gas temperature sensor 2 shares
there is a short circuit to the battery or ignition power ・ The DTC may be detected on a sensor which
supply with the signal circuit between the ECM and shares this circuit.
the exhaust gas temperature sensor 2. 19. If a problem is discovered, repair the GND circuit.
6. If a problem is discovered, repair the signal circuit. 20. Inspect the ECM harness connector for a contact
failure.
gas temperature sensor 2 signal circuit and GND 21. If a problem is discovered, repair the harness
circuit. connector.
8. Check the exhaust temperature sensor (before the 22. If the harness connector is normal, replace the ECM.
scan tool.
ECM Removal".
voltage： 0.1 V
9. If it is at or below the standard value, inspect to see ECM Installation".
the exhaust gas temperature sensor 2. 24. Perform the unit difference learning of the fuel
3. DTC P042D Confirm Resolution
exhaust gas temperature sensor 2 harness connector. 1. Clear the DTC using the trouble diagnosis scan tool.
12. If a problem is discovered, repair the harness 2. Turn the starter switch OFF for 30 seconds or longer.
connector.
3. Start the engine, and warm it up until the coolant
13. If the harness connector is normal, replace the temperature reaches the standard value.
4. Repeatedly rev the engine in neutral to increase the
engine rpm while checking the exhaust temperature
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas sensor (in front of the oxidation catalyst) display
temperature sensor Installation". with the trouble diagnosis scan tool.
14. Connect the test cable with fuse between the exhaust 5. Use the trouble diagnosis scan tool to confirm that
gas temperature sensor 2 signal circuit and normal the exhaust temperature sensor (before the oxidation
GND. catalyst) display does not exceed the standard value.
15. Check the exhaust temperature sensor (before the voltage： 4.8 V
scan tool.

Oil Pressure Sensor Circuit Low
connector.
DTC P0697
ECM Removal".
2. Disconnect the harness connector from the oil
pressure sensor.
ECM Installation".
circuit and normal GND of the oil pressure sensor
harness connector.
voltage： 4.5 V
if there is an open circuit or high resistance with the 2. Turn the starter switch OFF for 30 seconds or longer.
5 V power supply circuit between the ECM and the
oil pressure sensor.
supply circuit. 5. Use the trouble diagnosis scan tool to confirm that a
power supply circuit and signal circuit of the oil
pressure sensor harness connector.
8. Check the oil pressure sensor display with the
voltage： 4.5 V
there is a contact failure with the oil pressure sensor
harness connector.
connector.
11. If the harness connector is normal, replace the oil
pressure sensor.
Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure
sensor Removal".
oil pressure sensor.
failure.

Oil Pressure Sensor Circuit High
ECM Installation".
DTC P0697
2. Disconnect the harness connector from the oil
pressure sensor.
3. Check the oil pressure sensor display with the
signal circuit between the ECM and the oil pressure
sensor.
power supply.
the oil pressure sensor.
Note：
・ The oil pressure sensor shares the GND circuit
with other sensors.
8. Inspect the oil pressure sensor harness connector for
a contact failure.
connector.
10. If the harness connector is normal, replace the oil
pressure sensor.
sensor Removal".
failure.
connector.
ECM Removal".

System Voltage
1. DTC P0560 Diagnostics voltage： 18.0 V
1. Turn OFF the starter switch. 19. If it is at or below the standard value, inspect the
fuse.
2. Disconnect the harness connector from the mass air
flow sensor. 20. If the fuse is faulty, replace the fuse.
3. Use the trouble diagnosis scan tool to check if a DTC 21. If it is at or below the standard value, repair an open
is detected. circuit or high resistance in the ignition power supply
circuit between the fuse and dropping register.
4. If a DTC has not been detected, inspect the mass air
flow sensor harness connector for a contact failure. 22. Measure the voltage between the voltage supply
circuit of the dropping register and a normal GND.
connector. voltage： 13.0 V
6. If the harness connector is normal, replace the mass 23. If it is at or above the standard value, inspect to see if
air flow sensor. there is a contact failure with the dropping register
harness connector.
8. Leave the mass air flow sensor harness connector
connector.
disconnected.
9. Disconnect the harness connector from the dropping
resistance in the voltage supply circuit between the
register.
ECM and the dropping register.
10. Use the trouble diagnosis scan tool to check if a DTC
26. If a problem is discovered, repair the voltage supply
is detected.
circuit.
11. If a DTC has been detected, inspect the voltage
supply circuit between the ECM and dropping
failure.
register.
connector.
power supply. 29. If the harness connector is normal, replace the ECM.
12. If a problem is discovered, repair the voltage supply Refer to "1.Engine 1J.Electrical(4HK1)
circuit. ECM Removal".
13. If the voltage supply circuit is normal, inspect the 12 Refer to "1.Engine 1J.Electrical(4HK1)
V power supply circuit between the ECM and the ECM Installation".
mass air flow sensor.
power supply.
supply circuit. 1. Clear the DTC using the trouble diagnosis scan tool.
15. Check the resistance value of the dropping register. 2. Turn the starter switch OFF for 30 seconds or longer.
resistance： 45.0 to 55.0 Ω 3. Start the engine.
16. If the resistance value is outside the standard range, 4. Perform a test-run.
replace the dropping register.
17. Turn ON the starter switch. DTC has not been detected.
18. Measure the voltage between the ignition power
supply circuit of the dropping register and a normal
GND.

System Voltage High
1. Check if the battery charger has been recently
connected to the battery.
2. Start the engine, and idle it.
3. Check the ignition voltage display with the trouble
voltage： 32.0 V
charging system.
Generator Reassembly".
5. If a problem is discovered, repair the charging
system.
6. If the charging system is normal, replace the ECM.
ECM Removal".
ECM Installation".
3. Start the engine, and idle it.
4. Check the ignition voltage display with the trouble
diagnosis scan tool, and confirm that the value does
not exceed the standard value.
voltage： 32.0 V

Internal Control Module Memory Check Sum Error
1. Replace the ECM.
ECM Removal".
ECM Installation".

Control Module Programming Error
1. Confirm that the connecting sections of all tools are
securely connected.
2. Confirm that the programming device is operating
normally.
the correct injector ID code has been entered to the
ECM.
Note：
・ When the injector ID code has been correctly
input, clear the DTC using the trouble
has been detected.
7. If a DTC has been detected, replace the ECM.
ECM Removal".
ECM Installation".

Internal Control Module Random Access Memory (RAM) Error
1. Replace the ECM.
ECM Removal".
ECM Installation".

ECM/PCM Processor
1. Replace the ECM.
ECM Removal".
ECM Installation".

Internal Control Module A/D Processing Performance
1. DTC P060B Diagnostics
1. Replace the ECM.
ECM Removal".
ECM Installation".
2. DTC P060B Confirm Resolution

Throttle Actuator Control Range/Performance
1. DTC P0638 Priority DTC ・There should be no short to intake throttle position
sensor circuit.
DTC P0122
14. If a problem is discovered, repair the solenoid
DTC P0123
circuit.
15. If the solenoid circuit is normal, replace the intake
1. Remove the air intake hose from the intake throttle throttle valve.
valve.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake throttle valve Removal".
2. Inspect the intake throttle valve. throttle valve Installation".
・The intake throttle valve flow should not be limited. 16. Restore the actual unit.
・There should be no excessive deposit inside the throttle
bore of the intake throttle valve.
・There should be no bending with the butterfly valve of 18. Turn the starter switch OFF for 30 seconds or longer.
the intake throttle valve.
Note：
・The intake throttle valve should not be locked.
・ The starter switch must be once turned ON
3. If a problem is discovered, replace the intake throttle and then turned OFF before clearing the DTC.
valve.
throttle valve Removal". 20. Turn the starter switch OFF for 30 seconds or longer.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake 21. Start the engine.

throttle valve Installation". 22. Use the trouble diagnosis scan tool to check if a DTC
4. Turn OFF the starter switch. has been detected.
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.
11. Inspect the intake throttle valve circuit for high
resistance. Note：
・ The starter switch must be once turned ON
and then turned OFF before clearing the DTC.
13. Inspect the solenoid circuit between the ECM and
the intake throttle valve.
・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.

1. DTC P0641 Diagnostics voltage： 4.5 V
1. Turn OFF the starter switch. 17. If it is at or above the standard value, replace the
accelerator position sensor. Refer to "1.Engine 1B.Mechanical(4HK1) CKP
sensor Removal".
4. Measure the voltage between the accelerator position
sensor 5 V power supply circuit and GND of the
accelerator position sensor harness connector. 18. If it is at or below the standard value, turn the starter
switch OFF.
voltage： 5.5 V
pressure sensor.
supply with the accelerator position sensor 5 V 20. Turn ON the starter switch.
power supply circuit between the ECM and the
21. Measure the voltage between the accelerator position
accelerator position sensor.
6. If a problem is discovered, repair the accelerator accelerator position sensor harness connector.
position sensor 5 V power supply circuit.
voltage： 4.5 V
7. Inspect to see if there is a short circuit to the battery
or ignition power supply with the crankshaft position
pressure sensor.
sensor 5 V power supply circuit between the ECM
and the crankshaft position sensor. Refer to "1.Engine 1C.Fuel System(4HK1) Common
position sensor 5 V power supply circuit between the Refer to "1.Engine 1C.Fuel System(4HK1) Common
ECM and the crankshaft position sensor. rail assembly Installation".
9. Inspect to see if there is a short circuit to the battery Note：
or ignition power supply with the fuel pressure ・ Do not replace the fuel pressure sensor
sensor 5 V power supply circuit between the ECM separately. When a problem is found, replace
and the fuel pressure sensor. the common rail assembly.
10. If a problem is discovered, repair the fuel pressure 23. If it is at or below the standard value, inspect to see
sensor 5 V power supply circuit. if there is a short circuit to the GND with the
11. If it is at or below the standard value, measure the accelerator position sensor 5 V power supply circuit
voltage between the 5 V power supply circuit and between the ECM and the accelerator position
GND of the accelerator position sensor harness sensor.
connector. 24. If a problem is discovered, repair the accelerator
voltage： 4.5 V position sensor 5 V power supply circuit.
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.
14. Disconnect the harness connector from the position sensor 5 V power supply circuit.
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.
28. If a problem is discovered, repair the fuel pressure
sensor 5 V power supply circuit.
ECM Removal".
ECM Installation".

Malfunction Indicator Lamp (MIL) Control Circuit
1. DTC P0650 Diagnostics 22. Set the injector ID code on the ECM.
1. Confirm that the monitor panel operates properly. 23. Perform the unit difference learning of the fuel
24. If the diagnostic light does not turn on, remove the
3. Inspect the fuse.
diagnostic light bulb from the monitor panel.
4. If a problem is discovered, replace the fuse.
25. Inspect the diagnostic light bulb.
Note：
・ When the fuse is blown again, repair the cause
of fuse meltdown. 27. Inspect to see if there is an open circuit or high
resistance in the ignition power supply circuit
5. Turn OFF the starter switch. between the fuse and the monitor panel.
6. Disconnect the harness connector from the ECM. 28. If a problem is discovered, repair the ignition power
7. Turn ON the starter switch. supply circuit.
8. Check to see if the diagnosis light is off. 29. Inspect to see if there is an open circuit or high
resistance in the diagnostic light control circuit
9. If the diagnostic light is not turned off, repair the between the ECM and the monitor panel.
short circuit to GND in the diagnostic light control
circuit between the ECM and the monitor panel. 30. If a problem is discovered, repair the control circuit.
10. Turn OFF the starter switch. 31. Inspect the monitor panel harness connector for a
contact failure.
11. Remove the fuse.
12. Turn ON the starter switch. connector.
13. Measure the voltage between the diagnostic light 33. When the harness connector is normal, replace the
control circuit and GND of the ECM harness monitor panel.
connector.
voltage： 1.0 V
14. If it is at or above the standard value, repair the short
circuit to the battery or ignition power supply circuit 2. Turn the starter switch OFF for 30 seconds or longer.
in the diagnostic light control circuit between the 3. Turn the starter switch ON, and wait for 10 seconds.
ECM and the monitor panel.
16. Install the fuse. DTC has not been detected.
17. Connect the test cable with fuse between the
diagnostic light control circuit and GND of the ECM
harness connector.
19. If the diagnosis light comes on, inspect ECM harness
connector.
ECM Removal".
ECM Installation".

1. DTC P0651 Diagnostics 15. If it is at or above the standard value, replace the
atmospheric pressure sensor.
2. Disconnect the harness connector from the camshaft
if there is a short circuit to the GND with the
position sensor.
camshaft position sensor 5 V power supply circuit
3. Turn ON the starter switch. between the ECM and the camshaft position sensor.
4. Measure the voltage between the camshaft position 17. If a problem is discovered, repair the camshaft
sensor 5 V power supply circuit and GND of the position sensor 5 V power supply circuit.
camshaft position sensor harness connector.
voltage： 5.5 V with the atmospheric pressure sensor 5 V power
supply circuit between the ECM and the atmospheric
pressure sensor.
supply with the camshaft position sensor 5 V power 19. If a problem is discovered, repair the atmospheric
supply circuit between the ECM and the camshaft pressure sensor 5 V power supply circuit.
position sensor.
6. If a problem is discovered, repair the camshaft
ECM Removal".
or ignition power supply with the atmospheric
ECM Installation".
pressure sensor 5 V power supply circuit between the
ECM and atmospheric pressure sensor. 21. Set the injector ID code on the ECM.
8. If a problem is discovered, repair the atmospheric 22. Perform the unit difference learning of the fuel
pressure sensor 5 V power supply circuit. supply pump to the ECM.
9. If it is at or below the standard value, measure the 2. DTC P0651 Confirm Resolution
voltage between the camshaft position sensor 5 V
power supply circuit and GND of the camshaft
position sensor harness connector. 2. Turn the starter switch OFF for 30 seconds or longer.
10. If it is at or above the standard value, replace the 4. Perform a test-run.
camshaft position sensor.
Refer to "1.Engine 1B.Mechanical(4HK1) CMP DTC has not been detected.
sensor Removal".
11. If it is at or below the standard value, turn the starter
switch OFF.
14. Measure the voltage between the camshaft position
camshaft position sensor harness connector.
voltage： 4.5 V

ECM/PCM Power Relay Control Circuit/Open
2. Replace the main relay with a glow relay or normal
relay.
is detected.
5. If a DTC has not been detected, replace the main
relay.
6. Inspect the body grounding terminal for a contact
failure.
7. If a problem is discovered, repair the terminal.
8. Inspect the slow blow fuse.
9. If a problem is discovered, replace the slow blow
fuse.
Note：
of slow-blow fuse meltdown.
failure.
connector.
ECM Removal".
ECM Installation".

ECM/PCM Power Relay Control Circuit High
2. Remove the main relay.
4. Use the trouble diagnosis scan tool to see if DTC
P0685 is detected.
5. If the DTC P0685 is not detected, repair the short
circuit to the battery power supply of the power
supply circuit between the ECM and main relay.
7. Replace the main relay with a glow relay or normal
relay.
9. Use the trouble diagnosis scan tool to check if DTC
P0687 has been detected.
10. If the DTC P0687 is not detected, replace the main
relay.

1. DTC P0697 Diagnostics 15. Turn ON the starter switch.
1. Turn OFF the starter switch. 16. Measure the voltage between the DPD differential
pressure sensor 5 V power supply circuit and GND
2. Disconnect the harness connector from the DPD
of the DPD differential pressure sensor harness
differential pressure sensor.
connector.
voltage： 4.5 V
4. Measure the voltage between the DPD differential
17. If it is at or above the standard value, replace the oil
pressure sensor.
connector. Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure
sensor Removal".
voltage： 5.5 V
supply with the DPD differential pressure sensor 5 V 18. If it is at or below the standard value, turn the starter
power supply circuit between the ECM and the DPD switch OFF.
19. Disconnect the harness connector from the fuel filter
6. If a problem is discovered, repair the DPD pressure sensor.
differential pressure sensor 5 V power supply circuit.
21. Measure the voltage between the DPD differential
or ignition power supply with the oil pressure sensor
5 V power supply circuit between the ECM and oil
pressure sensor.
connector.
8. If a problem is discovered, repair the oil pressure
voltage： 4.5 V
filter pressure sensor.
or ignition power supply with the fuel filter pressure
sensor 5 V power supply circuit between the ECM Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
and the fuel filter pressure sensor. pressure sensor Removal".
10. If a problem is discovered, repair the fuel filter Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
pressure sensor 5 V power supply circuit. pressure sensor Installation".
11. If it is at or below the standard value, measure the 23. If it is at or below the standard value, inspect to see
voltage between the DPD differential pressure sensor if there is a short circuit to the GND with the DPD
5 V power supply circuit and GND of the DPD differential pressure sensor 5 V power supply circuit
differential pressure sensor harness connector. between the ECM and the DPD differential pressure
sensor.
voltage： 4.5 V
24. If a problem is discovered, repair the DPD
differential pressure sensor 5 V power supply circuit.
DPD differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust
with the oil pressure sensor 5 V power supply circuit
differential pressure sensor Removal".
between the ECM and oil pressure sensor.
26. If a problem is discovered, repair the oil pressure
differential pressure sensor Installation".
switch OFF.
with the fuel filter pressure sensor 5 V power supply
14. Disconnect the harness connector from the oil circuit between the ECM and fuel filter pressure
pressure sensor. sensor.
28. If a problem is discovered, repair the fuel filter
pressure sensor 5 V power supply circuit.
ECM Removal".
ECM Installation".

Fuel Rail Pressure (FRP) Too Low
DTC P0087 ・ Do not replace the fuel pressure sensor
DTC P0091 the common rail assembly.
DTC P0092 12. Inspect to see if there is clogging with the fuel
DTC P0192 system between the fuel tank and the fuel supply
pump.
DTC P0193
DTC P0201 fuel system.
DTC P0202 14. Inspect the fuel hose between the fuel tank and the
DTC P0203 fuel supply pump for a cut and crack.
DTC P0204 15. If a problem is discovered, replace the fuel hose.
DTC P2146 Note：
DTC P2149 ・ The fuel hose between the fuel tank and the
fuel supply pump becomes negative pressure
2. DTC P1093 Diagnostics state when the engine is running.
1. Turn OFF the starter switch. ・ When the fuel hose is not connected securely,
the air can enter.
2. Wait for the specified period of time until the fuel
pressure is released from the common rail. ・ When the engine RPM or the engine load
specified time： 2 min system, fluctuation in the common rail
3. Turn ON the starter switch. pressure is caused, and DTC P1093 may be
detected.
fuel rail pressure sensor display is within the 16. Check that an appropriate clamp is used between the
standard range. fuel tank and the fuel supply pump.
voltage： 0.9 to 1.0 V 17. If a problem is discovered, replace the clamp.
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
not become heavy.
failure.
connector. 20. Inspect the high-pressure side of the fuel system and
check for fuel leak between the fuel supply pump
and common rail.
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
cover.
・ Inspect for fuel leaks into the engine oil.
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
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：
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.
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
the pressure gauge.
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
inspection.
appropriate one.
specified value： 17.0 kPa { 128 mmHg / 5 inHg }
Note：
・ Fuel clogging is checked with the negative for a contact failure.
pressure amount in the fuel system.
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.
32. If a problem is discovered, repair the bent hose.
50. If the suction control valve harness connector and the 1. Clear the DTC using the trouble diagnosis scan tool.
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".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply DTC has not been detected.
pump Installation".
element Removal".
Note：
・ When replacing the fuel supply pump, it is
required to also replace the fuel filter element
at the same time.
52. If the negative pressure is normal, turn OFF the
starter switch.
53. Restore the fuel system.
55. Perform the injector stop test with the trouble
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
Injector Removal".
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.
Note：
・ The pressure limiter valve may be fixed open,
or the operation pressure may decrease.
・ Do not replace the pressure limiter valve
the common rail assembly.

Boost Temperature Sensor Circuit Low
DTC P0651
2. Remove the harness connector from the boost
temperature sensor.
3. Check the boost temperature sensor display with the
voltage： 4.5 V
boost temperature sensor.
with the signal circuit between the ECM and boost
temperature sensor.
failure.
connector.
ECM Removal".
ECM Installation".

Boost Temperature Sensor Circuit High
1. DTC P1113 Priority DTC GND circuit between the ECM and the boost
temperature sensor.
DTC P0651
Note：
・ The boost temperature sensor shares the
1. Turn OFF the starter switch. GND circuit with other sensors.
2. Remove the harness connector from the boost ・ The DTC set on a sensor which shares this
temperature sensor. circuit may be detected.
3. Turn ON the starter switch. 17. If a problem is discovered, repair the GND circuit.
4. Measure the voltage between the boost temperature 18. Inspect to see if there is an open circuit or high
sensor signal circuit and a normal GND. resistance in the signal circuit between the ECM and
the boost temperature sensor.
voltage： 5.5 V
there is a short circuit to the battery or ignition power 20. Inspect the ECM harness connector for a contact
supply with the signal circuit between the ECM and failure.
7. Connect the test cable with fuse between the boost 22. If the harness connector is normal, replace the ECM.
temperature sensor signal circuit and GND circuit.
8. Check the boost temperature sensor display with the ECM Removal".
voltage： 0.1 V ECM Installation".
9. If it is at or below the standard value, inspect to see 23. Set the injector ID code on the ECM.
11. Inspect boost temperature sensor harness connector
for a contact failure. 2. Turn the starter switch OFF for 30 seconds or longer.
12. If a problem is discovered, repair the harness 3. Start the engine.
connector.
Note：
temperature sensor.
・ Run the engine for 3 minutes or longer.
temperature sensor Removal". 5. Use the trouble diagnosis scan tool to confirm that a
14. Connect the test cable with fuse between the boost
temperature sensor signal circuit and a normal GND.
15. Check the boost temperature sensor display with the
voltage： 0.1 V

1. Replace the ECM.
ECM Removal".
ECM Installation".

1. Replace the ECM.
ECM Removal".
ECM Installation".

Fuel Pressure Sensor Circuit Low
failure.
connector.
pressure sensor.
ECM Removal".
circuit of the fuel filter pressure sensor harness
ECM Installation".
connector and normal GND .
voltage： 4.5 V
fuel filter pressure sensor.
Note：
・ The fuel filter pressure sensor shares the 5 V
power supply circuit with other sensors. 3. Start the engine.
supply circuit.
power supply circuit and signal circuit of the fuel
filter pressure sensor harness connector.
8. Check the fuel filter pressure sensor display with the
voltage： 4.5 V
there is a contact failure with the fuel filter pressure
connector.
pressure sensor Removal".
pressure sensor Installation".
fuel filter pressure sensor.

Fuel Pressure Sensor Circuit High
ECM Installation".
DTC P0697
pressure sensor.
3. Check the fuel filter pressure sensor display with the
signal circuit between the ECM and the fuel filter
pressure sensor.
power supply.
the fuel filter pressure sensor.
Note：
・ The fuel filter pressure sensor shares the GND
fuel filter pressure sensor harness connector.
connector.
pressure sensor Removal".
pressure sensor Installation".
failure.
connector.
ECM Removal".

Exhaust Gas Recirculation (EGR) Closed Position Performance
1. DTC P1404 Priority DTC ・There should be no short to EGR position sensor
circuit.
DTC P0404
14. If a problem is discovered, repair the solenoid
DTC P0409
circuit.
15. If the circuit is normal, replace the EGR valve.
1. Remove the EGR valve assembly from the engine.
Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1) EGR valve Removal".
2. Inspect the EGR valve. Devices(4HK1) EGR valve Installation".
・There should be nothing to limit flow inside the EGR 3. DTC P1404 Confirm Resolution
valve.
・There should be no excessive accumulates inside the
EGR valve. 2. Turn the starter switch OFF for 30 seconds or longer.
・There should be no bending with the valve shaft or
valve itself inside the EGR valve.
3. If a problem is discovered, repair or replace the EGR
valve. 5. Use the trouble diagnosis scan tool to confirm that a
5. Disconnect the harness connector from the EGR
valve.
6. Inspect the EGR valve harness connector for a
contact failure.
connector.
failure.
connector.
11. Inspect the EGR valve circuit between the ECM and
the EGR valve for an open circuit and high
resistance.
12. If a problem is discovered, repair the EGR valve
circuit.
13. Inspect the solenoid circuit between the ECM and
EGR valve.
power supply.
・There should be no short to other circuits.

PM Over Accumulation
1. DTC P1455 Diagnostics 12. If the DPD assembly has been replaced, use the
trouble diagnosis scan tool to perform DPD
1. Check with the operator if the DPD light has blinked
regeneration data reset.
before.
13. Inspect the mass air flow sensor with the trouble
2. If necessary, explain DPD regeneration.
・Check with the operator if the engine operating time
14. If a problem is discovered, replace the mass air flow
was short.
sensor.
・Ckeck with the operator if the idling time was too long.
3. Inspect the DPD differential pressure sensor hose.
boost pressure and atmospheric pressure are
・There should be no incorrect piping or disconnection. operating properly.
4. If a problem is discovered, repair the hose. 16. Inspect the air cleaner element.
5. Inspect the DPD differential pressure sensor. Refer to "1.Engine 1F.Induction(4HK1) Air cleaner
element Inspection".
・ DPD differential pressure sensor unit should not be
damaged. 17. If a problem is discovered, replace the air cleaner
・ There should be no dirt or foreign matter blocking the element.
DPD differential pressure sensor entrance.
18. Check the intake duct for a clogging, hole, and
・ There should be no detection error or slow response
leakage.
from the DPD differential pressure sensor.
19. If a problem is discovered, replace the intake duct.
6. If a problem is discovered, replace the DPD
differential pressure sensor. 20. Inspect the intake throttle valve for fixing.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust 21. If a problem is discovered, replace the intake throttle
differential pressure sensor Removal". valve.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust Refer to "1.Engine 1B.Mechanical(4HK1) Intake
differential pressure sensor Installation". throttle valve Removal".
7. When the DPD differential pressure sensor has been Refer to "1.Engine 1B.Mechanical(4HK1) Intake
replaced, perform the 0-point correction. throttle valve Installation".
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust 22. Inspect the turbocharger assembly.
differential pressure sensor Inspection".
8. Inspect the exhaust system. assembly Inspection".
・There should be no absence or damage of the exhaust 23. If a problem is discovered, replace the turbocharger
pipe gasket. assembly.
・There should be no exhaust gas leak from the exhaust
system.
assembly Removal".
・The exhaust system should not be modified.
・There should be no damage or excessive deposits on the Refer to "1.Engine 1F.Induction(4HK1) Turbocharger
oxidation catalyst. assembly Installation".
9. If a problem is discovered, repair or replace the 24. Inspect the quality of fuel.
exhaust system.
Note：
10. Inspect the DPD assembly. ・ An appropriate fuel is used.
Refer to "1.Engine 1G.Exhaust(4HK1) DPD 25. Turn the starter switch ON for 30 seconds.
Note：
・ Do not start the engine.
assembly.
・ This is for the DPD differential pressure sensor
to relearn.
26. Clear the DTC using the trouble diagnosis scan tool. 43. Check the exhaust differential pressure display when
the exhaust temperature (in front of the filter) display
has reached the standard value with the engine
revolution increased to the maximum revolution
28. Turn the starter switch OFF for 30 seconds or longer. speed without load.
29. Start the engine. Specified value： 150 ℃ { 302 °F }
30. Check the exhaust temperature (before the filter) 44. Use the trouble diagnosis scan tool to check if the
display with the trouble diagnosis scan tool. exhaust differential pressure display is at or below
the standard value.
31. Confirm that the exhaust temperature is at or below
the standard value. specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi }
Specified value： 130 ℃ { 266 °F } 45. If it is at or above the standard value, perform ash
removal.
32. If it is at or above the standard value, idle the engine
until it falls to or below the standard value. Refer to "1.Engine 1G.Exhaust(4HK1) DPD
33. Check the exhaust differential pressure display when
the exhaust temperature (in front of the filter) display 2. DTC P1455 Confirm Resolution
speed without load. 2. Use the trouble diagnosis scan tool to confirm that a
exhaust differential pressure data display is at or
below the standard value.
specified value： 7.5 kPa { 0.08 kgf/cm2 / 1.1 psi }
DPD filter.
36. If the DPD filter has been replaced, use the trouble
diagnosis scan tool to perform DPD regeneration
data reset.
37. When a DTC has been detected, clear it using the
39. Perform the DPD forced slow regeneration with the
Note：
・ After the DPD forced slow regeneration is
completed, replace the engine oil.
40. Check the exhaust temperature (before the filter)
the standard value.
until it falls to or below the standard value.

DPD Insufficient Regeneration
1. DTC P1471 Diagnostics 12. Inspect the air intake system.
1. Inspect the DPD differential pressure sensor hose. ・There should be no crush, limited flow, or damage of
the duct between the air cleaner and intake manifold.
・There should be no incorrect piping or disconnection.
・The intake system should not be modified.
2. If a problem is discovered, repair the hose. ・There should be no air leak with the intake system.
3. Inspect the DPD differential pressure sensor. 13. If a problem is discovered, repair the intake system.
・ DPD differential pressure sensor unit should not be 14. Use the trouble diagnosis scan tool to inspect the
damaged. mass air flow sensor.
・ There should be no dirt or foreign matter blocking the
sensor.
from the DPD differential pressure sensor. 16. Turn the starter switch ON for 30 seconds.
4. If a problem is discovered, replace the DPD Note：
differential pressure sensor. ・ Do not start the engine.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust ・ This is for the DPD differential pressure sensor
differential pressure sensor Removal". to relearn.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust 17. Start the engine.
18. Use the trouble diagnosis scan tool to check the DPD
5. When the DPD differential pressure sensor has been accumulation status and the DPD time status, and
replaced, perform the 0-point correction. confirm the corresponding area from the DPD status
table.
6. Inspect the exhaust system.
・There should be no absence or damage of the exhaust
pipe gasket.
system.
7. If a problem is discovered, repair or replace the
exhaust system.
8. Inspect the exhaust gas temperature sensor.
temperature sensor.
temperature sensor Removal". 19. If the situation falls in the area A or B, use the
trouble diagnosis scan tool to perform the DPD
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas forced regeneration.
Note：
10. Inspect the air cleaner element.
・ When a DTC has been detected, clear it using
Refer to "1.Engine 1F.Induction(4HK1) Air cleaner the trouble diagnosis scan tool.
20. If the situation falls in the area C or D, use the
11. If a problem is discovered, replace the air cleaner trouble diagnosis scan tool to perform the DPD
element. forced slow regeneration.
Note：
the standard value.
speed without load.
exhaust differential pressure display is at or below
the standard value.
26. If it is at or above the standard value, perform ash
removal.

Control Module Long Term Memory Performance
1. Confirm that the connecting sections of all tools are
securely connected.
2. Confirm that the programming device is operating
normally.
3. Turn the starter switch OFF, and wait for 30 seconds.
has been detected.
ECM Removal".
ECM Installation".

Sensor Reference Voltage Circuit
1. DTC P1655 Diagnostics 16. Measure the voltage between the boost sensor 5 V
power supply terminal and GND of the boost sensor
harness connector.
voltage： 4.5 V
sensor.
intake throttle valve.
4. Measure the voltage between the boost sensor 5 V
power supply terminal and GND of the boost sensor
harness connector.
voltage： 5.5 V
switch OFF.
supply with the boost sensor 5 V power supply
circuit between the ECM and the boost sensor. 19. Disconnect the harness connector from the EGR
valve.
6. If a problem is discovered, repair the boost sensor 5
V power supply circuit. 20. Turn ON the starter switch.
7. Inspect to see if there is a short circuit to the battery 21. Measure the voltage between the boost sensor 5 V
or ignition power supply with the intake throttle power supply terminal and GND of the boost sensor
position sensor 5 V power supply circuit between the harness connector.
ECM and the intake throttle valve.
voltage： 4.5 V
EGR valve.
or ignition power supply with the EGR valve
position sensor 5 V power supply circuit between the
ECM and EGR valve. Refer to "1.Engine 1H.Aux. Emission Control
10. If a problem is discovered, repair the EGR valve
position sensor 5 V power supply circuit. 23. If it is at or below the standard value, inspect to see
if there is a short circuit to the GND with the boost
11. If it is at or below the standard value, measure the
sensor 5 V power supply circuit between the ECM
voltage between the boost sensor 5 V power supply
and the boost sensor.
terminal and GND of the boost sensor harness
connector. 24. If a problem is discovered, repair the boost sensor 5
V power supply circuit.
voltage： 4.5 V
with the intake throttle position sensor 5 V power
boost sensor.
supply circuit between the ECM and the intake
Refer to "1.Engine 1F.Induction(4HK1) Boost throttle valve.
sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1) Boost position sensor 5 V power supply circuit.
13. If it is at or below the standard value, turn the starter with the EGR valve position sensor 5 V power
switch OFF. supply circuit between the ECM and EGR valve.
14. Remove the harness connector from the intake 28. If a problem is discovered, repair the EGR valve
throttle valve. position sensor 5 V power supply circuit.
15. Turn ON the starter switch. 29. Replace the ECM.
ECM Removal".
ECM Installation".

DPD Lamp Control Circuit
1. DTC P1669 Diagnostics 22. Set the injector ID code on the ECM.
1. Confirm that the monitor panel operates properly. 23. Perform the unit difference learning of the fuel
24. If the DPD light does not turn on, remove the DPD
3. Inspect the fuse.
light bulb from the monitor panel.
4. If a problem is discovered, replace the fuse.
25. Inspect the DPD light bulb.
Note：
of fuse meltdown. 27. Inspect to see if there is an open circuit or high
resistance in the ignition power supply circuit
5. Turn OFF the starter switch. between the fuse and the monitor panel.
6. Disconnect the harness connector from the ECM. 28. If a problem is discovered, repair the ignition power
7. Turn ON the starter switch. supply circuit.
8. Check to see if the DPD light is off. 29. Inspect to see if there is an open circuit or high
resistance in the DPD light control circuit between
9. If the DPD light is not turned off, repair the short the ECM and the monitor panel.
circuit to GND in the DPD light control circuit
between the ECM and the monitor panel. 30. If a problem is discovered, repair the control circuit.
10. Turn OFF the starter switch. 31. Inspect the monitor panel harness connector for a
contact failure.
11. Remove the fuse.
12. Turn ON the starter switch. connector.
13. Measure the voltage between the DPD light control 33. When the harness connector is normal, replace the
circuit and GND of the ECM harness connector. monitor panel.
voltage： 1.0 V 2. DTC P1669 Confirm Resolution
14. If it is at or above the standard value, repair the short 1. Clear the DTC using the trouble diagnosis scan tool.
circuit to the battery or ignition power supply circuit
in the DPD light control circuit between the ECM 2. Turn the starter switch OFF for 30 seconds or longer.
and the monitor panel. 3. Turn the starter switch ON, and wait for 40 seconds.
15. Turn OFF the starter switch. 4. Start the engine.
16. Install the fuse. 5. Use the trouble diagnosis scan tool to confirm that a
17. Connect the test cable with fuse between the DPD DTC has not been detected.
light control circuit and GND of the ECM harness
connector.
19. If the DPD light turns on, inspect the ECM harness
connector.
ECM Removal".
ECM Installation".

ECM Removal".
DTC P0641
ECM Installation".
circuit and GND of the accelerator position sensor.
voltage： 4.5 V
3. Start the engine, fully depress the accelerator pedal
and then release it while checking the accelerator
pedal position sensor 1 (APP1) display with the
4. Confirm that the trouble diagnosis scan tool does not
show a value at or below the standard value while
supply circuit.
depressing and then releasing the pedal.
voltage： 0.2 V
power supply circuit and sensor 1 signal circuit of
the accelerator position sensor. 5. Use the trouble diagnosis scan tool to confirm that a
8. Check the accelerator pedal position sensor 1 (APP1)
voltage： 4.5 V
there is a contact failure with the accelerator position
connector.
sensor 1 signal circuit between the ECM and
13. If a problem is discovered, repair the sensor 1 signal
circuit.
failure.
connector.

1. DTC P2123 Priority DTC 16. Perform the unit difference learning of the fuel
DTC P0641
accelerator position sensor. 3. Start the engine, fully depress the accelerator pedal
voltage： 0.1 V
4. If it is at or above the standard value, inspect the show a value at or above the standard value while
sensor 1 signal circuit between the ECM and the depressing and then releasing the pedal.
voltage： 4.9 V
power supply.
circuit.
6. Connect the test light between the accelerator
position sensor GND circuit and battery power
supply.
7. If the test light comes on, inspect the accelerator
position sensor harness connector for a contact
failure.
connector.
10. If the test light does not come on, inspect to see if
GND circuit between the ECM and the accelerator
position sensor.
failure.
connector.
ECM Removal".
ECM Installation".

ECM Removal".
DTC P0641
ECM Installation".
circuit and GND of the accelerator position sensor.
voltage： 4.5 V
3. Start the engine, fully depress the accelerator pedal
show a value at or below the standard value while
supply circuit.
depressing and then releasing the pedal.
voltage： 0.2 V
power supply circuit and sensor 2 signal circuit of
the accelerator position sensor. 5. Use the trouble diagnosis scan tool to confirm that a
voltage： 4.5 V
there is a contact failure with the accelerator position
connector.
sensor 2 signal circuit between the ECM and
circuit.
failure.
connector.

DTC P0641
accelerator position sensor. 3. Start the engine, fully depress the accelerator pedal
voltage： 0.1 V
4. If it is at or above the standard value, inspect the show a value at or above the standard value while
sensor 2 signal circuit between the ECM and the depressing and then releasing the pedal.
voltage： 4.9 V
power supply.
circuit.
6. Connect the test light between the accelerator
position sensor GND circuit and battery power
supply.
7. If the test light comes on, inspect the accelerator
position sensor harness connector for a contact
failure.
connector.
GND circuit between the ECM and the accelerator
position sensor.
failure.
connector.
ECM Removal".
ECM Installation".

Pedal Position Sensor 1 - 2 Voltage Correlation
1. DTC P2138 Priority DTC 19. Set the injector ID code on the ECM.
DTC P0641 20. Perform the unit difference learning of the fuel
DTC P2122
DTC P2123
DTC P2127
DTC P2128
4. While checking the DTC information with the
trouble diagnosis scan tool, fully depress and then
2. Disconnect the harness connector from the release the accelerator pedal.
3. Inspect the accelerator position sensor harness DTC has not been detected.
connector.
failure.
connector.
8. Inspect to see if there is high resistance in the circuit
between the ECM and accelerator position sensor.
10. Inspect to see if there is a short between circuits in
the signal circuit between the ECM and the
12. If the circuit is normal, replace the accelerator
position sensor.
17. While checking for a DTC with the trouble diagnosis
scan tool, fully depress and then release the
accelerator pedal.
ECM Removal".
ECM Installation".

1. DTC P2146 Diagnostics 15. Inspect the ECM harness connector for a contact
failure.
1. Turn the starter switch OFF.
connector.
head injector harness intermediate connector.
3. Turn the starter switch ON.
resistance with the charge voltage circuit between
4. Measure the voltage between the solenoid control the ECM and the injector harness intermediate
circuit and GND. connector.
Note： 18. If a problem is discovered, repair the charge voltage
・ Solenoid control circuit and GND of the first circuit.
cylinder injector 19. Remove the cylinder head cover.
・ Solenoid control circuit and GND of the fourth
cylinder injector
voltage： 12.0 V
5. If it is at or below the standard value, inspect to see looseness.
if there is a short circuit to the GND with the control
circuit between the ECM and injector harness
it.
22. Inspect to see if any foreign matter is attached to the
injector terminal.
7. Inspect the charge voltage circuit between the ECM
and the injector harness intermediate connector.
Note：
・ No short circuit to the battery or ignition power connector for a contact failure.
is present.
・ No short circuit to GND is present.
harness connector.
8. If a problem is discovered, repair the charge voltage
26. Check if insulation resistance of the first cylinder
circuit.
and fourth cylinder injector is at or above the
9. If the charge voltage circuit between the ECM and standard value.
the injector harness intermediate connector is
resistance： 1.0 Ω
normal, replace the ECM.
27. If it is at or below the standard value, replace the
relevant injector.
ECM Removal".
Injector Removal".
ECM Installation".
29. If it is at or above the standard value, repair or
replace the injector harness.
intermediate connector. 1. Clear the DTC using the trouble diagnosis scan tool.
14. Disconnect the harness connector from the ECM. 2. Turn the starter switch OFF for 30 seconds or longer.

1. DTC P2149 Diagnostics 15. Inspect the ECM harness connector for a contact
failure.
1. Turn the starter switch OFF.
connector.
head injector harness intermediate connector.
3. Turn the starter switch ON.
resistance with the charge voltage circuit between
4. Measure the voltage between the solenoid control the ECM and the injector harness intermediate
circuit and GND. connector.
Note： 18. If a problem is discovered, repair the charge voltage
・ Solenoid control circuit and GND of the second circuit.
cylinder injector 19. Remove the cylinder head cover.
・ Solenoid control circuit and GND of the third
cylinder injector
voltage： 12.0 V
5. If it is at or below the standard value, inspect to see looseness.
if there is a short circuit to the GND with the control
circuit between the ECM and injector harness
it.
22. Inspect to see if any foreign matter is attached to the
injector terminal.
7. Inspect the charge voltage circuit between the ECM
and the injector harness intermediate connector.
Note：
・ No short circuit to the battery or ignition power connector for a contact failure.
is present.
・ No short circuit to GND is present.
harness connector.
8. If a problem is discovered, repair the charge voltage
26. Check if insulation resistance of the first cylinder
circuit.
and fourth cylinder injector is at or above the
9. If the charge voltage circuit between the ECM and standard value.
the injector harness intermediate connector is
resistance： 1.0 MΩ
normal, replace the ECM.
27. If it is at or below the standard value, replace the
relevant injector.
ECM Removal".
Injector Removal".
ECM Installation".
29. If it is at or above the standard value, repair or
replace the injector harness.
intermediate connector. 1. Clear the DTC using the trouble diagnosis scan tool.
14. Disconnect the harness connector from the ECM. 2. Turn the starter switch OFF for 30 seconds or longer.

Barometric Pressure Circuit Low
ECM Installation".
DTC P0651
4. Measure the voltage between the atmospheric
pressure sensor 5 V power supply circuit and GND. 3. Start the engine.
voltage： 4.5 V 4. Perform a test-run.
5. If it is at or below the standard value, inspect to see 5. Use the trouble diagnosis scan tool to confirm that a
if there is an open circuit or high resistance with the DTC has not been detected.
supply circuit.
7. Connect the test cable with fuse between the
atmospheric pressure sensor 5 V power supply
circuit and the signal circuit.
8. Check the atmospheric pressure sensor display with
voltage： 4.5 V
there is a contact failure with the atmospheric
connector.
signal circuit between the ECM and the atmospheric
pressure sensor.
failure.
connector.
ECM Removal".

Barometric Pressure Circuit High
DTC P0651
atmospheric pressure sensor. 3. Start the engine.
3. Check the atmospheric pressure sensor display with 4. Perform a test-run.
voltage： 0.1 V DTC has not been detected.
signal circuit between the ECM and the atmospheric
pressure sensor.
power supply.
6. Connect the test light between the atmospheric
pressure sensor GND circuit and battery power
supply.
7. If the test light comes on, inspect the atmospheric
pressure sensor harness connector for a contact
failure.
connector.
GND circuit between the ECM and the atmospheric
pressure sensor.
failure.
connector.
ECM Removal".
ECM Installation".
DTC P242F (Flash Code 131)

DPD Restriction
1. DTC P242F Diagnostics 12. If the DPD assembly has been replaced, use the
1. Check with the operator if the DPD light has blinked
before.
13. Inspect the mass air flow sensor with the trouble
2. If necessary, explain DPD regeneration.
・Check with the operator if the engine operating time
was short.
sensor.
・Ckeck with the operator if the idling time was too long.
boost pressure and atmospheric pressure are
・There should be no incorrect piping or disconnection. operating properly.
4. If a problem is discovered, repair the hose. 16. Inspect the air cleaner element.
5. Inspect the DPD differential pressure sensor. Refer to "1.Engine 1F.Induction(4HK1) Air cleaner
damaged. 17. If a problem is discovered, replace the air cleaner
・ There should be no dirt or foreign matter blocking the element.
18. Inspect the intercooler.
from the DPD differential pressure sensor. Refer to "1.Engine 1F.Induction(4HK1)
Intercooler Inspection".
differential pressure sensor. 19. If a problem is discovered, replace the intercooler.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust 20. Check the intake duct for a clogging, hole, and
differential pressure sensor Removal". leakage.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust 21. If a problem is discovered, replace the intake duct.
22. Inspect the intake throttle valve for fixing.
7. When the DPD differential pressure sensor has been
23. If a problem is discovered, replace the intake throttle
replaced, perform the 0-point correction.
valve.
・There should be no absence or damage of the exhaust throttle valve Installation".
pipe gasket.
24. Inspect the turbocharger assembly.
system. Refer to "1.Engine 1F.Induction(4HK1) Turbocharger
・The exhaust system should not be modified. assembly Inspection".
・There should be no damage or excessive deposits on the
25. If a problem is discovered, replace the turbocharger
oxidation catalyst.
assembly.
exhaust system.
assembly Removal".
10. Inspect the DPD assembly.
Refer to "1.Engine 1G.Exhaust(4HK1) DPD assembly Installation".
26. Inspect the quality of fuel.
Note：
assembly.
・ An appropriate fuel is used.
27. Turn the starter switch ON for 30 seconds.
Note： 43. Confirm that the exhaust temperature is at or below
・ Do not start the engine. the standard value.
・ This is for the DPD differential pressure sensor Specified value： 130 ℃ { 266 °F }
to relearn.
28. Clear the DTC using the trouble diagnosis scan tool. until it falls to or below the standard value.
29. Perform the DPD regeneration data reset with the 45. Check the exhaust differential pressure display when
trouble diagnosis scan tool. the exhaust temperature 1 (in front of the filter)
display has reached the standard value with the
engine revolution increased to the maximum
31. Start the engine. revolution speed without load.
32. Check the exhaust temperature (before the filter) Specified value： 150 ℃ { 302 °F }
33. Confirm that the exhaust temperature is at or below exhaust differential pressure display is at or below
the standard value. the standard value.
Specified value： 130 ℃ { 266 °F } specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi }
34. If it is at or above the standard value, idle the engine 47. If it is at or above the standard value, perform ash
until it falls to or below the standard value. removal.
35. Check the exhaust differential pressure display when Refer to "1.Engine 1G.Exhaust(4HK1) DPD
the exhaust temperature (in front of the filter) display assembly Inspection".
2. DTC P242F Confirm Resolution
speed without load. 1. Turn ON the starter switch.
outside air temperature： 150 ℃ { 302 °F } 2. Use the trouble diagnosis scan tool to confirm that a
exhaust differential pressure display is at or below
the standard value.
DPD filter.
38. If the DPD filter has been replaced, use the trouble
diagnosis scan tool to perform DPD regeneration
data reset.
39. When a DTC has been detected, clear it using the
41. Perform the DPD forced slow regeneration with the
Note：

DPD Differential Pressure Sensor Circuit
1. DTC P2452 Priority DTC 13. Inspect the DPD differential pressure sensor harness
DTC P2456
connector.
・There should be no incorrect piping or disconnection.
2. If a problem is discovered, repair the hose. failure.
3. Inspect the DPD differential pressure sensor. 17. If a problem is discovered, repair the harness
connector.
damaged. 18. Inspect the signal circuit between the ECM and the
・ There should be no dirt or foreign matter blocking the DPD differential pressure sensor for a high
DPD differential pressure sensor entrance. resistance.
20. If the harness connector and circuit are normal,
replace the DPD differential pressure sensor.
pipe gasket. Note：
・There should be no exhaust gas leak from the exhaust ・ Do not start the engine.
system.
to relearn.
exhaust system.
8. Inspect the DPD assembly.
27. Perform the DPD forced regeneration with the
assembly.
Note：
10. If the DPD assembly has been replaced, use the
trouble diagnosis scan tool to perform DPD ・ When the DPD filter is replaced by a new one,
regeneration data reset. do not perform the DPD forced regeneration.
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.
speed without load.
exhaust differential pressure display is at or above
the standard value.

DPD Differential Pressure Sensor Circuit Range/Performance
connector.
DTC P2456
DPD differential pressure sensor for a high
1. Inspect the DPD differential pressure sensor hose. resistance.
・There should be no incorrect piping or disconnection. 16. If a problem is discovered, repair the signal circuit.
2. If a problem is discovered, repair the hose. 17. If the harness connector and signal circuit are
normal, replace the DPD assembly.
3. Inspect the DPD differential pressure sensor.
18. If the DPD assembly has been replaced, use the
damaged.
DPD differential pressure sensor entrance. 19. Restore the actual unit.
Note：
differential pressure sensor. ・ Do not start the engine.
to relearn.
differential pressure sensor Installation". 22. Perform the DPD regeneration data reset with the
replaced, perform the 0-point correction. 23. Turn the starter switch OFF for 30 seconds or longer.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust 24. Perform the DPD forced regeneration with the
differential pressure sensor Inspection". trouble diagnosis scan tool.
6. Inspect the exhaust system. 25. Use the trouble diagnosis scan tool to confirm that
・ There should be no missing or damage with the gasket
at or below the standard value.
of the exhaust pipe.
・ There should be no exhaust gas leak from the exhaust Specified value： 130 ℃ { 266 °F }
system.
・ The exhaust system should not be modified.
・ There should be no flow limitation or crush of the
exhaust system. 27. Check the exhaust differential pressure display when
exhaust system.
8. Turn OFF the starter switch. speed without load.
9. Disconnect the harness connector from the DPD Specified value： 150 ℃ { 302 °F }
10. Inspect the DPD differential pressure sensor harness exhaust differential pressure display is at or below
connector for a contact failure. the standard value.
11. If a problem is discovered, repair the harness specified value： 1.8 kPa { 0.02 kgf/cm2 / 0.3 psi }
connector.
12. Disconnect the harness connector from the ECM. removal.
13. Inspect the ECM harness connector for a contact Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust
failure. differential pressure sensor Inspection".

DPD Differential Pressure Sensor Circuit Low
1. DTC P2454 Priority DTC 13. If it is at or below the standard value, inspect the
signal circuit between the ECM and the DPD
DTC P0697
1. Turn OFF the starter switch. ・There should be no short to GND.
2. Disconnect the harness connector from the DPD 14. If a problem is discovered, repair the signal circuit.
3. Turn ON the starter switch. failure.
4. Measure the voltage between the DPD differential 16. If a problem is discovered, repair the harness
pressure sensor 5 V power supply circuit and GND. connector.
voltage： 4.5 V 17. If the harness connector is normal, replace the ECM.
5. If it is at or below the standard value, inspect to see Refer to "1.Engine 1J.Electrical(4HK1)
if there is an open circuit or high resistance with the ECM Removal".
DPD differential pressure sensor.
ECM Installation".
Note：
・ The DPD differential pressure sensor shares
the 5 V power supply circuit with other 19. Perform the unit difference learning of the fuel
sensors. supply pump to the ECM.
・ The DTC set on a sensor which shares this 3. DTC P2454 Confirm Resolution
supply circuit.
power supply circuit and signal circuit of the DPD 4. Perform a test-run.
8. Check the exhaust differential pressure display with DTC has not been detected.
voltage： 4.5 V
there is a contact failure with the DPD differential
connector.
11. If the harness connector is normal, replace the DPD

DPD Differential Pressure Sensor Circuit High
1. DTC P2455 Priority DTC 12. If a problem is discovered, repair the GND circuit.
failure.
connector.
3. Check the exhaust differential pressure display with
ECM Removal".
voltage： 0.1 V
ECM Installation".
signal circuit between the ECM and the DPD
differential pressure sensor. 17. Perform the unit difference learning of the fuel
power supply. 3. DTC P2455 Confirm Resolution
6. Connect the test light between the GND circuit and
battery power supply of the DPD differential
pressure sensor. 4. Perform a test-run.
7. If the test light comes on, inspect DPD differential 5. Use the trouble diagnosis scan tool to confirm that a
pressure sensor harness connector for a contact DTC has not been detected.
failure.
connector.
9. If the harness connector is normal, replace the DPD
GND circuit between the ECM and the DPD
Note：
・ The DPD differential pressure sensor shares
・ The DTC may be detected on a sensor which
shares this circuit.

DPD Differential Pressure Sensor Learned Position
DTC P2454
DTC P2455
3. Inspect the DPD differential pressure sensor harness
connector.
failure.
connector.
8. Inspect the circuit between the ECM and DPD
differential pressure sensor for an open circuit and
high resistance.
10. If the circuit is normal, replace the DPD differential
pressure sensor.
3. While checking the DTC information with the
trouble diagnosis scan tool, turn the starter switch
ON for 30 seconds.

DPD Regeneration Duration
1. DTC P2458 Priority DTC Refer to "1.Engine 1D.Cooling(4HK1) Cooling fan
belt Inspection".
DTC P0426
DTC P0427
Thermostat Inspection".
DTC P0428
Refer to "1.Engine 1D.Cooling(4HK1) Water pump
DTC P042B assembly Inspection".
DTC P042C Refer to "1.Engine 1D.Cooling(4HK1)
DTC P042D Radiator Inspection".
2. DTC P2458 Diagnostics 9. If a problem is discovered, repair the cooling system.
1. Inspect the DPD differential pressure sensor hose. 10. Turn the starter switch ON for 30 seconds.
・There should be no incorrect piping or disconnection. Note：

・ Do not start the engine.
2. If a problem is discovered, repair the hose.
3. Inspect the DPD differential pressure sensor. to relearn.
・ DPD differential pressure sensor unit should not be 11. Turn the starter switch OFF for 30 seconds.
damaged.
DPD differential pressure sensor entrance. 13. Use the trouble diagnosis scan tool to check the DPD
・ There should be no detection error or slow response accumulation status and the DPD time status, and
from the DPD differential pressure sensor. confirm the corresponding area from the DPD status
table.
pipe gasket.
system.
・There should be no incorrect detection or slow response 14. If the situation falls in the area A or B, use the
from the exhaust gas temperature sensor. trouble diagnosis scan tool to perform the DPD
7. If a problem is discovered, repair or replace the forced regeneration.
exhaust system. Note：
8. Inspect the engine cooling system for a factor ・ When a DTC has been detected, clear it using
causing overheat. the trouble diagnosis scan tool.
Coolant Inspection".
15. If the situation falls in the area C or D, use the
trouble diagnosis scan tool to perform the DPD
forced slow regeneration.
Note：
at or below the standard value.
18. Check the exhaust differential pressure data display
when the exhaust temperature (in front of the filter)
data display has reached the standard value with the
engine revolution increased to the maximum
revolution speed without load.
19. Confirm if the exhaust differential pressure data
display is at or below the standard value.
removal.

CAN-Bus Malfunction
1. DTC U0001 Diagnostics 5. Use the trouble diagnosis scan tool to confirm that a
3. Measure the resistance between the CAN-High side
terminal and CAN-Low side terminal.
Note：
・ Measure the resistance between the terminals
of the ECM harness connector.
resistance： about 120.0 Ω
4. If it is outside the standard range, inspect the CAN-
Low circuit and CAN-High circuit between the ECM
and the control unit of the actual unit.
power supply.
5. If a problem is discovered, repair the CAN circuit.
6. If the CAN circuit is normal, replace the control unit
of the actual unit.
7. Connect the harness connector to the ECM.
8. Disconnect the harness connector from the control
unit of the actual unit.
9. Measure the resistance between the CAN-High side
terminal and CAN-Low side terminal.
Note：
・ Measure the resistance between the terminals
of the ECM harness connector.
resistance： about 120.0 Ω
10. If it is outside the standard range, replace the ECM.
ECM Removal".
ECM Installation".
2. DTC U0001 Confirm Resolution

1. DTC U0073 Diagnostics Refer to "1.Engine 1J.Electrical(4HK1)
ECM Installation".
2. Measure the resistance between the terminals of the
termination resistor harness connector. 14. Perform the unit difference learning of the fuel
Note：
・ Make a measurement from the back with the 15. Turn OFF the starter switch.
harness connector connected. 16. Connect the harness connector to the ECM.
・ Confirm that the parallel resistance of the 120
Ω resistor in the termination resistor and that of
the 120 Ω resistor in the ECM are both 60Ω. 18. Measure the voltage between the CAN-High
terminal and GND of the termination resistor harness
resistance： 50.0 to 70.0 Ω
connector.
3. Disconnect the harness connector from termination
19. Measure the voltage between the CAN-Low terminal
resistor if the resistance value is outside the standard
and GND of the termination resistor harness
range.
connector.
4. Measure the resistance of the termination resistor.
20. If the voltage is outside the standard range, replace
5. If the resistance value is outside the standard range, the ECM.
replace the termination resistor.
6. Connect the harness connector to the termination ECM Removal".
resistor .
7. Disconnect the harness connector from the control ECM Installation".
unit of the actual unit.
8. Measure the resistance between the terminals of the
termination resistor harness connector.
Note：
・ Make a measurement from the back with the
harness connector connected. 24. Connect the harness connector to the control unit of
the actual unit.
9. If the resistance value is within the standard range,
replace the control unit of the actual unit. 26. Measure the voltage between the CAN-High
terminal and GND of the termination resistor harness
10. Disconnect the harness connector from the ECM. connector.
11. Measure the resistance between the terminals of the 27. Measure the voltage between the CAN-Low terminal
termination resistor harness connector. and GND of the termination resistor harness
Note： connector.
・ Make a measurement from the back with the voltage： 1.5 to 3.5 V
harness connector connected.
28. If the voltage is outside the standard range, replace
resistance： 110.0 to 130.0 Ω the control unit of the actual unit.
12. Replace the ECM if the resistance value is within the 29. If the voltage is within the standard range, replace
range of standard value. the termination resistor.
Refer to "1.Engine 1J.Electrical(4HK1) 2. DTC U0073 Confirm Resolution
ECM Removal".
1. Use the trouble diagnosis scan tool to clear the DTC.
has been detected.

Lost Communication with TCM
1. DTC U0101 Diagnostics
1. Inspect the CAN-Low circuit and CAN-High circuit
between the ECM and the control unit of the actual
unit.
power supply.
3. If the CAN circuit is normal, connect all harnesses.
7. Check the DTC.
8. If a DTC has been detected, replace the control unit
of the actual unit.
9. Connect all harnesses.
13. Check the DTC.
ECM Removal".
ECM Installation".

Lost Communication with VNT System
1. DTC U0110 Priority DTC
DTC P0045
DTC U0001
2. Remove the harness connector from the turbo control
unit.
4. Measure the voltage between the CAN-High circuit
and GND of the turbo control unit harness connector.
5. Measure the voltage between the CAN-High circuit
and GND of the turbo control unit harness connector.
6. If it is outside the standard range, inspect to see if
CAN-High circuit between the turbo control unit and
the ECM.
7. If a problem is discovered, repair the CAN-High
circuit.
resistance with the CAN-Low circuit between the
turbo control unit and the ECM.
9. If a problem is discovered, repair the CAN-Low
circuit.
10. Inspect the turbo control unit harness connector for a
contact failure.
connector.
12. Replace the turbo control unit.
DTC U0411 (Flash code 87)

Turbo Charger Control Module Signal Malfunction
1. DTC U0411 Priority DTC 20. Perform the unit difference learning of the fuel
DTC P0045
DTC U0001
1. Inspect the CAN circuit between the turbo control
unit and the ECM. 3. Start the engine.
・There should be no short to the battery or ignition 4. Perform a test-run.
power supply.
3. Inspect the turbo control unit harness connector for a
contact failure.
connector.
10. Check the DTC.
11. If a DTC has been detected, replace the turbocharger
assembly.
assembly Removal".
17. Check the DTC.
ECM Removal".
ECM Installation".

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65722_Maegaki 10.12.

9. When handling volatile materials, be extremely

Description General Information

Contents included in service information

1. Vehicle front 9. Gas or warm air

Recommended liquid gasket

Thread locking adhesive agent

： 358.9 to 539.4 N・m ： 430.5 to 711.0 N・m

： 490.8 to 810.5 N・m ： 554.1 to 830.6 N・m

1. Hex bolt, 4.8, 4 T 10. Hex bolt, non-thermal refining 8.8

Tightening torque for large/medium sizeFlare nut width across flat

Tapered thread for connectors and brass products

Item Engine model 4HK1

Function, Structure, Operation

1. Engine number stamping

2. Function, Structure, Operation 1. Engine structural diagram

2. Description of functions and operations Crankshaft

1. Electromagnetic pump 6. Fuel tank

Caution： Common rail

1. Pressure sensor 2. Pressure limiter

Fuel supply pump

1. Fuel temperature sensor 5. Camshaft nut

1. Water jacket 10. Radiator reserve tank

1. Fan guide 4. Seal unit

Thermostat temperature is 85ºC {185 °F}. The structure allows the

1. Jiggle valve 4. Gasket

5. Lubrication system A full-flow bypass integrated filter element, water

Oil pump structural diagram

1. Driven gear assembly 6. Drive gear assembly

6. Induction system Turbocharger structural diagram

1. Connector 6. Coolant inlet

1. DPD assembly 4. DPD differential pressure sensor

9. Electrical system 3 out of the 6 main diodes are referred to as positive

1. Lever assembly 6. Internal gear

Preheat system consists of the electronic control fuel injection system,

Fuel injection correction

About high altitude correction

Engine emergency stop function

Decrease in engine oil pressure

Electronic control fuel injection system Injection amount control

Fuel system supplied to the common rail is controlled by regulating

1. Electromagnetic pump 6. Fuel tank

1. First stage 2. Second stage

EGR Darker portions in the diagram represent large valve lift

EGR and turbine noise

Engine operation control

H, S, L and B of the mode map switch change as follows

When CAN controller exists on the actual unit side

Mode map switch control

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

Accelerator position switch Regulation mode switch

DPD the optimum value, the ECM detects the exhaust

ECM output circuit by controlling the ground or power supply

1. Overheat switch 9. Suction control valve

1. Suction control valve Fuel temperature sensor

1. Suction control valve

1. Pressure limiter 1. Fuel pressure sensor

Camshaft position sensor

Crankshaft position sensor

EGR position sensor

Fuel filter pressure sensor

Turbo actuator Diagnostic light

Note：・ If no error message has been displayed,