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4HK1-6HK1 Shop Manual
4HK1-6HK1 Shop Manual
WORKSHOP MANUAL
TROUBLESHOOTING MANUAL
4HK1-6HK1
ISUZU ENGINE
(Tier 3)
Section 1
WORKSHOP MANUAL
4HK1-6HK1
ISUZU ENGINE
(Tier 3)
R3807
R3807
Introduction IN-1
TO THE READER
• This manual was written for a skilled technician and • For any question or comment, or should you notice any
contains all the technical information needed to repair mistake concerning the contents of this manual,
this engine. please contact:
FURTHER REFERENCES
PAGE NUMBER
• Every page carries a number on the top right corner. Every page contains the following information:
Example: 1A - 1
Section number
IN-2 Introduction
UNITS OF MEASURE
This manual adopts the units of measure based on International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
The following table converts the International System units of measure in some of the main units belonging to other
system.
GENERAL INFORMATION
General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the model . . . . . . . . . . . . . . . . . . . . . . . 0A-6
General information . . . . . . . . . . . . . . . . . . . . . . 0A-7
0A-2 General Information
General Information
Service Precautions
In order to carry out work safely
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical
system, always remove the minus side cable from
the battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to
completely remove oil, water, and dirt etc. from the
various surfaces. Using the specified type of liquid
gasket, apply new liquid gasket to each of the
surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket
9. Pay close attention to the risk of ignition if you are surfaces, apply gasket remover liquid (Pando-
handling parts that carry a high voltage. 391D made by Three Bond Co., Ltd.) and leave
Furthermore, any oil or fat spilt onto rubber parts the part to stand for approximately 10 minutes,
must be wiped off immediately, as it will cause after which the old liquid gasket residue will be
deterioration of the rubber. easier to remove.
However, this should not be used on resin
components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when re-
installing the liquid gasket parts to each other. If
there are gaps between the two parts, re-apply the
liquid gasket. Some parts, especially the oil pan,
use the same size studs as a guide to eliminate the
need for knock pin positioning etc.
5. Re-install these parts within 7 minutes of applying
the liquid gasket.
0A-4 General Information
If more than 7 minutes passes, remove the
previous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.
Liquid gasket
Application procedure
1. Wipe the contact surfaces clean of all water, fat or
oil. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.
Notes:
If there are special regulations concerning the
application procedure in the repair document, please
follow those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
Important:
screw thread section clean of water, fat, and oil.
After tightening the bolt, do not apply excessive torque
The contact surfaces should be dry.
or try to rotate the bolt until at least one hour has
2. Apply Loctite to the top 1/3 of the screw. passed, and the Loctite has hardened.
3. Tighten the bolt to the correct tightening torque.
Procedure for using the Plastiguage
WSHK0185
General Information 0A-7
6HK1
WSHK0186
General information
Terminology, description of abbreviations
Terminology definitions
Term Explanation
Maintenance standard The generic name for reference values required for maintenance, such as nominal
dimension, selection of a reference point, and limit.
Nominal dimension Shows the standard value at the point of manufacture that does not include the
common difference.
Selection of a reference point Shows the standard value after assembling, repairing, or adjusting.
Limit When this value (dimensions) is reached, it shows that the part has reached its full
limit and must be replaced or repaired.
Front ⋅ rear, left ⋅ right, upper ⋅ These show each orientations of parts installed to the vehicle when looking from
lower the vehicle's forward direction.
Unit Units written to SI conventions (mainly torque, pressure, force)
[Example] Length: mm, Torque: N⋅m {kgf⋅m}
Warning Items that carry the warning mark pose a danger to life or threat of serious injury if
not strictly observed.
Caution Items that carry the caution mark may cause injury or lead to accidents if not strictly
observed.
Important Items that carry the important mark may cause the vehicle to break down, or may
prevent the guaranteed normal operation of the system or related parts if not strictly
observed.
0A-8 General Information
Term Explanation
Notes Items that should receive special mention within a work procedure.
N⋅m {kgf⋅m}
Strength 4.8
7T
classification 4T
Bolt head
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
section shape
* M10 × 1.5 19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}
M12 × 1.25
68.1 ~ 102.1 {6.9 ~
49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}
10.4}
* M12 × 1.75 45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}
M14 × 1.5
76.5 ~ 114.7 {7.8 ~ 83.0 ~ 124.5 {8.5 ~ 93.2 ~ 139.3 {9.5 ~ 100.8 ~ 151.1 {10.3 ~
11.7} 12.7} 14.2} 15.4}
* M14 × 2
71.6 ~ 106.9 {7.3 ~ 77.2 ~ 115.8 {7.9 ~ 88.3 ~ 131.4 {9.0 ~ 94.9 ~ 142.3 {9.7 ~
10.9} 11.8} 13.4} 14.5}
M16 × 1.5
104.0 ~ 157.0 {10.6 ~ 115.6 ~ 173.3 {11.8 ~ 135.3 ~ 204.0 {13.8 ~ 150.1 ~ 225.2 {15.3 ~
16.0} 17.7} 20.8} 23.0}
* M16 × 2
100.0 ~ 149.1 {10.2 ~ 109.4 ~ 164.2 {11.2 ~ 129.4 ~ 194.2 {13.2 ~ 142.5 ~ 213.8 {14.5 ~
15.2} 16.7} 19.8} 21.8}
M18 × 1.5
151.0 ~ 225.6 {15.4 ~ 195.2 ~ 293.2 {19.9 ~
— —
23.0} 29.9}
* M18 × 2.5
151.0 ~ 225.6 {15.4 ~ 196.1 ~ 294.2 {20.0 ~
— —
23.0} 30.0}
M20 × 1.5
206.0 – 310.0 {21.0 ~ 269.7 ~ 405.0 {27.5 ~
— —
31.6} 41.3}
* M20 × 2.5
190.2 ~ 286.4 {19.4 – 249.1 ~ 374.6 {25.4 ~
— —
29.2} 38.2}
M22 × 1.5
251.1 – 413.8 {25.6 ~ 362.8 ~ 544.3 {37.0 ~
— —
42.2} 55.5}
* M22 × 2.5
217.7 ~ 327.5 {22.2 ~ 338.3 ~ 507.0 {34.5 ~
— —
33.4} 51.7}
M24 × 2
358.9 ~ 539.4 {36.6 ~ 430.5 ~ 711.0 {43.9 ~
— —
55.0} 72.5}
* M24 × 3
338.3 ~ 507.0 {34.5 ~ 406.0 ~ 608.0 {41.4 ~
— —
51.7} 62.0}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
General Information 0A-11
N⋅m {kgf⋅m}
9.8
Strength classification 8.8
9T
Bolt head section
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
shape
M6 × 1
5.6 ~ 11.2 {0.6 ~ 6.6 ~ 12.2 {0.6 ~
— —
1.1} 1.2}
M8 × 1.25
13.4 ~ 25.7 {1.4 ~ 15.3 ~ 28.4 {1.6 ~ 16.7 ~ 30.4 {1.7 ~ 18.1 ~ 33.6 {1.9 ~
2.6} 2.9} 3.1} 3.4}
M10 × 1.25
31.3 ~ 52.5 {3.2 ~ 35.4 ~ 58.9 {3.6 ~ 37.3 ~ 62.8 {3.8 ~ 42.3 ~ 70.5 {4.3 ~
5.4} 6.1} 6.4} 7.2}
* M10 × 1.5
31.3 ~ 51.4 {3.2 ~ 34.5 ~ 57.5 {3.5 ~ 36.3 ~ 59.8 {3.7 ~ 40.1 ~ 66.9 {4.1 ~
5.2} 5.8} 6.1} 6.8}
M12 × 1.25
69.3 ~ 104.0 {7.1 ~ 77.7 ~ 116.5 {7.9 ~ 75.5 ~ 113.8 {7.7 ~ 85.0 ~ 127.5 {8.7 ~
10.6} 11.9} 11.6} 13.0}
* M12 × 1.75
64.8 ~ 96.1 {6.6 ~ 71.4 ~ 107.2 {7.3 ~ 71.6 ~ 106.9 {7.3 ~ 79.5 ~ 119.2 {8.1 ~
9.8} 10.9} 10.9} 12.2}
M14 × 1.5
106.2 ~ 158.8 {10.8 114.9 ~ 172.3 {11.7 113.8 ~ 170.6 {11.6 123.4 ~ 185.1 {12.6
~ 16.2} ~ 17.6} ~ 17.4} ~ 18.9}
* M14 × 2
100.6 ~ 149.8 {10.3 108.2 ~ 162.2 {11.1 106.9 ~ 160.0 {10.9 115.5 ~ 173.3 {11.8
~ 15.3} ~ 16.6} ~ 16.3} ~ 17.7}
M16 × 1.5
154.3 ~ 232.5 {15.7 171.1 ~ 256.7 {17.4 160.0 ~ 240.3 {16.3 176.9 ~ 265.3 {18.0
~ 23.7} ~ 26.2} ~ 24.5} ~ 27.1}
* M16 × 2
147.6 ~ 221.4 {15.0 162.5 ~ 243.8 {16.6 153.0 ~ 229.5 {15.6 168.5 ~ 252.7 {17.2
~ 22.6} ~ 24.9} ~ 23.4} ~ 25.8}
M18 × 1.5
222.5 ~ 334.3 {22.7 229.5 ~ 345.2 {23.4
— —
~ 34.1} ~ 35.2}
* M18 × 2.5
223.6 ~ 335.4 {22.8 230.5 ~ 346.2 {23.6
— —
~ 34.2} ~ 35.3}
M20 × 1.5
307.4 ~ 461.7 {31.4 316.8 ~ 475.6 {32.3
— —
~ 47.1} ~ 48.5}
* M20 × 2.5
284.0 ~ 472.1 {29.0 293.2 ~ 440.3 {29.2
— —
~ 43.5} ~ 44.9}
M22 × 1.5
413.6 ~ 620.5 {42.2 424.6 ~ 636.5 {43.3
— —
~ 63.3} ~ 64.9}
* M22 × 2.5
385.7 ~ 578.0 {39.3 394.2 ~ 592.3 {40.0
— —
~ 58.9} ~ 60.4}
M24 × 2
490.8 ~ 810.5 {50.0 554.1 ~ 830.6 {56.5
— —
~ 82.7} ~ 84.7}
* M24 × 3
462.8 ~ 693.1 {47.2 520.7 ~ 781.6 {53.1
— —
~ 70.7} ~ 79.7}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
0A-12 General Information
Designations for Isuzu standard bolt heads
Legend
1. Hexagon head bolt(4.8, 4T) 9. Hexagon head bolt(Un-refined 8.8)
2. Hexagon head bolt(4.8, 4T) 10. Hexagon head bolt(Un-refined 8.8)
3. Flange bolt(4.8, 4T) 11. Flange bolt(8.8)
4. Flange bolt(4.8, 4T) 12. Flange bolt(8.8)
5. Hexagon head bolt(7T) 13. Hexagon head bolt(9.8, 9T)
6. Flange bolt(7T) 14. Hexagon head bolt(9.8, 9T)
7. Hexagon head bolt (refined 8.8) 15. Flange bolt(9.8, 9T)
8. Hexagon head bolt (refined 8.8) 16. Flange bolt(9.8, 9T)
Flare nut
N⋅m {kgf⋅m}
Screw size PT(R) 1/8 PT(R) 1/4 PT(R) 3/8 PT(R) 1/12
— 2.0 ~ 14.7 4.9 ~ 15.7 9.8 ~ 16.7 9.8 ~ 17.7
(0.2 ~ 1.5) (0.5 ~ 1.6) (1.0 ~ 1.7) (1.0 ~ 1.8)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-1
ENGINE
ENGINE MECHANICAL (4HK1, 6HK1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1, 6HK1) . . . . . . . 1A-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-82
Precautions on Service Work . . . . . . . . . . . . . . 1A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-88
Main Data and Specifications . . . . . . . . . . . . . 1A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-94
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . 1A-14 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-101
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . 1A-103
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-16 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103
Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-104
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-110
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-114
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-24 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Turbocharger and Exhaust Manifold . . . . . . . . . 1A-25 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-25 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-27 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-32 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-119
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-51 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-124
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1A-126
Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-53 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-126
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-126
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-128
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-54 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-133
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-56 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-57 Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 1A-134
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-59 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-134
Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-134
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-138
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-62 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-64 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Fixing torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-67 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-69 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-70 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-146
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-150
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-150
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-72 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-153
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Lubrication System . . . . . . . . . . . . . . . . . . . . . . 1A-157
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-79 Precautions on Service Work . . . . . . . . . . . . 1A-157
1A-2 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check . . . . . . . . . . . . . . . . . . . . . . . 1A-158
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Oil Port Cover ASM . . . . . . . . . . . . . . . . . . . . . 1A-160
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-165
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-169
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-174
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-178
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-178
ENGINE MECHANICAL (4HK1, 6HK1) 1A-3
Name
1. Cast The Engine Model 2. Stamp An Engine Number
ENGINE MECHANICAL (4HK1, 6HK1) 1A-5
6HK1
WSHK0001
Name
1. Stamp An Engine Number
Name
1. Rocker Arm
2. Bridge Cap
3. Bridge
Tightening torque:
Rocker arm adjustment 22 N⋅m (2.2 kg⋅m/16 lb ft)
screw nut
Bridge adjustment screw 22 N⋅m (2.2 kg⋅m/16 lb ft)
nut
1A-8 ENGINE MECHANICAL (4HK1, 6HK1)
Adjustment table (4HK1)
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
{ { { {
No. 1 cylinder
Compression top dead center position
× × × ×
No. 4 cylinder
Compression top dead center position
{ { { { { {
No. 1 cylinder
Compression top dead center position
× × × × × ×
No. 6 cylinder
Compression top dead center position
with × mark.
(6HK1) cylinder is the compression TDC, that
4HK1
6HK1
WSHK0002
ENGINE MECHANICAL (4HK1, 6HK1) 1A-9
4HK1
WSHK0003
Note:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
• Install the cylinder head cover.
Refer to the “Cylinder Head Cover”.
Compression pressure inspection
• Warm-up the engine.
1
• Remove a negative terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
WSHK0004
built on the lower head cover (no fuel will be
injected). Name
1. Fuel Injection Harness Connector
Caution:
When the harness connector is removed, ECM judges
• Install the negative terminal of the battery.
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory • Turn on the starter to emit foreign matter within the
of ECM. cylinders.
(For how to clear memory of ECM, refer to the Engine • Install an adapter and a gauge of a compression
Control System Section) gauge of the special tool.
1A-10 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
Compression pressure MPa (psi) / 200 rpm
Standard 3.24 (469)
Limit 2.26 (327)
Differences among
294 kPa (43)
the cylinders
Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Remove a negative terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft)
• Install the negative terminal of the battery.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-11
Main Data and Specifications
Charging system
Generator type AC type
Power output V/A 24 - 50
Regulator type IC
1A-12 ENGINE MECHANICAL (4HK1, 6HK1)
Charging system
Generator type AC type
Power output V/A 24 - 120
Regulator type IC
Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5
Special tool
380.002.626
Compression gauge
EN-46722
Compression gauge
adapter
(4HK1)
380.002.627
Compression gauge
adapter
(6HK1)
1A-14 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
ENGINE MECHANICAL (4HK1, 6HK1) 1A-15
6HK1
WSHK0005
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
Removal
1. Remove the head cover.
2. Remove the gasket.
1A-16 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1 4HK1
Name Name
1. Head Cover 1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
6HK1
WSHK0006
WSHK0007
Name
1. Head Cover Name
1. Head Cover Case
3. Remove the fuel injector harness connector. 2. Fuel Injector Harness Connector
4. Remove the head cover case.
5. Remove the gasket.
Installation
1. Install the gasket on the lower cover.
2. Install the head cover case.
Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft),
6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft)
3. Install the fuel injector harness connector.
6HK1
Name
1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
WSHK0008
WSHK0007
Name
1. Head Cover Case
2. Fuel Injector Harness Connector
13 {1.3 / 9.6}
13 {1.3 / 9.6}
WSHK0009
1A-20 ENGINE MECHANICAL (4HK1, 6HK1)
Inlet Cover
Components
4HK1
Name
1. Case ASM 4. Inlet Pipe
2. Inlet Cover 5. Reed Valve
3. Inlet Pipe Gasket
ENGINE MECHANICAL (4HK1, 6HK1) 1A-21
6HK1
4
6
WSHK0177
Name
1. Case ASM 4. Inlet Pipe
2. Inlet Cover 5. Reed Valve
3. Inlet Pipe Gasket 4. Bolt
Removal 4HK1
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the inlet pipe.
3. Remove the case ASM.
• Remove the reed valve from the case ASM.
• Inspect the valve whether the carbon has not come
in contact around the valve.
1A-22 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
• Tighten up the stud part together with the common
rail.
WSHK0048
4. Remove the inlet cover.
• On the place where the case ASM is to be installed
inside the inlet cover (arrowed) is a bolt. Be careful
not to forget to remove it.
* 4HK1 is shown for illustration.
• Peel the liquid gasket off carefully.
2. Install the reed valve to the case ASM
Tightening torque: 9.8 N⋅m (1.0 kg⋅m/7.2 lb ft)
3. Install the case ASM.
• Apply the liquid gasket and mount within 7
minutes.
Installation
1. Install the inlet cover.
• Apply the liquid gasket (ThreeBond 1207C or
equivalent) by using a bead diameter of 2.5 – 5.5
mm (0.1 – 0.2 in) along a groove of the inlet cover.
WSHK0179
Name
1. Case ASM
2. Reed Valve
3. Bolt
6HK1
20 (2 / 15) 39 (3 / 29)
WSHK0063
ENGINE MECHANICAL (4HK1, 6HK1) 1A-25
Name
1. Oil Feed Pipe 5. Turbo Charger ASM
2. Water Return Pipe 6. Exhaust Adapter
3. Exhaust Manifold 7. Oil Return Pipe
4. Water Feed Pipe
1A-26 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
4 3 2
WSHK0012
Name
1. Oil Feed Pipe 4. Exhaust Adapter
2. Exhaust Manifold 5. Oil Return Pipe
3. Turbo Charger ASM
Removal
1. Loosen the radiator drain cock to drain coolant.
(4HK1 only)
2. Remove the air intake duct from the turbocharger
and the air cleaner.
3. Remove the charge air pipe from the turbocharger
and the charge air cooler.
4. Disconnect the front exhaust pipe.
5. Remove the EGR pipe.
6. Remove the oil feed pipe.
7. Remove the oil return pipe.
8. Remove the water feed pipe. (4HK1 only)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-27
• Remove the water return pipe. (4HK1 only) 6HK1
1 3 2
WSHK0013
Name Name
1. Water Return Pipe 1. Exhaust Manifold
2. Turbocharger
9. Remove the heat protector on the turbocharger. 3. Exhaust Adapter
10. Remove the exhaust adapter bolts.
11. Remove the four turbocharger clamping nuts.
12. Remove the turbocharger from the exhaust Inspection
manifold. • Inspection of exhaust manifold
13. Remove the exhaust manifold. Inspect the plane surface of the plane on which the
4HK1 manifold and the cylinder head are to be installed.
Caution:
If the plane surface exceeds the limit, replace it.
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
6HK1
Axial play mm (in)
Standard 0.06 – 0.09 (0.0024 – 0.0036)
Name
Limit 0.11 (0.0043)
1. Oil Outlet
2. Oil Inlet
Installation
1. Put the gasket in to install the exhaust manifold.
• 4HK1: Tighten up with the 2 nuts and 6 bolts
according to the order given on the figure.
Caution:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
Wheel shaft and bearing clearance manifold.
Use a dial gauge to measure the clearance between
the wheel shaft and the bearing.
4HK1
Clearance mm (in)
Standard 0.056 – 0.127 (0.0022 – 0.0050)
Limit 0.14 (0.0055)
6HK1
Clearance mm (in)
Standard 0.10 – 0.17 (0.0039 – 0.0067)
Limit 0.205 (0.0081)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-29
4HK1 4HK1
6HK1
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
6HK1
1 3 2
WSHK0014
Name
1. Water Feed Pipe
4HK1
Name
1. Oil Return Pipe
WSHK0015
1A-34 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Crankshaft Position Sensor
5. PTO Idle Gear Cover 11. Oil Pan
6. Flywheel 12. Fuel Supply Pump
1A-36 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
10
1
3
5 8
12
11
WSHK0017
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Idle Gear A Shaft
5. PTO Idle Gear Cover 11. PTO Idle Gear Shaft
6. Flywheel 12. Oil Pump
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
4. Remove the cylinder head ASM.
Refer to the “Cylinder Head”.
5. Remove the fuel supply pump ASM.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-37
Refer to “Fuel Supply Pump” in the fuel system 6HK1
section.
WSHK0064
7. Remove the flywheel.
* 4HK1 is shown for illustration. • Install the crankshaft stopper on the starter part of
6. Remove the crankshaft position sensor. • the flywheel housing to stop the crankshaft from
Remove the crankshaft position sensor before rotating.
remove flywheel.
Caution:
4HK1
Check if the stopper meshes with the ring gear without
fail and is installed properly.
Special tool
Crankshaft stopper: 380.002.628
Special tool
Slinger remover:
380.002.608 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
380.002.625 (For 6HK1)
Inspection
* 4HK1 is shown for illustration. 1. Measurement of idle gear backlash
13. Remove the flywheel housing. • Apply a dial gauge on the teeth of the idle gear to
be measured and move the gear to right and left
lightly to read how much the dial gauge shook
(never fail to fix the gear).
4HK1
2. Measurement of end clearance of the idle gear.
Outside diameter of idle gear shaft mm (in)
• Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance. Standard 29.959 – 29.980 (1.179 – 1.180)
Limit 29.80 (1.173)
• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
External diameter of the idle gear A shaft mm (in)
Axial play of idle gear mm (in) Standard 39.959 – 39.975 (1.573 – 1.574)
Standard 0.080 – 0.140 (0.003 – 0.006) Limit 39.80 (1.567)
Limit 0.20 (0.008)
Outside diameter of idle gear shaft mm (in) Clearance between the idle gear and the mm (in)
shaft
Standard 29.959 – 29.980 (1.179 – 1.180)
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 29.9 (1.177)
Limit 0.200 (0.0079)
External diameter of the idle gear A shaft mm (in)
Clearance between the idle gear A and the mm (in)
Standard 49.950 – 49.975 (1.967 – 1.968)
shaft
Limit 49.9 (1.965)
Standard 0.025 – 0.075 (0.0010 – 0.0030)
Limit 0.200 (0.0079)
4HK1
Tightening torque: 31 N⋅m (3.2 kg⋅m/23 lb ft)
Clearance between the idle gear and the mm (in) • After installation, apply engine oil to the shaft.
shaft
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 0.200 (0.0079)
Name
1. Idle Gear
2. Thrust Collar
3. Bolt
Name
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. PTO Gear 9. Idle Gear A
5. PTO Idle Gear
WSHK0043
4HK1
1A-44 ENGINE MECHANICAL (4HK1, 6HK1)
1
1 2
5
1
3
6
1
3
4
1
WSHK0044
7. Install the PTO idle gear.
• Apply engine oil over the part where the gear of the
idle gear shaft is to be put together.
• Put the idle gear and the shaft together and install
it on the location given on the figure and tighten up
with the specified torque.
5
3
2
Special tool
4HK1
Oil seal installer kit: 5-8840-2703-0 (J-43282)
6HK1
Oil seal setting tool: 380.001.712
• Apply engine oil to the oil seal lip.
Caution:
Do not allow engine oil to come in contact with the
outside oil seal and felt ring.
• Insert the oil seal (1) into the adapter (2).
• Insert the oil seal sleeve (3) to the adapter.
• Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-49
6HK1 13. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
14. Remove the oil drain adapter.
15. Install the O-ring on the fuel supply pump and
make the slits with an arrow meet and with the stud
bolt as a guide, install the fuel supply pump
tentatively.
Caution:
• When removing the fuel supply pump, if the stud
bolt on the cylinder block side loosens, or the stud
bolt is replaced, apply the Loctite No. 262 on the
side where the stud bolt is to be buried before
assembly.
B
Tightening torque:
1st step = 78 N⋅m (8.0 kg⋅m/58 lb ft)
2nd step = 60°
3rd step = 60°
Name
1. Plug Hole
2. Alignment Mark
16. Install the oil drain adapter ASM on the plug hole
and tighten with the specified torque.
Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in)
• Apply engine oil over the O-ring nice and thin and
install it.
Name
1. Adapter
2. O-Ring
ENGINE MECHANICAL (4HK1, 6HK1) 1A-51
Torque Specifications
31 {3.2 / 23}
76 {7.7 / 56}
19 {1.9 / 14}
78 {8 / 58} 60 60
6 {0.6 / 4}
WSHK0065
1A-52 ENGINE MECHANICAL (4HK1, 6HK1)
Special Tool
Illustration Tool Number/Description
380.002.628
Crankshaft stopper
380.002.608
Slinger remover
5-8840-2703-0
J-43282
Oil seal installer kit
(4HK1)
380.001.712
Oil seal setting tool
(6HK1)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-53
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
• Along with the camshaft bracket, remove the
rocker arm shaft ASM.
1A-54 ENGINE MECHANICAL (4HK1, 6HK1)
• Because the bolt(s) shown on the figure is are 6. Remove the camshaft bracket to take the shaft out.
designed to fix the rocker arm shaft, do not remove
it for now.
Name
Caution: 1. Camshaft Bracket
Pay full attention so as not to drop the bridge cap in the 2. Rocker Arm
gear case of the rear part of the cylinder head or the 3. Wave Washer
hole into which oil pours back in the front. 4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
Disassembly 7. Rocker Arm Shaft
1. Remove the camshaft bracket.
2. Remove the rocker arm. 7. Check if the oil hole is clogged of the camshaft
bracket (on the rear side).
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Disassemble according to the order (2) – (4)
thereafter.
Installation
1. Install the rocker arm shaft ASM.
• If the bridge cap comes off, apply engine oil over
the inside of the bridge cap and put it together with
the bridge.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
Tightening torque:
4HK1
Bolt (3) = 56 N⋅m (5.7 kg⋅m/41 lb ft)
Nut (1), Bolt (2), (4) = 27 N⋅m (2.8 kg⋅m/20 lb ft)
1A-58 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Camshaft Bracket Fixing Nut
2. Camshaft Bracket Fixing Bolt
3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
6HK1
Nut (1) – (4) and Bolt (10) – (13) =
27 N⋅m (2.8 kg⋅m/20 lb ft)
Bolt (5) – (9) = 56 N⋅m (5.7 kg⋅m/41 lb ft)
4 6 8 9 7 5 3 1
2
11 12 13 10
Camshaft ASM
Components
4HK1
Name
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
ENGINE MECHANICAL (4HK1, 6HK1) 1A-61
6HK1
WSHK0055
Name
1. Bolt 7. Sub Gear
2. Washer 8. Dish Spring
3. Gear 9. Snap Ring
4. Pin 10. Pin
5. Spring 11. Camshaft
6. Pin
Removal Caution:
Put the removed bearings in order with a tag, for
1. Remove the cylinder head cover.
example, by cylinder.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
5. Remove the camshaft ASM.
6. Remove the bearing lower.
1A-62 ENGINE MECHANICAL (4HK1, 6HK1)
WSHK0057
Name
Disassembly 1. Snap Ring
1. Remove the scissors gear ASM. (6HK1) 2. Dish Spring
3. Sub Gear
• Fix the hexagon portion of the camshaft in a vise
4. Spring
using a mouth ring. Use snap ring pliers to remove
5. Camshaft Gear
the sub gear.
2. Remove the camshaft gear.
Caution:
Take care not to damage to the cam portion and the • Remove the fastening bolts of the camshaft gear
journal portion of the camshaft. and put the block of wood in a puller to remove the
camshaft gear.
WSHK0056
Name
1. Wood
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
WSHK0057
Name WSHK0059
1. Snap Ring • Assemble onto the cylinder head.
2. Dish Washer
3. Sub Gear
4. Spring
5. Camshaft Gear
WSHK0056
1A-66 ENGINE MECHANICAL (4HK1, 6HK1)
Fixing torque
WSHK0060
Special Tool
Illustration Tool Number/Description
5-8840-2674-0
Scissors gear spring
wrench
WSHK0061
ENGINE MECHANICAL (4HK1, 6HK1) 1A-67
Installation 4HK1
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
4HK1
WSHK0066
6HK1
6HK1
Name
1. Bridge Cap
2. Bridge
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front. Caution:
Do not reuse the removed oil seal.
6. Remove the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home Inspection
position.
Check the valve spring.
• Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool 1. Free length
Valve spring replacer: 5-8840-2621-0 (J-43263)
• Measure free length of the spring and if it is shorter
Pivot: 8-9439-6862-0 (EN-46721)
than the specified limit, replace the spring.
4HK1
6HK1
6HK1
6HK1
Installation
1. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a valve
stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
3. Tension
• Use a spring tester to compress the spring to the
installation height. Measure tension of the
compressed spring. If the measurement is lower
than the limit, replace the spring.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-73
Special tool 3. Install the spring upper seat.
4HK1 4. Install the split collar.
Valve stem seal installer: 8-9439-6815-0 (EN-47685) • Apply compressed air over the cylinder from the
6HK1 glow plug holes to keep the valve at the home
Valve guide oil seal installer: 5-8840-2625-0 (J- position.
43267)
• Use a replacer to compress the valve spring and
install the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 8-9439-6862-0 (EN-46721)
Paint mark 5. Apply engine oil over the bridge and install it.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
Name
1. Spring Pitch
2. Paint Mark
1A-74 ENGINE MECHANICAL (4HK1, 6HK1)
Special Tool
Illustration Tool Number/Description
5-8840-2621-0
J-43263
Valve spring replacer
8-9439-6862-0
EN-46721
Pivot ASM
Name
1. Bridge Cap
2. Bridge
5-8840-2625-0
J-43267
Valve guide oil seal
installer
(6HK1)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-75
Cylinder Head
Components
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Disconnect the front exhaust pipe.
1A-76 ENGINE MECHANICAL (4HK1, 6HK1)
4. Remove the turbocharger.
Refer to the “Turbocharger and Exhaust Manifold”.
5. Remove the left-hand EGR adapter and right-hand
EGR pipe.
6. Remove the EGR water feed pipe.
7. Remove the EGR water return pipe.
8. Remove the EGR cooler.
9. Remove the water feed pipe for coolant water for
the EGR cooler and the water return pipe.
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal Nut
4. Nozzle Leak-Off Pipe
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
1
1 2
WSHK0019 WSHK0020
Name Name
1. High Pressure Pipe 1. Water Bypass
2. Leak-Off Pipe
20. Remove the EGR valve and EGR valve connector.
19. Remove the water bypass hose from the cylinder 21. Remove the cam angle sensor connector.
head side.
22. Remove the rocker arm shaft ASM.
• Remove the engine coolant temperature sensor Refer to “Rocker Arm Shaft ASM”.
connector.
23. Remove the camshaft ASM.
4HK1 Refer to “Camshaft ASM”.
24. Remove the bridge cap carefully so that it does not
fall into inside the engine.
25. Remove the bridge.
Caution:
Store the removed bridge and bridge cap so that they
can be placed in their original locations.
26. Remove the glow plug connector.
27. Remove the glow plug.
Name
1. Water Bypass
1A-78 ENGINE MECHANICAL (4HK1, 6HK1)
28. Remove the injection pipe clip, and remove the 31. If you have difficulty in removing the fuel injector,
injection pipe. set the fuel injector remover in the fuel injector,
4HK1 tighten the attachment part on the joint of the leak-
off pipe and pull out the fuel injector upward.
Special tool
Fuel injector remover: 380.002.601
Sliding hammer: 380.002.602
Caution:
When removing an fuel injector ID code, be sure to
attach the cylinder number.
When pulling out the fuel injector using a special tool,
check that the fuel injector sleeve does not come off.
Name
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
6HK1
Name
1. Sliding Hammer
2. Fuel Injector Remover
WSHK0021
3. Fuel Injector ASM
Name
1. Fuel Injection Pipe Caution:
2. Fuel Injection Pipe Clip Attach a cylinder number to the removed fuel injector
when storing it.
29. Remove the common rail. Be sure not to make the nozzle touch something.
• Remove the common rail pressure sensor
connector.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 8-9439-6862-0 (EN-46721)
• Remove the special tool, then remove the upper
sheet and springs.
Special tool
Nozzle sleeve remover: 380.001.720
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
Name
1. Nozzle Sleeve
– Improper installation
– Defective tightening of the cylinder head.
– Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening torque
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
• Check whether there is a crack between the
valve seats and in the cylinder head of the
exhaust port part, and replace the cylinder head
if there is serious damage or crack. Check the
collar if necessary.
Name
1. Nut
Gap mm (in)
Assembly standard 0.020 (0.00079) –
0.057 (0.00224)
Usage limit 0.1 (0.0039)
6HK1
Valve seat
• Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If the value exceeds the limit, replace the valve
insert or the cylinder head ASM.
4HK1
• Measure the contact width of the valve seat. If Repair of the seat surface
the seat contact surface has a scratch or is
• Remove carbon from the surface of the valve
rough, or if the abrasion of the contact surface
seat.
exceeds the limit, modify or replace it.
• Use a seat cutter to minimize the scratch and
Contact width of the valve seat mm (in) other roughness (15/45/75°-blade), thereby
returning the contact width to the standard
Standard Limit value.
Intake valve 2.5 (0.0984) 3.0 (0.1181)
Exhaust valve 2.0 (0.0787) 2.5 (0.0984)
Caution:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Contact surface of the valve seat
Do not let the valve cutter pilot waver inside the valve
• If the contact surface of the valve seat is guide.
defective, modify it or replace the valve, valve
guide and valve seat altogether.
Angle of the contact Exhaust side of 4HK1 and
surface: 6HK1: 45°
Intake side of 6HK1: 30°
ENGINE MECHANICAL (4HK1, 6HK1) 1A-87
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve
seat insert.
• Cool the valve seat insert for two to three
minutes. Contraction fur to cooling makes it
easier to remove the valve seat insert.
• Remove the valve seat insert, using a screw
driver. Be sure not to hurt the cylinder head.
Caution:
Remove compound completely after grinding.
Name
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
Caution:
Do not apply too much pressure with the press.
Attach compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm that it
Replace the valve seat insert has even contact all round.
1A-88 ENGINE MECHANICAL (4HK1, 6HK1)
Name Name
1. Press 1. Cylinder Head
2. Attach Compound 2. Oil Seal Installer
3. Valve Seat
2. Install the bridge guide.
• Apply engine oil on the outer diameter of the guide,
Reassembly then use the installer to hammer it into the depth of
the finishing part of the hole of the cylinder head.
1. Install the oil seal. (Note: the height of the bridge guide is about
• Install on the surface of injection pipe insert. 37.5 mm {1.48 in} from the upper surface of the
head)
• Hammer it in so that the seal does not incline.
Special tool
Caution: Bridge guide installer: 380.001.722
Be sure not to hurt the rip. Engine oil
Special tool
Oil seal installer: 380.001.719
3. Nozzle sleeve
• Install the O-ring on the nozzle sleeve, apply
engine oil.
Name
1. Apply Seal Material
2. O-Ring Name
1. Punch Bar
• Install the nozzle sleeve on the cylinder head, 2. Ball
insert the guide sleeve. 3. Guide Sleeve
4. Nozzle Sleeve
• Use the guide sleeve to push in so that the nozzle 5. Bracket
sleeve fully contacts with the under surface of the 6. Bolt
cylinder head.
4. Install the valve guide.
• Insert the sleeve and fix it with the tighten and bolt.
• Hammer in the valve guide from the upper surface
• Insert the ball (bearing steel ball 9.525 mm of the cylinder head, using the valve guide
{0.375 in}) into the guide sleeve, attach the punch replacer.
bar and hammer out the ball.
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
1A-90 ENGINE MECHANICAL (4HK1, 6HK1)
Special tool Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272) 4HK1
Valve stem seal installer: 8-9439-6815-0 (EN-47685)
6HK1
Valve guide oil seal installer: 5-8840-2625-0 (J-
43267)
5. Install the valve stem oil seal. 7. Install the valve spring.
• Apply engine oil on the outer diameter of the valve • Install the valve spring with the paint mark or the
guide, use the valve stem seal installer to install narrower side of the spring pitch on the under side
the oil seal. (the cylinder head side).
Caution:
After installation of the valve stem seal, confirm that the Paint mark
oil seal is not inclining and the garter spring is in place.
Intake side Light blue
Exhaust side Yellow
ENGINE MECHANICAL (4HK1, 6HK1) 1A-91
Name
1. Spring Pitch
2. Paint Mark Name
1. Idle Gear C
8. Install the spring upper seat. 2. Shaft
9. Install the split collar.
11. Install the idle gear C cover.
• Use a replacer to compress the valve spring and
install the split collar. • Apply liquid gasket (Loctite 262 or 962T) on the
outer diameter of the idle gear C cover, use the
Special tool sealing cup setting tool to hammer it in so that the
Valve spring replacer: 5-8840-2621-0 (J-43263) measurements follow the drawing.
Pivot: 8-9439-6862-0 (EN-46721)
Special tool
Sealing cup installer: 380.002.604
6HK1
Name
1. Thermostat
6HK1
WSHK0025
WSHK0014
Name • Install the heat protector.
1. Distance Tube
2. Conical Spring
Tightening torque: 10 N⋅m (1.0 kg⋅m/89 lb in)
3. Nut
16. Install the inlet cover.
• Tighten the exhaust manifold in the order • Apply liquid gasket (ThreeBond 1207C or
described in the drawing.
inlet cover, with the bead diameter of φ2.5 mm
equivalent) in accordance with the groove of the
Tightening torque: 34 N⋅m (3.5 kg⋅m/25 lb ft) (0.0984 in) – 5.5 mm (0.2165 in).
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
4HK1
• Tighten the stud bolts (6) and (9) jointly with the
common rail.
WSHK0026
Name
1. Grade Recognition Hole
Tightening torque:
M14 bolt (4HK1: 1 – 18, 6HK1: 1 – 26)
1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft)
2nd step = 147 N⋅m (15.0 kg⋅m/108 lb ft)
3rd step = 30° – 60°
M10 bolt (4HK1: 19, 20; 6HK1: 27, 28)
4th step = 38 N⋅m (3.9 kg⋅m/28 lb ft)
Use a stud bolt for (4HK1: 16).
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
4HK1
Caution:
Be sure not to hurt the head gasket when installing it.
6HK1
Name
1. Fuel Injector ASM
2. Fuel Injector Tighten Bolt
Caution:
Move it up and down to check if it moves smoothly.
12. Apply a thin coat of engine oil inside the bridge
cap, install it.
6HK1
WSHK0028
21. Install the terminal nuts on the fuel injector.
Tightening torque: 2 N⋅m (0.2 kg⋅m/18 lb in)
Caution:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
20. Install the fuel injector harness connector from
unified.
inside, tighten the harness bracket with the
designated torque. • Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb ft)
1A-100 ENGINE MECHANICAL (4HK1, 6HK1)
26. Connect the exhaust pipe.
• Connect the front exhaust pipe and tighten to the
specified torque.
Name
1. Fuel Injector
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
8-9439-6815-0
380.002.602 EN-47685
Sliding hammer Valve stem seal installer
(4HK1)
5-8840-2625-0
5-8840-2628-0 J-43267
J-43272 Valve guide oil seal
Valve guide replacer installer
(6HK1)
1A-102 ENGINE MECHANICAL (4HK1, 6HK1)
5-8840-0266-0
5-8840-2621-0
J-45059
J-43263
KM470-B
Valve spring replacer
Angle gauge
8-9439-6862-0
380.001.721
EN-46721
Nozzle sleeve installer
Pivot ASM
380.001.722 380.002.604
Bridge guide installer Sealing cup installer
380.001.719
Oil seal installer
380.001.720
Nozzle sleeve remover
380.002.601
Fuel injector remover
ENGINE MECHANICAL (4HK1, 6HK1) 1A-103
2
6
WSHK0184
Name
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
1. Remove the oil pan.
Refer to “Oil Pan”.
2. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
3. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
4. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
5. Remove the cylinder head.
Refer to the “Cylinder Head”.
6. Remove the connecting rod cap.
Caution:
Sort the removed bearings according to cylinders by
using tags.
Caution:
Be sure not to damage the oil jet and cylinder liner
when pushing out the connecting rod.
Caution:
Sort the disassembled piston pins, pistons and
connecting rods together in the order of cylinders.
Caution:
Sort the bearings in the order of cylinders when reusing
them so that they will not be confused with the bearing
of other cylinders.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Caution:
Sort the piston rings in the order of cylinders when
reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
4. Remove the connecting rod from the piston.
5. Piston
• Clean carbon carefully that is adhered to the head
of the piston and the groove of the piston ring.
Caution:
Do not use wire brush to clean the piston because it
scratches the piston.
Inspect the piston with eyes for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6. Measure the gap between the piston and the inner
diameter of the cylinder liner.
Cylinder liner inner diameter liner inner diameter both in the thrust and radial
• Use a cylinder bore dial indicator to measure the directions in the designated position.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-105
• Measurement position (from the upper surface of 6HK1
the cylinder block)
1. 20 mm (0.79 in) 2. 110 mm (4.33 in) Piston diameter mm (in)
3. 190 mm (7.48 in) Standard 114.974 – 114.989
• Measure the liner inner diameter based on the (4.52652 – 4.52711)
average value of the actual measurement values
on 6 positions.
Gap between the piston and the inner mm (in)
diameter of the cylinder liner
Cylinder liner inner diameter mm (in)
Standard 0.042 – 0.066
115.021 – 115.050 (4.52838 – 4.52952) (0.00165 – 0.00259)
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
Name
1. 20 mm (0.79 in)
2. 110 mm (4.33 in)
3. 190 mm (7.48 in) 7. Piston replacement
Piston outside diameter • You do not need to select grades because there is
• Use a micrometer to measure the outside diameter only one grade for each of the piston and the
of the piston in the right angle to the piston pin in cylinder liner inner diameter.
the designated position. If you replace the cylinder liner, you must select
the cylinder block (1, 2, 3) because there are two
• Measurement position (from the upper surface of types of the liner outer diameter.
the piston) 82 mm (3.2 in). • Refer to “Cylinder Block” if you replace the cylinder
liner.
4HK1
Caution:
Piston diameter mm (in) The head of piston has a marking of grade B or C when
Standard 114.920 – 114.949 it is shipped from the factory.
(4.52440 – 4.52554)
4HK1
• Measure the bush of the small edge of the
Piston pin outer diameter mm (in)
connecting rod. If the clearance between the
Standard 35.995 – 36.000 (1.4171 – 1.4173) bushing inner diameter and the pin diameter
exceeds the limit, replace the bushing or
Limit 35.970 (1.4161)
connecting rod ASM, and the pin.
6HK1
Piston pin and connecting rod small end mm (in)
Piston pin outer diameter mm (in) bushing clearance
Standard 40.0 (1.5748) Standard 0.012 – 0.027
(0.0005 – 0.0011)
Limit 39.95 (1.5728)
Limit 0.05(0.0020)
1A-108 ENGINE MECHANICAL (4HK1, 6HK1)
Standard 0.004 – 0.017 (0.00016 – 0.00067) • Use the bench press to replace the bush.
Limit 0.04 (0.0016)
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
11. Remove the bushing. (EN-47682)
• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
Name
1. Bolt
2. Connecting Rod Bushing Replacer
• Install the bearing cap and tighten the bolt with the
designated torque.
Apply molybdenum disulfide on the screw part and
the bearing surface.
Connecting rod bearing cap bolt torque: N⋅m 14. Select the connecting rod bearing.
(kg⋅m/lb ft) • Refer to the bearing selection table when installing
1st step 39 (4.0/29) a new connecting rod or replacing bearings in use.
2nd step 60° • Select and install the bearing, paying attention to
3rd step 30° the large edge hole diameter of the connecting rod.
Caution:
Do not rotate the crankshaft.
1A-110 ENGINE MECHANICAL (4HK1, 6HK1)
Reassembly
1. Install the bush
• Place the connecting rod bushing replacer base on
the bench press, set the connecting rod and
tighten the fixation bolt.
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
(EN-47682)
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
• Adjust the oil hole of the connecting rod and the oil
hole of the bush, and use the bench press to install
the bush.
Name
1. Grade Identification Color
ENGINE MECHANICAL (4HK1, 6HK1) 1A-111
Name Name
1. Setting Bar 1. Snap Ring
2. Connecting Rod 2. Front Mark
3. Nut 3. Forging Mark (Projecting)
4. Collar
5. Bushing 4. Apply enough engine oil on the piston pin, push it
6. Collar in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
• After installing the new bush, use a grinder to
machine the pin hole so that the pin clearance Caution:
equals the standard value. Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
Caution:
• Be sure not to make the connecting rod touch the
oil jet when pushing in the piston.
• Be sure not to hurt the inside of the liner when
pushing in the piston.
Special tool
Piston ring compressor: 5-8840-9018-0 (J-8037)
Name
1. Top Ring
2. Second Ring
3. Third Ring
4. Oil ring
Caution:
Note that the shapes are different for each piston ring.
Make sure that there is not gap in the position indicated
in the drawing when the oil ring coil expander was
installed.
Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, apply
engine oil on the bearing.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-113
5. Install the camshaft ASM.
Refer to “Camshaft ASM”.
6. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
7. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
8. Install the oil pan.
Refer to “Oil Pan”.
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
Tightening torque:
1st step = 39 N⋅m (4.0 kg⋅m/29 lb ft)
2nd step = 60°
3rd step = 30°
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Make sure that the crankshaft rotates smoothly.
Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
5-8840-2340-0
EN-47682 1-8522-1029-0
Connecting rod bushing Piston ring setting tool
replacer
5-8840-0266-0
5-8840-9018-0
J-45059
J-8037
KM470-B
Piston ring compressor
Angle gauge
ENGINE MECHANICAL (4HK1, 6HK1) 1A-115
Flywheel
Components
Name
1. Flywheel Housing 3. Washer
2. Flywheel ASM 4. Crankshaft Position Sensor
Removal 4HK1
1. Remove the starter motor.
• Remove the ground cable of the starter motor.
WSHK0030
2. Remove the crankshaft position sensor.
• Remove to prevent contact damage when the • Gradually loosen the flywheel installation bolts in
flywheel is removed. the order shown in the drawing so that the flywheel
does not rotate.
• Do not throw or drop because it is vulnerable to
shock. • After loosening all the bolts, remove the stopper to
* 4HK1 is shown for illustration. remove the flywheel.
3. Remove the washer and flywheel. 4. Take out the ring gear.
• Install the crankshaft stopper to the starter • Put a bar on the ring gear and hit it with a hammer
installing portion of the flywheel housing. to remove it.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-117
Inspection Installation
1. Visual check 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks and • After heating the ring gear with a gas burner
damages, and replace it if it has abnormality. equally, install it in the flywheel.
• Inspect the tooth part of the ring gear, replace the • In the case of shrinkage cooling of the ring gear,
ring gear if it has damage or serious wear. maintain the flatness by applying weight of 68.6 kN
(15,400 lbf).
2. Measurement of the friction surface
• Measure the depth of the flywheel friction surface. Caution:
• Install the ring gear so that the side with a pattern
• Adjust it if the measured value is within the faces forward.
standard value and the limit. • Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
• If the measured value exceeds the limit, replace
complete.
the flywheel.
Tightening torque:
1st step = 78 N⋅m (8.0 kg⋅m/58 lb ft)
2nd step = 120° – 150°
Special tool
Crankshaft stopper: 380.002.628
Angle gauge: 5-8840-0266-0 (J-45059)
6HK1
WSHK0030
• Install the ground cable of the starter motor.
78 {8 / 58} 60 60
8 {0.8 / 5.9}
WSHK0067
Special Tool
Illustration Tool Number/Description
380.002.628
Crankshaft stopper
5-8840-0266-0
J-45059
KM470-B
Angle gauge
1A-120 ENGINE MECHANICAL (4HK1, 6HK1)
Front Cover
Components
4HK1
ENGINE MECHANICAL (4HK1, 6HK1) 1A-121
6HK1
10 9 8
5
11
12 7 6
WSHK0171
Name
1. Adjusting Plate 7. Crankshaft Pulley
2. Generator 8. Water Pump ASM
3. Front Cover 9. Fan Belt
4. Oil Pan Gasket 10. Water Pump Pulley
5. Oil Pan 11. Spacer
6. Front Oil Seal 12. Fan ASM
Removal
1. Remove the front oil seal.
Refer to “Crankshaft Front Oil Seal”.
2. Remove the oil pan.
Refer to “Oil Pan”.
3. Remove the water pump.
Refer to the “Water Pump” in the cooling system
section.
4. Remove the front cover.
• Remove the generator adjust plate.
1A-122 ENGINE MECHANICAL (4HK1, 6HK1)
• Install within seven minutes after applying liquid
gasket.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
4HK1
Name
1. O-Ring
6HK1
Installation
1. Install the front cover.
• Clean the cylinder block front surface. In particular,
remove liquid gasket leaked during installation of
the crankcase.
Tightening torque
Oil relief valve: 39 N⋅m (4.0 kg⋅m/29 lb ft)
WSHK0032
Name
1. Bolt: L = 35
2. Bolt: L = 25
3. Bolt: L = 65
4. Bolt: L = 30
5. Oil Relief Valve
6HK1
Tightening torque
Front cover bolts (13 bolts): 18 N⋅m (1.8 kg⋅m/13
lb ft)
• Tighten bolt with (*) mark together with the adjust
plate of the generator.
Tightening torque
Stud bolt for water pump: 12.7 N⋅m (1.3 kg⋅m/9.4
lb ft)
1A-124 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
4HK1
39 {4 / 29}
39 {4 / 29}
24 {2.4 / 18}
WSHK0037
ENGINE MECHANICAL (4HK1, 6HK1) 1A-125
6HK1
39 (4 / 29)
20 (2 / 14)
39 (4 / 29)
18 (1.8 / 13)
WSHK0164
1A-126 ENGINE MECHANICAL (4HK1, 6HK1)
Removal 4HK1
1. Drain coolant.
2. Remove the starter.
• Disconnect the starter ground cable.
WSHK0030
3. Disconnect the upper radiator hose on the engine
side. 10. Remove the crankshaft front oil seal.
4. Disconnect the coolant reserve tank hose on the • Remove the oil seal off with a screwdriver or the
radiator side. like avoiding damage to the oil seal contact surface
5. Disconnect the lower radiator hose on the engine on the front cover and the shaft.
side.
6. Remove the radiator (with the fan guide) detaching
right and left brackets.
7. Remove the fan ASM.
• Remove the fan ASM unscrewing four mounting
bolts.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
Name
1. Felt
2. Slinger
3. Oil Seal
Caution:
Be sure to replace the slinger and oil seal as a set.
11. Remove the front slinger.
• Use the slinger remover to remove the front
slinger.
5
3
2
Caution:
Be sure to replace the slinger and oil seal as a set.
2. Install the crankshaft front oil seal.
• Press fit the oil seal using an oil seal installer,
setting tool.
Name
1. Adapter
• Apply engine oil to the lip of the oil seal and place it
on the front side adapter.
• Put the front side adapter ring in the sleeve and fix
the sleeve on the adapter with the center bolt and
Name a washer.
1. Oil Seal
2. Adapter (Front) • Tighten the bolt until the sleeve touches the
3. Adapter Ring (Front) adapter to press fit the front oil seal.
4. Fixing Bolt
5. Sleeve (Front)
6. Washer (Front)
7. Center Bolt
1A-130 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
Name
1. Oil Seal Name
2. Adapter Ring 1. Adapter Ring
3. Sleeve 2. Sleeve
4. Bolt and Washer 3. Adapter
4. Oil Seal
6HK1
WSHK0033
Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
5-8840-2703-0
380.002.628 J-43282
Crankshaft stopper Oil seal installer kit
(4HK1)
380.001.712
380.002.608
Oil seal setting tool
Slinger remover
(6HK1)
1A-134 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Flywheel 2. Crankshaft Rear Oil Seal
Removal
1. Remove the flywheel.
Refer to the “Flywheel”.
2. Remove the crankshaft rear oil seal.
• Remove the oil seal off with a screwdriver or the
like avoiding damage to the oil seal contact surface
on the flywheel housing and the shaft.
Name
1. Felt
2. Slinger
3. Oil Seal
ENGINE MECHANICAL (4HK1, 6HK1) 1A-135
3. Use the slinger remover to remove the slinger.
Caution:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
380.002.608 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
380.001.712 (For 6HK1)
5
3
2
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
Oil seal installer kit: 5-8840-2703-0 (J-43282)
6HK1 • After pressing in the slinger, make sure that the
Oil seal setting tool: 380.001.712 distance between crankshaft end surface and the
• Install the slinger (1) to the end of adapter (2). slinger is A as specified.
Install the adapter to the crankshaft (3).
• Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
1A-136 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
Name
Distance (A): 17.3±0.3 mm (0.7±0.01 in) 1. Adapter (Rear)
Distance (B): 10.8±0.1 mm (0.4±0.004 in) 2. Fixing Bolt
6HK1 3. Center Bolt
4. Sleeve (Rear)
5. Collar (Rear)
6. Adapter Ring (Rear)
7. Oil Seal
Special tool
4HK1
Oil seal installer kit: 5-8840-2703-0 (J-43282)
6HK1
A
Oil seal setting tool: 380.001.712
Caution:
• Put a collar on the fixing bolt and mount the
Be sure to replace the slinger and oil seal as a set.
adaptor onto the crankshaft.
2. Install the crankshaft rear oil seal.
• Press-fit the rear oil seal using an oil seal installer,
setting tool.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-137
• Apply engine oil to the lip of the oil seal and place it
in the rear side adapter.
• Put the rear side adapter ring in the sleeve and put
the sleeve on the adapter and fix with the center
bolt.
Name
1. Rear Part of The Crankshaft
380.002.608
Slinger remover
5-8840-2703-0
J-43282
Oil seal installer kit
(4HK1)
380.001.712
Oil seal setting tool
(6HK1)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-139
Crankshaft
Components
the replacer holes (arrowed holes in the figure). 15. Remove the lower thrust bearing.
4HK1 16. Remove the lower crankshaft bearings.
Special tool
Crankshaft gear puller: 380.002.613
Disassembly
Name
1. Remove the gear.
1. Alignment Mark
• Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-6818-0 (EN-47684) Inspection
1. Thrust clearance
• Set a dial gauge as shown and measure the
crankshaft thrust clearance.
Caution:
Measure the thrust clearance before dismounting.
Reassembly
1. Install the gear.
• Heat the gear to 170 – 250°C (338 – 482°F) and
install it aligning the groove on the gear with the
pin on the crankshaft.
• Insert the gear at one push into the flange with its
end side with the alignment mark “S” facing
outward. If you are fitting the gear while it is cold,
beat the gear in until it impinges on the end using
the installer.
1A-142 ENGINE MECHANICAL (4HK1, 6HK1)
Caution:
Turn the crankshaft about 30° to allow the bearings to
settle in.
Tightening torque:
M14 bolt 4HK1: (1 – 10), 6HK1: (1 – 14)
1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft)
2nd step = 132 N⋅m (13.5 kg⋅m/97 lb ft)
3rd step = 30° – 60°
M10 bolt 4HK1: (11 – 27), 6HK1: 15 – 39)
4th step = 37 N⋅m (3.8 kg⋅m/27 lb ft)
• Tighten bolts from 1 to 10 (M14) and confirm that
they are tightened to a torque of 142 N⋅m (14.5
kg⋅m/105 lb ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Do not rotate the crankshaft after tightening the
crankcase.
• Loosen the bolts and gently remove the
* 4HK1 is shown for illustration.
crankcase.
4HK1
• Measure the widest part of the Plastigauge
flattened by tightening the crankcase to determine
the clearance.
4HK1
6HK1
37 33 29 25 21 17 16 20 24 28 32 3639
14 10 6 2 3 7 11
13 9 5 1 4 8 12
38 34 30 26 22 18 15 19 23 27 31 35
WSHK0035
1A-144 ENGINE MECHANICAL (4HK1, 6HK1)
• If the journal oil clearance exceeds the limit, 4. Measure the journal and the crank pin diameters
replace the main bearings altogether or the and uneven wear.
crankshaft. • Measure outer diameters of the journal and the pin
and calculate differences between the maximum
• Remove the plastigauge from the bearing and and the minimum values. Take measurements at
crank pin. four positions for both the journal and the pin.
Inspection of crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil seal
contact surface for excessive wear and damage.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
4HK1
Standard 0.06 or less (0.0024 or less) Journal #1, 2, 4, 5 81.905 – 81.925 81.85
(3.22460 – 3.22538) (3.222)
Limit 0.45 (0.018)
Journal #3 81.891 – 81.911 81.85
(3.22408 – 3.22483) (3.222)
Pin 65.902 – 65.922 65.850
(2.59456 – 2.59535) (2.5925)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-145
6HK1
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
shall not polish the surface of the crankshaft.
Name
1. Upper Bearing
2. Oil Gallery
3. Grade Identification Color
4. Oil Groove
5. Lower Bearing
6. Grade Identification Color
1A-146 ENGINE MECHANICAL (4HK1, 6HK1)
Bearing selection table
4HK1
6HK1
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block and
apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Crankshaft Bearing Grade Selection.
Do not apply oil to the bearing installation surface on
the cylinder block and external surface of the bearing.
6HK1
mm(in)
12(0.47)
10
(0
2(0.08)
.4
)
2.5(0.1)
15
(0
10(
8(0.31)
.
59
0.4
5(0.2)
)
)
8(0.31)
8(0.31)
2.5(0.1) 2.5(0.1)
WSHK0036
ENGINE MECHANICAL (4HK1, 6HK1) 1A-149
• Apply Molybdenum Disulfide to M14 bolts’ threads 6HK1
and setting faces and tighten them to the specified
tightening torque in the sequence shown.
Special tool
WSHK0035
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
7. Install pistons and connecting rods.
Caution: Refer to the “Pistons and Connecting Rod”.
Confirm that the crankshaft turns smoothly. 8. Install the oil pump.
4HK1 Refer to the “Oil Pump”.
9. Install the timing gear train.
Refer to the “Timing Gear Train”.
10. Install the front cover.
Refer to the “Front Cover”.
11. Install the water pump.
Refer to the “Water Pump” in the Cooling System
Section.
12. Install the oil pan.
Refer to “Oil Pan”.
13. Install the crankshaft rear oil seal.
Refer to the “Crankshaft Rear Oil Seal”.
14. Install the crankshaft front oil seal.
Refer to “Crankshaft Front Oil Seal”.
15. Install the fuel supply pump.
Refer to the “Fuel Supply Pump”.
16. Install the cylinder head.
Refer to the “Cylinder Head”.
17. Install the camshaft ASM.
Refer to “Camshaft ASM”.
18. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
19. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
1A-150 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
8-9439-6818-0
380.002.613
EN-47684
Crankshaft gear installer
Crankshaft gear puller
ENGINE MECHANICAL (4HK1, 6HK1) 1A-151
5-8840-0266-0
J-45059
KM470-B
Angle gauge
1A-152 ENGINE MECHANICAL (4HK1, 6HK1)
Cylinder Block
Components
Caution:
You need not select cylinder liner bore grade since the
liners are only available in one size.
6. Cylinder block upper face warpage
• Pull out the cylinder liners and remove water stains
on the cylinder block.
Caution:
Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
6HK1
Lubrication System
Precautions on Service Work • Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the start and end of the application should
and apply the specified new fluid gasket at each be overlapped.
location.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
1A-158 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check 7. Stop the engine.
Oil pressure check 8. Remove the oil pressure gauge.
1. Check whether the engine oil is contaminated with 9. Install the oil pressure switch.
dirt, light oil, or water. If contaminated with dirt, 10. Start the engine and check for oil leakage.
light oil, or water (after examining the cause and
taking the appropriate measures for light oil or Engine oil
water contamination), replace the oil. • Ensure the engine is at a level ground. Before
2. Check the engine oil level. The oil level should be starting the engine or when 5 minutes or more
between the two holes of the level gauge. If the oil have elapsed after stopping the engine, check the
level is insufficient, replenish it. engine oil volume using the level gauge. The
3. Remove the oil pressure switch on the oil filter volume is appropriate if the engine oil is between
body. the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lower
4. Install the oil pressure gauge on the oil filter body.
limit. Also, check for contamination of the engine
oil.
Special tool
Oil pressure gauge: J43620-20
Hose: J43630
Connector (4HK1 only): J43630-14
Oil pressure testing adapter (4HK1 only): EN-46333
Name
1. Oil Pressure Testing Adapter (4HK1 only)
2. Connector (4HK1 only)
3. Hose
4. Oil Pressure Gauge
Name
5. Warm the engine. 1. Upper Limit
6. Measure the oil pressure, to check whether it is 2. Lower Limit
more than 343 kPa (50 psi) at 2000 rpm.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-159
Engine oil leakage
• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
Special Tool
Illustration Tool Number/Description
J-43620-20
Oil pressure gauge
J-43630
Hose
J-43630-14
Connector
(4HK1)
J-46333
Oil pressure testing
adapter
(4HK1)
1A-160 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Oil Pressure Switch 3. O-Ring
2. Oil Port Cover
Removal
1. Remove the oil pressure switch.
2. Remove the oil port cover.
3. Remove the O-ring.
Installation
1. Install the O-ring on the oil port cover.
Name
1. O-Ring
2. O-Ring
ENGINE MECHANICAL (4HK1, 6HK1) 1A-161
2. Install the oil port cover on the cylinder block and
tighten it to the specified torque.
Tightening torque:
4HK1 48 N⋅m (4.9 kg⋅m/35 lb ft)
6HK1 39.2 N⋅m (4.0 kg⋅m/29 lb ft)
Name
1. Bolt M10X L = 80
2. Bolt M10X L = 25
Oil Cooler
Components
4HK1
Name
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Common Rail
ENGINE MECHANICAL (4HK1, 6HK1) 1A-163
6HK1
5 1 2 3 4
WSHK0038
Name
1. EGR Cooler Water Return Pipe 4. Fuel Supply Pump
2. Oil Cooler 5. Suction Pipe
3. Common Rail
Removal
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the fuel supply pump.
Name
1. Bypass Hose Disassembly
2. EGR Cooler Water Return Pipe 1. Remove the element mounting bolts.
3. EGR Cooler Water Feed Pipe
2. Remove the element.
4. Suction Pipe
3. Remove the O-ring.
6HK1
1 2
WSHK0039 * 4HK1 is shown for illustration.
Name Name
1. Suction Pipe 1. Element
2. EGR Cooler Water Return Pipe 2. O-Ring
Name
1. O-Ring
* 4HK1 is shown for illustration. 2. O-Ring
3. Liquid Gasket
Name
1. Element – Align the oil cooler holes with the cylinder block
2. O-Ring studs.
– Install the oil cooler and glow plug controller
bracket to the cylinder block.
Installation – Tighten the bolts to the specified torque in the
1. Install the oil cooler ASM. order shown in the illustration.
• Apply liquid gasket (ThreeBond 1207B or Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)
equivalent) to the flange surface groove (cylinder • Liquid gasket quickly hardens.
block). Bead diameter must be between 2 and 4 Make it complete within 7 minutes after
mm (0.08 and 0.16 in). applying the liquid gasket.
Refer to the illustration for the offset position (no
more than 1 mm {0.04 in}). 4HK1
• Install the O-rings (1) and (2) to the oil passage
inlet and outlet. Do not allow the liquid gasket to
contact the O-ring.
1A-166 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 6HK1
WSHK0040 WSHK0041
2. Connect the water suction pipe.
Name
• Apply liquid gasket (ThreeBond 1207B) to the 1. Gasket
flange of the water suction pipe. Bead diameter 2. Suction Pipe
must be between 2 and 5 mm (0.08 and 0.20 in).
Refer to the illustration for the offset position (no
more than 1 mm {0.04 in}). (4HK1) Caution:
The water suction pipe must be installed immediately
• Install the water suction pipe to the oil cooler. Refer after the oil cooler (the pipe and cooler use the same
to the illustration. liquid gasket).
4HK1
• Tighten the bolts to the specified torque.
Oil Pan
Components
Removal
1. Drain engine oil.
2. Remove the oil pan.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-169
3. Remove the Oil strainer. 4HK1
WSHK0180
Installation
1. Install the oil strainer with new O-ring to the crank
case.
Tightening torque:
M8 Bolt (4HK1): 32 N⋅m (3.3 kg⋅m/24 lb ft)
M8 Bolt (6HK1): 24 N⋅m (2.4 kg⋅m/18 lb ft)
M10 Bolt: 48 N⋅m (4.9 kg⋅m/35 lb ft)
WSHK0181
• Apply the liquid gasket and install the oil pan within
7 minutes.
1A-170 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
6HK1
6HK1 • Fastening the oil pan from the part of A or B in
clock wise order.
• It tightens again by specified torque.
Tightening torque: 24.5 N⋅m (2.5 kg⋅m/18 lb ft)
Name
1. Oil Pan
2. Gasket
4HK1
• Tighten the locations (1), (2), (3), and (4) as shown
in the figure and then tighten others. (In any
sequence)
Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-171
Oil Pump
Components
Disassembly
* 4HK1 is shown for illustration. 1. Remove the driven gear and shaft.
12. Remove the idle gear A. 2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and oil
pump body using a thickness gauge.
6HK1
WSHK0043
• Align with the knock pin of the cylinder block and
install the flywheel housing.
6HK1
1
1 2
5
1
3
6
1
3
4
1
WSHK0044
ENGINE MECHANICAL (4HK1, 6HK1) 1A-177
5. Install the oil pan.
Refer to “Oil Pan”.
6. Install the rear seal of the crankshaft.
Refer to “Rear Oil Seal of Crankshaft”.
7. Install the flywheel.
Refer to the “Flywheel”.
8. Install the fuel supply pump ASM.
Refer to “Fuel Supply Pump” in the Fuel System
section.
9. Install the cylinder head ASM.
Refer to “Cylinder Head Cover”.
10. Install the camshaft ASM.
Refer to “Camshaft ASM”.
11. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
12. Tighten the cylinder head cover.
Refer to “Cylinder Head Cover”.
1A-178 ENGINE MECHANICAL (4HK1, 6HK1)
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
Cooling System 1B-1
ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Precautions on Service Work . . . . . . . . . . . . . . 1B-2
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
A List of Defective Phenomena . . . . . . . . . . . . . 1B-7
Main Data and Specifications . . . . . . . . . . . . . . 1B-7
Water Pump (4HK1) . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-11
Water Pump (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1B-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1B-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-26
1B-2 Cooling System
Cooling System
Precautions on Service Work Explanations on functions and operation
WARNING: Cooling water system
Do not remove the radiator cap when the cooling water The cooling water system, which is the forced
is at high temperature. Steam or boiling water will gush circulation system, consists of a water pump,
out and you may be burnt. To open the radiator cap, thermostat, and radiator as its main components. The
cover the cap with a thick cloth when the cooling water oil in automatic transmission is cooled due to the
is cool, release the pressure by slowly turning the cap, cooling water in the radiator.
and then remove the cap.
4HK1
Name
1. Water Jacket 10. Reservoir Tank
2. Drain Plug 11. Air Bleeding Plug
3. Oil Cooler 12. Water Outlet Pipe
4. Water Pump 13. Thermostat (2 units)
5. Drain Cock 14. Thermometer Unit
6. Radiator 15. Bypass Route
7. Cooling Fan 16. Turbocharger
8. Radiator Cap 17. EGR Cooler
9. Heater Core
Cooling System 1B-3
6HK1
10
8 9
11 14
12
13
7
6 1
3 2
5
WSHK0045
Name
1. Water Jacket 8. Radiator Cap
2. Drain Plug 9. Reservoir Tank
3. Oil Cooler 10. Water Outlet Pipe
4. Water Pump 11. Thermostat (2 units)
5. Drain Cock 12. Thermometer Unit
6. Radiator 13. Bypass Route
7. Cooling Fan 14. EGR Cooler
1B-4 Cooling System
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
Name
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve
Coolant
1. About the engine coolant concentration
• Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the
concentration of the engine coolant.
• Use only genuine Isuzu engine coolant.
• Use engine coolant with a mix ratio in the range
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
Name
1. Antifreeze Hydrometer
2. Radiator
Engine overheats
Engine overcools
Name
1. Fan 4. Fan Belt
2. Spacer 5. Water Pump ASM
3. Water Pump Pulley 6. Gasket
Removal
1. Drain the coolant.
2. Remove the four mounting bolts and then the fan
ASM and spacer, water pump pulley.
Cooling System 1B-9
Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 5. Remove the gasket.
4. Bolt
3. (2) and (3) that tighten the setting plate and water Inspection
pump together. Loosen the adjusting bolts (1) in 1. Appearance check
the generator and remove the fan belt. • Check for cracks or damage in the pump body.
• Check for cracks and corrosion in the impeller.
• Check for water leakage from the seal unit.
• If you find abnormalities, replace with the water
pump ASM.
2. Bearing nut check
• Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
• If you find abnormalities, replace with the water
pump ASM.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt
7. Pour coolant.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
3
1
3
2
1
Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
1 6
Name
1. Adapter 4. Bypass hose
2. Fan pulley 5. Water duct
3. Water pump 6. Water duct
Tightening torque:
Bolt (1) : 221.6 N⋅m (22.6 kg⋅m/163 lb ft)
Bolt (2) : 24.5 N⋅m (2.5 kg⋅m/18 lb ft)
Water pump
Alternator
1 Crankshaft
3
2
1
Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
1B-16 Cooling System
Torque Specifications
39(4 /29)
20(2 / 14)
221.6(22.6 / 163)
20(2 / 14)
52(5.3 / 38)
F06E100076
Cooling System 1B-17
Disassembly
15
14
13
11
12
16
10
8
7
6
5
3
2
1
Name
1. Center 9. Shaft
2. Dust cover 10. Water pump body
3. Snap ring 11. Dowel pin
4. Bearing 12. Seal unit
5. Bearing 13. Impeller
6. Spacer 14. Gasket
7. Bearing 15. Cover
8. Washer 16. Bolt
1B-18 Cooling System
1. Remove the rear cover from the water pump body. Inspection and Repair
2. Use a remover 380.002.615 to remove the impeller Make the necessary adjustments, repairs and part
from the water pump. replacements if excessive wear or damage is
3. Use a puller to remove the water pump center. discovered during inspection.
4. Remove the dust cover and snap ring.
Water pump impeller
5. Remove the water pump shaft with ball bearings.
• Use a plastic hammer to lightly tap on the water 1. Check the impeller for corrosion.
pump shaft from the impeller side.
NOTE :
2 To prevent damage to the water pump shaft, place soft
brass or copper sheets between the base plates and
the water pump shaft.
1B-20 Cooling System
• Position the pump shaft with bearings to the 4. Install the seal unit to the water pump body.
water pump body. • Press in the seal unit to the specified position
• Use a bench press to gradually press the water using a bench press and installer 1-85220-047-
pump shaft into the water pump body. 0.
Seal unit installation position A:
NOTE :
11.0 – 11.6 mm (0.433 – 0.457 in)
Do not drive the bearing into position with a hammer or
similar object. Bearing damage will result.
380.002.615
Impeller remover
380.002.616
Seal unit installer
1B-22 Cooling System
Thermostat
Components
Removal
1. Drain the coolant. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
2. Disconnect the water outlet pipe.
3. Remove the thermostat.
4. Remove the gasket from the thermostat.
Inspection
• Place the thermostat in water and increase the
temperature while stirring it sufficiently.
• Measure the temperature when the valve is just
opened and when it is fully open.
Cooling System 1B-23
Installation 6HK1
1. Mount the gasket on the thermostat and mount it at
the position shown in the figure.
• The thermostat with the jiggle valve (A) is
installed to the left side of the engine. The jiggle
valve faces the rear of engine.
• Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.
WSHK0024
Name
1. Thermostat
031EY00026
4HK1
Drive Belt
Components
Name
1. Crankshaft Pulley 5. Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Adjusting Plate
4. Generator 8. Water Pump Pulley
Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt
1B-26 Cooling System
Torque Specifications
ENGINE
Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2
Precautions on Service Work . . . . . . . . . . . . . .1C-2
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Fuel Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16
Torque Specifications . . . . . . . . . . . . . . . . . . .1C-20
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-21
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . .1C-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-24
Torque Specifications . . . . . . . . . . . . . . . . . . .1C-27
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-28
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1C-31
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32
Torque Specifications . . . . . . . . . . . . . . . . . . .1C-35
1C-2 Fuel System
Fuel System
Precautions on Service Work • Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
Parts of the fuel system such as the internal part of the
exposed ends of the hose or pipe.
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy. • If parts are to be replaced (fuel hose, fuel pipe,
They are therefore highly sensitive to foreign matter etc.) do not open the new part packaging until
and the entry of foreign matter could cause damage to installation.
the fuel passage. Therefore, effective measures should Discard gaskets and O-rings and replace them with
be taken to prevent the entry of foreign matter. new ones.
If water removal agent is used in the fuel then it will Work procedure
absorb moisture in the light oil and may cause rust. • The fuel opening must be quickly sealed when
Therefore, do not use water removal agent in the fuel removing the fuel pipe, injection pipe, fuel injector,
tank. fuel supply pump, and common rail.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the • The eyebolts and gasket must be stored in a clean
system. parts box with a lid to prevent adhesion of foreign
matter.
• Before beginning the service procedure, wash the
fuel line and the surrounding area. • Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
• Perform the service procedures with clean hands. out and make sure there is no fuel leakage after
Do not wear work gloves. starting the engine.
2 4HK1
3
1
6
7
5 6HK1
6 8
WSHK0068
Name
1. Common Rail 5. Fuel Tank
2. Fuel Filter 6. Supply Pump
3. Electromagnetic Pump 7. Fuel Injector
4. Pre-fuel Filter 8. Leak-Off Pipe
Fuel System 1C-3
Caution:
• Be careful foreign material does not into the fuel
system, because the precise fuel system is used.
Common rail
4HK1
Name
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
1C-4 Fuel System
6HK1
MFW41DMF000201
Name
1. Flow Damper 3. Fuel Inlet
2. Pressure Limiter 4. Pressure Sensor
Fuel System 1C-5
Fuel supply pump
4HK1
Name
1. Fuel Temperature Sensor 4. Camshaft Key
2. Suction Control Valve 5. Camshaft Nut
3. High Pressure Pipe
1C-6 Fuel System
6HK1
1 3
WSHK0046
Name
1. Fuel Temperature Sensor 3. High Pressure Pipe
2. Suction Control Valve 4. Camshaft Key
Fuel System 1C-7
Fuel injector Fuel filter
Name Name
1. Terminal Stud 1. Priming Pump
2. Part for Mounting Leak Off Pipe 2. Air Bleed
3. O-ring 3. Case
4. Part for Mounting Injection Pipe 4. Drain Plug
5. Parts Number
6. ID Code Plate
Function check
Air bleeding
1. Before starting the engine
a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
near the plug overflows.
c. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
After waiting for approximately a minute, loosen
the plug and bleed out the air in the fuel filter.
(This work must be repeated a minimum of
three times until no more air comes out from the
plug.)
d. Tighten the plug firmly and wipe the fuel in the
surrounding area. Operate the priming pump
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine.
1C-8 Fuel System
2. After starting the engine
a. Start the engine by rotating the starter without
depressing the accelerator pedal.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum. (Repeat
this operation several times)
e. Rotate the idling knob counterclockwise and
return to idling mode.
Caution:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.
Water drain
It is designed that the float inside of the water
sedimenter floats when water accumulates.
When the float level goes up to the aluminum body
section, be sure to drain the water.
Special Tool
Illustration Tool Number/Description
EN-47667
Fuel pressure/vacuum
gauge adapter
(4HK1)
380.002.629
Fuel pressure/vacuum
gauge ASM
1C-10 Fuel System
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Removal
1. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
2. Remove the bolts for mounting the fuel filter.
3. Remove the fuel filter ASM.
Installation
1. Install the fuel filter ASM.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Bleed out the air.
• Refer to “Fuel System”.
Fuel System 1C-11
380.002.630
Main filter wrench
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Installation
1. Assemble the Fuel Filter element.
2. To simplify air bleed, fill light oil in the case.
3. Tighten the case by hand. During this process take
adequate care that the light oil that is inside does
not flow out.
4. Use the filter wrench and tighten rotating by 1/3 to
2/3.
1C-12 Fuel System
Fuel Injector
Components
4HK1
Fuel System 1C-13
6HK1
11
8
7
10
12
5 3
1
2
WSHK0162
Name
1. Fuel Injection Pipe Clip 7. EGR Adapter
2. Fuel Injection Pipe 8. EGR Cooler
3. Fuel Injector Leak-Off Pipe 9. EGR Valve
4. Fuel Injector 10. Cylinder Head Cover
5. Fuel Injector Clamp 11. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 12. Fuel Injector Terminal
Name
6HK1 1. Cylinder Head Cover
WSHK0163
Name
1. EGR Adapter
2. EGR Valve
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak Off Pipe
Fuel System 1C-15
9. Remove the fuel injection pipe clips and the
injection pipes.
4HK1
6HK1
Name
1. Sliding Hammer
2. Remover
3. Fuel Injector ASM
Caution:
WSHK0021
• Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
Name will result in injector failure.
1. Fuel Injection Pipe
2. Pipe Clip Recording Fuel Injector Flow Rate Information from
the QR plate on the replaced injector housing;
10. Loosen the fuel injector clamp fixing bolts and Record all numbers of replaced fuel injector's from QR
remove the fuel injectors. plate.
If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the
leak-off pipe attachment part on the fuel injector. Use a
sliding hammer to force the fuel injector clamp off the
fuel injector.
Caution:
Do not remove the fuel injector sleeve.
Special tool
Fuel injector remover: 380.002.601
Sliding hammer: 5-8840-0019 (J-23907)
1C-16 Fuel System
3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown
in the illustration.
7. Use a spanner to carefully the sleeve nuts until the
fuel injector pipes contact the fuel injector and
common rail.
8. Tighten the fuel injection pipe clips to the specified
torque.
Name
1. QR Plate
2. Fuel Injector Flow Rate
3. Fuel Injector
Installation
Important:
Install each of the fuel injectors on its original position.
(the cylinder from which it was removed)
1. Install a new gasket and O-ring to each of the fuel
injector clamps. Refer to the illustration.
* 4HK1 is shown for illustration.
Name
1. Fuel Injection Pipe
2. Pipe Clip
Name
1. Gasket
2. Fuel Injector
3. Bolt
4. Fuel Injector Clamp
11. Install the nozzle leak off pipes together with the
new gaskets. Tighten the pipes to the specified
torque.
WSHK0028
14. Install the fuel injector terminal nuts to the injector.
15. Alternately tighten each nut 2 or 3 turns at a time
until the specified torque is reached.
Caution:
Do not overtighten the nuts. Damage to the terminal
studs will result.
* 4HK1 is shown for illustration.
12. Install the fuel injector harness connectors. Work
from the inside out.
13. Install the harness bracket and tighten the bolts to
the specified torque.
Tightening torque: 4HK1: 48 N⋅m (4.9 kg⋅m/35 lb ft)
6HK1: 22 N⋅m (2.2 kg⋅m/16 lb ft)
1C-18 Fuel System
Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)
Name
1. Fuel Injector * 4HK1 is shown for illustration.
2. Harness
Name
3. Terminal Nut
1. EGR Adapter
2. EGR Valve
16. Install the gasket to the cylinder head cover.
17. Install the cylinder head cover and tighten the bolts 20. Attach the engine harness connectors. Each
to the specified torque. composite connector should make a loud click
Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft) when it is securely attached.
6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft) Before Programming the Fuel Injector Flow Rate
Important:
DO NOT program the fuel injector flow rate unless you
are directed by a service procedure or you are directed
by a service bulletin. Programming the fuel injector at
any other time will not permanently correct a customers
concern.
Ensure the following conditions are met before
programming the ECM.
• System voltage for machine
– There is no charging system concern. All
charging system concerns must be repaired
before programming the ECM.
– Battery voltage is greater than 12 volts but less
than 16 volts. The battery must be charged
before programming the ECM if the battery
voltage is low.
– A battery charger is NOT connected to the
machine’s battery. Incorrect system voltage or
* 4HK1 is shown for illustration. voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
Name
1. Cylinder Head Cover – Turn OFF or disable and system that may put a
load on the machine’s battery.
18. Install the gasket to the EGR valve and tighten the • The ignition switch is in the proper position. DO
bolts to the specified torque. NOT change the position of the ignition switch
during the programming procedure, unless
Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) instructed to do so.
19. Install the gasket to the EGR adapter and tighten • All tool connections are secure.
the bolts to the specified torque. – RS-232
Fuel System 1C-19
– The connection at the data link connector
(DLC) is secure.
– Voltage supply circuit
• DO NOT disturb the tool harness while
programming. If an interruption occurs during the
programming procedure, programming failure or
ECM damage may occur.
• Surrounding environment
– Surrounding temperature must be between 0
and 50°C (32 and 122°F) during the
programming procedure. Excessively low or
high temperature may cause the programming
failure or ECM damage.
– Electromagnetic interference (EMI) on the tool
harness and ECM may cause the programming
failure or ECM damage.
Fuel Injector Flow Rate Programming Procedure
1. Connect the scan tool to the data link connector.
2. Connect the RS-232 to the scan tool and PC.
3. Start TIS 2000 and select the Service
Programming System (SPS).
4. In the "Select Diagnostic Tool and Programming
Process" screen, select the following menu.
• Diagnostic tool "Pass-Thru".
• Select Programming Process "Reprogram
ECU".
• ECU Location on the “Machine”.
Then, follow the SPS screen instructions.
5. Ensure that ALL programming contents are
entered correctly and were programmed
successfully by turning OFF the ignition for 30
seconds.
6. Using the scan tool to check each programmed
fuel injector flow rate.
7. Start the engine and let idle.
8. Inspect for a proper engine running condition and
2 (0.2 / 1.5)
12 (1.2 / 8.9)
30 (3.0 / 22)
24 (2.4 / 17)
6 (0.6 / 4.4)
44 (4.5 / 32)
WSHK0047
5-8840-0019-0
J-23907
Sliding hammer
380.002.601
Fuel injector remover
1C-22 Fuel System
6HK1
Name Name
1. Fuel Supply Pump 1. Fuel Supply Pump
2. O-ring 2. O-ring
3. Fuel Supply Pump Bracket 3. Fuel Supply Pump Bracket
Caution:
Take care not to twist the O-ring.
Name
1. Fuel Supply Pump
2. Fuel Supply Pump Gear
3. Nut
Fuel System 1C-25
4. Apply white paint to the top of the fuel supply pump 6HK1
gear tooth directly above the stamped ‘O’ mark.
Refer to the illustration.
WSHK0049
6. Remove the oil drain adapter.
7. Install the O-ring to the fuel supply pump.
* 4HK1 is shown for illustration.
8. Align the slits as shown in the illustration.
5. Turn the crankshaft in the normal direction of
9. Insert the stud bolts into the guides and
engine rotation until the No. 1 or No. 4 cylinder is
temporarily tighten them.
at TDC on the compression stroke.
Refer to the illustration. Caution:
4HK1 • If the stud bolts (cylinder block side) have been
loosened or replaced, apply Loctite 262 to the
recessed portion of the bolts.
Name
1. Plug Hole
2. Alignment Mark
WSHK0050
15. Install the fuel pipe and fuel leak-off pipe.
16. Start and idle the engine.
Important:
* 4HK1 is shown for illustration.
In order to make the fuel supply pump characteristic
Name learn into the ECM, let the engine idle until warm-up. If
1. Oil Drain Adapter the fuel system DTC' stored in the meantime, once
2. O-ring clear DTD and warm-up the engine again.
Common Rail
Components
4HK1
Name
1. Fuel Leak Off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Common Rail
4. EGR Cooler 9. Common Rail Bracket
5. EGR Adapter
Fuel System 1C-29
6HK1
WSHK0165
Name
1. Fuel Leak Off Pipe 5. EGR Adapter
2. Fuel Pipe 6. Injection Pipe Clip
3. EGR Valve 7. Injection Pipe (#1 to #6)
4. EGR Cooler 8. Common Rail
Parts of the fuel system such as the internal part of the • Cover the removed fuel hose with a lid, keep it
fuel injector, holes and clearances that form passages facing upward and secure it using wire, etc.
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter Note:
and the entry of foreign matter could cause damage to Cover the areas exposed during part removal to
the fuel passage. Therefore, effective measures should prevent the entry of foreign material into the fuel
be taken to prevent the entry of foreign matter. system.
3. Disconnect the connected of common rail pressure
sensor, and all the connectors.
Removal
4. Remove the EGR valve and the EGR adapter.
1. Remove the air intake pipe. 5. Tape the EGR case holes shut to prevent the entry
• Disconnect the connector for the intake air of foreign material.
temperature sensor.
2. Remove the fuel leak off hose from the leak off
pipe.
1C-30 Fuel System
4HK1 4HK1
6HK1 6HK1
2 1
2
WSHK0166 WSHK0167
Name Name
1. EGR Adapter 1. Fuel Injection Pipe
2. EGR Valve 2. Pipe Clip
6. Remove the injection pipe clip and remove the 7. Remove the fuel pipe.
injection pipes.
Note:
Note: Cover the areas exposed during part removal to
Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel
prevent the entry of foreign material into the fuel system.
system. 8. Remove the clip and the fuel leak off pipe.
Note:
Cover the areas exposed during part removal to
prevent the entry of foreign material into the fuel
system.
Fuel System 1C-31
4HK1
Name Name
1. Fuel Leak Off Pipe 1. Common Rail Bracket (4HK1)
2. Common Rail
6HK1
Disassembly
1. Remove the fuel pressure limiter.
4HK1
WSHK0051
Name
1. Fuel Leak Off Pipe
Caution:
• Do not grasp the pressure sensor, during the
common rail removal procedure.
• Take care not to damage the connector unit of the
pressure sensor.
1C-32 Fuel System
6HK1 6HK1
3 3
1 1
2 2
WSHK0168 WSHK0168
Name Name
1. Common Rail 1. Common Rail
2. Pressure Sensor 2. Pressure Sensor
3. Pressure Limiter 3. Pressure Limiter
Reassembly Installation
1. Install the fuel pressure limiter. 1. Tighten the common rail bracket to the specified
Tightening torque: 172 N⋅m (17.5 kg⋅m/127 lb ft) torque. (4HK1)
Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft)
4HK1
2. Tighten the common rail to the specified torque.
Tightening torque: 4HK1: 19 N⋅m (1.9 kg⋅m/14 lb ft)
6HK1: 25 N⋅m (2.5 kg⋅m/18 lb ft)
Caution:
• Do not grasp the pressure sensor, during the
common rail removal procedure.
• Take care not to damage the connector unit of the
pressure sensor.
Fuel System 1C-33
4HK1
Tightening torque 7
4HK1 (2): 18 N⋅m (1.8 kg⋅m/13 lb ft)
6HK1 (2): 10 N⋅m (1.0 kg⋅m/7.4 lb ft)
4HK1 (3): 12 N⋅m (1.2 kg⋅m/106 lb in) 1
6HK1 (3): 14.2 N⋅m (1.4 kg⋅m/126 lb in) 6
4HK1 (4): 8 N⋅m (0.8 kg⋅m/71 lb in)
4HK1 (7): 6 N⋅m (0.6 kg⋅m/53 lb in)
6HK1 (7): 8.8 N⋅m (0.9 kg⋅m/78 lb in)
8 5
2
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the specified torque.
WSHK0169
Tightening torque (6): 44 N⋅m (4.5 kg⋅m/32 lb ft)
5. Tighten the injection pipe and the clip using the
(8): 44 N⋅m (4.5 kg⋅m/32 lb ft)
specified mounting torque.
Injection pipe sleeve nut
Tightening torque: 44 N⋅m (4.5 kg⋅m/32 lb ft)
6HK1 6HK1
1 2
2
WSHK0167 WSHK0166
Name Name
1. Fuel Injection Pipe 1. EGR Adapter
2. Pipe Clip 2. EGR Valve
N.m
N m(kg (lb ft)
m/lb
39 (4.0 / 29)
24 {17}
(2.4 / 17)
25 (2.5 / 18.4)
44 (4.5
{33} / 33)
10 (1.0 / 7.4)
WSHK0172
Engine Electrical 1D-1
ENGINE
Engine Electrical
TABLE OF CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . .1D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . .1D-2
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .1D-3
General Description . . . . . . . . . . . . . . . . . . . . . .1D-3
Generator (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6
Torque Specifications . . . . . . . . . . . . . . . . . . . . .1D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-7
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .1D-14
General Description . . . . . . . . . . . . . . . . . . . . .1D-14
On-vehicle Service: Starting System . . . . . . . .1D-15
Starter (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Torque Specifications . . . . . . . . . . . . . . . . . . . .1D-17
Main Data and Specifications. . . . . . . . . . . . . .1D-18
Preheating System . . . . . . . . . . . . . . . . . . . . . . .1D-26
Glow Plug Replacement. . . . . . . . . . . . . . . . . .1D-26
Precautions on Service Work . . . . . . . . . . . . . .1D-27
A List of Defective Phenomena . . . . . . . . . . . .1D-27
Main Data and Specifications. . . . . . . . . . . . . .1D-28
Starter (6HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-29
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-29
Sectional view (reference) . . . . . . . . . . . . . . . .1D-30
Output Characteristic (reference). . . . . . . . . . .1D-31
Disassembly and Inspection of Starter. . . . . . .1D-32
Assembly of Starter . . . . . . . . . . . . . . . . . . . . .1D-38
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . .1D-42
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-42
Generator (6HK1) . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-44
Disassembly and Inspection of Generator . . . .1D-45
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-51
Bench Testing. . . . . . . . . . . . . . . . . . . . . . . . . .1D-52
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . .1D-53
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-53
1D-2 Engine Electrical
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound will be called out. The correct torque value
must be used when installing fasteners that require it. If
the above conditions are not followed, parts or system
damage could result.
Engine Electrical 1D-3
Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a 120-amp,
selfrectifying type with a built-in regulator. The battery
discharge indicator light is mounted in the instrument
panel.
ACG
11
10
12 13
5
4
2
WSHK0053
Name
1. Generator 8. Plate
2. Lower Mount Bolt 9. Bolt
3. Nut 10. ACG Adjust Bolt
4. Spring Washer 11. Sliding Piece
5. Washer 12. Washer
6. Bracket 13. Adjust Nut
7. Bracket Mount Bolt
1D-4 Engine Electrical
Maintenance Electrical Tests
The most common indication of charging system Before performing the following generator electrical
troubles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, the first step not defective and generator belts are not slipping. Also,
should be to check its condition as described under the battery must be fully charged for a valid test of the
“Diagnosis of Battery.” In the case of an undercharged charging system.
battery, check for battery drain caused by grounds or Notice:
by accessories left turned on. To avoid damage to the vehicle electrical system,
Keep the generator and all other electrical system always observe the following precautions:
terminals clean and tight. A loose or badly corroded • Do not polarize the generator.
terminal connection will create excessive resistance in
• Do not short across or ground any of the terminals
the system and result in hard starting, dim lights etc.
in the charging circuit except as specifically
Inspect the generator system at regular intervals and
instructed herein.
correct any potential causes of trouble before machine
performance is affected. • NEVER operate the generator with the output
terminal open-circuited.
Diagnosis of Charging System
• Be sure the generator and battery have the same
Trouble in the charging system will be evidenced as ground polarity.
one or more of the following three conditions:
• When connecting a charger or booster battery to
1. The battery discharge warning light will stay on. the vehicle battery, connect negative to negative
2. An undercharged battery as evidenced by slow and positive to positive.
cranking. 1. With the engine control switch “ON” and engine not
3. An overcharge, or overvoltage, condition. running, connect a voltmeter from terminal “E” to
ground. The voltmeter should show 0 volts.
Undercharged Battery 2. With the engine control switch “ON,” and engine
Inspection not running, connect a voltmeter from terminal “B”
1. Accessories to be sure none were left on for to ground. The voltmeter should read at least 24
extended periods. volts.
2. Drive belt for proper tension. Refer to “Generator 3. With the engine control switch “ON” and the engine
Drive Belt” later in this section. not running, connect a voltmeter from white wire
side of the connector to ground. The voltmeter
3. The ECM main relay has been ON stuck at the should show 24 volts.
ignition switch OFF position. (Battery voltage is
consumed.) 4. With the engine control switch “ON” and the engine
not running, the “charge” light should be on. This
4. Refer to “Diagnosis of Battery” earlier in this shows that the other circuit in the connection is
section. working.
5. Wiring and connections for corrosion or looseness. 5. With the engine running and the headlight high
Overcharge (or Overvoltage) condition beams turned on, read the voltage at the “B” post
A charging rate in excess of 29.5-volts for a prolonged on the generator. The voltmeter should read at
period may cause early electrical system failure. least 24 volts.
Blown fuses. light bulbs burned out, and even battery 6. If steps 1 through 4 are not OK, check connectors
failure may result. If this condition exists, test the in the harness for looseness or corrosion and
generator as described under “Generator Output Test” retest.
later in this section. 7. If step 5 voltage is low, substitute a known good
regulator and test again. If the voltage is still low,
Noisy Generator bench test the generator.
Inspection
1. Drive pulley for looseness.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
• Generator noise may also be caused by worn or
damaged diodes and/or starter.
Engine Electrical 1D-5
Generator (4HK1)
Removal
• Battery negative cable.
1. Electrical wiring at the generator.
2. Loosen the adjust nut.
3. Loosen the ACG adjust bolt.
4. Loosen the lower mount bolt.
5. Drive belt
1D-6 Engine Electrical
6. Generator. 2. ACG Adjust bolt.
3. Adjust nut.
Installation Tightening torque:
Lower Mount Bolt 76 N⋅m (7.7 kg⋅m/56 lb ft)
1. Generator.
Tightening torque: 4. Electrical wiring at the generator.
Lower Mount Bolt 127 N⋅m (13.0 kg⋅m/94 lb ft) • Battery negative cable.
Torque Specifications
52(5.3 / 38)
ACG
68(6.9 / 50)
127(13 / 94)
52(5.3 / 38)
WSHK0054
Engine Electrical 1D-7
Specifications Connector terminal
1 2
WSHK0101
Name
1. R Terminal
2. L Terminal
Internal connections
SG L
IC
REGULATOR
WSHK0102
1D-8 Engine Electrical
Disassembly of generator
5
6
12
7
8 3
11
10 9
13
18
15
14
19
23
21
20
2
1
17
16
22
WSHK0103
Disassembly Procedure
1. Screw 13. Collar
2. Cover 14. Ball Bearing
3. Through Bolt 15. Rotor Assembly
4. Rotor, Front Bracket Assembly 16. Screw
5. Nut, Washer 17. Field Coil Assembly
6. Pulley 18. Stator Assembly
7. Fan 19. Holder
8. Collar 20. Regulator Assembly
9. Screw 21. Bolt (B terminal)
10. Retainer 22. Condenser
11. Ball Bearing 23. Rectifier Assembly
12. Front Bracket Assembly is the reverse order of disassembly.
Engine Electrical 1D-9
Inspection and repair of generator 3. Diode for initiating excitation, Resistor
WSHK0106
WSHK0104
4. Field coil
Charge the condenser with a tester (at Ω × 1000
2. Condenser
• To judge the insulating condition of field coil,
WSHK0107
WSHK0105
1D-10 Engine Electrical
• Measure between the protrusion portions of field • Judge as normal if there is continuity between N
coil with a tester, and judge as normal if the lead of stator coil and three leads.
resistance is about 6.7Ω (20°C {68°F}).
WSHK0110
WSHK0108 6. Bearing
5. Stator coil • Check if the bearing rotates smoothly or has no
• To judge the insulating condition of stator coil, noise.
WSHK0111
WSHK0109
Engine Electrical 1D-11
Performance test
In the performance test of generator, connect as
follows and measure the regulated voltage and output
current.
Actual wiring diagram for performance test of IC regulator built-in generator
2 3 SW 1 SW 2
1 V E 6 7
WSHK0112
Disassembly Procedure
1. Voltmeter 5. Clamp Tester Ammeter
2. R Terminal 6. Battery 24 V
3. L Terminal 7. Variable Resistor
4. Charging Lamp 24 V-3 W
Action to be
Trouble symptom Trouble location Trouble cause
taken
Charging is Wiring and Open or short circuit, disconnection
Repair
impossible. ammeter
Generator. Open circuit, short to ground, short circuit in each coil Replace
Broken diode Replace
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Insufficient Wiring Open or short circuit, looseness in connection Repair
charging
Generator. Looseness of generator driven belt Repair
Layer or short circuit in field coil Replace
Layer or short circuit in stator coil Replace
Defective diode Replace
Poor contact in each terminal Repair
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Excessive Regulator Defective regulator.
Replace
charging
Unstable charging Wiring Intermittent contact or nearly disconnected connection
Repair
current in wiring
Generator. Looseness of generator driven belt Repair
Short circuit or nearly disconnected connection in field
Repair
coil
Short circuit or nearly disconnected connection in stator
Repair
coil
Poor contact in each terminal Repair
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Noisy generator Generator. Improper installation of generator Repair
Defective bearing Replace
Contact of rotor core and stator core Repair
Defective diode Replace
Short circuit in stator coil Replace
1D-14 Engine Electrical
Starting System
General Description
Name
1. Starter 3. Ground Cable
2. Nut 4. Bolt
Maintenance
Keep the starter’s exterior clean. Remove corrosion
from the terminals, leads, and connectors.
Tighten the starter to engine mounting bolts and the
electrical cable retaining nuts.
Engine Electrical 1D-15
Diagnosis of Starting System If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the
No Cranking, No Sound voltage is 18 volts or more, repair the starter. If the
• Discharged batteries. Turn on the headlights and voltage is less than 18 volts, clean and tighten the
check the brightness. If the headlights are dim, positive cable connections. If the voltage is still less
charge the batteries. Check for the cause of the than 18 volts, replace the positive cable.
discharged batteries.
• Sulfated battery terminals. Turn on the headlights. On-vehicle Service: Starting System
The headlights will be bright. Attempt to start the
engine. The headlights will be very dim or go out. Maintenance
Clean all the battery terminals and cable ends.
Keep starter terminals and all other terminals in the
• A starter that draws too much current. electrical system clean tight. A loose or corroded
• Starter relay won’t work. Attempt to start and listen connection or terminal will cause excessive resistance
for a “click” at the starter relay. If there is no “click,” in the system that will result in hard starting. At regular
check the starter relay control terminals with a test intervals, inspect the starting system to locate and
light. If the test light shows that power is getting to correct potential causes of trouble before the system
the starter relay, check the ground circuit with the performance is affected. Starting motors do not require
test light. If the ground circuit is OK, replace the lubrication.
starter relay.
• Engine control switch start circuit won’t close.
With the engine control switch turned to start,
check the starter relay with a test light. If the test
light doesn’t come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
• Starter relay power circuit isn’t closing. Attempt to
start. The starter relay “clicks.” Check the
secondary terminals with a test light. If the test light
lights on the battery side only, replace the starter
relay. If the test light lights on both terminals, check
for an open at the starter.
• Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
cranking the engine. If voltage is OK, replace the
starter.
Starter (4HK1)
Removal
1. Battery negative cable from the battery.
2. Cables and electrical leads from the starter.
3. Two mount nuts.
4. Starter.
Engine Electrical 1D-17
Installation 3. Cables and electrical leads to the starter.
1. Starter 4. Battery negative cable to the battery.
2. Two mount nuts.
Tightening torque:
Mount nuts 82.4 N⋅m (8.4 kg⋅m/61 lb ft)
Torque Specifications
S.S
S
B
P1
C3 C
P2
B
C2 C1
M
Fc
Ar
1 4 3
WSHK0113
Name
1. Starter Relay 3. Motor
2. Battery 4. Magnetic Switch
19
16
17 12
18
27 20 13
21 15
14
4 26
2
1 25
24
22
23
3
7
6
8
9
10
11
WSHK0114
Name
1. Clip Ring 15. Ball
2. Pinion Stopper, Pinion, Spring 16. Rubber Bushing
3. Lead Wire 17. Plate
4. Bolt 18. Spring
5. Magnetic Switch 19. Pin
6. Screw 20. Holder
7. Bolt 21. Shift Lever
8. Rear Bracket 22. E Clip
9. Brush Holder ASM 23. Overrunning Clutch ASM
10. Yoke ASM 24. Internal Gear
11. Armature 25. Washer
12. Cover 26. Drive Shaft ASM
13. Packing 27. Front Bracket ASM
14. Idle Gear Assembly is the reverse order of disassembly.
Engine Electrical 1D-21
Inspection and repair of starter Contact Point Check
Service limit of contact point is judged by damaged
1. Magnetic switch
condition on contact surface in the following procedure.
Never perform operational check on magnetic
Measure the load current on starter. Replace it if
switch as single unit.
voltage drop between terminals B and M is 0.3 V or
Inspection of coil more per 100 A.
• Check the pressure coil C1 and holding coil C2 for
open circuit using a tester. Caution:
Check the continuity between magnetic switch and Use a digital voltmeter to measure voltage drop. Using
M terminal. It has open circuit if no continuity. an analog voltmeter may damage itself.
(Resistance approx. 1.6Ω)
WSHK0117
WSHK0115 2. Armature
• Supply 24 V between M terminal of magnetic Bentness measurement of shaft
switch and case, push the plunger by hand, and Measure with a dial gauge, and repair or replace if
then release it. It is normal if it is not sucked. Coil is bentness is 0.05 mm (0.0020 in) or more.
defective if it is sucked.
Caution:
Perform this while the magnetic switch is set up.
WSHK0118
WSHK0116
1D-22 Engine Electrical
Inspection of commutator Inspection of armature coil
• Check the surface of commutator. File the • Using a growler tester, put probe on a armature
surface smooth with No.400 to 600 sand paper core. It is normal if probe does not vibrates.
if it is rough. Repair with a lathe if deflection is • Check with a tester. It is normal if there is no
0.1 mm (0.004 in) or more. continuity between commutator and shaft.
WSHK0119 WSHK0121
• Measure the depth of undercut and repair if it is 3. Field Coil
0.2 mm (0.008 in) or less.
• Check the field coil for open circuit with a tester. It
mm(in) is open circuit if there is no continuity between M
terminal in field coil and lead wire on brush side.
• Check between field coil and yoke with a tester. It
is normal if there is no continuity between them.
2
3
1
0.5-0.8
(0.02-0.03)
WSHK0120
Name
1. Repair is needed
2. Improper repair
3. Good WSHK0122
4. Overrunning clutch
Outside diameter of commutator
Measure the outside diameter of commutator with • Rotate the pinion by hand. It is normal if it is
a slide-caliper. If the measured value is less than rotated smoothly in one direction only.
the limit, replace it. Check the pinion tooth surface. Replace if it has
worn or damage.
mm (in)
Caution:
Standard Limit If the entire overrunning clutch is soaked in liquid when
32.4 (1.276) 31.4 (1.236) washing it, internal grease flows out, causing seizure.
Engine Electrical 1D-23
6. Bearing
• Check if the bearing outer race rotates smoothly by
hand.
WSHK0123
5. Reduction gear
• Check the reduction gear. It is normal if it has no
wear. WSHK0125
7. Brush height
• Measure the brush height. If it is less than the limit,
replace the brush.
mm (in)
Standard Limit
17 — 18 (0.669 — 0.709) 10 (0.394)
WSHK0124
1D-24 Engine Electrical
Handling of starter
1. Precautions on handling
• Improper gap between pinion and ring gear causes
faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in})
• Also, the front bracket is installed on the engine
side securely.
• Be sure to turn off the battery switch before
removal/installation of stater.
• Tightening/inserting wiring must be performed
properly. Improper work causes starting trouble
due to high contact resistance.
2. Precautions on starting
• Be careful with charging status of battery.
Insufficiently-charged battery causes starting
trouble.
• After checking engine starting, turn off the stater
switch immediately.
• One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.
• If the starter does not stop rotating when the starter
switch is turned off, turn off the battery switch
immediately. In this case, check the wiring, switch,
etc.
Engine Electrical 1D-25
Trouble countermeasure
Preheating System
Glow Plug Replacement
Installation Procedure
1. Install the glow plug.
Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft)
2. Install and tighten the glow connector with the
designated torque.
Tightening torque: 1.2 N⋅m (0.1 kg⋅m/11 lb in)
3. Install the EGR valve and the EGR adapter.
Name
1. EGR Adapter
2. EGR Valve
Name
1. EGR Adapter
2. EGR Valve
Caution:
Use a set of four glow plugs from the same
manufacturer.
Item Model
Preheating device model Glow plug
Glow plug rated voltage/ current (V-A) 23 – 3.5
Engine Electrical 1D-29
Starter (6HK1)
Specifications
4 7
8
3
1 13 12 11
10
WSHK0069
Name
1. Through Bolt 8. Pinion
2. Bearing 9. Bearing
3. Rear Bracket 10. Front Bracket
4. Brush Holder 11. Gear
5. Magnetic Switch 12. Yoke
6. Shift Lever 13. Armature
7. Gear Shaft
Engine Electrical 1D-31
Output Characteristic (reference)
r/min N.m kW V
6000 120 6 24
3000 60 3 12
2000 40 2 8
Terminal voltage
1000 20 1 4
0 0 0 0
0 200 400 600 800 1000 1200 1400 1500
Current (A)
WSHK0070
1D-32 Engine Electrical
18
19
27 21
9
6
28
29
14
16
17
15 5
20
4 26 8
3
2 22 10
1 25
24 13
23 12
30
11
12
WSHK0071
Disassembly Procedure
1. Snap Ring 16. Plate
2. Stop Ring 17. Packing
3. Pinion 18. Packing
4. Pinion Spring 19. Plate
5. Lead Wire with Terminal 20. Planetary Gear
6. Screw 21. Lever
7. Magnetic Switch 22. E-shaped Retaining Ring
8. Screw 23. Overrunning Clutch
9. Through Bolt 24. Internal Gear
10. Rear Bracket 25. Washer
11. Yoke Assembly 26. Gear Shaft
12. O-Ring 27. Front Bracket
13. Brush Holder 28. Bearing
14. Armature 29. Washer
15. Ball 30. Brush
Engine Electrical 1D-33
Disassembly
Caution:
• Before disassembling the starter, put alignment 5
marks on each magnet switch, yoke front bracket
and rear bracket to facilitate re-assembly. 4
Caution:
Do not reuse the removed O-ring.
WSHK0072 Also, do not reuse also O-ring on tightening screw.
2. Apply the pipe, which just fits the stop ring, on the 5. Apply a socket (outside diameter 32 mm
ring and tap the pipe with a hammer to remove the {1.260 in}) on a commutator of armature.
stop ring toward the pinion side once. Then, slide the brush on the socket to yoke
Then, remove the snap ring and remove the stop assembly and O-ring.
ring, pinion and pinion spring. This facilitates to re-assemble.
Caution: Caution:
Do not reuse the snap ring. Do not reuse the removed O-ring.
6. Remove the brush from brush holder by pulling up
the brush spring, and then remove the brush
holder.
7. Remove the armature.
Remove a bearing using a general puller.
8. Remove the plate in planetary gear and remove
the packing.
Then, remove the packing and plate on the lever
support.
9. Remove the internal gear, gearshift, overrunning
clutch and lever as a unit from front bracket.
1D-34 Engine Electrical
10. Remove the lever. • Check the armature coil for grounding (faulty
insulating) with a circuit tester.
Caution: Replace the armature if grounding is present.
Remember the direction of lever.
11. Remove the two E-shaped retaining ring.
To remove the overrunning clutch, rotate the spline
by one tooth to remove it from gearshift assembly.
Caution:
Do not reuse removed E-shaped retaining ring.
12. Remove the internal gear.
In this time, take out one washer which adjusts
axial play of gearshift.
WSHK0074
WSHK0076
Engine Electrical 1D-35
• Check the depth (undercut) of insulating mold of • Check the coil for grounding (faulty insulating) with
commutator. a circuit tester.
Remove abrasion powder on brush, and repair if Repair or replace the yoke assembly if grounding
faulty. is present.
2
3
WSHK0077 WSHK0079
3. Brush
Name
1. Good • Measure the length of the brush.
2. Insulating If it is worn to the limit, replace the brush holder
3. Commutator Segment assembly on the brush holder as a unit and only
4. Defective brush on the yoke assembly side.
• Make sure the brush moves smoothly in the brush
• Check the gears for wear or damage. holder. Also, check the brush spring pressure.
Replace the armature if fault is present.
• Check the bearings for noise, rattle or grease
leakage.
2. Field coil
• Check the coil for open circuit with a circuit tester.
Replace the yoke assembly if open circuit is
present.
WSHK0078
1D-36 Engine Electrical
• Check the brush holder for grounding (faulty
insulating) with a circuit tester.
Clean the brush holder before checking.
Replace the brush holder assembly if the
continuity is present when putting one probe of
circuit tester to brush holder plate (metal part) and
another one to insulated holder.
WSHK0081
5. Front bracket
Check the bearing and oil seal, and replace the
front bracket assembly (including bearing, oil seal)
if faulty.
6. Internal gear and planetary gear
Check the internal gear and planetary gear, and
WSHK0080 replace them if excessive wear or damage is
Name present.
1. Brush Length 7. Lever
2. Insulated Holder It the portion which contacts the overrunning
switch is worn, the protruded position of pinion will
4. Overrunning clutch and pinion be faulty.
Hold the housing of overrunning clutch by hand. (Refer to “4. Assembly” section to adjust the
Make sure that the pinion can be rotated by hand protruded position of pinion.)
with a light resistance in one direction and cannot
be in the opposite direction. Replace the
overrunning clutch if faulty.
Check the pinion, and replace it if wear or scratch
is present.
Caution:
Grease is present in overrunning clutch. Do not use
wash oil or cleaning agent for cleaning.
Wipe off stain on overrunning clutch with a cloth.
WSHK0082
Name
1. Worn Part
Engine Electrical 1D-37
8. Magnetic switch
Check the continuity between the M terminal and
the body, and replace the magnet switch if no
continuity is present.
Then, make sure that no continuity is present
between B terminal and M terminal. Replace the
magnet switch if continuity is present.
1 3
WSHK0083
Name
1. M Terminal
2. S Terminal
3. B Terminal
1D-38 Engine Electrical
Assembly of Starter
Assembly diagram: Assemble in the order of the numbers.
24
13
12
4 10
22
25
3
2
17
15
14
16 5
11
27 5 23
28
29 9 21
30 6
7 18
8 19
1
20
19
WSHK0084
Assembly Procedure
1. Brush 16. Ball
2. Washer 17. Armature
3. Bearing 18. Brush Holder
4. Front Bracket 19. O-Ring
5. Gear Shaft 20. Yoke Assembly
6. Washer 21. Rear Bracket
7. Internal Gear 22. Through Bolt
8. Overrunning Clutch 23. Screw
9. E-shaped Retaining Ring 24. Magnetic Switch
10. Lever 25. Screw
11. Planetary Gear 26. Lead Wire with Terminal
12. Plate 27. Pinion Spring
13. Packing 28. Pinion
14. Packing 29. Stop Ring
15. Plate 30. Snap Ring
Engine Electrical 1D-39
1. Lubricant locations and tightening torque
I 4.9~8.8
19.6~25.5
(0.5~0.9 / 3.6~6.5)
(2.0~2.6 / 14.4~18.8)
C B
H F
2.4~4.4
(0.25~0.45 / 1.8~3.2)
7.8~12.7 E A D
(0.8~1.3 / 5.8~9.4)
WSHK0085
Lubricant locations
Shown in
the Lubricant locations Lubricant agent
illustration
A Sleeve bearing and ball Molycote AG650
B Clutch shaft sliding surface MULTEMP 6129
C Spline portion and sliding portion of gearshift MULTEMP 6129
D Sliding portion of lever and overrunning clutch Molycote AG650
E Armature shift gear, planetary gear, internal gear Molycote AG650
F Under pinion MULTEMP 6129
G Outer surface of armature bearing (tiny amount) MULTEMP 6129
H Oil seal MULTEMP 6129
I Surface of plunger (tiny amount) MULTEMP 6129
2. Axial play of armature shift Pass the gear shaft through washer, internal gear
Adjustment is unnecessary (assemble the ball into and overrunning clutch. Then move the
a tip of shaft.) overrunning clutch by one tooth of spline to make
3. Axial play of gear shaft sure that the clutch cannot be pulled out.
Adjustment is unnecessary Assemble the E-shaped retaining ring.
Appropriate gap will be obtained automatically
when one washer (removed in step 12 of Caution:
disassembly procedure) is inserted between • Do not reuse removed E-shaped retaining ring.
internal gear and gearshift.
4. Assembly of gearshift
1D-40 Engine Electrical
• If assembling the E-shaped retaining ring prior to
the overrunning clutch, the clutch cannot be
assembled. Be careful with it.
3
3
2
2 5
1
WSHK0087
1
Name
WSHK0086 1. Pinion
2. Clutch Shaft
Name 3. Snap Ring
1. Overrunning Clutch 4. Stop Ring
2. Washer 5. Pinion Spring
3. Gear Shaft
4. E-shaped Retaining Ring 6. Check of the pinion protruded position
5. Internal Gear After assembling the starter, check the protruded
position of pinion.
5. Assembly of pinion How to measure and adjust
Assemble the pinion spring, pinion and stop ring to • Connect the starter to battery.
clutch shaft in this order, then assemble the snap When closing the switches SW1 and SW2, the
ring to the groove of clutch shaft at the end. pinion move forward to the cranking position
Then, pull strongly the stop ring toward the snap and the armature rotates.
ring side with a gear puller and fix both of them. Then, open the switch SW2 to stop the
armature rotating.
Caution:
• Assemble the pinion before assembling the
magnet switch to front bracket.
• Do not reuse the removed snap ring.
Engine Electrical 1D-41
• Push into or pull back a tip of the crankshaft
lightly by hand and measure the moving
distance of it.
Adjust by using one or two packings (0.5 mm
{0.020 in}) of magnet switch and front bracket
so that this measurement value is between 0.5
— 2.0 mm (0.020 — 0.079 in).
If this adjustment cannot be done, replace the
lever.
SW 1 B
S SW 2
M
1
WSHK0088
Name
1. Battery 24 V
WSHK0089
1D-42 Engine Electrical
No Load Test
1. After adjusting the protruded position of pinion,
connect the starter as shown in the illustration
above.
Caution:
Use a thick electric wire and tighten the connected 2 A SW B
portion securely. S
2. Close the switch and read the speed, current and M
voltage.
1 V 3
If the measured values are out of specified value,
disassemble and inspect again.
WSHK0090
Name
1. Battery 24 V
2. Ammeter
3. Voltmeter
Specifications
Generator (6HK1)
Specifications
Charging Circuit
B
3 4 5
L
2 L
R R
E 6
1
7
E
WSHK0091
Name
1. Field Coil 5. Key Switch
2. Stator Coil 6. Battery 24 V
3. Diode Trio 7. IC Regulator
4. Charging Lamp 8. Generator
Charging circuit and internal circuit are shown in the illustration above.
Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.
1D-44 Engine Electrical
Structure
5 6
4
7
8
1
9
10
WSHK0092
Name
1. Rear Bracket 6. Rotor
2. IC Regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front Bracket
5. Stator 10. Coil Assembly (Field Coil)
This generator has no brush. terminal (for direct current output), L terminal and R
Main parts are a rotor, stator, rectifier assembly, front terminal.
bracket, rear bracket, IC regulator, bearing, pulley and The L terminal is connected to field coil. Therefore, as
so on. well as R terminal, it becomes input terminal for
Moving parts are a rotor and pulley. A field coil is initiating excitation current until the generator starts to
secured to rear bracket. generate electric power.
Six main diodes and two additional diodes are used to It also provides function as output terminal. (Current
convert three-phase alternating current, generated in capacity is 1 A.)
stator coil, into direct current. Among six main diodes, The charging lamp will be off if the voltage on L
there are three positive diodes and three negative terminal reaches battery voltage.
diodes. Both bearings are sealed, therefore periodic lubricant is
In addition, three tiny diodes, called trio diode, are used not necessary.
to supply field current. IC regulator cannot be disassembled. Handle it as
This generator has three terminals, which are B assembly.
Engine Electrical 1D-45
10
5 7
6
4
1 3
11
12
13
14
15
WSHK0160
Name
1. Nut Washer 9. Ball Bearing
2. Pulley, Fan 10. Screw
3. Collar 11. Cover
4. Through Bolt 12. Rectifier Assembly
5. Front Bracket 13. Regulator Assembly
6. Ball Bearing 14. Stator Assembly
7. Retainer 15. Field Coil Assembly
8. Rotor Assembly
1D-46 Engine Electrical
11
10
6 8
7
5
3
2
1 4
12
13
14
15
16
17
18
WSHK0161
Name
1. Nut Washer 10. Ball Bearing
2. Pulley, Fan 11. Field Coil Assembly
3. Key 12. Connector Set
4. Collar 13. Screw
5. Through Bolt 14. Terminal Set
6. Front Bracket 15. Cover
7. Ball Bearing 16. Rectifier Assembly
8. Retainer 17. Regulator Assembly
9. Rotor Assembly 18. Stator Assembly
Disassembly Caution: 2. Hold the rotor with a vise without deforming the
To facilitate re-assembly, put alignment marks on front rotor ball.
bracket and rear bracket before disassembly. Remove the nut which fixes pulley, and remove the
1. Remove out the four through-bolts. pulley, fan, spacer and front bracket.
Pry between stator and front bracket with a tip of
Caution:
flathead screwdriver and separate the front bracket
Do not lose a half-moon key when removing the pulley.
pulley rotor assembly from stator rear bracket
assembly carefully. Caution:
To hold the rotor with a vise, grip the portion A. Portion
Caution:
B is not strong enough to be gripped.
Take care not to damage the stator coil.
Engine Electrical 1D-47
5. To remove the coil assembly from rear bracket,
firstly remove the screw A (which fixes coil terminal
portion to IC regulator).
Removing a screw B (which fixes the coil assembly
to rear bracket) prior to screw A may cause damage
B
to terminal portion.
Hold the coil assembly by hand not to damage to
terminal portion.
Then, remove the screw B and remove the coil
assembly.
A A
1
1
A
WSHK0093
Name
1. Ball
Caution:
Do not lose the tube.
1D-48 Engine Electrical
2 4
12
7
8
13
11
9
1
10
WSHK0095
Name
1. IC Regulator 8. Cap
2. Rectifier 9. Nut
3. B terminal 10. Terminal Bolt
4. Terminal Bolt 11. Terminal Bolt
5. B terminal 12. Terminal Bolt
6. Cap 13. Rectifier
7. Nut
Engine Electrical 1D-49
5
1
N
6
WSHK0159
Name
1. IC Regulator 4. B terminal
2. Terminal Bolt 5. Tube
3. Nut 6. Rectifier
Inspection
1. Stator
Check visually for damage, loose connection and
discoloration of coil.
WSHK0096
• Check the continuity between two lead wires of Name
stator coil with a circuit tester. Replace the stator if 1. Stator Coil Lead
no continuity is present.
• Check the continuity between lead wire of stator
coil and core with a circuit tester. Replace the
stator if continuity is present.
1D-50 Engine Electrical
2. Rotor 4. Rectifier assembly
• Check the bearings for noise, rattle or grease • Check the continuity between positive diode,
leakage (wipe off if tiny amount of grease). additional diode positive heat sink on positive side
Replace it if faulty. It is easier to check for noise and four diode terminals with a circuit tester.
and rattle when it is press-fitted into shaft than The positive diode has short circuit if continuity is
when it is a single unit. present in both directions. Replace the rectifier
assembly.
The positive diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
• Negative diode and additional diode on negative
side
1
Check the continuity between negative heat sink
and four diode terminals with a circuit tester.
The negative diode has short circuit if continuity is
present in both directions. Replace the rectifier
assembly.
The negative diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
2
• Diode trio (three tiny diodes)
Check the continuity in both directions with a circuit
tester.
WSHK0097 The diode is faulty if continuity is present in both
directions or no continuity is in both directions.
Name Replace the rectifier assembly.
1. Stator Coil Lead
2. Core
3. Coil assembly
Measure the resistance between terminal portions 2
with a circuit tester.
Replace the coil assembly if the value is out of
specified value.
1 3
1
WSHK0099
Name
2
1. Diode Terminal Portion
2. Positive Diode
3. A Part of Negative Diode
5. Front bearing
WSHK0098 Check the bearings for noise, rattle or grease
leakage (wipe off if tiny amount of grease).
Name Replace them if faulty. It is easier to check for
1. Terminal noise and rattle when the bearing is press-fitted
2. Terminal Portion into bracket than when it is a single unit.
Engine Electrical 1D-51
6. Regulator
The regulator cannot be checked with a circuit
tester. After re-assembling the generator, check it
to make sure that regulator controls the voltage for
generator.
Assembly
Assembly can be performed in the reverse order of
disassembly. However, be careful with the following.
1. Lubrication is not necessary. Bearing is filled with
grease and is sealed.
Caution:
Keep a bearing with resin band for rotor shaft away
from oil. Wipe off oil on bearing box area of rear
bracket. Oil may cause creep.
2. Use a high temperature solder (melting point:
230°C {446°F}).
Using a soldering iron (with 180 — 270 watt),
soldering must be performed quickly (within five
seconds) not to heat the rectifier.
3. Tightening torque
• Pulley fixing nut:
132 — 162 N⋅m {13.5 — 16.5 kg⋅m/97 — 119 lb
ft}
• Through bolt:
12.8 — 18.6 N⋅m {1.3 — 1.9 kg⋅m/9 — 14 lb ft}
• Bearing retainer fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Coil assembly fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Rectifier fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Regulator fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Nut for B terminal bolt:
4.9 — 8.7 N⋅m {50 — 88 kgf⋅cm/43 — 77 lb in}
4. Assembly of rear bracket to stator assembly and
front bracket to rotor assembly
• The rotor bearing and rear bracket are engaged
tightly. Heat the bearing box area of rear bracket to
50 — 60°C (122 — 140°F) prior to assembly.
• After re-assembling the generator, rotate the pulley
to confirm that the rotor rotates smoothly.
1D-52 Engine Electrical
Bench Testing 4. Set the generator speed to approx. 5000 rpm and
read an ammeter. If the value is 5 A or less, read
Bench testing is performed as follows.
indication on a voltmeter. This is regulated voltage.
If an ammeter shows 5 A or more, keep charging
Regulated voltage check
for a while until it shows below 5 A or replace the
1. Wire as shown in the illustration. battery with full-charged one.
Use an ammeter with 100 A rating and a voltmeter If regulated voltage is out of specified value,
with 30 V rating. replace the regulator.
Specifications
ENGINE
Exhaust System and Turbocharger
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2
Precautions on Service Work . . . . . . . . . . . . . . . 1F-2
Explanations on Functions and Operation . . . . . 1F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . . 1F-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 1F-5
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
A List of Defective Phenomena . . . . . . . . . . . . . 1F-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
Turbocharger (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1F-7
Table of Specifications . . . . . . . . . . . . . . . . . . . . 1F-7
Turbocharger Structured Diagram . . . . . . . . . . . 1F-8
Disassembly and Inspection of Turbocharger . . 1F-9
Assembly of Turbocharger . . . . . . . . . . . . . . . . 1F-15
Turbocharger (4HK1) . . . . . . . . . . . . . . . . . . . . . 1F-21
Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . 1F-22
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-22
1F-2 Exhaust System and Turbocharger
EGR System
Precautions on Service Work Explanations on Functions and Operation
Perform EGR related assembly according to the usual Re-circulate a part of the exhaust gas of the EGR
procedure of temporarily fitting and then permanently system in the intake manifold. Reduce the combustion
tightening the parts so that unnecessary stresses are temperature and inhibit NOx generation since inert
not applied on the parts. gases may be mixed up in the intake air.
An electronic control system is used in this EGR to
balance the requirements of operability and low
emissions. A DC motor is operated using the control
current of the Engine Control Module (ECM) to control
the EGR.
Refer to the chapter on Engine Control System for
details on fault diagnosis of the EGR system.
Name
1. EGR Cooler 3. EGR Valve DC Motor
2. Engine Control Module (ECM)
Exhaust System and Turbocharger 1F-3
Name
1. EGR Adapter 4. EGR Pipe
2. Cooling Water Pipe (out) 5. Cooling Water Pipe (in)
3. EGR Cooler 6. EGR Valve
Removal
1. Drain the coolant.
2. Disconnect the EGR valve connector.
3. Remove the EGR pipe.
1F-4 Exhaust System and Turbocharger
2. Install the EGR cooler.
• Temporarily fit the EGR cooler to the bracket.
Notice:
Temporarily tighten the bolts.
3. Install the EGR adapter.
• Temporarily fit the EGR adapter between the EGR
cooler and exhaust manifold.
Notice:
Temporarily tighten the bolts.
4. Install the EGR pipe.
• Insert the gasket between the two ends of the EGR
pipe and temporarily fit it.
Notice:
Temporarily tighten the bolts.
During temporary assembly, tighten the nuts
* 4HK1 is shown for illustration. and bolts to the specified torque in the order
shown in the illustration.
Name
1. EGR Adapter
2. Cooling Water Pipe (out)
3. EGR Cooler
4. EGR Pipe
5. Cooling Water Pipe (in)
Caution:
After removing the EGR valve and EGR adapter, seal
so that foreign matter does not enter.
Inspection
Installation Name
1. Mount the EGR valve. 1 ~ 9 Show the Order of Tighten Bolts and Nuts.
• Insert the gasket and temporarily fit the EGR valve. Tightening torque
Notice: 1, 2: 28 N⋅m (2.9 kg⋅m/21 lb ft)
Temporarily tighten the bolts. 3, 4, 5, 6: 24 N⋅m (2.4 kg⋅m/18 lb ft)
Exhaust System and Turbocharger 1F-5
Torque Specifications
Exhaust System
A List of Defective Phenomena
• Vibration or rattling noise from the exhaust system
• Clogging of exhaust system
• Exhaust leakage or noise
Troubleshooting
Vibration or rattling noise from the exhaust system
Turbocharger (6HK1)
Table of Specifications
Assembly
Item Service limit
specifications
Turbine shaft Axial play mm (in) 0.06 — 0.09
0.11 (0.00433)
(0.00236 — 0.00354)
Radial play mm (in) 0.10 — 0.17
0.205 (0.00807)
(0.00394 — 0.00669)
Journal outside diameter (A) mm (in) — φ 11.380 (0.44803)
Sealing groove width (B) mm (in) — 1.33 (0.05236)
Runout mm (in) — 0.11 (0.00433)
Sealing Turbine side (bearing housing) (F) mm (in) — 17.03 (0.67047)
insertion part Compressor side (seal plate) (H) mm (in) — 14.05 (0.55315)
Oil thrower Sealing groove width (G) mm (in) — 1.52 (0.05984)
Bearing Bearing housing inner diameter (B) mm (in) — φ 16.11 (0.63425)
φ 23.020 (0.90630)
housing Thrust bearing inside diameter for (L) mm (in)
—
press-fit portion
Thrust Bearing pad height at compressor side (J) mm (in) 0.0 — 0.060
—
bearing (0.0 — 0.00236)
Thrust collar thickness (K) mm (in) — 2.950 (0.11614)
H
F L
B A
K
E G
WSHK0126
1F-8 Exhaust System and Turbocharger
Turbocharger Structured Diagram
4 5
2 3
10 9
1 8
WSHK0127
Name
1. Turbine Housing 6. Seal Plate
2. Heat Protector 7. Compressor Impeller
3. Floating Metal 8. Seal Ring
4. Oil Thrower 9. Seal Ring
5. Compressor Housing 10. Turbine Shaft
Exhaust System and Turbocharger 1F-9
Disassembly and Inspection of Turbocharger
Disassembly diagram: disassemble in the order of the numbers.
4 2
3
6
5
13
14
17
16
16
15
8
18
7
11
12
10
9
WSHK0128
Disassembly Procedure
1. Compressor Housing 10. Seal Ring
2. Nut 11. Gasket
3. Compressor Impeller 12. Heat Protector
4. Seal Plate 13. Thrust Bearing
5. Oil Thrower 14. Thrust Collar
6. Seal Ring 15. Snap Ring
7. G Coupling 16. Floating Metal
8. Turbine Housing 17. Thrust Bearing
9. Turbine Shaft 18. Bearing Housing
1F-10 Exhaust System and Turbocharger
Disassembly 1. Compressor housing
• Put alignment marks between the compressor
Inspection Prior to Disassembly housing and the seal plate, and tap the
• Measurement of axial play of turbine shaft compressor housing to drive it out.
• Liquid gasket is applied to the mating surfaces of
Axial play mm (in) the compressor and the seal plate.
0.06 — 0.09
Assembly specifications Caution:
(0.0024 — 0.0035)
Take care not to damage the impeller during removal of
Service limit 0.11 (0.0043)
the compressor housing.
If it exceeds the service limit, check the thrust
metal, the thrust bushing, and the oil thrower.
WSHK0131
Name
WSHK0129 1. Alignment Mark
• Measurement of radial play of turbine shaft
2. Nut
Radial play mm (in)
• The nut is left-hand screw.
0.10 — 0.17 3. Compressor impeller
Assembly specifications
(0.00394 — 0.00669)
• Attach the box spanner to the turbine-side shaft
Service limit 0.205 (0.00807) end of the turbine shaft, and remove the nut.
• Remove the impeller from the turbine shaft.
If it exceeds the service limit, check the floating
• Washing of impeller
metal.
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic scraper
or hard brush.
Caution:
Do not use a wire brush.
WSHK0130
Exhaust System and Turbocharger 1F-11
• Washing of turbine housing
Soak in the cleaning solvent to remove the foreign
matters.
WSHK0132
Name
1. Left-hand Thread WSHK0134
9. Turbine shaft
4. Seal plate
• Hold the heat protector lightly by hand, and take
• Loosen the pot small screw.
out the turbine shaft.
• Lightly tap the bearing housing in the seal plate
• If it is hard to remove, lightly tap the compressor-
with a wooden hammer.
side shaft end with a wooden hammer.
• Liquid gasket is applied to the mating surfaces of
• Washing of turbine shaft
the seal plate and the bearing housing.
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic scraper
or hard brush.
Caution:
• Do not use a wire brush.
• Foreign matters remaining on the surface causes
the unbalance of weight. Therefore, wash it
thoroughly.
• Take care not to damage the floating metal contact
surface of the shaft and the seal ring groove.
WSHK0133
5. Oil thrower
• Remove the oil thrower from the seal plate.
6. Seal ring; oil thrower
7. G coupling
• Loosen the nut and remove the G coupling from
the turbine housing and the center housing.
8. Turbine housing
• Remove the center housing from the turbine
housing.
WSHK0135
1F-12 Exhaust System and Turbocharger
10. Seal ring Impeller
• Remove the seal ring from the turbine shaft. • Check the impeller for scratch, dent or crack.
11. Gasket
12. Heat protector
• Remove the heat protector from the bearing
housing.
13. Thrust bearing (compressor side)
• Loosen the Plate small screw with a screwdriver,
and remove the thrust bearing and the thrust collar.
14. Thrust collar
15. Snap ring
• Remove the turbine-side snap ring with snap ring
pliers.
16. Floating metal
• Draw out the floating metal from the bearing
housing.
17. Thrust bearing (turbine side)
• Using a brass bar, push out the compressor-side WSHK0137
floating metal from the turbine-side bearing
housing, together with the thrust bearing. Heat protector
• Check the heat protector for damage, thermal
Caution: deformation or corrosion.
• while pushing out with a bar, take care that they do
not run on to damage the snap ring.
Removal of snap ring (also to be done after step
17.)
• Remove the 2 snap rings from the bearing housing
with snap ring pliers.
18. Bearing housing
Inspection
Compressor housing
• Check the compressor housing for crack or
damage, and replace if defective.
WSHK0138
Turbine shaft
• Measure the journal outer diameter of the turbine
shaft, and the groove width of the seal ring
insertion part.
WSHK0139 WSHK0141
Name Oil thrower
1. Journal outer diameter • Inspection of damage on the oil thrower sliding
2. Ring groove width surface, measurement of the seal ring groove
width
• Measurement of turbine shaft runout
Seal ring groove width G mm (in)
Turbine shaft runout mm (in)
Service limit
Service limit 0.011 (0.00043)
G 1.52 (0.0598)
Thrust collar
• Measure the thrust collar thickness (K), and
replace with new one if it exceeds the service limit.
WSHK0140
Seal plate
• Inspection of damage on the seal plate,
measurement of inner diameter of the seal ring WSHK0142
insertion part
Thrust bearing
Inner diameter of the seal mm (in) • Replace the compressor-side and the turbine-side
ring insertion part thrust bearings with new ones.
Service limit
φ 14.05 (0.5531)
Floating metal
H
• Replace the floating metal with new one.
1F-14 Exhaust System and Turbocharger
Bearing housing
• Check the casting surface for peeling from
oxidation-deterioration, dent or crack. Replace with
new one if faulty.
mm (in)
Location Service limit
Bearing housing inner diameter (B) 16.11
(0.6343)
Turbine-side seal ring insertion (F) 17.03
part (0.6705)
Turbine-side thrust bearing (L) 23.02
press-fit part inner diameter (0.9063)
F B L
WSHK0143
G coupling
• Replace with new one.
Seal ring
• Replace with new one.
Others
• Check the bolts for deformation, and replace with
new ones if faulty. Also, replace the Plate small
screw with new one.
Exhaust System and Turbocharger 1F-15
Assembly of Turbocharger
Assembly diagram: Assemble in the order of the numbers.
18
15 17
16
13
14
9
8
4
3
3
11
1
12
10
6
5
7
WSHK0144
Assembly Procedure
1. Bearing Housing 10. Gasket
2. Snap Ring 11. Turbine Housing
3. Floating Metal 12. G Coupling
4. Thrust Bearing 13. Seal Ring
5. Seal Ring 14. Oil Thrower
6. Heat Protector 15. Seal Plate
7. Turbine Shaft 16. Compressor Impeller
8. Thrust Collar 17. Nut
9. Thrust Bearing 18. Compressor Housing
1F-16 Exhaust System and Turbocharger
Assembly
1. Bearing housing
• Check that the bearing housing is free of damage
and foreign matters.
2. Snap ring
• Install the 2 snap rings to the bearing housing with
snap ring pliers.
• After assembling the floating metal (turbine side),
install the snap ring at the position shown in the 1
figure.
WSHK0146
Name
1. Apply Oil.
4. Thrust bearing
a. Press-fitting of turbine-side thrust bearing
1
• Press-fit the turbine-side thrust bearing into the
bearing housing.
• Position the pawl of the turbine-side thrust
bearing for more than 2 mm (0.0787 in) apart
WSHK0145 from the existing press-fitting part.
• Do not press the thrust bearing pad surface
Name
during press-fitting.
1. Turbine-Side Floating Metal
• The press-fit pressure must be between 215.6
3. Floating metal N {22.0 kgf} and 1862 N {190 kgf}.
• Apply oil to the floating metal, and assemble it to • After press-fitting, remove the dust powder
the bearing housing. using vacuum.
After securing it with a snap ring, assemble the
compressor-side floating metal.
Caution:
• Place the snap ring with its rounded-side facing to
the floating metal.
• Assemble the inner snap ring with its end gap
facing to the oil outlet-direction of the housing, to
prevent it from blocking the oil path.
• Assemble the turbine-side snap ring to the housing
with its end gap facing to the direction as shown in
the illustration.
• Apply oil to the floating metal before assembly.
1
0
12
WSHK0148
8. Thrust collar
120
• Apply engine oil to the thrust collar, and install ti to
the turbine shaft.
WSHK0147
Name
1. Common Tolerance
5.Seal ring
•Insert the seal ring to the turbine shaft.
1
•Use new seal ring.
6.Heat protector
•Install the heat protector to the bearing housing.
7.Turbine shaft
•Apply engine oil to the journal portion of the turbine
shaft, and insert it from the turbine side of the
bearing housing.
• Take care not to damage the floating metal with the
turbine shaft. Also, insert with the end gap of the
seal ring facing to the oil inlet side so that its core WSHK0149
matches with the turbine shaft.
Name
1. Apply Oil.
9. Thrust bearing
• Apply engine oil to the metal portion of the thrust
bearing, and insert it to the bearing housing.
• Apply Loctite to the Plate small screw threads, and
install it using torque screwdriver.
Tightening torque: 3.7 N⋅m (0.38 kgf⋅m/33 lb in)
1F-18 Exhaust System and Turbocharger
d. Tighten to the specified torque using a torque
wrench.
Tightening torque: 83 N⋅m (8.5 kgf⋅m/61 lb ft)
e. Perform (c) and (d) of the above step again.
1 2
1 A 3
1 2
4 6
WSHK0150
Name 5
1. Apply Oil.
WSHK0151
12. G coupling
a. Check that it does not run on the turbine
housing or the bearing housing.
b. Tighten temporarily to the specified torque
using a torque wrench.
Tightening torque: 83 N⋅m (8.5 kgf⋅m/61 lb ft)
c. Hammering: Perform the hammering of (1) to
(6) in the numerical order, using the following
procedure.
Exhaust System and Turbocharger 1F-19
B
A
150 ~ 200 mm
2 (6 ~ 8 in) 3 4
7 6
WSHK0153 WSHK0154
16. Compressor impeller
1. Approx. φ 13 mm (0.5 in)
Name
• Insert the compressor impeller to the turbine shaft.
2. Hammer
3. G Coupling
4. Bearing Housing
5. Gasket
6. Heat Shield Plate
7. Turbine Housing
WSHK0156
Exhaust System and Turbocharger 1F-21
Turbocharger (4HK1)
Inspection of Turbocharger
Inspection
Caution:
Turbocharger on 4HK1 engine cannot be overhauled
structurally.
WSHK0129
• Inspection of radial play of turbine shaft
Insert a thickness gauge into the gap between the
compressor impeller and housing, and measure
the clearance.
The thickness gauge to be inserted must be 0.2
mm (0.0078 in) or less.
1F-22 Exhaust System and Turbocharger
Measurement Tool
WSHK0158
Other Material
Name Usage
Besco super engine oil Floating metal sliding portion
Thrust bushing sliding portion
Thrust bearing sliding portion
Turbine shaft journal portion
ThreeBond No. 1207 Housing installing surface of the seal plate
Flange of the compressor housing
Loctite No. 242 Seal plate tightening screw thread
Section 2
TROUBLESHOOTING MANUAL
4HK1-6HK1
ISUZU ENGINE
(Tier 3)
R3807
R3807
In troducti on
This Troubleshooting Manual describes the structure and the troubleshooting of
electronic control fuel injection system (common rail type) in 4HK1 and 6HK1
industrial engines.
Use this manual sufficiently to perform service work properly and quickly.
For any question or comment, or should you notice any mistake concerning the
content of this manual, please contact:
Control System
Engine Control
(Electronic control fuel injection system (Common rail type))
Table of Contents
Intake system check . . . . . . . . . . . . . . . . . . . 1E-167
How to use this manual . . . . . . . . . . . . . . . . . . 1E-3 Exhaust system check . . . . . . . . . . . . . . . . . 1E-168
Table of abbreviation . . . . . . . . . . . . . . . . . . . . 1E-4 EGR control system check . . . . . . . . . . . . . . 1E-169
List of parts according to engine control specifications QOS system check . . . . . . . . . . . . . . . . . . . . 1E-172
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5 List of diagnostic trouble code . . . . . . . . . . . . . 1E-177
About colors of wirings . . . . . . . . . . . . . . . . . . . 1E-6 DTC: P0087 (Flash code 227) Common rail low
About wiring diagrams . . . . . . . . . . . . . . . . . . . 1E-7 pressure fault (No pressure feed in supply
How to read trouble diagnosis section . . . . . . . 1E-8 pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-201
Precautions on Service Work . . . . . . . . . . . . . 1E-10 DTC: P0088 (Flash code 118) Common rail pressure
Procedure of trouble diagnosis . . . . . . . . . . . 1E-11 is abnormally high (1st or 2nd stage) . . . . . . 1E-209
Interview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-13 DTC: P0089 (Flash code 151) Common rail pressure
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . 1E-15 fault (Excessive pressure feed in supply
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . 1E-15 pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-214
How to read DTC . . . . . . . . . . . . . . . . . . . . . . 1E-16 DTC: P0090 (Flash code 247) SCV drive system
Confirmation after repair . . . . . . . . . . . . . . . . 1E-18 open circuit, +B short or ground short . . . . . 1E-219
List of final check items . . . . . . . . . . . . . . . . . 1E-18 DTC: P0107 (Flash code 71) Barometric pressure
How to clear DTC . . . . . . . . . . . . . . . . . . . . . . 1E-19 sensor circuit input is low (open circuit or ground
CNH - EST Diagnostic tool . . . . . . . . . . . . . . . 1E-20 short). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-225
How to Inspect Injector . . . . . . . . . . . . . . . . . . 1E-22 DTC: P0108 (Flash code 71) Barometric pressure
How to use injector checker . . . . . . . . . . . . . . 1E-22 sensor circuit input is high (+5 V short) . . . . 1E-232
Method to identify using non-contact infrared DTC: P0112 (Flash code 22) Intake air temperature
thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-26 sensor fault (low voltage fault, GND short, short
How to use flash tool . . . . . . . . . . . . . . . . . . . . . 1E-28 circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-239
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-28 DTC: P0113 (Flash code 22) Intake air temperature
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-29 sensor fault (high voltage fault, open circuit or short to
EMPS Component Parts . . . . . . . . . . . . . . . . 1E-31 power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-245
ECM (Hardware) Compatibility . . . . . . . . . . . . 1E-32 DTC: P0117 (Flash code 23) Engine coolant
System Requirements for EMPS Software temperature sensor fault (low voltage fault, GND
(Recommended) . . . . . . . . . . . . . . . . . . . . . . 1E-32 short, short circuit) . . . . . . . . . . . . . . . . . . . . 1E-253
EMPS (Software) Setup Procedure . . . . . . . . 1E-33 DTC: P0118 (Flash code 23) Engine coolant
EMPS Operation Procedure . . . . . . . . . . . . . . 1E-37 temperature sensor input is high (open circuit or short
How to use breaker box . . . . . . . . . . . . . . . . . . 1E-79 to power supply) . . . . . . . . . . . . . . . . . . . . . . 1E-260
Engine Control System . . . . . . . . . . . . . . . . . . . 1E-82 DTC: P0182 (Flash code 211) Fuel temperature
Description of function and operation . . . . . . . 1E-82 sensor fault (low voltage fault, GND short) . . 1E-268
Engine Control Module (ECM) . . . . . . . . . . . . 1E-91 DTC: P0183 (Flash code 211) Fuel temperature
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 1E-112 sensor fault (high voltage fault, open circuit or short to
Engine harness location . . . . . . . . . . . . . . . . 1E-128 power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-274
Connector list . . . . . . . . . . . . . . . . . . . . . . . . 1E-140 DTC: P0192 (Flash code 245) Common rail pressure
List of function checks . . . . . . . . . . . . . . . . . . . 1E-143 sensor fault (low voltage fault, short circuit) . 1E-282
OBD system check . . . . . . . . . . . . . . . . . . . . 1E-144 DTC: P0193 (Flash code 245) Common rail pressure
Diagnosis lamp illumination circuit system sensor fault (high voltage fault) . . . . . . . . . . 1E-288
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-146 DTC: P0201 (Flash code 271) Open circuit in
Diagnosis lamp blinking circuit system check 1E-148 injection nozzle #1 drive system . . . . . . . . . . 1E-295
Scan tool power supply circuit system check 1E-151 DTC: P0202 (Flash code 272) Open circuit in
Scan tool communication circuit system injection nozzle #2 drive system . . . . . . . . . . 1E-302
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-153 DTC: P0203 (Flash code 273) Open circuit in
Starting circuit system check . . . . . . . . . . . . 1E-156 injection nozzle #3 drive system . . . . . . . . . . 1E-309
Starting system check . . . . . . . . . . . . . . . . . 1E-162 DTC: P0204 (Flash code 274) Open circuit in
Fuel system check . . . . . . . . . . . . . . . . . . . . 1E-165 injection nozzle #4 drive system . . . . . . . . . . 1E-316
1E-2 Electronic control fuel injection system (Common rail type)
DTC: P0205 (Flash code 275) Open circuit in DTC: P1277 (Flash code 24) Accelerator sensor 1
injection nozzle #5 drive system . . . . . . . . . 1E-323 fault (low voltage fault) . . . . . . . . . . . . . . . . . 1E-501
DTC: P0206 (Flash code 276) Open circuit in DTC: P1278 (Flash code 24) Accelerator sensor 1
injection nozzle #6 drive system . . . . . . . . . 1E-328 fault (high voltage fault) . . . . . . . . . . . . . . . . 1E-506
DTC: P0219 (Flash code 543) Overrun . . . . 1E-333 DTC: P1282 (Flash code 24) Accelerator sensor 2
DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault) . . . . . . . . . . . . . . . . . 1E-511
fault (low voltage fault, open circuit) . . . . . . . 1E-335 DTC: P1283 (Flash code 24) Accelerator sensor 2
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault) . . . . . . . . . . . . . . . . 1E-516
fault (high voltage fault, short to power supply circuit, DTC: P1345 (Flash code 16) Cam sensor out of
ground open circuit) . . . . . . . . . . . . . . . . . . . 1E-343 phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-521
DTC: P0335 (Flash code 15) Crank sensor fault (no DTC: P1625 (Flash code 416) Main relay
signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-351 fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-526
DTC: P0336 (Flash code 15) Crank sensor fault DTC: P1630 (Flash code 36) A/D conversion
(signal fault) . . . . . . . . . . . . . . . . . . . . . . . . . 1E-358 fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-533
DTC: P0340 (Flash code 14) Cam sensor fault (no DTC: P1631 (Flash code 55) Voltage fault in 5-V
signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-364 power supply 1 . . . . . . . . . . . . . . . . . . . . . . . 1E-535
DTC: P0341 (Flash code 14) Cam sensor fault (signal DTC: P1632 (Flash code 55) Voltage fault in 5-V
fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-371 power supply 2 . . . . . . . . . . . . . . . . . . . . . . . 1E-538
DTC: P0380 (Flash code 66) Glow relay circuit DTC: P1633 (Flash code 55) Voltage fault in 5-V
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-377 power supply 3 . . . . . . . . . . . . . . . . . . . . . . . 1E-541
DTC: P0381 (Flash code 67) Glow plug lamp circuit DTC: P1634 (Flash code 55) Voltage fault in 5-V
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-382 power supply 4 . . . . . . . . . . . . . . . . . . . . . . . 1E-544
DTC: P0487 (Flash code 44) EGR position sensor DTC: P1635 (Flash code 55) Voltage fault in 5-V
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-387 power supply 5 . . . . . . . . . . . . . . . . . . . . . . . 1E-550
DTC: P0488 (Flash code 45) EGR valve control List of trouble symptom . . . . . . . . . . . . . . . . . . 1E-551
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-393 Engine start failure . . . . . . . . . . . . . . . . . . . . 1E-555
DTC: P0522 (Flash code 294) Engine oil pressure Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-565
sensor fault (low voltage fault, open circuit, ground Engine hunting, rough idling . . . . . . . . . . . . . 1E-559
short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-399 Engine output shortage . . . . . . . . . . . . . . . . 1E-563
DTC: P0523 (Flash code 295) Engine oil pressure Exhaust gas contains a lot of white smoke. . 1E-568
sensor fault (high voltage fault, short to power supply, Exhaust gas contains a lot of black smoke. . 1E-571
ground short) . . . . . . . . . . . . . . . . . . . . . . . . 1E-405 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-574
DTC: P0601 (Flash code 53) ROM fault . . . 1E-413 Fuel consumption deteriorates. . . . . . . . . . . 1E-576
DTC: P0603 (Flash code 54) EEPROM fault 1E-415 Oil consumption deteriorates. . . . . . . . . . . . . 1E-579
DTC: P0606 (Flash code 51/52) CPU fault . 1E-417 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-581
DTC: P0611 (Flash code 34) Charge circuit fault
(bank 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-419
DTC: P0612 (Flash code 34) Charge circuit fault
(bank 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-422
DTC: P0650 (Flash code 77) Diagnosis lamp circuit
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-425
DTC: P1093 (Flash code 227) No pump pressure
feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-430
DTC: P1095 (Flash code 225) Pressure limiter
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-439
DTC: P1112 (Flash code 295) Boost temperature
sensor fault (low voltage fault, ground short) 1E-449
DTC: P1113 (Flash code 295) Boost temperature
sensor fault (high voltage fault, open circuit, short to
power supply circuit) . . . . . . . . . . . . . . . . . . 1E-457
DTC: P1173 (Flash code 542) Overheat . . . 1E-463
DTC: P1225 (Flash code 31) Idle UP/DOWN switch
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-469
DTC: P1261 (Flash code 158) Injection nozzle
common 1 drive system fault . . . . . . . . . . . . 1E-473
DTC: P1262 (Flash code 159) Injection nozzle
common 2 drive system fault . . . . . . . . . . . . 1E-484
DTC: P1271 (Flash code 24) Accelerator sensor 1-2
comparison fault . . . . . . . . . . . . . . . . . . . . . . 1E-495
Electronic control fuel injection system (Common rail type) 1E-3
This manual describes about engine-related trouble diagnosis, and is closely related
to the machine trouble diagnosis. Always refer to both manuals for the trouble
diagnosis.
This manual consists of the following contents. This section “How to use this manual”
describes about abbreviations and instructions to use this manual. Therefore, if you
are familiar with Isuzu manuals, start with Precautions on service work and Basic
procedure of trouble diagnosis.
Engine
Function
6W 6U 6H 4H 4J
PCV m m Controls the fuel pressure feed of supply pump.
SCV m m m Controls the fuel pressure feed of supply pump.
CMP sensor m m m Detects camshaft position of engine (used for identifying cylinder.)
G sensor Detects cam position of supply pump (used for identifying
m m
cylinder.)
CKP sensor m m m m m Detects crankshaft position (used for engine control in general.)
1E-6 Electronic control fuel injection system (Common rail type)
About colors of wirings
All harnesses are identified by using different colors of
claddings. The harness for the main circuit in a certain
electrical system is identified by using a single color,
while the harness for the sub circuit uses a color in
stripes. Sizes and colors coding in a wiring diagram are
as follows.
e.g.
Red (stripe color)
Harness size(0.5mm2)
Name
1. Single color
2. Color stripe
Engine control
module (ECM)
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
Engine
2 E-98 1 E-98 coolant
Fuel temperature sensor temperature Engine oil pressure sensor
sensor
3 E-90
CKP sensor A
*
CAN LOW CAN HIGH Engine
0.75 control
R module
(ECM)
Vehicle
speed sensor 37 E-57 18 E-57
4 H-6
A
Meter
Machine
control unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSWG0078
TSWG0120
ECM control
DTC
Sensor output
R3808
1E-12 Electronic control fuel injection system (Common rail type)
Step 1 Confirm the user’s complaint
• Organize the trouble conditions using a check list.
Information:
Control System
Engine Control
(Electronic control fuel injection system (Common rail type)) About types of system trouble diagnosis
Table of Contents
Engine Control System . . . . . . . . . . . . . . . . . . . 10D-4
Precautions on service work . . . . . . . . . . . . . . 10D-4
Description of function and operation . . . . . . . 10D-7
DTC: P0238 (Flush code 32). . . . . . . . . . . . 10D-230
DTC: P0335 (Flush code 15). . . . . . . . . . . . 10D-235
DTC: P0336 (Flush code 15). . . . . . . . . . . . 10D-240
System diagnostic method is a standardized method to
1 Engine component location diagram. . . . . . . 10D-16
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 10D-28
Procedure of trouble diagnosis . . . . . . . . . . . 10D-47
DTC: P0107 (Flush code 71) . . . . . . . . . . . 10D-143
DTC: P0340 (Flush code 14). . . . . . . . . . . . 10D-244
DTC: P0341 (Flush code 14). . . . . . . . . . . . 10D-249
DTC: P0487 (Flush code 44). . . . . . . . . . . . 10D-262
repair all the electric/electronic (E/E) systems. The
Interview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-49 DTC: P0488 (Flush code 45). . . . . . . . . . . . 10D-267
DTC: P0108 (Flush code 71) . . . . . . . . . . .
Trouble diagnosis with scan tool . . . . . . . . . . . 10D-56
DTC: P0112 (Flush code 22). . . . . . . . . . . .
Precautions on handling Tech 2 . . . . . . . . . . 10D-60
10D-148
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . 10D-51
10D-153
DTC: P0522 (Flush
(
DTC: P0523 (Flush
(
code294). . . . . . . . . . . . 10D-262
code294). . . . . . . . . . . . 10D-267
DTC: P0601 (Flush code 53). . . . . . . . . . . . 10D-272
faults in E/E system often occur in the following stages,
How to use Tech 2. . . . . . . . . . . . . . . . . . . . . 10D-62
DTC: P0113 (Flush code 22). . . . . . . . . . . . 10D-158
How to use injector checker . . . . . . . . . . . . . 10D-87
DTC: P0117 (Flush code 23). . . . . . . . . . . . 10D-164
List of function checks. . . . . . . . . . . . . . . . . . 10D-88
DTC: P0603 (Flush code 54). . . . . . . . . . . . 10D-273
DTC: P0606 (Flush code 51/52) . . . . . . . . . 10D-274
DTC: P0611 (Flush code 34) . . . . . . . . . . . . 10D-275
different from general machine fault.
OBD system check. . . . . . . . . . . . . . . . . . . . . . 10D-89 DTC: P0612 (Flush code 34). . . . . . . . . . . . 10D-278
Diagnosis lamp illumination circuit system check10D-
91
Diagnosis lamp blinking circuit system check 10D-93
DTC: P0615 (Flush code 19). . . . . . . . . . . . 10D-281
DTC: P0650 (Flush code 77). . . . . . . . . . . . 10D-286
DTC: P1093 (Flush code 227). . . . . . . . . . . 10D-291
1. Early stage of fault;
Scan tool power supply circuit system check 10D-96 DTC: P1094 (Flush code 226). . . . . . . . . . . 10D-299
Scan tool communication circuit system check. 10D- DTC: P1095 (Flush code 225). . . . . . . . . . . 10D-306
98
Starting circuit system check. . . . . . . . . . . . 10D-101
DTC: P1112 (Flush
( code 542) . . . . . . . . . . . 10D-314
DTC: P1113 ((Flush code 158). . . . . . . . . . . 10D-322 2 • As the fault occurs for a short period and singly,
Starting system check . . . . . . . . . . . . . . . . . 10D-106 DTC: P1173 (Flush code 542) . . . . . . . . . . . 10D-314
Fuel system check . . . . . . . . . . . . . . . . . . . 10D-109
Intake system check . . . . . . . . . . . . . . . . . . 10D-111
Exhaust system check . . . . . . . . . . . . . . . . 10D-112
DTC: P1261 (Flush code 158). . . . . . . . . . . 10D-322
List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397
DTC: P1262 (Flush code 159). . . . . . . . . . . 10D-330
DTC: P1271 (Flush code 24). . . . . . . . . . . . 10D-338
a customer often does not notice and miss it. In
EGR control system check . . . . . . . . . . . . . 10D-113 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P1277 (Flush code 24). . . . . . . . . . . . 10D-343
QOS system check . . . . . . . . . . . . . . . . . . . 10D-116
List of diagnostic trouble code . . . . . . . . . . . . 10D-120
DTC: P1278 (Flush code 24). . . . . . . . . . . . 10D-348
Engine hunting, rough idling . . . . . . . . . . . . 10D-404
DTC: P1282 (Flush code 24). . . . . . . . . . . . 10D-353
this stage, customer’s complaint is indefinite
DTC: P0088 (Flush code 118). . . . . . . . . . . 10D-129 DTC: P1283 (Flush code 24). . . . . . . . . . . . 10D-358
Engine output shortage . . . . . . . . . . . . . . . . 10D-408
DTC: P0089 (Flush code 151) . . . . . . . . . . 10D-133
DTC: P0091/P1291 (Flush code 247/248) . 10D-138
DTC: P0092 (Flush code 71) . . . . . . . . . . . 10D-140
DTC: P128 5 (Flush code 16). . . . . . . . . . . . 10D-363
DTC: P128 5 (Flush code 416). . . . . . . . . . . 10D-367
DTC: P129 0 (Flush code 36). . . . . . . . . . . . 10D-373
and it is impossible to reproduce the trouble.
DTC: P0107 (Flush code 71) . . . . . . . . . . . 10D-143 DTC: P1345 (Flush code 16). . . . . . . . . . . . 10D-363
DTC: P0108 (Flush code 71) . . . . . . . . . . . 10D-148
DTC: P0112 (Flush code 22). . . . . . . . . . . . 10D-153
DTC: P0113 (Flush code 22). . . . . . . . . . . . 10D-158
DTC: P1625 (Flush code 416). . . . . . . . . . . 10D-367
DTC: P1630 (Flush code 36). . . . . . . . . . . . 10D-373
DTC: P1631 (Flush code 55). . . . . . . . . . . . 10D-374
However, the engine control module (ECM)
DTC: P0117 (Flush code 23). . . . . . . . . . . . 10D-164
DTC: P0118 (Flush code 23). . . . . . . . . . . . 10D-169
DTC: P0182 (Flush code 211). . . . . . . . . . . 10D-174
DTC: P1632 (Flush code 55). . . . . . . . . . . . 10D-377
DTC: P1633 (Flush code 55). . . . . . . . . . . . 10D-380
DTC: P1634 (Flush code 55). . . . . . . . . . . . 10D-383
may store the fault.
DTC: P0183 (Flush code 211). . . . . . . . . . . 10D-178 DTC: P1635 (Flush code 55). . . . . . . . . . . . 10D-386
DTC: P0192 (Flush code 245) . . . . . . . . . . 10D-183
DTC: P0193 (Flush code 245) . . . . . . . . . . 10D-188
DTC: P0201 (Flush code 271) . . . . . . . . . . 10D-193
DTC: U2104 (Flush code 84). . . . . . . . . . . . 10D-389
DTC: U2106 (Flush code 85). . . . . . . . . . . . 10D-393
List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397
= Past fault (history trouble)
DTC: P0202 (Flush code 272) . . . . . . . . . . 10D-198 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P0203 (Flush code 273) . . . . . . . . . . 10D-203
DTC: P0204 (Flush code 274) . . . . . . . . . . 10D-208
DTC: P0205 (Flush code 275) . . . . . . . . . . 10D-213
Engine hunting, rough idling . . . . . . . . . . . . 10D-404
Engine output shortage . . . . . . . . . . . . . . . . 10D-408
Exhaust gas contains a lot of white smoke.. 10D-411
2. Middle stage of fault;
DTC: P0206 (Flush code 276) . . . . . . . . . . 10D-218 Exhaust gas contains a lot of black smoke.. 10D-414
DTC: P0219 (Flush code 543) . . . . . . . . . . 10D-223
DTC: P0237 (Flush code 32) . . . . . . . . . . . 10D-225
Programming . . . . . . . . . . . . . . . . . . . . . . . . . 10D-416
Rewriting of ECM (On-board) • The fault occurs for a short period and singly,
TSWG0156
but repeats intermittently and definitely occurs
Name under a specific condition. A customer’s
1. Diagnosis for each DTC complaint (contents of the fault) is clear but
2. List of trouble symptom description of condition of the fault is not clear.
Therefore, it is possible to reproduce the trouble
if a mechanic could figure out the conditions.
= Intermittent trouble (intermittent)
3. Stage that fault is real;
• The fault occurs on a steady basis and a
customer’s complaint is realistic and clear.
Therefore, it is possible for a mechanic to
reproduce the fault. However, sometimes there
are multiple causes.
= Current fault (present trouble)
Electronic control fuel injection system (Common rail type) 1E-13
Interview 2. All of complaints from customers do not always
mean troubles.
Interview
3. Extra repair steps are caused if the trouble
1. Comprehend the contents of a customer’s condition is not correctly reported to a mechanic in
complaint using “Check list (engine control charge.
system)”.
• The check list helps to diagnose, repair, and
<Reference>
recheck after repair work in the maintenance shop.
Do not interview blindly. Interview about the trouble
presumed by symptoms (cases).
2. Evaluate the trouble information correctly.
Figure out specifically based on 5W1H.
Example: The temperature is low, at the time of
starting, constantly, in the vicinity of the engine
portion, metallic noise, etc.
TSWG0155
TSWG0160
Name
1. Trouble symptom
2. Frequency of trouble occurrence / trouble
conditions
Because:
1. It may be impossible to reproduce the trouble
symptom at a service shop.
1E-14 Electronic control fuel injection system (Common rail type)
TSWG0155
Electronic control fuel injection system (Common rail type) 1E-15
Pre-inspection Trouble Diagnosis
Output components:
Output components are diagnosed if their responses to
commands from control units are relevant. Check
whether there are open circuit and the values exceed
the range.
Though the following does not include all the output
components to be confirmed, these circuits are
included.
• Suction control valve (SCV)
• Lamp, relay control
• Magnetic valve
• Diagnosis lamp
Electronic control fuel injection system (Common rail type) 1E-17
At code [23]
Goes off
At code [413]
ON
Goes off
About DTC indicated by blinking of diagnosis lamp If there is intermittent (intermittent trouble)
While the engine stops, both the current and past DTCs The trouble situation not occurring constantly is called
are displayed. intermittent (intermittent trouble). Perform the following
While the engine is operated, the lamp illuminates only steps to solve the intermittent trouble.
if the current DTC occurs. 1. Check the DTC information and data display.
2. Evaluate symptom and situation explained by the
How to read DTC by trouble display monitor
customer.
When a DTC occurs, it is displayed on trouble display 3. Check the circuits or the electric system
monitor on the machine. components using check sheet or other methods.
How to read DTC by a scan tool
If the trouble is not detected
DTC can be read using a scan tool.
In this case, the machine is judged as it operates
Note: properly. The condition explained by the customer may
Refer to “Trouble diagnosis with scan tool, be the normal condition. Confirm the customer’s
Operation procedure” for work procedure. complaint comparing with the condition of the machine
to that of another machine. That condition may mean
If the DTC (diagnostic trouble code) is stored an intermittent trouble. Confirm the complaint in the
situation the customer explains before returning the
Perform service correctly according to the specified machine to the customer.
DTC chart.
1. Confirm the complaint again.
If the complaint can not be fully detected or
If there is no DTC
identified, the machine must be diagnosed again.
Select symptom from the diagnostic chart according to Confirm the complaint one more time. The
symptom. Complete the service following diagnostic complaint may be an intermittent trouble as
procedure. You may also perform inspection by defined in “If there is intermittent”, but it may also
referring function diagnosis. be possible that the machine is normal.
2. Repair and confirm.
If there is no applicable symptom If the problem is confirmed, repair it. Confirm that
1. Confirm the complaint in detail. the machine operates properly and the symptoms
2. Create diagnostic plan. are corrected. This includes test on the machine or
3. Use wiring diagram and principle of operation. other procedures to confirm that the trouble is
Ask for technical support when repair history is solved under following conditions:
available for similar case. Connect technician’s • Confirm by testing in the situation that the
knowledge with the effective usage of available service customer described.
information. • If DTC is diagnosed, reproduce the situation
found while the DTC is set, and confirm the
repair by checking a scan tool data.
1E-18 Electronic control fuel injection system (Common rail type)
Confirmation after repair About confirmation of machine repair
It is effective for confirmation of machine repair to use
Confirmation of machine repair on-board diagnosis (OBD) system check. Mechanic
If an electronic control system is repaired, it is should perform the following steps to diagnose the
necessary to confirm that repair is properly performed machine after repair.
after the repair work. If this confirmation is not properly 1. Review and record the DTC (diagnostic trouble
performed, it may happen that the diagnosis lamp code) or scan tool data used in diagnosis.
comes on again or a trouble in operability occurs in the 2. Clear the DTC.
course of delivering the machine to the customer. 3. Operate the machine based on scan tool data.
Especially as for intermittent (trouble), it is needed to
4. Confirm the DTC status information of specified
reproduce and confirm the situation according to the
DTC used in diagnosis until the diagnostic test
customer’s complaint.
relating that DTC is performed by control unit.
In the case of confirmation of repair by on-board
diagnosis (OBD) system check, performing these steps
is extremely important. Failure to perform these steps
may require unnecessary repair.
Confirmation of powerful electric wave transmitter; if • Do not install mobile communication equipment
faults are found in these items, inform a customer of the with high output.
following check items as required.
• An antenna should be installed as far away from Caution:
control unit/sensors or electrical systems on the If confirming repair using on-board diagnosis
machine as possible. system check, perform the following steps. If not
following these steps, unnecessary repair may be
• Antenna codes should be installed at least 20 cm
needed.
(7.8 in) away from control units/sensors or
electrical systems on the machine. • Review and record the scan tool data related to
DTC which is diagnosed.
• Do not put the antenna codes and other wire
together. Keep the antenna codes as far away from • Clear the DTC.
other wire as possible. • Operate the machine while checking the
• When installing an additional equipment, follow its relevant scan tool data.
installation manual to install it securely.
Electronic control fuel injection system (Common rail type) 1E-19
How to clear DTC Clear with ECM (intermittent trouble)
The DTC stored in ECM will be cleared if the same one
Clear of DTC is not valid within 20 ignition cycles.
The DTC, which have been stored in the engine control
module (ECM) upon trouble occurrence, will not be
erased even if the faulty parts are repaired, unless it is
compulsory cleared in the following procedure.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
TSWG0023
Note:
• Refer to the machine’s manual for the locations
of memory clear switch and diagnosis switch.
• Perform the same procedure to clear memory
regardless of forms of switches (switches,
connectors). (ON = Connection, OFF =
Disconnection)
1E-20 Electronic control fuel injection system (Common rail type)
R3808
The EST system allows carrying out diagnoses onmainmachine assemblies by detecting the operating parameters
of electronic control components (control units, sensors etc.) and the check of flow--rates, pressures and
temperatures; it is further arranged for searching inconveniences and detect data for electronically--controlled CNH
engines.
TSWG0211
Name
1. Injector checker body 3. Test harness for 4-cylinders
2. Test harness for 6-cylinders
* To prevent wrong connection, the end of corrugate tube of connection harness for 6-cylinders is wrapped by
identification tape (red) for 4-5-6 cylinder side harness.
Electronic control fuel injection system (Common rail type) 1E-23
Each part of injector checker • Do not turn the selection switch excessively
after it is turned to stopper.
Start switch
This is used to stop the cylinder selected by the cylinder
4 selection switch. Injection of selected cylinder stops
approx. 2.4 seconds.
Operation lamp
This comes on while injector is checked (approx. 2.4
3 5 seconds) after starting button is pressed.
Note:
2 Do not use any switches and operate the machine
while the lamp comes on. Otherwise, diagnosis
result is not correct.
1 Holder
TSWG0212 Holders are used to hang or fix the body. They are
tightened on the body. To use the holders, loosen the
Name screws to move.
1. Main switch
2. Battery lamp Note:
3. Operation lamp • When using or storing holders, be sure to
4. Cylinder selection switch tighten them to fix.
5. Start button • Be careful not to tighten screws excessively.
This may damage the body.
Main switch
This is used to switch ON and OFF of injector checker
function.
Note:
Be sure to turn it to OFF before removing/installing
harness.
Battery lamp
This comes on when the battery (9V) in the body gets
low (7.2V or less).
If the battery lamp comes on, replace the battery as
soon as possible. (Refer to Battery Replacement)
Note:
When using the main switch, it comes on
momentarily due to voltage change. If the battery
lamp does not come on when using the main TSWG0221
switch, check the battery. Replace it if it gets low
(7.2V or less). Precautions on handling the body
• The body is a precision equipment. Do not drop
Cylinder selection switch it or make a high impact on it.
This is used to switch a cylinder to be checked. Turn it • The body is drip-proof type. However, avoid
(1 → 2 → 3 → 4 → 5 → 6).
left fully before check, and then start to check clockwise using it in rainy day or operating with wet
hands to prevent water from entering through
connector connection.
Note:
• Power for the body must be supplied from
• One rotation of cylinder selection switch allow internal battery, not from external one.
to check twice for each cylinder. At the third
• Prevent foreign matter from entering into the
time or later, turn the selection switch left back
body while replacing battery.
to the original position and start to check.
1E-24 Electronic control fuel injection system (Common rail type)
• Do not use screws to tighten battery holder 4. Connect the test harness to the engine side.
except original ones. This may cause body
damage or battery damage and electric Note:
leakage. • Be careful not to let the metal parts of test
• Do not disassemble the body in any harness and connector contact glow plug
circumstances. Contact the machine connector. Protect it with cloth to prevent short
manufacturer or ISUZU Industrial Engine during operation of key switch.
Service Dept. if it is faulty. • Do not connect wrong connector. (Confirm the
identification tape (red) before connecting.)
Injector test • DTC will be detected if disconnecting or
1. Check the DTC. connecting the harness with the key switch to
• If DTC unrelated to injector is detected, repair or ON. Turn it to OFF during work.
check to eliminate the faults before test.
2. Turn the key switch to OFF.
3. Disconnect the injector connector from engine on
the machine. (4-cylinder: one, 6-cylinder: two)
4HK1
TSWG0215
Note:
Be careful not to let the metal parts of connector
contact glow plug connector while connecting the
TSWG0213
harness.
6HK1
#4,5,6
#1,2,3
TSWG0216
TSWG0223
Electronic control fuel injection system (Common rail type) 1E-25
5. Connect the test harness to the body. 15. Perform a test drive, and check that there are no
• Do not directly place the body on the engine. faults.
• Avoid high vibration and impact.
Battery Replacement
1. Remove the two screws on the side of the body.
TSWG0214
Note:
Do not operate the body and the machine while the
operation lamp comes on.
10. Confirm that the lamp goes off and repeat check of
the remaining cylinders as steps 8 and 9.
11. Replace the injector in the cylinder of which engine
vibration level and exhaust noise did not change.
Note:
For work procedure, refer to “Engine section” in
the service manual. TSWG0218
Note:
DTC will be detected if disconnecting or connecting
the harness with the key switch to ON. Turn it to
OFF during work.
Method to identify
1. Method of judgment by an injector balance test
using a diagnostic tool with KW or CAN
communication such as EST Diagnostic tool.
• For the procedure of a balance test, refer to the
“Injector balance test” in “How to use scan tool”.
2. Method of judgment by such an injector balance
test that the injector power line is broken for a short
time using an injector checker without
communication with the ECM.
TSWG0219
• Refer to “How to use injector checker”.
4. Disconnect the connector from battery, and replace 3. Method of judgment by measuring and comparing
the battery. the rising trend of the exhaust temperature using a
non-contact infrared thermometer.
Method to measure
Use a non-contact infrared thermometer capable of
measuring 500°C (932°F), and continuously measure
at a rated point (for excavators, the points on two pump
relief) on the engine which you can stably measure.
Measuring period should be 3 to 5 minutes after the
engine stabilized. Measure and compare the exhaust
pipe temperature of each cylinder, and judge as faulty
cylinder if the temperature of certain cylinder is
TSWG0220 significantly lower than others.
5. Restore in the reverse order.
Comparing exhaust pipe temperature of engine unit
Note: alone
• Prevent foreign matter from entering in while
Note:
removing the battery.
Reference for test on engine unit. Test results will
• Do not tighten the battery holder screws show similar tendency when trouble occurs
excessively. although variation may differ depending on
• Do not replace the battery holder screws with machine type and measuring conditions.
other than original ones.
• Be sure to use specified battery. Note:
Be careful not to continue the test condition for a
long time. Otherwise the test result may be
incorrect due to heat conduction of the exhaust
pipe.
Electronic control fuel injection system (Common rail type) 1E-27
Changes in the temperature in the normal condition Changes in the temperature when injection in one
of No. 2 to No. 5 cylinders stops
500
(932) 500
(932)
400
400 (752)
(752)
300
C ( F)
(572)
C ( F)
#2 - #5
300 200
#6
(572) (392)
100
(212)
200
(392) 0
TSHK0135 (32)
TSHK0137
In the normal condition, the temperature of the No. 6
cylinder keeps lower than others. When injection in one of No. 2 to No. 5 cylinders stops,
the temperature of the stopped cylinder keeps lower
Changes in the temperature when injection in 1st or than normal cylinders.
No. 6 cylinder stops
Refer to the relevant section for the reference value of
each machine manufacturer.
500
(932)
400
(752)
300
(572)
C ( F)
200
(392)
100
(212) #1/#6
0
(32)
TSHK0136
Introduction
Only the person with approval of the machine manufacturer or engine manufacturer
can reflash ECM using EMPS.
Electronic control fuel injection system (Common rail type) 1E-29
Cautions
1. Always turn the POWER switch of EMPS selector 6. Avoid using and storing it in a place that it may
to OFF before connecting/disconnecting the cables. contact water or chemicals. When cleaning, use
Before turning on the POWER switch of EMPS cloth with mild detergent, not highly-volatile solvent
selector, make sure that the cables are connected such as thinner, and wipe out using dry cloth.
securely.
DATA ECM
SELECT POWER
POWER READY READ ON
WRITE OFF
POWER
OWER ON
O
11
5 4 3 2 1
6 7 8 9 10
TSWG0222
Names
1. Selector
2. ECM POWER switch
3. DATA SELECT switch
4. READY lamp
5. POWER lamp
6. RS-232C connector
7. ECM connector
8. Fuse
9. POWER switch
10. ECM connection cable
11. Battery cable
(Caution) Power supply: You can use an AC adapter, however, AC adapter is not provided in the component parts. Prepare
an AC adapter that meets the specification. Available DC plug model number is MP-121C (outer diameter: 5.5 mm
inner diameter: 2.1 mm, DC 12 V – 0.5 A).
1E-32 Electronic control fuel injection system (Common rail type)
Ɣ Using EMPS can reflash the ECM of industrial common rail engine only.
Ɣ Using EMPS cannot reflash the ECM of industrial engine (RED-4 type injection system) that meets Phase 2
Emission Standards.
(1) Insert the “EMPS setup CD” into the CD-ROM drive.
This automatically starts up the setup program, and the following message appears.
Read the license agreement. If you agree to the terms, click [Agree to the terms of this agreement] and click the [OK]
button.
If you do not agree, click [Disagree to the terms of this agreement] and click the [OK] button to end the setup.
1E-34 Electronic control fuel injection system (Common rail type)
(2) Enter the user name and password, and then click the [Next] button.
(4) After the user name and password are verified, the following display appears.
Click the [Next] button.
Electronic control fuel injection system (Common rail type) 1E-35
(5) In the following display, confirm the installation destination and click the [Next] button.
To change the installation destination, click the [Browse] button and select the folder you want to install.
(6) This starts the setup, and the following display appears.
To cancel the setup halfway, click the [Cancel] button.
1. Preparation
2. EMPS Selector Connection
3. Startup
4. User Authentication Screens
4.1 User Authentication Screen (Normal)
4.2 User Authentication Screen (Compulsory Reflash)
4.3 OEM Manufacturer Selection Screen
5. Connection Confirmation Screen
5.1 PC Setting
6. Switch Confirmation Screen (1)
7. Main Menu
7.1 External Power Confirmation Screen
7.2 Voltage Confirmation Screen
8. Selected Item Confirmation Screen
9. Switch Confirmation Screen (2)
10. Former ECM Parts Number Confirmation Screen
11. New ECM Parts Number Search Screen
12. New ECM Parts Number Search Confirmation Screen
13. Replacement ECM Parts Number Confirmation Screen
14. Switch Confirmation Screen (3)
15. Switch Confirmation Screen (4)
16. READY LED Confirmation Screen (1)
17. Switch Confirmation Screen (5)
18. Reflashing Execution Confirmation Screen
19. Switch Confirmation Screen (6)
20. Switch Confirmation Screen (7)
21. READY LED Confirmation Screen (2)
22. Switch Confirmation Screen (8)
23. Reflashing Result Confirmation Screen
24. Switch Confirmation Screen (9)
25. Cable Removal Confirmation Screen
26. Final Result Confirmation Screen
27. Memory Clear
28. Recover Point
29. Error Messages
30. Error Code List
1E-38 Electronic control fuel injection system (Common rail type)
1. Preparation
1. Printed label with update parts number is necessary to proceed reflashing in all countries except the US. Proceed
next steps to get updated parts number. Contact pt_service@notes.isuzu.co.jp in order to obtain the updated parts
number label. If engine is certified in the US, it is not necessary to replace the label. Proceed all steps.
After reflashing, you need to write down the new Parts Number on a label and attach it on the ECM.
2. Check the serial number of the selector, and have your user ID and password ready.
3. Check the engine serial number.
4. To perform compulsory reflash, obtain the specific password from the machine manufacturer or the engine
manufacturer.
Using battery
Electronic control fuel injection system (Common rail type) 1E-39
(Caution)
٨ When drawing power from a battery : <Do not use an AC adapter at the same time.>
٨ When drawing power with the AC adapter : <Use the optionally available adapter.>
Use a DC plug (model number: MP-121C; outer diameter: 5.5 mm
inner diameter: 2.1 mm, DC 12 V – 0.5 A).
: <Prepare an AC adapter that matches the rating (12V/24V) of
the ECM.>
: <Do not use an AC adapter at the same time with a battery.>
٨ Do not roll up the ECM harness. Data communication error will result.
٨ Make sure that the POWER switch of EMPS selector is turned to OFF before connecting/disconnecting the
ECM harness. Damage to EMPS or ECM selector will result.
1E-40 Electronic control fuel injection system (Common rail type)
3. Startup
Double-click the EMPS icon on your Windows desktop to display the initial startup screen.
Clicking the [OK] button displays the connection procedure screen shown below.
Electronic control fuel injection system (Common rail type) 1E-41
㩷 㩷 㩷 㩷 Normal:
Compatible parts number with reflashed parts
number is searched automatically and updated.
㩷 㩷 㩷 㩷 㩷 Compulsory reflash:
An arbitrary parts number is designated and
updated. Select this when reflashing was failed,
or when reflashing the parts number with no
compatibility.
Specific password is necessary.
㩷 㩷 㩷 㩷 㩷 Campaign:
This is performed at the campaign designated
by manufacturer. After reflashing, send the
campaign log file created to the administrator.
Select [Normal Update], [Enforce Update] (compulsory reflash), or [Campaign Update], and then click the [Next] button.
One of the following operations is performed when the [Next] button is clicked.
Selected Option Settings/Operation Performed
Normal Update Advances to "4.1 User Authentication Screen (Normal)."
Enforce Update Advances to "4.2 User Authentication Screen (Compulsory
Reflash)."
Campaign Update Advances to "4.1 User Authentication Screen (Normal)."
Check the content, and click the [OK] button to advance to next.
1E-42 Electronic control fuel injection system (Common rail type)
After selecting the COM port (Communication port) and transmission bit rate (Bit/sec), click [Next] to advance to "6.
Switch Confirmation Screen (1)."
Next button Performs a check and then displays "6. Switch Confirmation Screen (1)."
One of the error messages will appear if an error is discovered by the check that is performed when the [Next] button is
clicked. Go to "29. Error Messages."
1E-44 Electronic control fuel injection system (Common rail type)
5.1 PC Setting
Normally select COM1 if RS232-C is used for connection.
In the case of a PC that is not equipped with an RS232-C port, connect using a commercially available USB conversion
cable. For details about port settings, refer to the user documentation that comes with the USB conversion cable.
6. In the displayed items for communication ports, confirm the COM port to which the EMPS is connected.
Electronic control fuel injection system (Common rail type) 1E-45
Turn on the power switch, and then click the [Next] button.
This starts selector confirmation, and displays the message shown below.
If response from the selector is normal, advance to "7. Main Menu" screen.
One of the following messages will appear if any abnormality is discovered. Click [Return to User Authentication
screen], and check the user ID. To continue the process as is, click [Continue process].
7. Main Menu
This is the EMPS main menu.
After configuring Select Tool, Select ECM Location, and Select Program Process, click the [Next] button.
Clicking the [Yes] button on the external power confirmation screen advances to "8. Selected Item Confirmation
Screen."
If an external power supply cannot be connected, click the [No] button to return to "7. Main Menu."
Clicking the [Help] button will display the message shown below.
Electronic control fuel injection system (Common rail type) 1E-47
Clicking the [Yes] button on the voltage confirmation screen advances to "8. Selected Item Confirmation Screen."
If battery voltage cannot be confirmed, click the [No] button to return to "7. Main Menu."
Clicking the [Help] button will display the message shown below.
This starts selector confirmation, and displays the message shown below.
If response from the selector is normal, advance to "10. Former ECM Parts Number Confirmation Screen."
One of the messages will appear if any abnormality is discovered. Go to "29. Error Messages."
If a communication error occurs, advance to the "28. Recover Point" screen.
Back button Returns to "10. Former ECM Parts Number Confirmation Screen."
Next button Performs a check and then advances to "12. New ECM Parts Number
Search Confirmation Screen."
A message will appear if an error is discovered by the check that is performed when the [Next] button is clicked.
Go to "29. Error Messages."
1E-50 Electronic control fuel injection system (Common rail type)
XYSZ-01
AIMI
Electronic control fuel injection system (Common rail type) 1E-51
The following message will appear during the CD check if a CD is not inserted or if the version does not match.
Click the [OK] button to exit the program.
This will start data confirmation, display the message shown below, and advance to "15. Switch Confirmation Screen
(4)."
This will start data confirmation, display the message shown below, and advance to "18. Reflashing Execution
Confirmation Screen."
1E-54 Electronic control fuel injection system (Common rail type)
One of the messages shown below will appear if an error occurs during reflashing. (Refer to [30. Error Code List].)
Click the [Yes] button to return to "18. Reflashing Execution Confirmation Screen."
Click [No] to advance to "28. Recover Point."
Electronic control fuel injection system (Common rail type) 1E-55
This will start data confirmation, display the message shown below, and advance to "20. Switch Confirmation Screen
(7)."
This will start communication with the selectors and advance to "21. READY LED Confirmation Screen (2)."
A message will appear if an error occurs during communication. Go to "29. Error Messages."
If a communication error occurs, advance to the "28. Recover Point" screen.
1E-56 Electronic control fuel injection system (Common rail type)
This starts data confirmation. After confirmation is complete, advance to "23. Reflashing Result Confirmation Screen."
A message will appear if an error occurs during confirmation. Go to "29. Error Messages."
If a communication error occurs, advance to the "28. Recover Point" screen.
Electronic control fuel injection system (Common rail type) 1E-57
Check the content and click the [OK] button to advance to "24. Switch Confirmation Screen (9)."
1E-58 Electronic control fuel injection system (Common rail type)
XYSZ-01
AIMI
1E-60 Electronic control fuel injection system (Common rail type)
After memory clear is complete, click the [Clearing memory is completed.] button to exit the program.
Electronic control fuel injection system (Common rail type) 1E-61
The procedure that can be continued depends on where the communication error was generated.
Item Description
Continue the procedure from Connection Confirmation Returns to "5. Connection
screen. Confirmation Screen."
Continue the procedure from Main Menu screen. After the Switch Confirmation Screen
is displayed, returns to "7. Main Menu
Screen."
Continue the procedure from Current ECM Parts Number After the Switch Confirmation Screen is
Confirmation screen. displayed, returns to "10. Former ECM
Parts Number Confirmation Screen."
Continue the procedure from confirmation process after After the Switch Confirmation Screen is
reflashing. displayed, returns to "20. Switch
Confirmation Screen (7)."
For some processes, a switch confirmation screen will appear. Configure switch settings as instructed, and then
click the [Next] button.
Switch Confirmation screen for "Continue the procedure from Main Menu screen."
1E-62 Electronic control fuel injection system (Common rail type)
Switch Confirmation screen for "Continue the procedure from Current ECM Parts Number Confirmation screen."
Switch Confirmation screen for "Continue the procedure from confirmation process after reflashing."
To exit the program without continuing, click the [Cancel] button. After the message shown below appears, click the
[OK] button to exit the program.
Electronic control fuel injection system (Common rail type) 1E-63
Depending on the setup and operating environment, any one of the following error messages may appear during
startup.
Error Type Error Message Description Response
Operating The system is not Reinstall the system.
environment ready because
setting error operating
environment setting is
not correct.
(Refer to "30. Error
Code List".)
One of the following error messages appear if the ID and/or password is not input, or if the input is incorrect.
Error Type Error Message Description Response
No input ID not input. Enter your ID.
Database read Service address is not Check the Data CD. Contact
error found in the database. your administrator if there is
no fault.
Electronic control fuel injection system (Common rail type) 1E-65
Parts Number Parts Number cannot Click the [Yes] button for
acquisition be obtained. integrated confirmation
process. To cancel the
process, click the [No] button.
Execution
confirmation of
integrated
confirmation process -
if clicking the [Yes] in
the massage above
Search error Parts number search Click the [OK] button and follow
failed. the next screen.
0002 Operating environment setting error Work folder does not exist.
Reinstall the EMPS.
If the error occurs again, contact the administrator.
0003 Operating environment setting error INI file does not exist.
Reinstall the EMPS.
If the error occurs again, contact the administrator.
Campaign
0171 Campaign log could not be output. Campaign decoding error
0172 Campaign log could not be output. Campaign file coupling error
0173 Campaign log could not be output. No file being coupled for campaign
0174 Campaign log could not be output. Encryption error
0175 Desktop folder could not be obtained. Desktop cannot be obtained.
0176 File copy cannot be performed. Desktop cannot be copied.
Electronic control fuel injection system (Common rail type) 1E-79
Note:
The pin No. of ECM in diagnostic procedure
matches with the pin No. of breaker box.
1 2
A
TSWG0049
Name
1. Breaker box 2. Adapter harness
Caution:
Be sure to turn off the key switch before the
connectors are disconnected.
3
1
TSWG0050
Name
1. Breaker box 3. ECM
2. Adapter harness 4. To machine-side harness
2 2
1
TSWG0052
Name
1. Breaker box
2. ECM
3. Digital multi-meter
TSWG0051
TSWG0053
Name
1. Breaker box
2. ECM
3. Digital multi-meter
TSWG0054
Name
1. Breaker box
2. ECM
3. Oscilloscope
Caution:
During inspection and measurement, interference
of measurement lead on breaker box or mistaking
terminal to be measured may cause damage to
ECM or sensors. Work with extreme care.
1E-82 Electronic control fuel injection system (Common rail type)
About engine control (common rail) system • EGR (Exhaust gas recirculation)
General and detailed description in engine control • Idle speed control
system The engine control system also has the following
system control functions other than engine control.
The engine control system is electronic control system
which maintains optimum combustion status of engine • QOS (Quick On Start) system
all the time according to operating conditions. It • Engine speed signal output
consists of the following components. • Self-diagnosis function
• Electronic control fuel injection system (Common • CAN (Controller Area Network) communication
rail type) (SAE J1939/21, SAE J1939/11)
Correction
Engine coolant temperature correction ECT sensor input
Barometric Pressure
Fuel temperature boost pressure correction
Correction between cylinders
Q-key correction
QR correction *
SCV opening
time determination Injector coil energizing time
Timing determination
Common rail
Injector coil
SCV
Injector
Supply pump
Fuel tank
TSHK0001
Electronic control fuel injection system (Common rail type) 1E-83
About fuel injection correction
ECM calculates the basic injection amount based on
the signals from accelerator position sensor, boost
pressure sensor, CKP sensor, CMP sensor, etc. It
regulates the opening/closing period of SCV or electric
conduction of injector according to the common rail
pressure, engine coolant temperature, etc. at this time,
30
System realization engine speed
TSWG0175
TSHK0002
(226 )
100%
Fuel fiow
(248 )
(221 )
Engine coolant temperature
TSWG0169
1E-86 Electronic control fuel injection system (Common rail type)
System schematic diagram
4HK1
Supply pump
Pre filter
Injector
Fuel tank
Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor
TSHK0037
6HK1
Flow damper
Supply pump
Pre filter
Injector
Fuel tank
Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor
TSHK0038
Electronic control fuel injection system (Common rail type) 1E-87
Fuel system
Fuel is supplied from fuel tank to supply pump, then
supplied to common rail after pressurized by the pump.
At this time, the system operates the suction control
valve (SCV) by the signal from ECM to control fuel
amount supplied to common rail.
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
EGR (Exhaust gas recirculation) On 4HK1-TC and 6HK1-TC machines, the EGR system
Exhaust Gas Recirculation system is abbreviated to has the check valve to stop backward flow of EGR gas
EGR system. It recirculates part of exhaust gas into and flows it in one way direction, leading to increase the
intake manifold to mix an inert gas with intake air. This amount of EGR.
leads to lower the combustion temperature to limit
emissions of nitrogen oxide (NOx).
It controls amount of EGR by opening/closing the EGR
valve installed between exhaust manifold and intake
manifold. It determines amount of EGR, based on the
engine speed and load rate on engine (fuel injection
amount), and operates the EGR valve to control the
amount of EGR.
The cooling system (EGR cooler) equipped on the EGR
gas passage allows to cool down high temperature
EGR gas and mix it with new air to lower the
combustion temperature further, resulting in limiting
NOx effectively (Cooled EGR).
1E-88 Electronic control fuel injection system (Common rail type)
EGR control
ECM operates the motor according to engine speed,
engine load, etc. to control amount of EGR valve lift.
Amount of valve lift is detected by EGR position sensor.
The dark color area in the figure shows that the valve
lift amount is large, and the darkest color area shows
that the valve lift amount is almost 100%.
Accelerator position
No idle EGR
Engine speed
TSHK0066
EGR valve
Intake air
Intake air temperature sensor
Engine speed
ECT sensor
Engine load
TSWG0005
Electronic control fuel injection system (Common rail type) 1E-89
Idling control UP
At warm-up operation, using the “Idling control selector While pressing the “UP” side of switch, the engine
switch” allows to control the lowest idling speed. Also, speed increases, resulting in increasing the idling
using the “Idling control selector switch” allows to speed.
automatically set the lowest idling speed to the DOWN
optimum value according to engine coolant While pressing the “DOWN” side of switch, the engine
temperature. speed decreases, resulting in decreasing the idling
speed. However, the idling speed does not decrease
Note: below the lowest speed.
Since specifications vary depending on each The engine speed controlled by idling control switch is
machine. Available functions also vary. stored in ECM when the key switch is turned to OFF.
The same speed can be achieved at the next operation.
Idling control selector switch
Using the “Idling control selector switch” allows to Speed limit control
switch the idling control function.
Speed limit control means that the engine control
Idling control switch module (ECM) controls fuel injection amount, based on
vehicle speed signal and engine speed, so that the
Using the “Idling control switch” allows to control the machine speed does not exceed the setting value.
idling speed. The vehicle speed signal is sent from vehicle speed
sensor to pulse matching box. The pulse matching box
Note:
corrects the signal to match with the machine, and
Refer to the machine’s manual for the locations of
sends it to ECM, meter, etc. The ECM recognizes the
idling control selector switch and idling control
engine speed by the signal from crankshaft position
switch.
(CKP) sensor.
The highest speed varies depending on engine
model, machine specifications and warm-up
condition of engine.
Meter,
Other ECU
1 sec
1
Diag
lamp
0
1 sec
15 sec
3 times
TSWG0006
Note:
If it does not blink, the speed limit control is not
active.
TSWG0119
Electronic control fuel injection system (Common rail type) 1E-91
Preheating control
QOS (Quick On Start) system
The ECM determines the period required for glow (pre-
glow, glow, after-glow), and operates the glow relay and
QOS indicator lamp. QOS system allows to make the
starting at cold weather easier and reduce white smoke
and noise at starting. When turning the key switch to
ON, the ECM detects the engine coolant temperature
by signal from engine coolant temperature (ECT)
sensor and changes the period for glow so that the
proper starting conditions can be achieved all the time.
Also, after-glow function allows to stabilize idling
immediately after starting.
Glow relay
Glow plug
QOS indicator lamp
LCD or Lamp) Engine coolant temperature sensor
TSWG0007
Engine Control Module (ECM) The ECM monitors the information sent from various
sensors all the time and controls each system of the
About functions of ECM
powertrain. The ECM performs the diagnostic function
Note: of the system, detects operational problems of the
Refer to the machine’s manual for the locations of system, gives a warning through diagnosis lamp to a
ECM. driver and stores DTC (diagnostic trouble code). The
area where the trouble occurred can be identified by
the DTC to assist a mechanic to perform repair work.
The ECM sends the voltage of 5 V to supply the power
to various sensors or switches. The ECM controls the
output circuits by controlling the ground or power
supply circuit through a certain device.
TSWG0008
1E-92 Electronic control fuel injection system (Common rail type)
ECM voltage Removal of ECM
The ECM energizes standard voltage to various 1. Turn the key switch to OFF.
switches and sensors. The resistance value of the ECM 2. Disconnect the battery cable from negative
is quite high so that the ECM can energize a voltage terminal.
like this. The voltage actually applied to the circuit is 3. Remove the parts (relay etc.) around the ECM to
low, and it does not sometimes comes on even if the facilitate removal of it.
test light is connected to the circuits. The voltmeter
4. Disconnect the ECM connector from ECM. (81-pin,
usually used in a service shop may not indicate a
40-pin connectors)
correct reading because the input impedance is too low.
A digital multi-meter which has an input impedance of 5. Loosen the installing bolts (nuts) and remove the
10 MΩ should be used to get an correct reading of the ECM.
voltage.
Note:
Installation method and locations vary depending
Electrically erasable programmable read only
on each machine. Refer to the machine’s manual.
memory (EEPROM)
EEPROM has programs which is necessary for ECM to Installation of ECM
control the operation of powertrain and information for
Install the ECM in the reverse order of removal.
calibration.
EGR valve position learning is required after replacing
If fault is found in the EEPROM, replace the ECM.
the ECM.
Examples of programs to control powertrain and
information for calibration in ECM are the following 1. Turn the key switch to “ON”.
items. 2. Turn the key switch to “OFF”.
• Engine model 3. Leave as it is for 10 seconds.
• Engine number Failure to perform the EGR valve position learning may
result in detection of DTC for EGR.
• ECM part number
• DTC About ECM power off
• Learning value for interval correction of cylinders
The power supply inside the ECM does not go off for
• QR about 10 seconds after turning the key switch OFF. If
• Q-key the ECM power needs to be off such as for memory
• Learning value for EGR correction clear, wait for more than 10 seconds after turning the
key switch OFF.
Precautions on ECM service work
Note:
• Be sure to use the ECM with the part number
corresponding to the machine.
• If performing welding on the machine,
disconnect the battery cable from the negative Key switch
ON
terminal beforehand.
TSWG0176
Electronic control fuel injection system (Common rail type) 1E-93
Engine component location diagram
(Component location, its form and parts to be used vary
depending on each machine.)
4HK1
13 12 11 10
7 6
9
1
2
8
3 4
TSHK0003
1E-94 Electronic control fuel injection system (Common rail type)
6HK1
13 12 11 10
7 6
2
8
3 4
TSHK0004
Name
1. Engine coolant temperature (ECT) sensor 8. Suction control valve (SCV)
2. Overheating switch 9. Fuel temperature (FT) sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR valve
Electronic control fuel injection system (Common rail type) 1E-95
Supply pump SCV (suction control valve)
4HK1 4HK1
2 1
TSHK0005 TSHK0007
6HK1 6HK1
1
3
TSHK0006 TSHK0008
Name Name
1. SCV 1. SCV
2. Fuel temperature (FT) sensor
3. Feed pump The SCV (suction control valve) is installed onto supply
pump section and controls pressure feed of fuel
The supply pump pressurizes fuel using engine output, (discharge amount) to common rail. The engine control
and pressure-feeds fuel to common rail. Supply pump module (ECM) regulates period of electric conduction
has also SCV (suction control valve), fuel temperature of SCV to regulate the fuel discharge amount.
(FT) sensor and feed pump.
Removal
Note: • Do not replace the SCV.
For work procedure, refer to “Engine section” in
• If it is faulty, replace it as supply pump ASM.
the service manual.
1E-96 Electronic control fuel injection system (Common rail type)
4HK1 Fuel temperature (FT) sensor
TSHK0127 TSWG0011
Removal
• Do not replace the FT sensor.
• If it is faulty, replace it as supply pump ASM.
TSHK0111
TSHK0110
Electronic control fuel injection system (Common rail type) 1E-97
Common rail Flow damper
4HK1 4HK1
4 4
3 3
1 2 1 2
TSHK0009 TSHK0009
6HK1 6HK1
4 4
3 3
1 2 1 2
TSHK0010 TSHK0010
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The common rail receives fuel from supply pump, holds The flow damper is installed onto outlet port to each
the common rail (fuel) pressure and distributes fuel to injector of common rail, limits pressure pulsation in
each cylinder. The common rail has common rail common rail and prevents over-injected fuel from
pressure sensor, flow damper and pressure limiter. injector. When the flow damper operates, fuel supply to
injector is stopped.
Note:
For work procedure, refer to “Engine section” in Removal
the service manual. • Do not replace the flow damper.
• If it is damaged, replace it as common rail ASM.
1E-98 Electronic control fuel injection system (Common rail type)
Pressure limiter Common rail pressure sensor
4HK1 4HK1
4 4
3 3
1 2 1 2
TSHK0009 TSHK0009
6HK1 6HK1
4 4
3 3
1 2 1 2
TSHK0010 TSHK0010
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The pressure limiter operates to release the pressure in The common rail pressure sensor is installed onto
common rail when the pressure becomes extremely common rail, detects fuel pressure in common rail,
high. converts the pressure into the voltage signal and sends
it to engine control module (ECM). Voltage becomes
Removal higher as pressure becomes higher, and lower as one
• Do not replace the pressure limiter. does lower. ECM calculates the actual common rail
• If it is damaged, replace it as common rail ASM. pressure (fuel pressure) based on the voltage signal
sent from sensors and uses it for fuel injection control
etc.
Electronic control fuel injection system (Common rail type) 1E-99
Removal Injector
• Do not replace the common rail pressure sensor.
• If it is damaged, replace it as common rail ASM.
4HK1
Note:
For work procedure, refer to “Engine section” in
the service manual.
TSHK0112
TSWG0017
1E-100 Electronic control fuel injection system (Common rail type)
The engine coolant temperature (ECT) sensor is Crankshaft position (CKP) sensor
installed onto engine block, and the thermistor changes
the resistance according to the temperature.
Resistance is low at high engine coolant temperature
and high at low engine coolant temperature. The
engine control module (ECM) energizes the voltage (5
V) to the ECT sensor through pull up resistance, and
calculates engine coolant temperature based on
change of voltage to use for various controls such as
fuel injection etc. If the resistance is low (temperature is
high), the voltage becomes low; if the resistance is high
(temperature is low), the voltage becomes high.
Removal
• Disconnect the connector and remove it with
19mm-wrench
TSWG0019
Removal
• Disconnect the connector, and remove the 10mm-
TSHK0116
mounting bolt and sensor.
Installation 4HK1
• Apply Loctite 572 before installing it.
Tightening torque: 19.6 — 29.4 N⋅m {2 — 3 kg⋅m/
14 — 22 lb⋅ft}
10mm
TSHK0123
Electronic control fuel injection system (Common rail type) 1E-101
6HK1 6HK1
15
10mm
1
TSHK0118 TSWG0152
Removal
• Scissors gear is installed to the cam gear of 6HK1
engine. When the cam gear has been removed,
ensure that the scissors gear is installed properly.
15 • Disconnect the connector, and remove the 10mm-
mounting bolt and sensor.
1 4HK1
TSHK0040
10mm
TSHK0124
1E-102 Electronic control fuel injection system (Common rail type)
6HK1 4HK1
10mm
27mm
TSHK0117 TSHK0122
Installation 6HK1
• Apply a coat of engine oil to the O-ring.
Tightening torque: 7.8±2N⋅m {0.8±0.2 kg⋅m/69±18
lb⋅in}
27mm
TSHK0109
Installation
• Tightening torque: 41 N⋅m{4.2 kg⋅m/30 lb⋅ft}
TSWG0020
Note: Note:
Refer to the machine’s manual for the location of Do not disassemble the EGR position sensor. If it is
barometric pressure sensor. faulty, replace it as EGR valve ASM.
4HK1
10mm
TSHK0113
TSHK0115
Installation
• Tightening torque: 4 — 6 N⋅m {0.4 — 0.6 kg⋅m/35
Boost pressure sensor — 53 lb⋅ft}
TSWG0022
19mm
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
TSHK0126 TSWG0023
Note:
Refer to the machine’s manual for the locations of
DLC.
Diagnostic switch
19mm
The diagnosis switch shorts the DLC terminals No. 1
and No. 4 (or No. 5) to make the diagnosis lamp blink to
indicate DTC.
Note:
Refer to the machine’s manual for the locations and
form of diagnosis switch.
Note: Note:
Refer to the machine’s manual for the locations of Refer to the machine’s manual for the locations of
diagnosis lamp. mode selector switch.
1E-106 Electronic control fuel injection system (Common rail type)
Wiring diagram of engine control module (ECM)
(*: Refer to the machine’s manual for fuse capacity.)
4HK1
(15A)*
24
Engine stop switch 107 CKP sensor
47 106
Diagnostic lamp
6 108
Engine oil pressure lamp
17
Key switch
Glow relay
83 Fuel temperature
sensor
Glow plug
(60A)* 99
CMP sensor
98
100
Key switch
Main relay 21 87
40 82
(ST)
94 U
EGR valve
93 V
(30A)* position sensor
92 W
2
(100A)*
Vehicle speed
19
Fuel pump relay sensor
121
Battery
(10A)*
M
Charge 117 Injector #4
lamp O/H lamp O/H switch
116
Generator
R Injector #3
L 120
Safty relay B terminal
E Sterter 118 Injector #2
R S S terminal SCV
B C B terminal 105
113
89
97
42
Accelerator
63 8 Tachometer
position
sensor 64
41
20 18
Barometric 61 37
pressure 71
sensor 60
Intake air 72
temperature 38 7 TOOL
sensor
72 52 1
Data link connector
Boost 95 4
pressure 91 5
sensor 109
Boost 74
temperature 81
sensor
43
U 111 62
EGR valve V
M 103 1
motor W 110
3
Memory clear switch 32 4
TSHK0011
Electronic control fuel injection system (Common rail type) 1E-107
6HK1
(15A)*
24 107 CKP sensor
Engine stop switch 106
47
Diagnostic lamp 108
6
Engine oil pressure lamp
Key switch
17 80
QOS indicator lamp 67 Engine oil
11 79 pressure sensor
(ON)
Glow relay 83
Fuel temperature
sensor
Glow plug 99
(60A)* CMP sensor
98
100
87
Key switch
Main relay
21
82
40 Common rail
(ST)
(30A)* 90
2 101 pressure sensor
5
(10A)*
94 U EGR valve
93 V position sensor
92 W
46
(100A)*
19 Vehicle speed
Fuel pump relay sensor
121
Injector #1
119
Battery
(10A)*
Fuel pump
114 Injector #2
ECM
M
Charge
lamp O/H lamp O/H switch
117 Injector #3
116
Generator
R
L Injector #4
115
Safty relay B terminal
E Sterter Injector #5
120
R S S terminal
B C B terminal Injector #6
118
SCV
105
42 113
Accelerator
position 63 89
sensor 64 97
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor
38 7 TOOL
Boost 95
52 1 Data link connector
pressure 91
sensor 109 4
5
Boost 74
temperature 81
sensor
43
U 111 62
EGR valve V 103
M 1
motor W 110
3
Memory clear switch
32 4
TSHK0036
1E-108 Electronic control fuel injection system (Common rail type)
Pin arrangement of engine control module (ECM)
TSWG0026
81-pin connector
40-pin connector
40 E-57
E-57
B+
2
(30A)*
E-57
B+
5
(MAIN)*
Battery
TSWG0027
4HK1
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
Starter for ECM control, glow circuit
(60A)*
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
TSHK0012
Electronic control fuel injection system (Common rail type) 1E-113
6HK1
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Key switch
ACC
B
START
OFF
ON
A
(ON) (ST)
BBr C
Safty relay
START
OFF
E-57
C
C
B
10
B
Glow
plug
Generator
Glow relay
B
L
(100A)*
(60A)*
H-22
B/W
H-1
5
1
1
(15A)*
Battery
TSHK0025
6HK1
Battery B
Generator
(100A)* L
(15A)* (60A)*
B C
Safety relay
L S
Glow
relay
A A
1 H-22
B Br C B ACC Br C
5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
START START
1 H-1
Key switch
10 E-57
Engine control
module (ECM)
Glow relay
control
Glow
plug
TSWG0068
CAN, GND, DLC circuits
CAN LOW CAN HIGH
Engine control
module (ECM)
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
DLC
Machine control unit
5 FL-150 4 FL-150
A A
Meter
3 H-6
1 E-164
Engine control
module (ECM)
Tachometer signal
CAN HIGH CAN LOW
TSHK0014
4HK1
Injector circuit
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
Engine control
Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4 module (ECM)
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Cylinder No. 5 Cylinder No. 6 Cylinder No. 4 Cylinder No. 2 Cylinder No. 1 Cylinder No. 3
2 E-161
SCV
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
Engine contorol
module (ECM)
B+
TSHK0016
Electronic control fuel injection system (Common rail type) 1E-121
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)
pressure sensor circuit
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Vehicle
speed sensor A
Meter
Machine
control
unit
Engine CAN HIGH CAN LOW
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSHK0017
Boost temperature sensor, boost pressure sensor circuit
Engine control
module (ECM)
5V Boost pressure
sensor signal
5V
Boost temperature
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
Engine control
Accelerator Accelerator module (ECM)
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
(15A)*
Idling selector
Idle up Idle down Mode map Mode map Mode map
switch
switch switch switch 0 switch 1 switch 2
Engine control
module (ECM)
Idling selector Idle up Idle down Mode map Mode map Mode map
TSWG0037
switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal
Electronic control fuel injection system (Common rail type) 1E-127
Memory clear switch, engine stop switch circuit
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)
(15A)*
Key switch (ON)
Engine control module (ECM)
control unit
Machine
E-57
18
E-57
CAN LOW
37
E-57
47
E-57
32
B
B
TSWG0038
1E-128 Electronic control fuel injection system (Common rail type)
Engine harness location
4HK1
:Engine harness
13 12 11 10
7 6
9
1
2
8
3 4
TSHK0020
Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR position sensor
98003-428 SENSOR:BOOST PRESS
E80 E75
EGR VALVE 1 2 3
E113 0.75 0.75 0.75
R/L L R/W
SENSOR:COMMON RAIL 1 2 3
0.75 0.75 0.75
4
0.75
L G/Y G/W G/B
5 6 7 8
1 2 3
0.5 0.5 0.5 0.75 0.75 0.75 0.75
L/W Br L L/W W/L W/B W/R
H94
1 2 3 4 INJECTOR
1 .2 5 1 .2 5 1 .2 5 1 .2 5
W R R W
5 6 7 8
0 .7 5 0 .7 5 0 .7 5 0 .7 5
L L /R L /Y L /W
E163
SENSOR:MAT(BOOST TEMP)
1 2
0.75 0.75
R/L B/R
E161
1 2
1 2
0.75 0.75 SCV 1 2
0 .7 5 0 .7 5 R/W R/B
B /Y R /B 0.5 0.5
1 Y V /W
3 0.75
0 .7 5 G SENSOR:NE.CRANK
R
1 2 3
0.75 0.75 0.75
B/Y L/Y W/B
SENSOR:OIL PRESSRE
E76
1
5
B/W
H22
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/Y B/Y L
3 2 1 4 3 2 1 8 7 6 5
0.75 0.75 0.75 0.75 0.75 0.75 13 14 15 16
Y/G R/W R/B G/Y G/W G/B 0.75 0.75 0.75 0.75
L L/R L/Y L/W 0.5 0.5 0.75 0.75
6 5 4 8 7 6 5 Br L/W B/R L
12 11 10 9
0.75 0.75 0.75 0.75 0.75 17 18 19 20
G R W/L W/B W/R 0.75
R/L
H6 H8 H12 H20
TSHK0034
1E-130 Electronic control fuel injection system (Common rail type)
E75 E98
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CKP +
2 Boost pressure sensor Vout 2 CKP GND
3 Boost pressure sensor Vcc
E112
E76 Terminal
Number
Terminal
Number 1 CMP shield
1 Engine oil pressure sensor GND 2 CMP GND
2 Engine oil pressure sensor Vout 3 CMP +
3 Engine oil pressure sensor Vcc
E113
E80 Terminal
Number
Terminal
Number 1 Common rail pressure sensor GND
1 EGR Vcc 2 Common rail pressure sensor Vout
2 EGR hall sensor W 3 Common rail pressure sensor Vcc
3 EGR hall sensor V
E161
4 EGR hall sensor U
5 EGR GND Terminal
Number
6 EGR motor W
1 SCV — Hi
7 EGR motor V
2 SCV — Lo
8 EGR motor U
E163
E90
Terminal
Terminal Number
Number
1 Boost temperature sensor GND
1 ECT GND
2 Boost temperature sensor +
2 ECT +
3 ECT meter E164
Terminal
E93
Number
Terminal 1 Overheating switch
Number
1 Fuel temperature sensor GND H1
2 Fuel temperature sensor + Terminal
Number
1 Glow
H6
Electronic control fuel injection system (Common rail type) 1E-131
Terminal H20
Number
Terminal
1 SCV−Lo Number
2 SCV−Hi 1 CKP +
3 Fuel temperature sensor + 2 CKP GND
4 ECT meter 3 CKP shield
5 — 4 CMP +
6 Overheating switch 5 CMP GND
6 CMP shield
H8
7 ECT +
Terminal 8 Boost pressure sensor Vcc
Number
9 Engine oil pressure sensor Vcc
1 EGR hall sensor U
10 Engine oil pressure sensor Vout
2 EGR hall sensor V
11 Engine oil pressure sensor GND
3 EGR hall sensor W
12 Common rail pressure sensor Vcc
4 —
13 Common rail pressure sensor Vout
5 EGR motor U
14 Common rail pressure sensor GND
6 EGR motor V
15 Boost temperature sensor +
7 EGR motor W
16 Boost pressure sensor Vout
8 —
17 Boost pressure sensor GND
H12 18 —
Terminal 19 —
Number 20 —
1 —
H22
2 —
3 Injector power supply 2 Terminal
Number
4 Injector power supply 1
1 Glow
5 OS — INJ3 signal/Injector #4
6 OS — INJ2 signal/Injector #3 H94
7 OS — INJ4 signal/Injector #2
Terminal
8 OS — INJ1 signal/Injector #1 Number
9 — 1 Injector power supply 1
10 — 2 Injector power supply 2
11 — 3 Injector power supply 2
12 — 4 Injector power supply 1
5 OS — INJ1 signal/Injector #1
6 OS — INJ4 signal/Injector #2
7 OS — INJ2 signal/Injector #3
8 OS — INJ3 signal/Injector #4
1E-132 Electronic control fuel injection system (Common rail type)
Cylinder head
H94 H94
(Male connector (Female connector on injector side)
on ECM side)
TSHK0044
Electronic control fuel injection system (Common rail type) 1E-133
1E-134 Electronic control fuel injection system (Common rail type)
6HK1
:Engine harness
13 12 11 10
7 6
2
8
3 4
TSHK0021
Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR position sensor
98013-710
1 2 3 4
0.75 1.25 1.25
G/B R R
5 6 7 8
0.75 0.75
L/R L/Y
H95
INJECTOR 2(#4.5.6 )
H94
INJECTOR 1(#1.2.3 )
1 2 3 4
0.75 1.25 1.25
L W W
5 6 7 8
1
5 0.75 0.75
B/W L/W G/R 1 2 3 4
0.75 0.75 0.75 0.75
L G/Y G/W G/B
H1 5 6 7 8
0.75 0.75 0.75 0.75
GLOW PLUG L/W W/L W/B W/R
E80
1 2
EGR VALVE
0 .7 5 0 .7 5
B/Y R /B
3 1 2 3
0 .7 5 0.75 0.75 0.75
E93
E163
1 2 3
0 .5 0 .5 0 .5
L /W Br L
1 2 3
0.75 0.5 0.5
E113 B/W V/W Y
1 2
1 2 3 0.5 0.5
0.75 0.75 0.75
B/Y L/Y W/B
E76 Y V /W
E98
SENSOR:OIL PRESSRE
SENSOR:NE.CRANK
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/Y B/Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16
0 .7 5 0 .7 5 0 .7 5 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.75 0.75
Y/G R /W R /B G/Y G/W G/B L L/R L/Y L/W Br L/W B/R L 1
TSHK0035
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20 5
0 .7 5 0 .7 5 0.75 0.75 0.75 0.75 0.75 0.75 B/W
G R W/L W/B W/R G/R G/B R/L
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CKP +
2 Boost pressure sensor Vout 2 CKP GND
3 Boost pressure sensor Vcc
E112
E76 Terminal
Number
Terminal
Number 1 CMP shield
1 Engine oil pressure sensor GND 2 CMP GND
2 Engine oil pressure sensor Vout 3 CMP +
3 Engine oil pressure sensor Vcc
E113
E80 Terminal
Number
Terminal
Number 1 Common rail pressure sensor GND
1 EGR Vcc 2 Common rail pressure sensor Vout
2 EGR hall sensor W 3 Common rail pressure sensor Vcc
3 EGR hall sensor V
E161
4 EGR hall sensor U
5 EGR GND Terminal
Number
6 EGR motor W
1 SCV — Hi
7 EGR motor V
2 SCV — Lo
8 EGR motor U
E163
E90
Terminal
Terminal Number
Number
1 Boost temperature sensor GND
1 ECT GND
2 Boost temperature sensor +
2 ECT +
3 ECT meter E164
Terminal
E93
Number
Terminal 1 Overheating switch
Number
1 Fuel temperature sensor GND H1
2 Fuel temperature sensor + Terminal
Number
1 Glow
H6
Electronic control fuel injection system (Common rail type) 1E-137
Terminal H20
Number
Terminal
1 SCV−Lo Number
2 SCV−Hi 1 CKP +
3 Fuel temperature sensor + 2 CKP GND
4 ECT meter 3 CKP shield
5 — 4 CMP +
6 Overheating switch 5 CMP GND
6 CMP shield
H8
7 ECT +
Terminal 8 Boost pressure sensor Vcc
Number
9 Engine oil pressure sensor Vcc
1 EGR hall sensor U
10 Engine oil pressure sensor Vout
2 EGR hall sensor V
11 Engine oil pressure sensor GND
3 EGR hall sensor W
12 Common rail pressure sensor Vcc
4 —
13 Common rail pressure sensor Vout
5 EGR motor U
14 Common rail pressure sensor GND
6 EGR motor V
15 Boost temperature sensor +
7 EGR motor W
16 Boost pressure sensor Vout
8 —
17 Boost pressure sensor GND
H12 18 —
Terminal 19 —
Number 20 —
1 —
H22
2 —
3 Injector power supply 2 Terminal
Number
4 Injector power supply 1
1 Glow
5 OS — INJ3 signal/Injector #3
6 OS — INJ2 signal/Injector #5 H94
7 OS — INJ4 signal/Injector #6
Terminal
8 OS — INJ1 signal/Injector #1 Number
9 — 1 —
10 — 2 OS — INJ1 signal/Injector #1
11 OS — INJ6 signal/Injector #4 3 Injector power supply 1
12 OS — INJ5 signal/Injector #2 4 Injector power supply 2
5 —
6 OS−INJ3 signal/Injector #3
7 OS−INJ5 signal/Injector #2
8 —
1E-138 Electronic control fuel injection system (Common rail type)
H95
Terminal
Number
1 —
2 OS−INJ6 signal/Injector #4
3 Injector power supply 2
4 Injector power supply 1
5 —
6 OS−INJ4 signal/Injector #6
7 OS−INJ2 signal/Injector #5
8 —
H95
(Female connector on injector side)
In cylinder head
H94
(Female connector
on injector side)
H95
(Male connector on ECM side)
H94
(Male connector on ECM side)
TSWG0041
Electronic control fuel injection system (Common rail type) 1E-139
H94/H95 connector
Name
1. Engine harness-side connector
2. Cylinder head outside connector
3. Cylinder head inside connector
4. Injector harness-side connector
1E-140 Electronic control fuel injection system (Common rail type)
Connector list
No. Connector Face No. Connector Face
E-75
Engine
E-27 harness
1 2 3
side
(male 003-501
#1 injector (Silver) terminal) (Black)
E-76
Engine
E-29 harness 1 2 3
side
003-501
(male
#2 injector (Silver) terminal) (Black)
E-80
Engine
E-31 harness
side
(male
#3 injector (Silver) terminal) (Black)
E-90
Engine 1 2
E-33 harness
3
side
(male 003-500
#4 injector (Silver) terminal) (Light gray)
E-93
Engine
E-35 harness
side
(male
#5 injector (Silver) terminal) (Green)
E-98
Engine
E-37 harness
side
(male
#6 injector (Silver) terminal) (Dark gray)
E-56 E-112
Machine Engine
harness harness
side side
(female (male
terminal) (Black) terminal) (Black)
E-57 E-113
Machine Engine
harness harness
side side
(female (male
terminal) (Black) terminal) (Black)
Electronic control fuel injection system (Common rail type) 1E-141
Engine Engine
harness harness
side side
(male (male
terminal) (Black) terminal) (Black)
E-161 H-6
Engine Machine
harness harness
side side
(male (female
terminal) (Light gray) terminal)
E-163 H-8
Engine Engine
harness harness
side side
(male (male
terminal) (Gray) terminal) (Black)
H-8
Machine
E-164 harness
side
000-009 (female
(Silver) terminal)
FB-124 H-12
Engine Engine
harness harness
side side
(male (male
terminal) (Black) terminal) (Black)
FL-150 H-12
Engine 1 2 3 4 5 6 7 8 Machine
harness 9 10 11 12 13 14 15 16 harness
side side
(male 016-500 (female
terminal) terminal)
FL-269 H-20
1 2 3 4
5 6 7 8
Engine 1 2 3 Machine
9 10 11 12
harness harness 13 14 15 16
side side 17 18 19 20
(male 003-502 (male 020-500
terminal) terminal)
H-20
4 3 2 1
8 7 6 5
Engine
12 11 10 9
H1 harness- 16 15 14 13
side 20 19 18 17
000-009 (female 020-501
(Silver) terminal) (Light gray)
1E-142 Electronic control fuel injection system (Common rail type)
Engine Cylinder
harness- head
side inside
(female (female
terminal) (Light gray) terminal) (Dark gray)
H22 H-95
Machine Injector
harness harness
side side
(male (male
terminal) terminal)
H-94
Engine
harness
side
(male
terminal) (Dark gray)
H-94
Cylinder
head
outside
(female
terminal) (Dark gray)
H-94
Cylinder
head
inside
(female
terminal) (Dark gray)
H-94
Injector
harness
side
(male
terminal)
H-95
Engine
harness
side
(male
terminal) (Gray)
H-95
Cylinder
head
outside
(female
terminal) (Dark gray)
Electronic control fuel injection system (Common rail type) 1E-143
Interview Inspection to comprehend the trouble symptom and diagnose properly based on a
customer’s complaint.
OBD system check Inspection to identify defective point of engine control system (inspection
procedure)
Diagnosis lamp illumination Inspection when diagnosis lamp does not come on when starter switch is turned
circuit system check ON.
Diagnosis lamp blinking circuit Inspection when diagnosis lamp does not blink (remains on) when diagnostic
system check switch is turned ON.
Scan tool power supply circuit Inspection when scan tool (EST Diagnostic tool) does not operate.
system check
Scan tool communication Inspection when scan tool (EST Diagnostic tool) cannot communicate with ECM.
circuit system check
Starting circuit system check Inspection when starter does not operate.
Starting system check Inspection when starter operates but engine does not start.
Fuel system check Inspection when relevant points to fuel system may be faulty (inspection
procedure).
Intake system check Inspection when relevant points to intake system may be faulty (inspection
procedure).
Exhaust system check Inspection when relevant points to exhaust system may be faulty (inspection
procedure).
EGR control system check Inspection when relevant points to EGR may be faulty (inspection procedure).
QOS control system check Inspection when relevant points to QOS (glow) may be faulty (inspection
procedure).
CAN communication check Inspection when fault relevant to machine control unit and CAN communication
between scan tool and ECM may exist.
Machine-side check Inspection when fault relevant to machine function (inspection procedure) may
exist.
In the subsequent part of this manual, “scan tool” indicates scan tools including EST Diagnostic tool.
1E-144 Electronic control fuel injection system (Common rail type)
OBD system check
About OBD system check Note for OBD system check
OBD system check is systematic method to check the Important:
problems which caused by engine control system • If there is no complaint for operationality, never
malfunction. It is the first procedure of all complaint perform this diagnostic step unless otherwise
diagnosis for operationality. Use of this diagnostic step instructed in other items.
properly enables to shorten the diagnosis period and to • Before the diagnosis, check the service
prevent unnecessary replacement of proper parts. information.
• Never erase DTCs unless otherwise instructed
Test description
in the diagnostic step.
2. Communication disability with scan tool is caused by • If fault is found in the engine starting system,
fault in the communication circuit between each ECU refer to “Electrical system” in the service
and scan tool. manual “Engine section”.
4. If DTC is detected, proceed to the relevant DTC
• Ensure the battery is fully charged.
diagnosis by referring to the list of DTC. If more than
one DTC is detected, start with the one with smallest • Make sure the battery cable is normal and
DTC number unless otherwise instructed in the securely connected.
diagnostic step. • Make sure the ground cable of ECM is
connected to the proper position securely.
(15A)*
A A
Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp
3 H-6
1 E-164
Machine
control unit O/H switch
Tachometer signal
CAN HIGH CAN LOW
TSHK0022
Note:
5 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
Replace the ECM.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
6 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
1E-148 Electronic control fuel injection system (Common rail type)
Diagnosis lamp blinking circuit system check
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
TSHK0023
Note:
If breaker box is not available, refer to “On-
3 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Verify repair. Go to Step 4.
1. Check for following in the circuit between
diagnosis connector and ground.
• Open circuit
4 • High resistance —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Verify repair. Go to Step 5.
Check the diagnosis lamp blinking condition
again.
1. Turn the key switch to “ON”.
5 2. Connect the diagnosis connector. —
3. Check the diagnosis lamp.
Go to “Diagnostic
Does the diagnosis lamp blink? aid”. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1E-150 Electronic control fuel injection system (Common rail type)
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
Electronic control fuel injection system (Common rail type) 1E-151
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
TSHK0023
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
4 —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 9. Go to Step 5.
1. Connect the scan tool.
2. Turn the key switch to “ON”.
5 3. Communicate with ECM using scan tool. —
Go to “Diagnostic
Does it communicate with ECM properly? aid”. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Engine
control
Glow Glow relay control module
plug (ECM)
TSHK0024
Electronic control fuel injection system (Common rail type) 1E-157
Starter safety relay control
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)
Starter
B
Battery B
Generator
(100A)* L
(15A)* (60A)*
B C
Safty relay
L S
Glow relay
A A
1 H-22
B Br C B ACC Br C
5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
START START
1 H-1
Key switch
10 E-57
Engine
control
module (ECM)
Glow relay control
Glow
plug
TSHK0026
Note:
If breaker box is not available, refer to “On-
5 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 12.
1. Turn the key switch to “OFF”.
2. Remove the starter cut relay.
6 3. Check for continuity between the starter —
cut relay switch-side terminals.
Is the trouble detected? Go to Step 7. Go to Step 8.
Replace the starter cut relay.
7 —
Is the procedure completed? Go to Step 13. —
1. Turn the key switch to “OFF”.
2. Remove the starter relay.
3. Connect the battery to the starter relay
8 coil-side terminal. —
4. Check for continuity between the starter
relay switch-side terminals.
Is the trouble detected? Go to Step 9. Go to Step 10.
Replace the starter relay.
9 —
Is the procedure completed? Go to Step 13. —
Turn the key switch to “START”.
10 — Go to “Diagnostic
Does the starter operate? aid”. Go to Step 11.
Electronic control fuel injection system (Common rail type) 1E-159
Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1. Turn the key switch to “OFF”.
2. Remove the starter cut relay.
18 3. Check for continuity between the starter —
cut relay switch-side terminals.
Is the trouble detected? Go to Step 19. Go to Step 20.
Replace the starter cut relay.
19 —
Is the procedure completed? Go to Step 13. —
1. Turn the key switch to “OFF”.
2. Remove the starter relay.
3. Connect the battery to the starter relay
20 coil-side terminal. —
4. Check for continuity between the starter
relay switch-side terminals.
Is the trouble detected? Go to Step 9. Go to Step 10.
Name
1. Breaker box
2. DMM
Electronic control fuel injection system (Common rail type) 1E-161
2 E-161
SCV
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
Engine control
module(ECM)
B+
TSHK0027
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
Note:
8 For work procedure, refer to “Engine —
section” in the service manual.
Note:
6 For work procedure, refer to “Engine —
section” in the service manual.
TSWG0168
Name
1. Reed valve
2. EGR valve
3. Exhaust side
4. Intake side
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Circuit description
The ECM operates the EGR valve based on engine
speed, engine coolant temperature, intake air
temperature, fuel injection amount, and barometric
pressure. The EGR motor drives the EGR valve, and
the EGR position sensor detects the EGR valve
opening angle.
±3%
coolant temperature is 70°C (158°F).
3 3. Check the value for “EGR position” using
scan tool.
Is “EGR position” within the specified value? Normal system Go to Step 4.
1. Perform “EGR control test” using scan
tool.
4 2. Press the “Up” “Down” soft key. ±3%
3. Check the value for “EGR position”.
Is “EGR position” within the specified value? Go to Step 6. Go to Step 5.
Replace the EGR valve.
After replacing the EGR valve or ECM, the
EGR valve position learning must be
performed in the following procedure.
1. Turn the key switch to “ON”.
5 2. Turn the key switch to “OFF”. —
3. Leave as it is for 10 seconds.
Failure to perform above procedure may result
in detection of DTC for EGR.
Is the procedure completed? Go to Step 6. —
1. Check for damage or gas leakage in the
EGR pipe.
6 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 7. —
1. Start the engine.
2. Warm-up the engine until the engine
±3%
coolant temperature is 70°C (158°F).
7 3. Check the value for “EGR position” using
scan tool.
Is “EGR position” within the specified value? Verify repair. Go to Step 3.
1. Remove the EGR valve.
2. Check the EGR valve for anchoring,
clogging, etc.
8 3. If the trouble is detected, repair as —
required.
Is the trouble detected? Go to Step 9. Normal system
Replace the EGR valve.
After replacing the EGR valve or ECM, the
EGR valve position learning must be
performed in the following procedure.
1. Turn the key switch to “ON”.
9 2. Turn the key switch to “OFF”. —
3. Leave as it is for 10 seconds.
Failure to perform above procedure may result
in detection of DTC for EGR.
Is the procedure completed? Go to Step 10. —
Electronic control fuel injection system (Common rail type) 1E-171
TSWG0150
EGR hysteresis
ON
OFF
60
(140 F)
TSWG0206
1E-172 Electronic control fuel injection system (Common rail type)
QOS system check
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Engine
control
Glow Glow relay control module
plug (ECM)
TSHK0024
Electronic control fuel injection system (Common rail type) 1E-173
(15A)*
A A
Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp
3 H-6
1 E-164
Machine
control unit O/H switch
Tachometer signal
CAN HIGH CAN LOW
TSHK0022
Does the QOS indicator lamp come on? Go to Step 12. Go to Step 8.
1. Turn the key switch to “OFF”.
2. Remove the QOS indicator lamp.
8 3. Check the QOS indicator lamp for blow —
out.
Is the trouble detected? Go to Step 9. Go to Step 10.
1. Replace the QOS indicator lamp.
2. Turn the key switch to “ON”.
9 3. Check the QOS indicator lamp. —
Does the QOS indicator lamp come on? Go to Step 12. Go to Step 10.
1. Disconnect the ECM connector.
2. Measure the resistance between the QOS
indicator lamp terminal and the harness 10 MΩ or
10
between ECM and the ground. more
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0089 151 Common rail Common rail • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure is 40 sec. vibration, rough
fault abnormal more. MPa (5802 psi) idling, output
(Excessive increase • DTC P0089, or more higher lowering, blow up
pressure P0192, P0193, or than target rail fault, black smoke
feed in P1635 is not pressure. emitted, and
pump) detected. excessive output
• Coolant are possible.
temperature is Back-up:
60°C (140°F) or Limited injection
more, and 375 rpm amount 3 (multi-
or more. injection stopped)
• Duty to SCV is Target RP upper
40% or more, or limit (80 MPa
SCV target {11603 psi})
pressure feed is 90
mm3/sec
(0.0055cu⋅in/sec)
or less.
P0090 247 SCV drive Open/short • Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/ 18V or more. specified value possible depending
short or harness • DTC P1630 is not for 2 seconds or on the condition of
ground short detected. more, or when open/short circuit.
• SCV drive duty is difference Black smoke
between 10 — between target emitted, excessive
90%. and actual output
current exceeds Back-up:
specified value Limited injection
for 2 seconds or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0107 71 Barometric Open/short • Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure circuit/ voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault deterioration more. voltage is lower m (8200 ft)
(low voltage of sensor or • DTC P1630 or than 0.5 V. • Black smoke
fault) harness P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric Approx. 4 Due to back-up ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault harness more. voltage is more m (8200 ft)
(high voltage • DTC P1630 or than 3.8 V. • Black smoke
fault) P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
Electronic control fuel injection system (Common rail type) 1E-179
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0112 22 Intake air Short circuit • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or temperature sec. Back-up:
sensor fault harness more. sensor voltage is Intake air
(low voltage • DTC P1630 or less than 0.1 V. temperature default
{−4°F}, at running:
80°C {176°F})
EGR stopped
P0118 Engine Open/short • Key switch input Engine coolant Approx. 4 At normal ON *2
coolant circuit/ voltage is 18V or temperature sec. temperature: Black
temperature breakage of more. sensor voltage is smoke emission,
sensor fault sensor or • DTC P1630 or more than 4.85 greater engine
(high voltage harness P1633 is not V. combustion noise
fault) detected. possible.
• 3 minutes or more During idling at low
has elapsed after atmospheric
starting engine. temperatures:
Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant
temperature default
{−4°F}, at running:
80°C {176°F})
EGR stopped
1E-180 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0182 211 Fuel Short circuit • Key switch input Combustion Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(low voltage • DTC P1630 or less than 0.1 V. Fuel temperature
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0204 274 Open circuit Open/short • Main relay power No injector 4 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #4 electrical 18V or more. signal exists. idling, output
drive system wiring No. 4 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0204 is Back-up:
not detected. Injection for cylinder
#4 stopped, EGR
stopped
P0219 543 Overrun Engine • Key switch input When the engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed exceeds sec. Back-up:
abnormally more. setting value Limited injection
high (depending on amount 1
the machine Limitation is lifted if
manufacturer) the speed
decreases
P0237 32 Boost Open/short • Key switch input Boost pressure Approx. 3 Operationality is ON *2
pressure circuit/ voltage is 18V or sensor voltage is sec. affected.
sensor fault breakage of more. less than 0.1V. Back-up:
(low voltage sensor or • DTC P1630 or Specified back-up
fault) harness P1634 is not value (depending
detected. on the machine
manufacturer)
P0238 Boost Short circuit • Key switch input Boost pressure Approx. 3 Black smoke ON *2
pressure in sensor or voltage is 18V or sensor voltage is sec. emitted
sensor fault harness more. more than 4.9V. Back-up:
(high voltage • DTC P1630 or Specified back-up
fault) P1634 is not value (depending
detected. on the machine
manufacturer)
P0335 15 Crank Open circuit • CMP sensor Cam signal When • Output lowering, ON *1
sensor fault in sensor/ pulse is normal. exists but no trouble white smoke
(no signal) wiring • DTC P0335, crank signal. occurs 14 emission, intense
P0336, P0340, out of 21 engine vibration
P0341 or P1345 is samples. possible
not detected. • Engine stall
• Engine is running. possible (restart is
possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank Broken • CMP sensor Number of pulse When • Output lowering, ON *1
sensor fault teeth/ pulse is normal. for crank signal trouble white smoke
(signal fault) unnecessary • DTC P0335, is mismatched. occurs 14 emission, intense
signal mixed P0336, P0340, out of 21 engine vibration
(such as P0341 or P1345 is samples. possible
short circuit not detected. • Engine stall
with other • Engine is running. possible (restart is
wiring) possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
1E-182 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0340 14 Cam sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no in sensor/ voltage is 18V or exists but no trouble change during
signal) wiring more. cam signal. occurs 7 engine running.
• Crank pulse is out of 8 • After engine stalls,
normal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal teeth/ voltage is 18V or for cam signal is trouble change during
fault) unnecessary more. mismatched. occurs 7 engine running.
signal mixed • Crank pulse is out of 8 • After engine stalls,
(such as normal. samples. engine will not start.
short circuit • DTC P0335, Back-up:
with other P0336, P0340, Engine running
wiring) P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short • Key switch input No glow relay When Operationality is not ON *1
fault circuit/ power supply monitor signal trouble affected.
damage of voltage is higher exists against occurs 25 Back-up:
relay or than 16 V but lower glow relay drive out of 30 Back-up: No back-
harness than 32 V. indication. samples. up action
P0381 67 Glow lamp Open/short • Key switch input Glow lamp drive When Operationality is not ON
fault circuit/ voltage is 18 V or indication signal trouble affected.
damage of more. is unmatched occurs 25 Back-up:
lamp or • DTC P0381 is not with glow lamp out of 30 Back-up: No back-
harness detected. monitor signal. samples. up action
P0487 44 EGR Open/short • Main relay input EGR position Approx. 3 Operationality is not ON *1
position fault circuit/ voltage is 18V or output signal is sec. affected.
(Brushless damage of more. abnormal. Back-up:
specification sensor • DTC P1630 or Instruction to fully
) harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/ • DTC P1630, Difference Approx. 10 Operationality is not ON *2
control fault open circuit P1635, P0487, between target sec. affected.
or valve P0488, or P1635 is valve lift and Back-up:
engage/ not detected. actual position is Instruction to fully
stuck in • Main relay voltage more than 20%. close EGR valve
drive motor is between 20 —
side 32 V.
• Difference
between target
EGR opening
angle and actual
one is 20% or less.
P0522 294 Engine oil Open/short • Key switch input Engine oil Approx. 4 Operationality is not ON *1
pressure circuit/ voltage is 18V or pressure sensor sec. affected.
sensor fault breakage of more. voltage is less Back-up:
(low voltage sensor or • DTC P1633 is not than 0.1V. Back-up: No back-
fault) harness detected. up action
P0523 Engine oil Short circuit • Key switch input Engine oil Approx. 4 Operationality is not ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. affected.
sensor fault harness more. voltage is more Back-up:
(high voltage • DTC P1633 is not than 4.85V. Back-up: No back-
fault) detected. up action
Electronic control fuel injection system (Common rail type) 1E-183
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
— Reflash failure — Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
— — Back-up:
Back-up: No back-
up action
P0606 51 CPU fault CPU fault Sub-CPU Nearly Output lowering ON *2
detects main simultaneo Back-up:
CPU fault in 100 us to fault Limited injection
msec after key occurrence amount 2 (multi-
switch ON. injection stopped)
(SUB-CPU SUB-CPU stops
resets CPU.) CPU.
—
Sub-CPU Nearly Unable to start ON Diagnosed
detects main simultaneo Back-up: for
CPU fault in 100 us to fault Limited injection 100msec
msec after key occurrence amount 2 (multi- only after
switch ON. injection stopped) KEY-ON.
(SUB-CPU SUB-CPU stops
resets CPU.) CPU.
52 CPU Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
monitoring fault has elapsed after does not change simultaneo Back-up:
IC fault key switch ON. for 20 msec or us to fault Limited injection
• Key switch input more. occurrence amount 1
power supply
voltage is higher
than 16 V.
P0611 34 Charge ECU charge • Main relay power When charge Approx. Intensive engine ON *2
circuit fault circuit 1 fault supply voltage is circuit bank 1 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 1 stop
(#1, #4 cylinders
stopped), EGR
stopped
P0612 Charge ECU charge When charge Approx. Intensive engine ON
circuit fault circuit 2 fault circuit bank 2 1.5 sec. vibration, rough
(bank 2) (internal voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 2 stop
(#2, #3 cylinders
stopped), EGR
stopped
P0650 77 Check Lamp fault • Key switch input No check engine Approx. Operationality is not Does *2
engine lamp voltage is 18V or lamp monitor 1.5 sec. affected. not
fault more. signal exists. Back-up: come
• DTC P0650 is not Back-up: No back- on.
detected. up action
1E-184 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1093 227 No pump Fuel leakage • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure (large voltage is 18V or pressure is 30 sec. vibration, rough
feed (fuel amount) more. MPa (4351 psi) idling, output
leakage) • 1200 rpm or more or more lower lowering, blow up
• Duty to SCV is than target rail fault, black smoke
33% or less, or pressure. emitted, engine
pressure feed is stall, and excessive
28000mm3/sec output are possible.
(1.7cu⋅in/sec) or Back-up:
more. Limited injection
• DTC P0192, amount 3 (multi-
P0193, P1093, injection stopped)
P0090, P1291, Target RP upper
P1292, or P1635 is limit (80 MPa
not detected. {11603 psi})
P1095 225 Pressure Pressure • Key switch input Pressure limiter Approx. 1 Output lowering, ON *1
limiter open limiter is voltage is 18V or is opened. sec. hunting
opened. more. Back-up:
• DTC P1095, Limited injection
P0192, P0193, amount 1
P1630, or P1635 is
not detected.
• 50 rpm or more
P1112 295 Boost Open/short • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature circuit/ voltage is 18V or temperature sec. affected.
sensor fault breakage of more. sensor voltage is Back-up:
(low voltage sensor or • DTC P1634 is not less than 0.1 V. Back-up: No back-
fault) harness detected. up action
P1113 Boost Short circuit • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(high voltage • Coolant more than Back-up: No back-
fault) temperature is 4.95V. up action
50°C (122°F) or
more.
• 3 (or 5) minutes
have passed after
engine starting
(depending on the
machine
manufacturer)
• DTC P1634 is not
detected.
P1173 542 Overheat Overheat • Key switch input • Coolant Approx. 5 Operationality is not Does *2
condition voltage is 18V or temperature is sec. affected. not
more. more than Back-up: come
• DTC P1630, 120°C (248°F). Back-up: No back- on.
P1633, P0117, or up action
P0118 is not
detected.
• Under operation
P1261 158 Injection Open/short • Main relay power No injector 1 and Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 4 monitor input sec. vibration, rough
common 1 injector 18V or more. signal exists. idling, output
drive system common 1- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0611, P1261 and Back-up:
fault P0201; DTC Common 1 stop
P0611, P1261 and (#1, #4 cylinders
P0202; DTC stopped), EGR
P0611, P1261 and stopped
P0203.
Electronic control fuel injection system (Common rail type) 1E-185
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1262 159 Injection Open/short • Main relay power No injector 2 and Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 3 monitor input sec. vibration, rough
common 2 injector 18V or more. signal exists. idling, output
drive system common 2- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0612, P1262 and Back-up:
fault P0204; DTC Common 2 stop
P0612, P1262 and (#2, #3 cylinders
P0205; DTC stopped), EGR
P0612, P1262 and stopped
P0206.
P1271 24 Accelerator Difference in • Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between 2 system come
fault between • DTC P1630, accelerator fault...Accelerator on.
accelerator P1631, P1271, sensors 1 and 2 opening angle is
sensors 1-2 P1277, P1278, is 45% or more. controlled to 0%.
is 45% or P1282, or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1277 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1277, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1278 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1278, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1282 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1282, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
1E-186 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1283 24 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1283, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does not ON *1
out of phase gear/ voltage is 18V or pulse does not trouble change during
crankshaft more. exist in crank occurs 7 engine running.
gear • DTC P0335, gap position. out of 8 • After engine stalls,
installing P0336, P0340, samples. engine will not start.
angle is out P0341, P1345, or Back-up:
of phase, or P1635 is not Specified back-up
damage in detected. value (depending
gear. • CMP sensor on the machine
pulse is normal. manufacturer)
• Crank pulse is
normal.
P1625 416 Main relay Open/ • Key switch input Main relay Approx. 2 Engine does not ON *2
system fault ground short voltage is 18V or system voltage sec. start.
(Not enter) circuit in more. is 1V or less with Back-up:
harness, • DTC P1630 is not main relay coil Back-up: No back-
relay OFF detected. output ON. up action
anchoring • 3 seconds or
more has elapsed
after key switch
ON.
• Main relay drive
indication ON
Harness +B • DTC P1625 or Relay does not Approx. 5 Vehicle power ON *1
short, relay P0606 is not cut off despite of sec. supply cannot be
ON detected. main relay coil shut off.
anchoring output OFF Back-up:
indication. Back-up: No back-
up action
P1630 36 A/D A/D A/D conversion Immediatel Output lowering, ON *2
conversion conversion failure y Black smoke
fault fault emitted
Back-up:
Analog sensor
system default
— processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Electronic control fuel injection system (Common rail type) 1E-187
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1631 55 Voltage fault Power • DTC P1630 is not Key switch Approx. Accelerator opening ON *2
in 5-V power supply detected. power supply 0.5 sec. angle is controlled
supply 1 wiring short • Key switch input voltage is 5.5V to 0%.
to sensor, or power supply or more, or 4.5V Back-up:
breakage in voltage is between or less, when Same to accelerator
element/ 16 — 32 V. battery voltage is sensor fault
circuit for between 16V —
power 32V.
P1632 Voltage fault supply • DTC P1630 is not Key switch Approx. Due to back-up ON *2
regulation
in 5-V power detected. power supply 0.5 sec. equivalent to 2500
inside ECM.
supply 2 • Key switch input voltage is 5.5V m (8200 ft)
power supply or more, or 4.5V • Black smoke
voltage is between or less, when emitted at high
16 — 32 V. battery voltage is altitude
between 16V — • Output shortage at
32V. low altitude
Back-up:
Same to barometric
pressure and intake
air temperature
sensor fault
P1633 Voltage fault • DTC P1630 is not Key switch Approx. Startability ON *2
in 5-V power detected. power supply 0.5 sec. deteriorates at low
supply 3 • Key switch input voltage is 5.5V temperatures or
power supply or more, or 4.5V black smoke
voltage is between or less, when emission is
16 — 32 V. battery voltage is possible, output
between 16V — lowering or
32V. operationality is
affected depending
on conditions.
Back-up:
Same to coolant
temperature, fuel
temperature, and oil
pressure sensor
fault
P1634 Voltage fault • DTC P1630 is not Key switch Approx. Operationality is ON *2
in 5-V power detected. power supply 0.5 sec. affected.
supply 4 • Key switch input voltage is 5.5V Back-up:
power supply or more, or 4.5V Same to boost
voltage is between or less, when pressure and boost
16 — 32 V. battery voltage is temperature sensor
between 16V — fault
32V.
P1635 Voltage fault • DTC P1630 is not Key switch Approx. Engine blow up, ON *2
in 5-V power detected. power supply 0.5 sec. output lowering,
supply 5 • Key switch input voltage is 5.5V black smoke
power supply or more, or 4.5V emission, engine
voltage is between or less, when stall are possible.
16 — 32 V. battery voltage is Back-up:
between 16V — Same to rail
32V. pressure sensor
fault and EGR
position sensor fault
U2104 84 CAN Bus CAN • Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault communicati voltage is 12V or detected. continuous Back-up:
on fault more. ly Running at 1500
rpm.
U2106 85 CAN timeout CAN • DTC U2104 is not CAN data At 1 sec. Set to idle speed. ON *3
fault communicati detected. reception does continuous Back-up:
on fault • Key switch input not complete at ly Specified back-up
voltage is 12V or a set time. value (depending
more. on the machine
manufacturer)
1E-188 Electronic control fuel injection system (Common rail type)
About recovery from failure *2
There are three modes for recovery from failure. When the DTC has recovered to normal condition in the
To clear the trouble displayed on the monitor of the ignition cycle that the DTC is detected, the diagnosis
machine, one more ignition cycle may be needed after lamp and back up mode will also be recovered.
the following ignition cycle.
1 2
*1
Key ON
Even if the DTC has restored normally, the diagnosis switch
and
lamp and back-up mode are not restored in the ignition Engine
cycle that the DTC is detected. After turning the key run OFF
Key ON
switch
and
Engine ON
run OFF
Back-up
mode
OFF
ON
TSWG0166
Diag
lamp
OFF
Name
1. DTC is detected.
2. Recovery to normal.
ON
Back-up
mode
*3
OFF
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
TSWG0165 be recovered normally, but the diagnosis lamp does not
go off.
Name
1. DTC is detected. 1 2
2. Repair and inspection
3. Returned to normal. Key ON
switch
and
Enigne
run OFF
ON
Diag
lamp
OFF
ON
Back-up
mode
OFF
TSWG0207
Name
1. DTC is detected.
2. Recovery to normal.
Electronic control fuel injection system (Common rail type) 1E-189
6HK1
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0087 227 No pump Common rail 900 rpm or more Actual rail Approx. 3 Intense engine ON *1
pressure pressure pressure is 15 sec. vibration, rough
feed (fuel does not MPa (2176 psi) idling, output
leakage) increase to or less at 900 lowering, blow up
the required rpm or more. fault, black smoke
area. emitted, and
excessive output
are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0088 118 Common rail Common rail • Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or more than 185 sec. vibration, rough
fault abnormal more. MPa (26832 idling, output
(1st stage) increase • DTC P0088, psi). lowering, blow up
P0192, P0193, or fault, black smoke
P1635 is not emitted, and
detected. excessive output
• Actual rail are possible.
pressure is 2 MPa Back-up:
(290 psi) or more, Limited injection
and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Common rail Common rail • Key switch input Common rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure fault sec. vibration, rough
fault abnormal more. (1st stage) is idling, output
(2nd stage) increase • DTC P0088, completed, and lowering, blow up
P0192, P0193, or rail pressure is fault, black smoke
P1635 is not more than 190 emitted, and
detected. MPa (27557 excessive output
• Actual rail psi). are possible.
pressure is 2 MPa Back-up:
(290 psi) or more, Limited injection
and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0089 151 Common rail Common rail • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure is 40 sec. vibration, rough
fault abnormal more. MPa (5802 psi) idling, output
(Excessive increase • DTC P0089, or more higher lowering, blow up
pressure P0192, P0193, or than target rail fault, black smoke
feed in P1635 is not pressure. emitted, and
pump) detected. excessive output
• Coolant are possible.
temperature is Back-up:
60°C (140°F) or Limited injection
more, and 375 rpm amount 3 (multi-
or more. injection stopped)
• Duty to SCV is Target RP upper
40% or more, or limit (80 MPa
SCV target {11603 psi})
pressure feed is 90
mm3/sec
(0.0055cu⋅in/sec)
or less.
1E-190 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0090 247 SCV drive Open/short • Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/ 18V or more. specified value possible depending
short or harness • DTC P1630 is not for 2 seconds or on the condition of
ground short detected. more, or when open/short circuit.
• SCV drive duty is difference Black smoke
between 10 — between target emitted, excessive
90%. and actual output
current exceeds Back-up:
specified value Limited injection
for 2 seconds or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0107 71 Barometric Open/short • Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure circuit/ voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault deterioration more. voltage is lower m (8200 ft)
(low voltage of sensor or • DTC P1630 or than 0.5 V. • Black smoke
fault) harness P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault harness more. voltage is more m (8200 ft)
(high voltage • DTC P1630 or than 3.8 V. • Black smoke
fault) P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
P0112 22 Intake air Short circuit • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or temperature sec. Back-up:
sensor fault harness more. sensor voltage is Specified back-up
(low voltage • DTC P1630 or less than 0.1 V. value (depending
fault) P1632 is not on the machine
detected. manufacturer)
P0113 Intake air Open/short • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault deterioration more. sensor voltage is Intake air
(high voltage of sensor or • DTC P1630 or more than 4.95 temperature default
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0117 23 Engine Short circuit • Key switch input Engine coolant Approx. 4 Start ability ON *2
coolant in sensor or voltage is 18V or temperature sec. deteriorates at low
temperature harness more. sensor voltage is temperatures or
sensor fault • DTC P1630 or less than 0.1 V. black smoke
(low voltage P1633 is not emission is
fault) detected. possible, output
lowering depending
on conditions.
Back-up:
Specified back-up
value (depending
on the machine
manufacturer)
P0118 Engine Open/short • Key switch input Engine coolant Approx. 4 At normal ON *2
coolant circuit/ voltage is 18V or temperature sec. temperature: Black
temperature breakage of more. sensor voltage is smoke emission,
sensor fault sensor or • DTC P1630 or more than 4.85 greater engine
(high voltage harness P1633 is not V. combustion noise
fault) detected. possible.
• 3 minutes or more During idling at low
has elapsed after atmospheric
starting engine. temperatures:
Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant
temperature default
{−4°F}, at running:
80°C {176°F)
EGR stopped
P0182 211 Fuel Short circuit • Key switch input Combustion Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(low voltage • DTC P1630 or less than 0.1 V. Specified back-up
fault) P1633 is not value (depending
detected. on the machine
manufacturer)
P0183 Fuel Open/short • Key switch input Combustion Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault breakage of more. sensor voltage is Fuel temperature
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0201 271 Open circuit Open/short • Main relay power No injector 1 Approx. Intense engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #1 electrical 18V or more. signal exists. idling, output
drive system wiring No. 1 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault, output
injector P1261, or P0201 is lowering
not detected. Back-up:
Injection for cylinder
#1 stopped, EGR
stopped
P0202 272 Open circuit Open/short • Main relay power No injector 2 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #2 electrical 18V or more. signal exists. idling, output
drive system wiring No. 2 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1261 or P0202 is Back-up:
not detected. Injection for cylinder
#2 stopped, EGR
stopped
P0203 273 Open circuit Open/short • Main relay power No injector 3 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #3 electrical 18V or more. signal exists. idling, output
drive system wiring No. 3 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1261 or P0203 is Back-up:
not detected. Injection for cylinder
#3 stopped, EGR
stopped
P0204 274 Open circuit Open/short • Main relay power No injector 4 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #4 electrical 18V or more. signal exists. idling, output
drive system wiring No. 4 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0204 is Back-up:
not detected. Injection for cylinder
#4 stopped, EGR
stopped
P0205 275 Open circuit Open/short • Main relay power No injector 5 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #5 electrical 18V or more. signal exists. idling, output
drive system wiring No. 5 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0205 is Back-up:
not detected. Injection for cylinder
#5 stopped, EGR
stopped
P0206 276 Open circuit Open/short • Main relay power No injector 6 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #6 electrical 18V or more. signal exists. idling, output
drive system wiring No. 6 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0206 is Back-up:
not detected. Injection for cylinder
#6 stopped, EGR
stopped
P0219 543 Overrun Engine • Key switch input When the engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed exceeds sec. Back-up:
abnormally more. setting value Limited injection
high (depending on amount 1
the machine Limitation is lifted if
manufacturer) the speed
decreases
Electronic control fuel injection system (Common rail type) 1E-193
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0237 32 Boost Open/short • Key switch input Boost pressure Approx. 3 Operationality is ON *2
pressure circuit/ voltage is 18V or sensor voltage is sec. affected.
sensor fault breakage of more. less than 0.1V. Back-up:
(low voltage sensor or • DTC P1630 or Boost pressure
fault) harness P1634 is not default setting (150
detected. kPa {21.8 psi})
Boost pressure
correction/EGR
stopped
P0238 Boost Short circuit • Key switch input Boost pressure Approx. 3 Black smoke ON *2
pressure in sensor or voltage is 18V or sensor voltage is sec. emitted
sensor fault harness more. more than 4.9V. Back-up:
(high voltage • DTC P1630 or Boost pressure
fault) P1634 is not default setting (150
detected. kPa {21.8 psi})
Boost pressure
correction/EGR
stopped
P0335 15 Crank Open circuit • CMP sensor Cam signal When • Output lowering, ON *1
sensor fault in sensor/ pulse is normal. exists but no trouble white smoke
(no signal) wiring • DTC P0335, crank signal. occurs 14 emission, intense
P0336, P0340, out of 21 engine vibration
P0341 or P1345 is samples. possible
not detected. • Engine stall
• Engine is running. possible (restart is
possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank Broken • CMP sensor Number of pulse When • Output lowering, ON *1
sensor fault teeth/ pulse is normal. for crank signal trouble white smoke
(signal fault) unnecessary • DTC P0335, is mismatched. occurs 14 emission, intense
signal mixed P0336, P0340, out of 21 engine vibration
(such as P0341 or P1345 is samples. possible
short circuit not detected. • Engine stall
with other • Engine is running. possible (restart is
wiring) possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
1E-194 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0340 14 Cam sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no in sensor/ voltage is 18V or exists but no trouble change during
signal) wiring more. cam signal. occurs 7 engine running.
• Crank pulse is out of 8 • After engine stalls,
normal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal teeth/ voltage is 18V or for cam signal is trouble change during
fault) unnecessary more. mismatched. occurs 7 engine running.
signal mixed • Crank pulse is out of 8 • After engine stalls,
(such as normal. samples. engine will not start.
short circuit • DTC P0335, Back-up:
with other P0336, P0340, Engine running
wiring) P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short • Key switch input No glow relay When Operationality is not ON *1
fault circuit/ power supply monitor signal trouble affected.
damage of voltage is higher exists against occurs 25 Back-up:
relay or than 16 V but lower glow relay drive out of 30 Specified back-up
harness than 32 V. indication. samples. value (depending
on the machine
manufacturer)
P0381 67 Glow lamp Open/short • Key switch input Glow lamp drive When Operationality is not
fault circuit/ voltage is 18 V or indication signal trouble affected.
damage of more. is unmatched occurs 25 Back-up:
lamp or • DTC P0381 is not with glow lamp out of 30 Back-up: No back-
harness detected. monitor signal. samples. up action
P0487 44 EGR Open/short • Main relay input EGR position Approx. 3 Exhaust gas is ON *1
position fault circuit/ voltage is 18V or output signal is sec. affected.
(Brushless damage of more. abnormal. Back-up:
specification sensor • DTC P1630 or Instruction to fully
) harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/ • DTC P1630, Difference Approx. 10 Exhaust gas is ON *2
control fault open circuit P1635, P0487, between target sec. affected.
or valve P0488, or P1635 is valve lift and Back-up:
engage/ not detected. actual position is Instruction to fully
stuck in • Main relay voltage more than 20%. close EGR valve
drive motor is between 20 —
side 32 V.
• Difference
between target
EGR opening
angle and actual
one is 20% or less.
P0522 294 Engine oil Open/short • Key switch input Engine oil Approx. 4 Operationality is not ON *1
pressure circuit/ voltage is 18V or pressure sensor sec. affected.
sensor fault breakage of more. voltage is less Back-up:
(low voltage sensor or • DTC P1633 is not than 0.098 V. Back-up: No back-
fault) harness detected. up action
Electronic control fuel injection system (Common rail type) 1E-195
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0523 294 Engine oil Short circuit • Key switch input Engine oil Approx. 4 Operationality is not ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. affected.
sensor fault harness more. voltage is more Back-up:
(high voltage • DTC P1633 is not than 4.85 V. Back-up: No back-
fault) detected. up action
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
— Reflash failure — Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
— — Back-up:
Back-up: No back-
up action
P0606 51 CPU fault CPU fault Sub-CPU Nearly Output lowering, ON *2
detects main simultaneo hunting
CPU fault in 100 us to fault Back-up:
msec after key occurrence Limited injection
switch ON. amount 2 (multi-
(SUB-CPU injection stopped)
resets CPU.) SUB-CPU stops
— CPU.
Sub-CPU Nearly Unable to start Diagnosed
detects main simultaneo Back-up: for
CPU fault in 100 us to fault Limited injection 100msec
msec after key occurrence amount 2 (multi- only after
switch ON. injection stopped) KEY-ON.
(SUB-CPU SUB-CPU stops
resets CPU.) CPU.
52 CPU Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
monitoring fault has elapsed after does not change simultaneo Back-up:
IC fault key switch ON. for 20 msec or us to fault Limited injection
• Key switch input more. occurrence amount 1
power supply
voltage is higher
than 16 V.
P0611 34 Charge ECU charge • Main relay power When charge Approx. Intensive engine ON *2
circuit fault circuit 1 fault supply voltage is circuit bank 1 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 1 stop
(#1, #2, #3 cylinders
stopped), EGR
stopped
P0612 34 Charge ECU charge When charge Approx. Intensive engine ON
circuit fault circuit 2 fault circuit bank 2 1.5 sec. vibration, rough
(bank 2) (internal voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 2 stop
(#4, #5, #6 cylinders
stopped), EGR
stopped
P0650 77 Check Lamp fault • Key switch input No check engine Approx. Operationality is not Does *2
engine lamp voltage is 18V or lamp monitor 1.5 sec. affected. not
fault more. signal exists. Back-up: come
• DTC P0650 is not Back-up: No back- on.
detected. up action
1E-196 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1093 227 No pump Fuel leakage • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure (large voltage is 18V or pressure is 30 sec. vibration, rough
feed (fuel amount) more. MPa (4351 psi) idling, output
leakage) • 1200 rpm or more or more lower lowering, blow up
• Duty to SCV is than target rail fault, black smoke
33% or less, or pressure. emitted, engine
pressure feed is stall, and excessive
28000mm3/sec output are possible.
(1.7cu⋅in/sec) or Back-up:
more. Limited injection
• DTC P0192, amount 3 (multi-
P0193, P1093, injection stopped)
P0091, P0092, Target RP upper
P1291, P1292, or limit (80 MPa
P1635 is not {11603 psi})
detected.
P1095 225 Pressure Pressure • Key switch input Pressure limiter Approx. 1 Output lowering ON *1
limiter open limiter is voltage is 18V or is opened. sec. Back-up:
opened. more. Limited injection
• DTC P1095, amount 1
P0192, P0193,
P1630, or P1635 is
not detected.
• 50 rpm or more
P1112 295 Boost Open/short • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature circuit/ voltage is 18V or temperature sec. affected.
sensor fault breakage of more. sensor voltage is Back-up:
(low voltage sensor or • DTC P1634 is not less than 0.1 V. Back-up: No back-
fault) harness detected. up action
P1113 Boost Short circuit • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(high voltage • Coolant more than Back-up: No back-
fault) temperature 50°C 4.95V. up action
(122°F) or more, or
3 (or 5) minutes
have passed after
engine starting
(depending on the
machine
manufacturer).
• DTC P1634 is not
detected.
P1173 542 Overheat Overheat • Key switch input • Coolant Approx. 5 Operationality is not Does *2
condition voltage is 18V or temperature is sec. affected. not
more. more than Back-up: come
• DTC P1630, 120°C (248°F) Back-up: No back- on.
P1633, P0117, or while engine is up action
P0118 is not operated.
detected.
• Under operation
P1261 158 Injection Open/short • Main relay power No injector 1, 3, Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 5 monitor input sec. vibration, rough
common 1 injector 18V or more. signal exists. idling, output
drive system common 1- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0611, P1261 and Back-up:
fault P0201; DTC Common 1 stop
P0611, P1261 and (#1, #2, #3 cylinders
P0202; DTC stopped), EGR
P0611, P1261 and stopped
P0203.
Electronic control fuel injection system (Common rail type) 1E-197
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1262 159 Injection Open/short • Main relay power No injector 2, 4, Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 6 monitor input sec. vibration, rough
common 2 injector 18V or more. signal exists. idling, output
drive system common 2- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0612, P1262 and Back-up:
fault P0204; DTC Common 2 stop
P0612, P1262 and (#4, #5, #6 cylinders
P0205; DTC stopped), EGR
P0612, P1262 and stopped
P0206.
P1271 24 Accelerator Difference in • Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between 2 system come
fault between • DTC P1630, accelerator fault...Accelerator on.
accelerator P1631, P1271, sensors 1 and 2 opening angle is
sensors 1-2 P1277, P1278, is 45% or more. controlled to 0%.
is 45% or P1282, or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1277 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1277, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1278 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1278, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1282 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1282, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
1E-198 Electronic control fuel injection system (Common rail type)
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1283 24 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1283, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does not ON *1
out of phase gear/ voltage is 18V or pulse does not trouble change during
crankshaft more. exist in crank occurs 7 engine running.
gear • DTC P0335, gap position. out of 8 • After engine stalls,
installing P0336, P0340, samples. engine will not start.
angle is out P0341, P1345, or Back-up:
of phase, or P1635 is not Specified back-up
damage in detected. value (depending
gear. • CMP sensor on the machine
pulse is normal. manufacturer)
• Crank pulse is
normal.
P1625 416 Main relay Open/ • Key switch input Main relay Approx. 2 Engine does not ON *2
system fault ground short voltage is 18V or system voltage sec. start.
(Not enter) circuit in more. is 1V or less with Back-up:
harness, • DTC P1630 is not main relay coil Back-up: No back-
relay OFF detected. output ON. up action
anchoring • 3 seconds or
more has elapsed
after key switch
ON.
• Main relay drive
indication ON
Harness +B • DTC P1625 or Relay does not Approx. 5 Vehicle power ON *1
short, relay P0606 is not cut off despite of sec. supply cannot be
ON detected. main relay coil shut off.
anchoring output OFF Back-up:
indication. Back-up: No back-
up action
P1630 36 A/D A/D A/D conversion Immediatel Output lowering, ON *2
conversion conversion failure y Black smoke
fault fault emitted
Back-up:
Analog sensor
system default
— processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Electronic control fuel injection system (Common rail type) 1E-199
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1631 55 Voltage fault Power • DTC P1630 is not Key switch Approx. Accelerator opening ON *2
in 5-V power supply detected. power supply 0.5 sec. angle is controlled
supply 1 wiring short • Battery voltage is voltage is 5.5V to 0%.
to sensor, or between 16V — or more, or 4.5V Back-up:
breakage in 32V. or less. Same to accelerator
element/ sensor fault
circuit for
P1632 Voltage fault • DTC P1630 is not Key switch Approx. Due to back-up ON *2
power
in 5-V power detected. power supply 0.5 sec. equivalent to 2500
supply 2 supply • Battery voltage is voltage is 5.5V m (8200 ft)
regulation
between 16V — or more, or 4.5V • Black smoke
inside ECM.
32V. or less. emitted at high
altitude
• Output shortage at
low altitude
Back-up:
Same to barometric
pressure and intake
air temperature
sensor fault
P1633 Voltage fault • DTC P1630 is not Key switch Approx. Startability ON *2
in 5-V power detected. power supply 0.5 sec. deteriorates at low
supply 3 • Battery voltage is voltage is 5.5V temperatures or
between 16V — or more, or 4.5V black smoke
32V. or less. emission is
possible, output
lowering or
operationality is
affected depending
on conditions.
Back-up:
Same to coolant
temperature, fuel
temperature, and oil
pressure sensor
fault
P1634 Voltage fault • DTC P1630 is not Key switch Approx. Operationality is ON *2
in 5-V power detected. power supply 0.5 sec. affected.
supply 4 • Battery voltage is voltage is 5.5V Back-up:
between 16V — or more, or 4.5V Same to boost
32V. or less. pressure and boost
temperature sensor
fault
P1635 Voltage fault • DTC P1630 is not Key switch Approx. Engine blow up, ON *2
in 5-V power detected. power supply 0.5 sec. output lowering,
supply 5 • Battery voltage is voltage is 5.5V black smoke
between 16V — or more, or 4.5V emission, engine
32V. or less. stall are possible.
Back-up:
Same to rail
pressure sensor
fault and EGR
position sensor fault
1E-200 Electronic control fuel injection system (Common rail type)
About recovery from failure *2
There are three modes for recovery from failure. When the DTC has recovered to normal condition in the
To clear the trouble displayed on the monitor of the ignition cycle that the DTC is detected, the diagnosis
machine, one more ignition cycle may be needed after lamp and back up mode will also be recovered.
the following ignition cycle.
1 2
*1
Key ON
Even if the DTC has restored normally, the diagnosis switch
and
lamp and back-up mode are not restored in the ignition Engine
cycle that the DTC is detected. After turning the key run OFF
Key ON
switch
and
Engine ON
run OFF
Back-up
mode
OFF
ON
TSWG0166
Diag
lamp
OFF
Name
1. DTC is detected.
2. Recovery to normal.
ON
Back-up
mode
*3
OFF
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
TSWG0165 be recovered normally, but the diagnosis lamp does not
go off.
Name
1. DTC is detected. 1 2
2. Repair and inspection
3. Returned to normal. Key ON
switch
and
Enigne
run OFF
ON
Diag
lamp
OFF
ON
Back-up
mode
OFF
TSWG0207
Name
1. DTC is detected.
2. Recovery to normal.
Electronic control fuel injection system (Common rail type) 1E-201
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply
pump)
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
1E-202 Electronic control fuel injection system (Common rail type)
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Description of circuit
The engine control module (ECM) monitors the
pressure inside of common rail based on the signal
from common rail pressure sensor. If the pressure is
low, ECM controls the SCV of supply pump to increase
the pressure inside of common rail. If fuel supply to the
supply pump is insufficient or the supply pump is faulty,
the pressure inside of common rail cannot be
increased.
Actual rail pressure is 15 MPa (2176 psi) or less for 3 Test description
seconds or more.
Numbers below indicate step numbers in the chart.
10. If the “Common rail pressure sensor” displays more
than the specified value when the common rail
:Desired rail puressure pressure sensor connector is removed, the circuit
:Actual rail presure beyond the sensor is normal including ECM.
Absolute pressure
30MPa(4351psi)
Actual 1 P1093
t2 > 5sec
t1 > 3sec
15MPa Actual 2
(2176psi) P0087
TSHK0130
5 Note: —
For work procedure, refer to “Engine
section” in the service manual.
8 Note: —
For work procedure, refer to “Engine
section” in the service manual.
racing: ±5
5. Race it quickly for about 5 times. psi); At idling,
6. Check for “Differential fuel rail pressure”
on the data display using scan tool. MPa (±725
psi)
Is each value of “Fuel rail pressure” (at engine
stopped, idling and racing) around the
specified value? Go to Step 16. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
10 4.8V
4. Check for “Common rail pressure sensor”
on the data display using scan tool.
Is the “Common rail pressure sensor” more
than the specified value? Go to Step 13. Go to Step 11.
1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
11 using breaker box or DMM. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 18. Go to Step 12.
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this
section for check and rewriting of ECM.
Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
±5 MPa (±725
2. Start the engine.
16 3. Select the “Actuator test” from the menu.
4. Select the “Rail pressure control” in the psi)
“Common rail system”.
5. Press the “Up” soft key to check the value
of “Differential fuel pressure”.
Is “Differential fuel rail pressure” within the
specified value? Go to Step 18. Go to Step 17.
Replace the supply pump.
17 —
Is the procedure completed? Go to Step 18. —
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
18 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0087 detected? Go to Step 2. Go to Step 19.
Check if DTC is detected.
19 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Use the injector checker to stop injection in the
injector, and check the change in engine
sound.
20 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 22. Go to Step 21.
Electronic control fuel injection system (Common rail type) 1E-207
21 Note: —
For work procedure, refer to “Engine
section” in the service manual.
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply Name
1. Breaker box
2. DMM
Characteristics of common rail pressure sensor
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
1E-210 Electronic control fuel injection system (Common rail type)
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Diagnostic aid
presure
T>1sec=P1095
If the intermittent trouble is suspected, followings may
be the cause.
200 MPa • Improper connection of harness connector
(29008psi)
• Defective harness routing
190 MPa T • Worn harness cladding
(27557psi)
185 MPa
• Wire disconnection inside harness cladding
(26832psi) Following inspections are necessary to detect these
T causes.
T>5sec=P0088
• Improper connection of harness connector and
ECM connector
– Poor connection of terminal from connector
– Unmatched terminals are fitted.
TSHK0043
– Damage of connector lock
Action taken when DTC is set – Poor contact between terminal and wire
• Trouble is displayed on the monitor of the • Damaged harness
machine* or diagnosis lamp comes on. (* Nothing – Visually check the harness for damage.
is displayed depending on the machine – Check the relevant items on the scan tool data
manufacturer) display while moving the connector and the
harness which are related to the sensor. The
variation of the display indicates the faulty part.
6 Note: —
For work procedure, refer to “Engine
section” in the service manual.
Note:
7 For work procedure, refer to “Engine —
section” in the service manual.
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
1E-214 Electronic control fuel injection system (Common rail type)
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in
supply pump)
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
Electronic control fuel injection system (Common rail type) 1E-215
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
pressure ±5
2. Start the engine. Differential
4 3. Check for “Differential fuel rail pressure”
on the data display using scan tool. MPa (±725
psi)
Is “Differential fuel rail pressure” within the Go to “Diagnostic
specified value? aid”. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Wait for 2 minutes before the common rail
internal pressure goes down.
3. Turn the key switch to “ON”. Do not start Differential
−30 MPa (−
engine. pressure
5
4. Check for “Differential fuel rail pressure”
4351 psi)
on the data display using scan tool.
Is “Differential fuel rail pressure” the specified
value? Go to Step 6. Go to Step 7.
Electronic control fuel injection system (Common rail type) 1E-217
Note:
8 —
For work procedure, refer to “Engine
section” in the service manual.
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
About common rail pressure sensor On-board check procedure for sensors
3 2 1
2 1
TSWG0055 TSWG0197
Name Name
1. Power supply 1. Coupling connector between engine — the
2. Signal machine
3. GND 2. Machine harness
3. Sensor connector
4. Engine harness
Characteristics of common rail pressure sensor
1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
(V) the wiring of sensor connector.
4.2 3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
0 200(29008)
MPa(psi)
TSWG0201
Electronic control fuel injection system (Common rail type) 1E-219
DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short
2 E-161
SCV
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
Engine control
module(ECM)
B+
TSHK0027
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
4 —
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 6.
Electronic control fuel injection system (Common rail type) 1E-221
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Short circuit between terminals
• Short circuit to power supply circuit or
ignition power supply circuit
• Short circuit to other signal circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 6.
Check the SCV body. Between
3.2±0.3 Ω;
1. Turn the key switch to “OFF”. terminals:
2. Disconnect the harness from the SCV.
6 Each terminal
3. Measure the resistance between the SCV
∞Ω (at normal
to SCV body:
connector terminals.
Is the resistance specified value? temperature) Go to Step 8. Go to Step 7.
Replace the supply pump (SCV).
Note:
7 For work procedure, refer to “Engine —
section” in the service manual.
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
TSHK0007 1. SCV-HI
2. SCV-LO
6HK1
TSHK0008
Name
1. SCV
Name
1. Breaker box
2. DMM
1E-224 Electronic control fuel injection system (Common rail type)
On-board check procedure for sensors • If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
3 • If only step 1 is faulty, replace the sensor.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 9. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to barometric pressure
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the barometric pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1E-228 Electronic control fuel injection system (Common rail type)
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
16 If breaker box is not available, refer to “On- —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 17.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
17 —
• Short circuit to barometric pressure
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 8.
1 2 3
TSWG0058
1E-230 Electronic control fuel injection system (Common rail type)
Characteristics of barometric pressure sensor Breaker box inspection procedure
The output voltage of barometric pressure sensor Perform the inspection in the following procedure if
changes according to the barometric pressure. there is such an instruction to use breaker box in the
The scan tool with CAN communication displays a fixed step. After inspection, return to the diagnostic step.
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 40 kPa (5.8 psi) or 127 kPa (18.4 psi) is not
changed.
When error occurs, error value (127 kPa {18.4 psi}) is
displayed. The following illustration shows the
correlation between physical value and voltage
displayed in the scan tools with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
2.279198
Name
1. Breaker box
2. DMM
1.009671
TSWG0205
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the barometric pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the barometric pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
Electronic control fuel injection system (Common rail type) 1E-235
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
16 board check procedure for sensors”. —
Important:
If the barometric pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.
Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 8.
Electronic control fuel injection system (Common rail type) 1E-237
About barometric pressure sensor Characteristics of barometric pressure sensor
The output voltage of barometric pressure sensor
changes according to the barometric pressure.
The scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 40 kPa (5.8 psi) or 127 kPa (18.4 psi) is not
changed.
When error occurs, error value (127 kPa {18.4 psi}) is
displayed. The following illustration shows the
correlation between physical value and voltage
1 2 3
displayed in the scan tools with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
TSWG0058
Name
1. Power supply
2.279198
2. GND
3. Signal
1.009671
TSWG0205
Name
1E-238 Electronic control fuel injection system (Common rail type)
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
15 board check procedure for sensors”. —
changed.
When error occurs, error value (214°C {419°F}) is
displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
4.8691
Name
1. Signal
2. GND
0.1797
-40 120
(-40) (248) F
TSWG0180
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
1E-244 Electronic control fuel injection system (Common rail type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
TSWG0197
Electronic control fuel injection system (Common rail type) 1E-245
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open
circuit or short to power supply circuit)
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
1E-248 Electronic control fuel injection system (Common rail type)
Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the IAT sensor.
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
17 board check procedure for sensors”. —
Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 19.
1E-250 Electronic control fuel injection system (Common rail type)
Note:
If breaker box is not available, refer to “On-
19 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.
changed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
4.8691
Name
1. Signal
2. GND
0.1797
-40 120
(-40) (248) F
TSWG0180
Electronic control fuel injection system (Common rail type) 1E-251
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
Name
1. Breaker box
2. DMM
1E-252 Electronic control fuel injection system (Common rail type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
6 • Short circuit to ECT sensor ground —
circuit
• Short circuit to ground
2. Measure the resistance of ECT sensor,
and check if the measured value is within
the normal range.
3. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the ECT sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
15 • Short circuit to ECT sensor ground —
circuit
• Short circuit to ground
2. Measure the resistance of ECT sensor,
and check if the measured value is within
the normal range.
3. If the trouble is detected, repair or replace
as required.
Is the procedure completed? — Go to Step 7.
2 1
1 2 3
TSWG0061
Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
1E-258 Electronic control fuel injection system (Common rail type)
Characteristics of ECT sensor Breaker box inspection procedure
The output voltage of ECT sensor changes according Perform the inspection in the following procedure if
to the engine coolant temperature. The scan tool with there is such an instruction to use breaker box in the
CAN communication displays a fixed value when the step. After inspection, return to the diagnostic step.
(V)
4.8691
Name
1. Breaker box
2. DMM
0.1797
-40 120
(-40) (248) F
TSWG0180
Electronic control fuel injection system (Common rail type) 1E-259
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Electronic control fuel injection system (Common rail type) 1E-263
Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the ECT sensor.
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
17 board check procedure for sensors”. —
Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.
Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 19.
Electronic control fuel injection system (Common rail type) 1E-265
Note:
If breaker box is not available, refer to “On-
19 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.
(V)
TSWG0061
4.7441
Name
1. Sensor GND (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
0.2129
-40 120
(-40) (248) F
TSWG0181
1E-266 Electronic control fuel injection system (Common rail type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.
Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
15 —
board check procedure for sensors”.
-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210
(V)
0.1973
-30 120
(-22) (248) F
TSWG0203
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Electronic control fuel injection system (Common rail type) 1E-277
Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the supply pump (FT sensor).
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
17 board check procedure for sensors”. —
Important:
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 19.
Electronic control fuel injection system (Common rail type) 1E-279
Note:
If breaker box is not available, refer to “On-
19 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.
changed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
4.5195
Name
1. GND
2. Signal
0.1973
-30 120
(-22) (248) F
TSWG0203
1E-280 Electronic control fuel injection system (Common rail type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
25
step. After inspection, return to the diagnostic step.
20
15
10
-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and common rail pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
7 board check procedure for sensors”. —
Note:
8 —
For work procedure, refer to “Engine
section” in the service manual.
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
3 2 1
TSWG0055
Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
About common rail pressure sensor 2. DMM
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
Electronic control fuel injection system (Common rail type) 1E-287
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the common rail pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Electronic control fuel injection system (Common rail type) 1E-291
Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the common rail (common rail
pressure sensor).
Note:
9 —
For work procedure, refer to “Engine
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
3 2 1
TSWG0055
Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
About common rail pressure sensor 2. DMM
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
1E-294 Electronic control fuel injection system (Common rail type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Electronic control fuel injection system (Common rail type) 1E-297
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front
5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault
7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.
Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
Electronic control fuel injection system (Common rail type) 1E-299
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
Electronic control fuel injection system (Common rail type) 1E-301
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
1E-304 Electronic control fuel injection system (Common rail type)
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front
5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault
7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.
Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
1E-306 Electronic control fuel injection system (Common rail type)
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
1E-308 Electronic control fuel injection system (Common rail type)
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Electronic control fuel injection system (Common rail type) 1E-311
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front
5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault
7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.
Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
Electronic control fuel injection system (Common rail type) 1E-313
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
Electronic control fuel injection system (Common rail type) 1E-315
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
1E-318 Electronic control fuel injection system (Common rail type)
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front
5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault
7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.
Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
1E-320 Electronic control fuel injection system (Common rail type)
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
1E-322 Electronic control fuel injection system (Common rail type)
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
1E-324 Electronic control fuel injection system (Common rail type)
Cylinder No. and injection order Back-up mode
• Injection for cylinder #5 stopped, EGR stopped
3
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set
4
7 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
5 to history trouble and the key switch is turned
“OFF” then “ON” again.
6 • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1E-326 Electronic control fuel injection system (Common rail type)
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Electronic control fuel injection system (Common rail type) 1E-329
Cylinder No. and injection order Back-up mode
• Injection for cylinder #6 stopped, EGR stopped
3
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set
4
7 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
5 to history trouble and the key switch is turned
“OFF” then “ON” again.
6 • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
Electronic control fuel injection system (Common rail type) 1E-331
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75 Br
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
• Key switch input voltage is 18V or more. If the intermittent trouble is suspected, followings may
be the cause.
• DTC P1630 or P1634 is not detected.
• Improper connection of harness connector
DTC set condition • Defective harness routing
• Boost pressure sensor voltage is 0.1V or less for 3 • Worn harness cladding
seconds or more. • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
Action taken when DTC is set causes.
• Trouble is displayed on the monitor of the • Improper connection of harness connector and
machine* or diagnosis lamp comes on. (* Nothing ECM connector
is displayed depending on the machine – Poor connection of terminal from connector
manufacturer) – Unmatched terminals are fitted.
– Damage of connector lock
Back-up mode – Poor contact between terminal and wire
• Specified back-up value (depending on the • Damaged harness
machine manufacturer) (4HK1) – Visually check the harness for damage.
• Boost pressure default setting (150 MPa {21756 – Check the relevant items on the scan tool data
psi}) (6HK1) display while moving the connector and the
• Boost pressure correction/EGR stopped (6HK1) harness which are related to the sensor. The
variation of the display indicates the faulty part.
Recovery from failure
Refer to “List of diagnostic trouble code” and “About Test description
recovery from failure” in this section for recovery from Numbers below indicate step numbers in the chart.
failure. 3.. In case of present trouble, the “MAP (manifold
absolute pressure) sensor” displays less than the
The conditions to clear the MIL/DTC threshold value. If more than the threshold value,
• The present trouble turns to history trouble when identify the cause by referring to “Diagnostic aid”.
the condition is out of the range from DTC set 5. If “MAP (manifold absolute pressure) sensor”
condition (recovery from failure). displays more than the specified value when terminals
• The diagnosis lamp will go off after the code turns between the boost pressure sensor connector are
to history trouble and the key switch is turned shorted, the circuit beyond the sensor is normal
“OFF” then “ON” again. including ECM.
Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and boost pressure sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to boost pressure sensor
ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
1E-338 Electronic control fuel injection system (Common rail type)
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
16 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and boost pressure sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
17 —
• Short circuit to boost pressure sensor
ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.
1E-340 Electronic control fuel injection system (Common rail type)
About boost pressure sensor Characteristics of boost pressure sensor
The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with CAN
communication displays a fixed value when the value
exceeds the threshold voltage. Therefore, judge as it is
more than the threshold value if the value of 40 MPa
(5802 psi) or 350 MPa (50763 psi) is not changed.
When error occurs, error value (508 MPa {73679 psi}) is
displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
3 2 1 with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
TSWG0062 4.75026
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply
0.100082
40(5802) 350(50763)
MPa(psi)
TSWG0063
Electronic control fuel injection system (Common rail type) 1E-341
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
1E-342 Electronic control fuel injection system (Common rail type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the boost pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
1E-346 Electronic control fuel injection system (Common rail type)
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
16 board check procedure for sensors”. —
Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.
Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.
1E-348 Electronic control fuel injection system (Common rail type)
About boost pressure sensor Characteristics of boost pressure sensor
The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with CAN
communication displays a fixed value when the value
exceeds the threshold voltage. Therefore, judge as it is
more than the threshold value if the value of 40 MPa
(5802 psi) or 350 MPa (50763 psi) is not changed.
When error occurs, error value (508 MPa {73679 psi}) is
displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
3 2 1 with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both voltage and physical
value.
(V)
TSWG0062 4.75026
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply
0.100082
40(5802) 350(50763)
MPa(psi)
TSWG0063
Electronic control fuel injection system (Common rail type) 1E-349
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75 Br
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
6 • Open circuit —
• High resistance
• Short circuit to ground
• Short circuit between terminals
• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the CKP sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1E-354 Electronic control fuel injection system (Common rail type)
Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
TSWG0064 TSHK0129
4HK1
TSHK0042
TSHK0128
1E-356 Electronic control fuel injection system (Common rail type)
6HK1 Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
TSWG0151
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75 Br
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
TSWG0064 TSHK0129
4HK1
TSHK0042
TSHK0128
Electronic control fuel injection system (Common rail type) 1E-363
6HK1 Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
TSWG0151
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM
TSWG0197
1E-364 Electronic control fuel injection system (Common rail type)
DTC: P0340 (Flash code 14) Cam sensor fault (no signal)
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75 Br
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 15. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and CMP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Open circuit
• High resistance
• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 15. Go to Step 8.
1. Check for followings in the shield circuit
between ECM and CMP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
8 —
• Open circuit
• High resistance
• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 15. Go to Step 10.
Replace the CMP sensor.
9 —
Is the procedure completed? Go to Step 10. —
Electronic control fuel injection system (Common rail type) 1E-367
Note:
11 For work procedure, refer to “Engine —
section” in the service manual.
Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
15
TSWG0152
Name Name
2. −
1. Shield 1. CMP sensor
3. +
About CKP sensor and CMP sensor signals
4HK1 4HK1
15
1
1
TSHK0040
TSHK0042
Electronic control fuel injection system (Common rail type) 1E-369
6HK1 Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
TSWG0151
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75 Br
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
7 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
Note:
10 For work procedure, refer to “Engine —
section” in the service manual.
Note:
12 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
13 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
15
TSWG0152
Name Name
2. −
1. Shield 1. CMP sensor
3. +
About CKP sensor and CMP sensor signals
4HK1 4HK1
15
1
1
TSHK0040
TSHK0042
1E-376 Electronic control fuel injection system (Common rail type)
6HK1 Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
TSWG0151
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM
TSWG0197
Electronic control fuel injection system (Common rail type) 1E-377
DTC: P0380 (Flash code 66) Glow relay circuit fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)
(100A)*
Starter
B
Battery B
Generator
(15A)*
(60A)*
(10A)*
1 H-22
0.5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
TSWG0072
Note:
If breaker box is not available, refer to “On-
8 board check procedure for sensors”. —
• Open circuit
• Short circuit to ground circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Remove the glow relay.
3. Turn the key switch to “ON”.
9 —
4. Check for “Glow relay” on the data display
using scan tool.
Is the “Glow relay” displayed “OFF”? Go to Step 11. Go to Step 10.
1E-380 Electronic control fuel injection system (Common rail type)
Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
(15A)*
A A
Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp
3 H-6
1 E-164
Machine
control unit O/H switch
Tachometer signal
CAN HIGH CAN LOW
TSHK0022
6 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
Note:
If breaker box is not available, refer to “On-
10 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 14. Go to Step 12.
Replace the meter.
11 —
Is the procedure completed? Go to Step 14. —
Replace the QOS indicator lamp bulb.
12 —
Is the procedure completed? Go to Step 14. —
13 Is EMPS available? — Go to Step 14. Go to Step 15.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
3 —
• Short circuit to EGR position sensor
ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 4.
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 3. Turn the key switch to “OFF” for more than —
10 seconds, and then start the engine.
4. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
5. Check the DTC.
Go to “Diagnostic
Is DTC P0487 detected? Go to Step 5. aid”.
Replace the EGR valve (EGR position sensor).
Note:
5 For work procedure, refer to “Engine —
section” in the service manual.
Note:
8 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
TSWG0158
Name
1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V Name
4. Position sensor signal U 1. Breaker box
5. Position sensor ground 2. DMM
6. Motor drive W
7. Motor drive V
8. Motor drive U
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Open circuit
• Short circuit to ground
• Short circuit to power supply circuit or
ignition power supply circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 6.
Replace the EGR valve.
Note:
6 For work procedure, refer to “Engine —
section” in the service manual.
Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
TSWG0158
Electronic control fuel injection system (Common rail type) 1E-397
EGR valve check Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
TSWG0150
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
9 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
14 board check procedure for sensors”. —
TSWG0164 (V)
4.85
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply
0.496
0 1088.5(157.9)
kPa(psi)
TSWG0202
1E-404 Electronic control fuel injection system (Common rail type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
TSWG0197
Electronic control fuel injection system (Common rail type) 1E-405
DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to
power supply, ground short)
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the engine oil pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
1E-408 Electronic control fuel injection system (Common rail type)
Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the engine oil pressure sensor.
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
16 board check procedure for sensors”. —
Important:
If the engine oil pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.
Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1E-410 Electronic control fuel injection system (Common rail type)
Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.
About engine oil pressure sensor Characteristics of engine oil pressure sensor
The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 0 kPa (0 psi) or 1088.5 kPa (157.9 psi) is
not changed.
When error occurs, error value (1016 kPa {147.4 psi})
is displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
1 2 3 EST Diagnostic tool and scan tools with KW
communication can display both physical value and
voltage.
TSWG0164 (V)
4.85
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply
0.496
0 1088.5(157.9)
kPa(psi)
TSWG0202
Electronic control fuel injection system (Common rail type) 1E-411
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Note:
4 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
4 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
4 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
TSHK0023
Note:
8 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
TSHK0023
Note:
8 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
(15A)*
A A
Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp
3 H-6
1 E-164
Machine
control unit O/H switch
Tachometer signal
CAN HIGH CAN LOW
TSHK0022
6 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
Note:
If breaker box is not available, refer to “On-
10 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 12.
Replace the meter.
11 —
Is the procedure completed? Go to Step 16. —
Replace the diagnosis lamp bulb.
12 —
Is the procedure completed? Go to Step 16. —
13 Is EMPS available? — Go to Step 14. Go to Step 15.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
Electronic control fuel injection system (Common rail type) 1E-431
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Absolute pressure
5
30MPa(4351psi)
Actual 1 P1093
2
t2 > 5sec
t1 > 3sec
15MPa Actual 2
(2176psi) P0087
TSHK0130
1
TSHK0039
Action taken when DTC is set
Name • Trouble is displayed on the monitor of the
1. Fuel pump strainer machine* or diagnosis lamp comes on. (* Nothing
2. Pre-fuel filter is displayed depending on the machine
3. Electromagnetic pump filter manufacturer)
4. Main fuel filter
5. Gauze filter Back-up mode
Filter clogging in the fuel system may establish the DTC • Limited injection amount 3 (multi-injection stopped)
set condition. Check as required. • Target RP upper limit (80 MPa {11603 psi})
5 Note: —
For work procedure, refer to “Engine
section” in the service manual.
8 Note: —
For work procedure, refer to “Engine
section” in the service manual.
Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
15 —
For work procedure, refer to “Engine
section” in the service manual.
±5 MPa
2. Start the engine.
16 3. Select the “Actuator test” from the menu.
4. Select the “Rail pressure control” in the (±725 psi)
“Common rail system”.
5. Press the “Up” soft key to check the value
of “Common rail pressure”.
Is “Common rail pressure” within the specified
value? Go to Step 18. Go to Step 17.
Replace the supply pump.
Note:
17 For work procedure, refer to “Engine —
section” in the service manual.
1
2
3 2 1
3
TSHK0106
TSWG0055 Name
Name 1. Electromagnetic Pump
3. − terminal
1. Sensor ground 2. + terminal
2. Sensor signal
3. Sensor power supply
3. Blow air into the inlet of the electromagnetic pump
with your mouth.
Electromagnetic pump inspection procedure • The internal seal may be stuck. Blow air to
1. Turn the key switch to ON, and check for pulsation eliminate sticking.
in the fuel hose.
• It is normal if pulsation exists.
2. Disconnect the electromagnetic pump connector,
and connect 24V power supply to the 2
electromagnetic pump side to check if the pump
operates.
• If it operates properly, there may be open
circuit, short circuit or poor contact in the
machine-side harness. Repair the faulty part,
and check again from Step 1.
• If the electromagnetic pump does not operate,
replace the pump. 1
TSHK0107
Name
1. Fuel inlet port
2. Fuel outlet port
Name
1. Breaker box
2. DMM
TSWG0197
Electronic control fuel injection system (Common rail type) 1E-439
DTC: P1095 (Flash code 225) Pressure limiter open
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
1E-440 Electronic control fuel injection system (Common rail type)
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
4
3
Common rail
presure
T>1sec=P1095
5 200 MPa
(29008psi)
190 MPa T
(27557psi)
185 MPa
2 (26832psi)
T
T>5sec=P0088
TSHK0043
1
TSHK0039
Action taken when DTC is set
Name • Turns the diagnosis lamp ON.
1. Fuel pump strainer
2. Pre-fuel filter Back-up mode
3. Electromagnetic pump filter
4. Main fuel filter • Limited injection amount 1
5. Gauze filter • Output goes down to about 50% since fuel flow is
limited.
Filter clogging in the fuel system may establish the DTC
set condition. Check as required. Recovery from failure
Refer to “List of diagnostic trouble code” and “About
Preconditions when DTC is set
recovery from failure” in this section for recovery from
• Key switch input voltage is 18V or more. failure.
• DTC P1095, P0192, P0193, P1630, or P1635 is
not detected. The conditions to clear the MIL/DTC
• 50 rpm or more • The present trouble turns to history trouble when
the condition is out of the range from DTC set
DTC set condition condition (recovery from failure).
• When pressure limiter is opened. • The diagnosis lamp will go off after the code turns
• When common rail pressure is more than 200 MPa to history trouble and the key switch is turned
(29008 psi) for 1 second or more. “OFF” then “ON” again.
• DTC set condition in the case of high common rail • Using the scan tool, or memory clear switch and
pressure is described below. diagnostic switch operation enables to clear DTCs.
Only P1095 is detected if the fuel pressure
overshoots due to entry of air. Diagnostic aid
Followings are suspected as the cause.
• Air mixed in the high-pressure fuel pipe.
• Injector internal trouble
• Supply pump internal trouble
• Fuel system pipe fault (clogging etc.)
• Fuel filter fault (temporary clogging due to waxing
at low temperatures, improper tightening of filter
cartridge, etc.)
• Fuel tank fault (temporary clogging, air mixed due
to fuel shortage, air mixed due to modified fuel pipe
for additional tank etc.)
1E-442 Electronic control fuel injection system (Common rail type)
• Pressure limiter trouble (operation under specified Test description
pressure, degradation of sealability) Numbers below indicate step numbers in the chart.
• ECM trouble 8. If the “Common rail pressure sensor” displays more
• Common rail pressure sensor trouble than the specified value when the common rail
• Running out of fuel pressure sensor connector is removed, the circuit
beyond the sensor is normal including ECM.
Note:
• Bleeding air from fuel must be
performed correctly, following the
procedure.
• For work procedure, refer to “Engine
section” in the service manual.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
13 —
For work procedure, refer to “Engine
section” in the service manual.
Note:
For work procedure, refer to “Engine
section” in the service manual.
Note:
• Bleed air completely after the parts are
replaced. If air bleeding is not
17 sufficient, P1095 may be detected due —
to overshoot of fuel pressure.
• For work procedure, refer to “Engine
section” in the service manual.
Is the procedure completed? Go to Step 18. —
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
18 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1095 detected? Go to Step 2. Go to Step 19.
Check if other DTC is detected.
19 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
4. Connect the DMM between the common
rail pressure sensor connector signal
terminal and the ground.
20 0V
Is the DMM indication specified value?
Note:
If the display of DMM is not specified value,
ECM side wiring, wrap-around in ECM or
short circuit may be the cause.
If it is specified value, ECM side wiring is
normal. Go to Step 13. Go to Step 9.
Electronic control fuel injection system (Common rail type) 1E-447
About common rail pressure sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply Name
1. Breaker box
Characteristics of common rail pressure sensor 2. DMM
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and boost temperature
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to boost temperature
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the boost temperature sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1E-452 Electronic control fuel injection system (Common rail type)
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
16 If breaker box is not available, refer to “On- —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 17.
1. Check for followings in the signal circuit
between ECM and boost temperature
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
17 —
• Short circuit to boost temperature
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.
is not changed.
When error occurs, error value (214°C {419°F}) is
displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both physical value and
voltage.
(V)
4.9824
1.1719
-40 120
(-40) (248) F
TSWG0204
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
Electronic control fuel injection system (Common rail type) 1E-455
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
Note:
If breaker box is not available, refer to “On-
5 board check procedure for sensors”. —
Important:
If the boost temperature sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.
Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”. Note:
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the boost temperature sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
If breaker box is not available, refer to “On-
15 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 7.
Electronic control fuel injection system (Common rail type) 1E-461
About boost temperature sensor Characteristics of boost temperature sensor
The output voltage of boost temperature sensor
changes according to the boost temperature. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage.
changed.
When error occurs, error value (214°C {419°F}) is
displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
EST Diagnostic tool and scan tools with KW
communication can display both physical value and
voltage.
(V)
4.9824
Name
1. Signal
2. GND
1.1719
-40 120
(-40) (248) F
TSWG0204
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
1E-462 Electronic control fuel injection system (Common rail type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Description of circuit
The engine coolant temperature (ECT) sensor is
installed in the thermostat housing. The ETC sensor is
the thermistor-type sensor, and the value of resistance
and output voltage change according to the engine
coolant temperature. As the engine coolant
temperature increases, the resistance becomes small,
and the voltage lowers. The ECM detects the engine
coolant temperature based on the signal from the ECT
sensor to perform various controls.
The ECM sets the DTC when it judges that the engine
coolant temperature exceed certain level based on the
signal from the ECT sensor.
1E-464 Electronic control fuel injection system (Common rail type)
Main trouble symptom The conditions to clear the MIL/DTC
• Output lowering • The present trouble turns to history trouble when
• Fuel flow is regulated during overheat when the the condition is out of the range from DTC set
temperature exceeds 108°C (226°F). condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
(226 )
Diagnostic aid
100%
If the intermittent trouble is suspected, followings may
be the cause.
• Improper connection of harness connector
Fuel fiow
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
−40°C
3. Turn the key switch to “ON”.
14 4. Check the display of the “Engine coolant
(−40°F)
temperature”.
Is the “Engine coolant temperature” more than
the specified value? Go to Step 6. Go to Step 5.
Electronic control fuel injection system (Common rail type) 1E-467
About ECT sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
2 1 step. After inspection, return to the diagnostic step.
1 2 3
TSWG0061
Name
1. Sensor GND (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter) Name
1. Breaker box
Characteristics of ECT sensor 2. DMM
(V)
4.7441
0.2129
-40 120
(-40) (248) F
TSWG0181
1E-468 Electronic control fuel injection system (Common rail type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
(15A)*
Engine control
module (ECM)
Idling selector Idle up Idle down Mode map Mode map Mode map
switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal
TSWG0082
Note:
8 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Measure the resistance between the No. 1
cylinder injector drive circuit and the
6 ground. 10 MΩ
4H: H94 male-side No. 5
6H: H94 male-side No. 2
Is the resistance more than the specified
value? Go to Step 7. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Measure the resistance between the No. 2
cylinder (4H: No. 4 cylinder) injector drive
7 circuit and the ground. 10 MΩ
4H: H94 male-side No. 8
6H: H94 male-side No. 7
Is the resistance more than the specified 4H: Go to Step 12.
value? 6H: Go to Step 8. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Measure the resistance between the No. 3
8 cylinder injector drive circuit and the 10 MΩ
ground.
6H: H94 male-side No. 6
Is the resistance more than the specified
value? Go to Step 12. Go to Step 11.
Electronic control fuel injection system (Common rail type) 1E-477
Note:
23 For work procedure, refer to “Engine —
section” in the service manual.
Note:
25 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
26 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
1E-482 Electronic control fuel injection system (Common rail type)
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
3 3
3 E-35 3 E-37 E-27 E-31
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Turn the key switch to “OFF”.
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Measure the resistance between the No. 4
6 cylinder (4H: No. 2 cylinder) injector drive 10 MΩ
circuit and the ground.
4H: H94 male-side No. 7
6H: H95 male-side No. 2
Is the resistance more than the specified
value? Go to Step 7. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Measure the resistance between the No. 5
7 cylinder (4H: No. 3 cylinder) injector drive 10 MΩ
circuit and the ground.
4H: H94 male-side No. 6
6H: H95 male-side No. 7
Is the resistance more than the specified 4H: Go to Step 12.
value? 6H: Go to Step 8. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-95).
3. Measure the resistance between the No. 6
8 cylinder injector drive circuit and the 10 MΩ
ground.
6H: H95 male-side No. 6
Is the resistance more than the specified
value? Go to Step 12. Go to Step 11.
1E-488 Electronic control fuel injection system (Common rail type)
Note:
23 For work procedure, refer to “Engine —
section” in the service manual.
Note:
25 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
26 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Name
1. Breaker box
2. DMM
Electronic control fuel injection system (Common rail type) 1E-493
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
6 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
8 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
9 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
0 99.8 (%)
TSWG0200
1E-500 Electronic control fuel injection system (Common rail type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to AP sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1E-504 Electronic control fuel injection system (Common rail type)
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the AP sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
About AP sensor
Refer to the machine’s manual for installing position of
the AP sensor.
1E-510 Electronic control fuel injection system (Common rail type)
Characteristics of AP sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
(V) step. After inspection, return to the diagnostic step.
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and AP sensor 1 using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to AP sensor 1 ground
circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1E-514 Electronic control fuel injection system (Common rail type)
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the AP sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
About AP sensor
Refer to the machine’s manual for installing position of
the AP sensor.
1E-520 Electronic control fuel injection system (Common rail type)
Characteristics of AP sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
(V) step. After inspection, return to the diagnostic step.
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75 Br
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Back-up mode
Specified back-up value (depending on the machine
manufacturer)
1E-522 Electronic control fuel injection system (Common rail type)
Recovery from failure • Defective harness routing
Refer to “List of diagnostic trouble code” and “About • Worn harness cladding
recovery from failure” in this section for recovery from • Wire disconnection inside harness cladding
failure. • Excessive air mixed in the fuel.
Following inspections are necessary to detect these
The conditions to clear the MIL/DTC causes.
• The present trouble turns to history trouble when • Improper connection of harness connector and
the condition is out of the range from DTC set ECM connector
condition (recovery from failure). – Poor connection of terminal from connector
• The diagnosis lamp will go off after the code turns – Unmatched terminals are fitted.
to history trouble and the key switch is turned – Damage of connector lock
“OFF” then “ON” again.
– Poor contact between terminal and wire
• Using the scan tool, or memory clear switch and
• Damaged harness
diagnostic switch operation enables to clear DTCs.
– Visually check the harness for damage.
Diagnostic aid – Check the relevant items on the scan tool data
display while moving the connector and the
If the intermittent trouble is suspected, followings may
harness which are related to the sensor. The
be the cause.
variation of the display indicates the faulty part.
• Improper connection of harness connector
TSWG0064 TSHK0129
4HK1
Name
1. Signal
TSHK0128 2. GND
3. Power supply
Electronic control fuel injection system (Common rail type) 1E-525
4HK1 About CKP sensor and CMP sensor signals
4HK1
15
1
1
TSHK0040
TSHK0042
6HK1
6HK1
15
1
1
TSWG0152
TSWG0151
Name
1. CMP sensor Name
1. CKP signal
2. CMP signal
1E-526 Electronic control fuel injection system (Common rail type)
DTC: P1625 (Flash code 416) Main relay fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)
(MAIN)* (30A)*
B+ B+
Engine control
module (ECM)
TSWG0071
Note:
5 Refer to the machine’s manual for installing —
position and installation/removal
procedures of the main relay.
Note:
If breaker box is not available, refer to “On-
10 board check procedure for sensors”. —
• Open circuit
• Short circuit to ground circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 15. Go to Step 12.
Replace the main relay.
11 —
Is the procedure completed? Go to Step 15. —
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
19 Refer to the machine’s manual for installing —
position and installation/removal
procedures of the main relay.
Name
1. Breaker box
2. DMM
1E-532 Electronic control fuel injection system (Common rail type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Main trouble symptom Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
• Output lowering failure.
• Black smoke emitted
The conditions to clear the MIL/DTC
DTC set condition
• The present trouble turns to history trouble when
• Analog/digital conversion failure the condition is out of the range from DTC set
condition (recovery from failure).
Action taken when DTC is set • The diagnosis lamp will go off after the code turns
• Turns the diagnosis lamp ON. to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
Note:
4 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
A A Engine control
module (ECM)
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
TSHK0029
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSHK0030
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Engine control
module (ECM)
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
V U
EGR valve
TSHK0028
Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Symptom Description
Engine start failure Crank speed is slow.
Crank speed is normal but engine does not start (no first
combustion).
Engine starts (first combustion exists) but cannot maintain
stable engine speed, or no blow up.
Engine stall Engine cranks but take long time before start. It operates
eventually, or starts but stops immediately.
Engine hunting, rough idling Engine idle speed is rough, or idle speed changes. In a more
severe case, engine or machine vibrates. In any serious
situations, the engine stalls.
Engine output shortage, lag down Engine output is lower than expected, and output does not
change with the accelerator lever (throttle lever) released,
engine response deteriorates.
Exhaust gas contains a lot of white smoke. A lot of white smoke emitted while running.
Exhaust gas contains a lot of black smoke. A lot of black smoke emitted while running.
Noise Abnormal sound occurs from the engine.
Fuel consumption deteriorates. Fuel consumption is remarkably more than that indicated in
the machine’s manual. The situation shown here is that the
problem is not found on the machine side and the engine
needs to be checked.
Oil consumption deteriorates. Oil consumption is remarkably lower than that indicated in the
machine’s manual. The situation shown here is that the
problem is not found on the machine side and the engine
needs to be checked.
Electronic control fuel injection system (Common rail type) 1E-551
Engine start failure
Pre-inspection Diagnostic aid
Before using this paragraph, perform the “OBD system • If the crank sensor is faulty, crank more than 60
check” and check all the following items. rpm for 14 seconds or more since it is not judged
• Check if excessive load is applied to the machine on cranking for less than 14 revolutions.
side. • When the engine is running at low speed, the DTC
• ECM and diagnosis lamp operate properly. of crank sensor fault may not be detected. If an
• Check the DTC. intermittent trouble is found, raise the engine
speed up to No Load Max, and check if DTC
• Scan tool data shows normal operating range.
related to crank sensor is detected.
• Check the condition of the machine to identify the
• Fuel system fault (run out of fuel, frozen fuel, air
applicable symptom from “List of trouble
mixed in fuel pipe, faulty filter [clog in main filter,
symptom”. Perform the procedure described in the
gauze filter], pipe fault, fuel quality, fuel tank
symptom chart.
[foreign matter, fuel suction fault])
• Check with the customer if correct engine oil and
• Intake system fault (clogging in filter, intake pipe
fuel are used.
fault, etc.)
Visual check • Supply pump fault (no fuel pressure feed)
• Common rail fault (flow damper or pressure limiter
Careful visual check is required for some symptom
is activated, degradation of sealability)
procedures. By this inspection, the problem can be
corrected without performing further inspection, and • Injector fault (no fuel injection)
time can be saved. • System down due to trouble
This inspection includes the following items. • Engine body fault
This inspection includes the following items. (seizure, compression pressure shortage, other
• There is no dirt or clogging in fuel filter. mechanical trouble)
• There is no poor contact in connector (it must be • ACG trouble
connected with click sound). Especially for CKP • Machine side related equipment trouble
sensor and CMP sensor. (oil pressure pump etc.)
• The terminal voltage of battery is not low. • Effect of commercial electrical equipment (radio,
• Wire is connected, tightened or cut properly. lamp, etc.)
• Commercial accessory power supply is not • ECM trouble
bifurcated from ECM power supply. (body, power supply, ground, etc.)
• ECM ground is not contaminated and installed to • Check the connector for poor contact, the harness
the proper position securely. for fault such as wear or bend, and the wire inside
• Pipes and hoses relevant to fuel, air and oil are the harness for loosened wire causing short circuit
free of crack or twist, and are properly connected. to other circuits. Also, perform the function
Thoroughly check for any oil leakage and clogging. diagnosis to check the operation and control of
• Fuel system is free from oil leakage, and pipe is each part. Repair if faulty.
not damaged or dent.
• Intake system parts for fault.
• Exhaust system parts for fault.
9 Note: —
For work procedure, refer to “Engine
section” in the service manual.
10 Note: —
Refer to the machine’s manual for charge
warning.
Note:
For work procedure, refer to “Engine
section” in the service manual.
Note:
16 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
17 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
2 Note: —
Refer to the machine’s manual for check
and repair.
4 Note: —
Refer to the machine’s manual for charge
warning.
Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
2 Note: —
Refer to the machine’s manual for check
and repair.
Note:
4 —
For work procedure, refer to “Engine
section” in the service manual.
8 Note: —
For work procedure, refer to “Engine
section” in the service manual.
Note:
20 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
21 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
22 after replacing or rewriting the ECM. —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
4 Note: —
Refer to the machine’s manual for check
and repair.
Note:
6 —
For work procedure, refer to “Engine
section” in the service manual.
15 Note: —
For work procedure, refer to “Engine
section” in the service manual.
Note:
17 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
18 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
19 after replacing or rewriting the ECM. —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
9 Note: —
For work procedure, refer to “Engine
section” in the service manual.
Note:
12 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
13 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.
TSWG0150
5 Note: —
For work procedure, refer to “Engine
section” in the service manual.
11 Note: —
For work procedure, refer to “Engine
section” in the service manual.
3 1
6 7 8 9 10
TSWG0163
Name
1. Exhaust pipe 6. Secondary EGR cooler
2. To intercooler 7. From intercooler
3. From air cleaner 8. EGR valve
4. EGR duct 9. EGR duct
5. Primary EGR cooler 10. EGR duct
Check the above intake/exhaust system for fault such as clogging, crush or breakage.
Besides the inspection location of engine body, check the air cleaner, intercooler and muffler.
Electronic control fuel injection system (Common rail type) 1E-579
Oil consumption deteriorates.
Pre-inspection Visual check
Before using this paragraph, perform the “OBD system Careful visual check is required for some symptom
check” and check all the following items. procedures. By this inspection, the problem can be
• Oil consumption varies depending on handling of corrected without performing further inspection, and
each machine. Check the machine manufacturer’s time can be saved. This inspection includes the
measure of oil consumption (A). following items.
Measure of oil consumption/hour • If bluish-white smoke is emitted continuously while
Measure of oil consumption for engine alone: engine running.
42{4.2qts}/100 hours • If blow-by gas is emitted.
• Check the actual oil consumption (B). • If oil is mixed in the coolant.
Actual oil consumption /hour • Pipes and hoses relevant to oil are free of crack or
• Refer to the list of inspection and maintenance twist, and are properly connected. Thoroughly
items of the operation manual for proper inspection check for any oil leakage and clogging.
depending on the operation time. • Lubrication system is free from oil leakage, and
• If the operation time exceeds 3000 hours, inspect pipe is not damaged or dent.
by referring to the machine’s manual. • Intake system parts for fault (turbocharger check).
• ECM and diagnosis lamp operate properly.
• Check the DTC. Diagnostic aid
• Check the condition of the machine to identify the • Intake system fault (rise/decline of oil, excessive
applicable symptom from the table of contents. blow-by gas)
Perform the procedure described in the symptom • Engine body fault (oil combustion, excessive blow-
chart. by gas)
• Check with the customer if correct engine oil and Also, perform the function diagnosis to check the
fuel are used. operation and control of each part. Repair if faulty.
Note:
Use the operation mode mentioned in the
machine’s manual to make comparison.
Explain this to the
Is the oil consumption within specified value? customer. Go to Step 2.
Check for oil leakage. Repair or replace the
2 faulty part. —
Is the procedure completed? Verify repair. Go to Step 3.
Check if bluish-white smoke is emitted while
engine running.
3 If it is emitted only at the starting, go to —
“Exhaust gas contains a lot of white smoke.”
Is bluish-white smoke emitted? Go to Step 4. Go to Step 6.
Check the blow-by gas quantity.
4 —
Is it more than the specified value? Go to Step 7. Go to Step 5.
1E-580 Electronic control fuel injection system (Common rail type)
Note:
8 For work procedure, refer to “Engine —
section” in the service manual.
Note:
9 For work procedure, refer to “Engine —
section” in the service manual.
Note:
10 For work procedure, refer to “Engine —
section” in the service manual.
11 Note: —
For work procedure, refer to “Engine
section” in the service manual.
Special Tool
Tool No. Tool No.
Illustration Illustration
Tool name Tool name
IJC
380.060.159
EST Diagnostic tool
Scan tool
R3808
5-8840-0632-0
Terminal remover
5-8840-0388-0
Weather pack terminal
remover
5-8840-0385-0
Breaker box
5884003850
Engine module
programming system
EMPS