Sec 15D (4HL1)

Symptom (4HL1) 15D-1
Engine
Symptom
(4HL1)
Table of Contents
Intermittent conditions of engine..................................15D-2
Hard start.......................................................................15D-6
Rough, unstable.............................................................15D-8
High idle speed............................................................15D-10
Cuts out.......................................................................15D-11
Surges..........................................................................15D-13
Lack of power, sluggishness or sponginess................15D-15
Hesitation, sag or stumble...........................................15D-17
Abnormal combustion noise.......................................15D-19
Poor fuel economy......................................................15D-20
Black smoke................................................................15D-22
White smoke................................................................15D-24
Engine has overheated.................................................15D-26
Engine has overcooled................................................15D-27
Engine does not stop...................................................15D-28
Starter overrun.............................................................15D-29
Defect of charging system...........................................15D-30
Abnormal sound in generator......................................15D-32
Vibrations and rattling sounds from the exhaust system
.....................................................................................15D-33
Clogging of the exhaust system..................................15D-34
Exhaust gas leak, noise...............................................15D-35
Defect of turbocharger................................................15D-36
Engine does not turn over...........................................15D-38
15D-2 Symptom (4HL1)
Intermittent conditions of engine

1. Intermittent conditions of engine description of symptom
1. Important preliminary inspections before starting
Before using the symptom list, perform the Diagnostic System Check - Engine Controls and check all of the following items.
・ The check engine warning light is operating normally.
・ The scan tool data is within the normal range of operation values.
・ If checking the customer's complaint and verifying the applicable symptom in the table of contents, inspect the items
presented for the symptom.
2. Visual inspection and actual inspection
Careful visual inspection and actual inspection are required for some symptom procedures. This procedure is extremely
important. By conducting visual and actual inspections, it is possible to save valuable time by fixing problems without
performing further inspections. Check for the following items.
・ The ground of the ECM should be clean and firmly secured in the correct position.
・ The vacuum hose should be correctly connected without cracking or twisting.
・ Conduct a thorough inspection to make sure that there are no leaks or clogging in the vacuum hose.
・ The air intake duct should not be crushed or damaged.
・ The exhaust pipe should not be crushed or damaged.
・ The wiring and terminals of engine harnesses should be appropriately connected, and they should not be pinched or
disconnected.
3. Intermittent conditions
If an intermittent condition exists, inspect for improper installation of electronic equipment. Inspect whether there is any
electronic equipment, light, or mobile phone that was additionally installed. Verify that any device that was additionally
installed is not connected to the serial data circuits such as CAN or Keyword.
Depending on the problem, the check engine warning light may not illuminate, or a DTC may not be stored. An intermittent
condition is often caused by an improper electrical connection or wiring. Conduct a careful visual inspection, or conduct an
actual inspection to see whether the following conditions exist in the suspected connector.
・ Incomplete connection between connectors
・ Seating failures of terminals
・ Damage or deformation of terminals
Repair or replace the connector terminal of the circuit with the problem, and appropriately connect. Remove the terminals
from the connector body and inspect the wires of the terminals for poor connections.
Connect the DMM to the suspected circuit and perform a vehicle road test. If an abnormal value is displayed when the
malfunction occurs, it can be determined that there is a problem in the monitored circuit. The scan tool is useful in detecting
intermittent conditions. The scan tool has the following convenient functions.
・ The snapshot function can be used to record the engine parameters.
・ The snapshot function can be used to review the recorded information and know the particular operation condition
that resulted in the malfunction.
・ Freeze Frame/Failure Records are useful in identifying the locations of intermittent conditions.
・ Review the information recorded in the Freeze Frame/Failure Records, store the Freeze Frame/Failure Records, and
operate the vehicle under the DTC set conditions.
・ By using the plot function of the scan tool, it is possible to graph the selected data parameters.
・ The plot function of the scan tool can be used to review the recorded information and check the location of the
intermittent condition.
In order to detect intermittent conditions, use the data recording function of the data recording module (DRM). The DRM
includes a function for storing engine log data when a DTC is set. Up to 3 log data entries can be stored in the DRM memory.
If an entry exceeding the maximum storage count is set, the oldest log data is overwritten. However, if the same DTC is set
again within 8 hours, that DTC is not stored in the DRM memory.
Instead of a DTC operation, the manual trigger switch stores the log data by arbitrary operation of the driver in the event of
incorrect vehicle performance operation. If the driver presses and releases the manual trigger switch once, that time becomes
a trigger, and any log data after the trigger is stored in the DRM memory. When there is available space in the DRM memory,
the log data is stored in that space. However if an entry exceeding the maximum storage count is set, the oldest log data is
overwritten.
Check for improper installation of optional electronic accessories such as lights or mobile phones. Under the following
conditions, DTCs are not recorded, and the check engine warning light may illuminate intermittently.
・ The ground of the ECM is loose or dirty.
・ The check engine warning light circuit is intermittently shorted to ground.
・ The diode has an open circuit.
Note：
・ A relay, ECM drive solenoid, or switch malfunction may cause the generation of a large surge voltage or
surge current. Normally, this problem will occur when the malfunctioning component is operating.
In the following list of symptoms, causes for each symptom are organized. There is no significance to the order of this
procedure. If the value on the scan tool does not indicate a malfunction, the next procedure to perform should be the one that
can be most easily inspected or is most likely to be the cause.
Use the following list when diagnosing symptoms of complaints.
・ Intermittent engine conditions
・ Hard start
・ Rough, unstable
・ High idle speed
・ Cuts out
・ Surges
・ Lack of power, sluggishness or sponginess
・ Hesitation, sag or stumble
・ Abnormal combustion noise
・ Poor fuel economy
・ Black smoke
・ White smoke
There is no current problem, but a past DTC exists. Or, there is a complaint from the customer not related to a DTC, and that
symptom cannot be reproduced.
4. Preliminary inspection
Perform the Diagnostic system check - engine controls.
5. Wire harness and connector
Intermittent open or short circuits may be caused by vibrations in the wire harnesses and connectors due to fluctuations in
engine torque, bumps in the road, etc. Perform the following inspections.
・ Shake the related connectors or wiring while monitoring the scan tool data.
・ Shake the related connectors or wiring and monitor component operation while turning the components ON and OFF
using the scan tool.
・ Start the engine, and shake the related connectors and wiring while checking the operation status of the engine.
If moving the wire harness or connector affects the data displayed or the component or system operation, inspect the wire
harness and connector as necessary.
6. Electrical connections or wiring
Intermittent conditions are caused by poor wire harness connections, loose terminals, or problems in the wire harness. Check
for the following conditions.
・ Is there any improper mating of the connector halves or improper seating of the terminals in the connector body?
・ Are there any improperly formed, damaged, or loose terminals?
・ Are there any poor terminal-to-wire harness connections or bent terminals?
・ Is there any corrosion or water intrusion?
・ Are there any broken wire harnesses?
・ Is the wire harness pinched, cut, or damaged?
・ Is the wire harness coming in contact with hot exhaust components?
Note：
・ Worn or damaged insulation can allow moisture to enter the wiring. The conductor can corrode inside the
insulation, with little visible evidence. Check for swollen or stiff sections of the wire harness in the suspected
circuits.
7. Control module power supply and ground, and component power supply and ground
Various symptoms can occur due to poor connections at the power supply or ground.
Test all control module power supply circuits. In many vehicles, there are multiple circuits that supply power to the control
module. Other components in the system have separate power supply circuits that also need to be tested. Inspect the
connections and fuses of the module and the component connectors, as well as intermediate connections between the power
supply, the module, and the components. A test lamp or a DMM may indicate that voltage is present, but neither of them tests
whether the circuit is carrying sufficient current. Check whether sufficient current necessary to operate the components is
flowing in the circuit.
Test all control module ground circuits and system ground circuits. Some control modules have multiple ground circuits.
Other components in the system have a separate ground that also needs to be tested. Inspect whether the ground is clean and
is securely connected to the ground point. Inspect the connections of the components and the splice pack. Check whether
sufficient current necessary to operate the components is flowing in the circuit.
8. Effects caused by temperature
An intermittent condition may occur when a component or connection reaches its operating temperature. For intermittent
conditions that may occur only when the components or connections are cold or only when they are hot, failure records or
snapshot data can be helpful, where possible.
If an intermittent condition is related to heat, review the data relating to the following items.
・ High ambient temperature
・ Heat emitted from under the cab or by the engine
・ Heat generated due to poor wire harness connections or a high electrical load
・ Higher than normal load conditions due to towing, etc.
If an intermittent condition is related to low temperatures, review the data relating to the following.
・ Low ambient temperature
・ The symptom occurs only on a cold start.
・ The symptom goes away when the vehicle warms up.
Note：
・ If the temperature is extremely low, a connection area or component may freeze. Inspect for water intrusion.
Based on the information from the customer, determine if the failure is caused by temperature.
9. EMI and electrical noise
Some electronic components and circuits are sensitive to EMI or other types of electrical noise.
Inspect for wire harnesses that are placed too close to high-voltage or high-current components such as injection components,
motors, and generators. These components may generate electrical noise which interferes with normal circuit operations.
Check for a surge voltage or surge current generated by a relay or switch malfunction. Normally, this problem will occur
when the malfunctioning component is operating.
Inspect for improper installation of non-factory or aftermarket electronic equipment such as lights, radios, amplifiers, electric
motors, remote starters, and alarm systems. Electromagnetic disturbance may occur while this electronic equipment is in use,
but not when not in use.
Inspect the generator for a malfunctioning rectifier circuit that may be allowing AC noise into the electrical system.
10. Incorrect ECM programming
The situations in which reprogramming an ECM is appropriate are limited.
・ An ECM from another vehicle is installed.
・ A revised software/calibration file has been released for this vehicle.
Do not reprogram the ECM with the same software/calibration files that are already present in the ECM. This is not an
effective repair for a drivability problem.
Check that the ECM contains the correct software/calibration. If an incorrect program is found, use the most recent software/
calibration to reprogram the ECM.
11. Reproduction of failure conditions
If none of the previous tests are successful, attempt to duplicate or record the failure conditions.
Freeze Frame/Failure Records, where applicable, contain the conditions that were present when the DTC was set.
・ Review and store the Freeze Frame/Failure Records.
・ Operate the vehicle under the same conditions that were stored in the Freeze Frame/Failure Records.
・ The vehicle must be operated under the DTC set conditions.
If an abnormal value is displayed on the DMM when the problem occurs, this can be helpful in identifying the defective area.
An alternative method is to operate the vehicle with the DMM connected to the suspect circuit.
12. Scan tool snapshot
Snapshots can be taken using the scan tool. The snapshot function can be used to record ECU data in chronological order and
analyze it. The scan tool also has a graph function which can display graph data individually or in combination for
comparison. The snapshot function can be used to set up the manual trigger or automatic trigger when a DTC is set.
Analyzing the recorded data allows malfunctioning components to be identified.
13. DRM memory
Use the data stored in the DRM memory, or use the manual trigger switch. The DRM has the ability to store engine log data
when a DTC is set. The manual trigger switch stores the log data when voluntarily operated by the driver on the occasion of
an incorrect vehicle performance event, as opposed to when a DTC event occurs. If the driver presses and releases the manual
trigger switch once, that time becomes a trigger, and any log data after the trigger is stored in the DRM memory.
Hard start
1. Hard start description of symptom
The engine cranks but does not start for an extended period of time. The engine does eventually run, or may start but
immediately stops.
2. Hard start diagnostics
Perform the Diagnostic system check-engine controls.
Perform the Fuel supply pump functional inspection.
Verify that the driver is using the correct starting procedure.
Ensure that the ground of the ECM is free of dirt and is fixed securely in the correct position.
Inspect whether the harness connector is properly connected.
Inspect the fuel type and quality.
Verify the Injector ID Code of each cylinder.
Check the scan tool data list.
Check for related Service Bulletins.
2. Sensor inspection
Compare the Engine Coolant Temperature, Intake Air Temperature, and Fuel Temperature parameters while the engine is
cold. If the difference between the temperature values is 5°C {9°F} or more when the engine is cold, inspect for high
resistance in each circuit and for a sensor malfunction.
Observe the Fuel Rail Pressure Sensor parameter on the scan tool. It is normal if the Fuel Rail Pressure Sensor display shows
0.9 to 1.0 V when the ignition switch is turned ON without starting the engine after the engine has been OFF for 1 minute or
more. If not, inspect for high resistance in each circuit and for a sensor malfunction.
The CKP sensor is securely installed, and the sensor rotor is not damaged.
The CMP sensor is securely installed, and the camshaft gear is not damaged.
3. Fuel system inspection
Inspect for air in the fuel system.
Inspect for water in the fuel.
Inspect whether the fuel is frozen.
Inspect the fuel filter for clogging.
Inspect for external fuel leakage and excessive engine oil.
Inspect for fuel leakage from the pressure limiter and injector.
Inspect for collapsing, twisting, improper tightening, cracking, or clogging in the fuel system between the fuel tank and the
fuel supply pump.
Inspect the vent valve and hose of the fuel tank for clogging.
{The piping may be clogged due to foreign material from the fuel tank entering the fuel system.}
Inspect the fuel supply pump operation.
{The fuel supply pump must be timed with the engine, and the adjusted value should be learned by the ECM.}
Perform Injector Cutoff with a scan tool.
Perform Injector Forced Drive with a scan tool.
Observe the FRP Regulator Feedback Current (Fuel Rail Pressure) parameter on the scan tool.
4. Air intake system inspection
Inspect the air cleaner, air intake duct, and intercooler for clogging, holes, or leakage.
Inspect for any condition that restricts flow within the turbocharger intake duct.
Inspect for a stuck intake throttle valve.
Inspect the inlet cover for clogging or leakage.
5. Exhaust system inspection
Inspect whether the exhaust system flow is restricted.
If the exhaust brake remains ON, inspect the electrical system, solenoid valve, and DTC status.
If the exhaust brake remains ON, inspect the exhaust brake shaft for sticking.
6. Engine mechanical inspection
Inspect the compression pressure of the engine.
Inspect for improper idle gear timing.
Inspect the valve clearance.
Inspect the valve spring for damage and fatigue.
Inspect the camshaft for wear.
7. Electrical system inspection
Inspect the cranking speed.
Inspect the battery for deterioration.
Rough, unstable
1. Rough, unstable description of symptom
The engine idling speed is not constant. The engine or vehicle may shake in severe situations. The engine idling speed may
vary. Any of these conditions can be severe enough to cause the engine to stall.
2. Rough, unstable diagnostics
Remove the air cleaner and inspect for contamination, collapsing in the air duct, or any condition that restricts the flow.
When idling the engine in neutral, observe the Fuel Rail Pressure parameter. It is normal if the value is always in the range of
30 to 35 MPa {4,350 to 5,080 psi} after the engine is warmed up.
fuel supply pump.
Observe the Fuel Compensation parameter for each cylinder on the scan tool while idling.
Observe the FRP Regulator Feedback Current (Fuel Rail Pressure) parameter on the scan tool.
Inspect the basic components of the engine including the camshaft, the cylinder head, and the pistons.
7. Other inspections
EMI may cause engine failure.
The scan tool can usually detect EMI by checking the engine speed. EMI occurs when rotation speed sharply increases even
when the actual engine speed hardly changes. If any problem is found, inspect whether any high-voltage component such as
injector wiring is connected to the area around the sensor circuit.
Inspect the engine mounting for abnormal conditions.
Inspect the crank pulley for a malfunction.
Inspect the generator or A/C compressor.
Inspect the generator output voltage.
Inspect the operation of the A/C.
High idle speed

1. High idle speed description of symptom
The idling speed is higher than normal regardless of the engine coolant temperature.
2. High idle speed diagnostics
Compare the Engine Speed parameter with the value of the tachometer in the instrument panel cluster using the scan tool.
Inspect the engine oil level.
When idling the engine in neutral, observe the Fuel Rail Pressure parameter. It is normal if the value is always in the range of
30 to 35 MPa {4,350 to 5,080 psi} after the engine is warmed up.
Observe the Accelerator Pedal Position parameter. It is normal if the Accelerator Pedal Position parameter changes linearly
from 0 to 100% according to the accelerator pedal operation.
Observe the Idle Up Sensor parameter. It is normal if the Idle Up Sensor parameter shows 0.6 V or less at the maximum
position in the counterclockwise direction. If not, inspect for high resistance in the low reference circuit and for a sensor
malfunction.
Observe the PTO Remote Throttle Sensor parameter. It is normal if the PTO Remote Throttle Sensor parameter shows 0.4 V
or less at the minimum position. If not, inspect for high resistance in the low reference circuit and for a sensor malfunction.
Remove and visually inspect the injector.
{The tip of the injector may be damaged.}
Cuts out
1. Cuts out description of symptom
Constant jerking according to the engine speed {Usually, it is notable when the engine load increases}. Continuous hissing
sounds {boiling sounds} are generated from the exhaust system when the engine is idling, the engine speed is low or
accelerating abruptly, and fuel deficiency occurs, which results in engine stop.
2. Cuts out diagnostics
0.9 to 1.0 V when the ignition switch is turned ON without starting the engine after 1 minute or more has passed since the
stop of engine operation. If not, inspect for high resistance in each circuit and for any sensor failure.
With the vehicle in neutral and idling, completely depress the accelerator pedal while checking the Fuel Rail Pressure
parameter and Desired Fuel Rail Pressure parameter. The difference displayed should always be maintained within -5 to 5
MPa {-725 to 725 psi}.
fuel supply pump.
Inspect the vent valve and the hose of the fuel tank for clogging.
{The piping may be clogged due to foreign material from the fuel tank having entered the fuel system.}
Perform the Injector Cutoff with a scan tool.
Perform the Injector Forced Drive with a scan tool.
EMI may cause engine failure.
The scan tool can usually detect EMI by checking the engine speed. EMI occurs when rotation speed sharply increases even
when the actual engine speed hardly changes. If any problem is found, inspect whether any high-voltage component such as
injector wiring is connected to the area around the sensor circuit.
Surges
1. Surges description of symptom
The vehicle speeds up and slows down with no change in the accelerator pedal position.
2. Surges diagnostics
The driver must be familiar with A/C compressor operation.
Make sure the Vehicle Speed parameter matches the value in the vehicle speedometer with a scan tool.
0.9 to 1.0 V when turning the ignition switch to the ON position without starting the engine after the engine has been OFF for
1 minute or more. If not, inspect for high resistance in each circuit and for any sensor failure.
Observe the Fuel Rail Pressure parameter and Desired Fuel Rail Pressure parameter while completely depressing the
accelerator pedal with the vehicle in neutral and idling. The difference displayed should always be maintained within -5 to 5
MPa {-725 to 725 psi}.
fuel supply pump.
Inspect the vent valve and the hose of the fuel tank for clogging.
{The piping may be clogged due to foreign material from the fuel tank having entered the fuel system.}
Inspect the intake throttle valve for sticking.
Inspect the inlet cover for clogging or air leakage.
Inspect the turbocharger wastegate valve.
Inspect the output voltage of the generator.
Check the tire for deformation that may cause symptoms in a particular speed range.
Lack of power, sluggishness or sponginess

1. Lack of power, sluggishness or sponginess description of symptom
The engine output is less than expected. The engine speed hardly increases or does not increase at all even when the
accelerator pedal is depressed.
2. Lack of power, sluggishness or sponginess diagnostics
Compare the vehicle with a similar vehicle. Check if any problem exists in the vehicle.
Check whether the tire size was changed.
Check if excessively heavy loads are carried.
Inspect for clutch slip.
Inspect for brake drag.
Inspect whether the transmission shift pattern and the down shift operation are normal.
Inspect the fuel quality.
Inspect the engine oil level and oil quality.
Make sure the Vehicle Speed parameter matches the value in the vehicle speedometer with a scan tool.
Observe the Fuel Rail Pressure parameter and Desired Fuel Rail Pressure parameter while fully depressing the accelerator
pedal with the vehicle in neutral and idling. The difference between the displays should always be maintained within -5 to 5
MPa {-725 to 725 psi}.
Observe the Boost Pressure parameter and Barometric Pressure parameter while the ignition switch is ON and the engine is
OFF. It is normal if the difference between both parameters is within 7.0 kPa {1.0 psi}.
fuel supply pump.
Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear or damage.
Inspect the valve spring for breakage and fatigue.
Inspect whether the engine has overheated.
Hesitation, sag or stumble

1. Hesitation, sag or stumble description of symptom
Response is delayed for a moment when the accelerator pedal is depressed. This occurs at every vehicle speed. Usually, this
situation is most notable when starting the vehicle from the stopped state. Engine stalling may occur in severe situations.
2. Hesitation, sag or stumble diagnostics
Compare the vehicle with a similar vehicle. Check if any problem exists in the vehicle.
Inspect whether the transmission shift pattern and the down shift operation are normal.
MPa {-725 to 725 psi}.
fuel supply pump.
Inspect whether the engine has overheated.
Abnormal combustion noise

1. Abnormal combustion noise description of symptom
Engine knocking occurs repeatedly. Usually, it becomes particularly notable when accelerating. A sharp metallic sound is
produced when the throttle opening angle is changed.
2. Abnormal combustion noise diagnostics
Perform the Diagnostic system check - engine controls.
Check if any problem exists in the vehicle.
Inspect whether smoke is present with combustion noise.
MPa {-725 to 725 psi}.
If there is excessive smoke, inspect for an injector that is stuck open. Inspect the combustion chamber for fuel intrusion.
Inspect the basic components of the engine including the camshaft, the cylinder head, and the pistons.
Inspect the combustion chamber for excessive oil intrusion.
Inspect for any other cause that generates a similar sound, such as loose components, brackets, mounts, or a deteriorated
clutch damper spring.
Poor fuel economy

1. Poor fuel economy description of symptom
The fuel mileage measured in an actual road test and in multiple fuel measurements is significantly lower than the predicted
value. Also, it is significantly lower than the fuel mileage obtained in the previous road test.
2. Poor fuel economy diagnostics
Verify the driver's driving habits.
Check whether the A/C is always ON or the defroster mode is ON.
Verify that the tire air pressure is appropriate.
Check if the tire size has been changed.
Check if excessively heavy loads are carried.
Check if acceleration is excessive or too frequent.
Inspect for clutch slip.
Inspect for brake drag.
Inspect the drive belt tension.
Instruct the owner to check fuel consumption again after refilling fuel.
Inspect whether the odometer is operating properly.
cold.
If the difference between the temperature values is 5°C {9°F} or more when the engine is cold, inspect for high resistance in
each circuit and for a sensor malfunction.
Inspect for fuel leakage.
4. Cooling system inspection
Inspect the engine coolant level.
Inspect whether the engine thermostat is always open, and inspect for an incorrect heat range.
Inspect whether the engine cooling fan is always ON.
Black smoke
1. Black smoke description of symptom
Black smoke is generated when the engine is under load, idling, or hot, or when starting the engine in a cold state.
2. Black smoke diagnostics
MPa {-725 to 725 psi}.
Perform the Pre Injection Stop with a scan tool.
Inspect for oil intrusion into the combustion chamber.
Inspect for excessive blow-by gas.
White smoke
1. White smoke description of symptom
White smoke is generated when the engine is under load, idling, or hot, or when starting the engine in a cold state.
2. White smoke diagnostics
MPa {-725 to 725 psi}.
If there is excessive smoke, inspect for an injector that is stuck open. Inspect the combustion chamber for fuel intrusion.
Perform the Pre Injection Stop with a scan tool.
Inspect for oil intrusion into the combustion chamber.
Inspect the movement of the thermostat.
Engine has overheated

1. Engine has overheated diagnostics
Engine coolant is insufficient.
・ Inspect coolant.
・ Refill engine coolant.
Insufficient engine oil or use of improper engine oil
・ Refill or change engine oil.
Loose fan belt
・ Adjust or replace.
Excessive fuel injection quantity
・ Diagnose the engine control system.
Defective radiator cap
・ Replace.
Radiator clogging
・ Clean or replace.
Restricted exhaust system
Thermostat malfunction
・ Replace.
Water pump malfunction
・ Replace.
Defective cylinder head gasket
・ Replace.
Engine has overcooled

1. Engine has overcooled diagnostics
Thermostat malfunction
・ Replace.
Engine does not stop

1. Engine does not stop diagnostics
Engine control system malfunction
・ Diagnose the engine control system.
Starter overrun
1. Starter overrun diagnostics
Improper return from the ignition switch contact point
・ Replace the ignition switch.
Improper return from the starter relay contact point
・ Replace the starter relay.
Magnetic switch coil short circuit
・ Replace the magnetic switch.
Defect of charging system

1. Defect of charging system diagnostics
1. Will not charge at all.
Battery failure
・ Replace.
Open circuit, short circuit, or disconnections in the wiring or ammeter
・ Repair.
Open circuit, poor ground, or short circuit in each coil of the generator, or broken diode
・ Replace.
IC regulator malfunction
・ Replace.
Poor connections at IC regulator terminal
・ Repair.
2. Insufficient charge
Battery failure
・ Replace.
Open circuit, short circuit, or disconnections in the wiring or ammeter
・ Repair.
Generator drive belt looseness
・ Adjust.
Stator coil layer short circuit
・ Replace.
Diode failure
・ Replace.
Poor terminal connections
・ Replace.
・ Replace.
・ Repair.
3. Over charged.
・ Replace.
4. The charge voltage is unstable.
Intermittent contact or near open circuit of wiring
・ Repair.
Generator drive belt looseness
・ Adjust.
Short circuit or near open circuit in the stator coil
・ Repair.
Poor terminal connections
・ Repair.
・ Replace.
・ Repair.
Abnormal sound in generator

1. Abnormal sound in generator diagnostics
Loose belt tension
・ Adjust.
Bearing failure
・ Replace.
The rotor core is in contact with the stator core.
・ Repair.
Diode failure
・ Replace.
Short circuit or near open circuit in the stator coil
・ Repair.
Vibrations and rattling sounds from the exhaust system

1. Vibrations and rattling sounds from the exhaust system diagnostics
Looseness or improper installation of components
・ Retighten after aligning the connections, or inspect the hanger, mounting brackets, and clamps for damage.
Clogging of the exhaust system

1. Clogging of the exhaust system diagnostics
The exhaust brake valve is ON.
・ Inspect the electrical system and each magnetic valve, and check the DTC status. Repair if a malfunction is detected.
・ Inspect the exhaust brake valve shaft for stiffness. Replace if abnormal conditions are found.
Clogged or deformed exhaust pipe
・ Repair or replace.
Exhaust gas leak, noise

1. Exhaust gas leak, noise diagnostics
Improper installation or connection
・ Retighten after aligning the connections.
Broken or burnt exhaust pipe or silencer
・ Replace the damaged parts.
Defective exhaust system components such as clamps, pipes, and silencer
・ Replace the defective parts.
Internal breakage of the silencer
・ Replace the damaged parts.
Defect of turbocharger
1. Defect of turbocharger diagnostics
1. When output has dropped although the engine appears to be normal
Deformed or broken turbine fins or compressor fins
・ Replacement
Fins and housing make contact with each other.
・ Replacement
Large amounts of carbon deposits adhering to the turbine exhaust outlet come into contact with the turbine fins
When manually turned, the turbine shaft catches on something or the rotation is heavy.
・ Replacement
The clearance in the axial direction or rotational direction of the turbine shaft is large.
・ Measure and replace if it exceeds the specified value.
2. When output has dropped although the turbocharger appears to be basically normal.
Gas leakage from the exhaust sections
Excessive exhaust resistance caused by deformed exhaust muffler, etc., or carbon clogging
Contamination of the air cleaner element
Clogging in the intercooler cooling section
・ Cleaning
Stuck exhaust brake valve
Defective boost pressure sensor
・ Replacement
Problems with the vehicle, such as dragging of the brakes
・ Repair.
Battery performance deterioration, and low voltage or excessive voltage due to a defective generator
3. When there are abnormal vibrations in the turbocharger.
The cause is bearing damage and contact of the rotating section with the surrounding sections. Degraded oil, foreign material
entering the oil feed pipe, clogging of the oil filter, or repeated sudden starting and stopping can cause bearing failure.
・ Replacement
If there is no problem in the lubricating oil system, but there is damage from contact found in the rotating section and the
surrounding sections, it is probable that the rotating section has become unbalanced or the shaft has been bent. This is caused
by worn bearing or damage to the turbine wheel or compressor wheel made by flying foreign material.
・ Replacement
4. When oil is leaking into the exhaust or intake pipe, and the color of exhaust becomes white.
Raised oil level due to dirty or clogged oil separator
Clogging, collapsing, or deformation of the oil return pipe
Large turbine shaft clearance
・ Measure the clearance and replace if it exceeds the specified value.
Degraded engine oil
・ Change engine oil.
5. When noise is generated from the turbocharger.
Air leakage from coupling of the rubber hose, etc., on the compressor outlet side or gas leakage from the exhaust system
・ Repair.
Contact of the turbine fins and housing
・ Replacement
Internal breakage due to foreign material catching
・ Replacement
Worn or seized turbine shaft bearing
・ Replacement
Engine does not turn over

1. Engine does not turn over diagnostics
1. The starter does not rotate even when the ignition switch is turned ON.
Complete battery discharge
・ Replace the battery.
Insufficient battery charge
・ Charge or replace the battery.
Battery relay failure
・ Replace.
Open circuit in the wiring circuit, or poor connections
Ignition switch contact failure or improperly tightened terminal
Poor connections at the starter relay contact point or improperly tightened terminal
Short circuit or open circuit in the magnetic switch coil
・ Replace.
Blown out fuse
・ Replace.
2. The starter turns but the flywheel does not turn.
Tips of the starter pinion teeth are worn
・ Replace.
Worn ring gear
・ Replace.
Improper adjustment of the magnetic switch
・ Adjust or repair.
Clutch slipping
・ Replace the clutch or starter.
Breakage of the reduction gear
・ Replace the gear or starter.
3. The starter pinion meshes with the ring gear, but the engine does not turn.
Improper tightening of the wiring circuit terminal
・ Repair.
Armature or field coil short circuit
・ Replace the starter.
Stained commutator
・ Repair or replace the starter.
Weakened brush spring or worn brush
・ Replace the brush spring or brush.
Bearing lock
・ Replace the bearing or starter.
Poor connections at the magnetic switch contact point
・ Replace the magnetic switch.
Internal engine seizing
・ Disassemble and repair.

Sec 15D (4HL1)

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Sec 15D (4HL1)

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Symptom (4HL1) 15D-1

Intermittent conditions of engine

High idle speed

Lack of power, sluggishness or sponginess

Hesitation, sag or stumble

Abnormal combustion noise

Poor fuel economy

Engine has overheated

Engine has overcooled

Engine does not stop

Defect of charging system

Abnormal sound in generator

Vibrations and rattling sounds from the exhaust system

Clogging of the exhaust system

Exhaust gas leak, noise

Engine does not turn over

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