S7-Lxje03c 1
Uploaded by
PHÁT NGUYỄN THẾS7-Lxje03c 1
Uploaded by
PHÁT NGUYỄN THẾMENU
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner's Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys-
tems in these vehicles.
Manual Name Pub. No.
S1-LXJE03A
Chassis Workshop Manual
S1-LXJE03A EWD
J05E Engine Workshop Manual S5-LJ05E04A
S7-LXJE03C 2/7
S7-LXJE03C 3/7
S7-LXJE03C 4/7
Trouble shooting Workshop Manual
S7-LXJE03C 5/7
S7-LXJE03C 6/7
S7-LXJE03C 7/7
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL No. S7-LXJE03C 1/7 (U.S.A.), S7-LXJE04C 1/7 (CANADA)
CHAPTER MODELS HINO 155, 155h, 195, 195h
Production Code XFC710, XFC720, XFC740, XJC700, XJC710, XJC720, XJC740
GENERAL INTRODUCTION 1-001
ENGINE 2-001 (J05E)
INDEX: TROUBLE SHOOTING GROUP 1/2
GENERAL INTRODUCTION
ENGINE
HYBRID
WORKSHOP TRANSMISSION
MANUAL CLUTCH
PROPELLER SHAFT
AXLE
DIFFERENTIAL
BRAKE
STEERING
SUSPENSION
FRAME AND FRAME ACCESSORY
CAB MOUNTING AND CAB SUSPENSION
BODY CONSTRUCTION
BODY INSIDE ACCESSORY
BODY OUTSIDE ACCESSORY
AIR BAG AND SEAT BELT
All rights reserved. This manual may not be
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd. HEATER AND AIR CONDITIONER
INDEX: TROUBLE SHOOTING GROUP 2/2
ELECTRICAL
CONTROL SYSTEM
GENERAL INTRODUCTION 1–1
GENERAL INTRODUCTION
1
1-001
HOW TO IDENTIFY VEHICLE TYPE .............. 1-2
HOW TO IDENTIFY VEHICLE TYPE ...........................1-2
VEHICLE TYPE ......................................................1-2
VEHICLE IDENTIFICATION NUMBER (VIN)
STRUCTURE ..........................................................1-3
APPEARANCE OF VEHICLE ......................... 1-4
APPEARANCE.............................................................1-4
APPEARANCE OF VEHICLE .................................1-4
SAFETY INSTRUCTIONS AND
READINESS TO WORK .................................. 1-5
WARNING ....................................................................1-5
GENERAL PRECAUTIONS ....................................1-5
IDENTIFICATION INFORMATION ........................1-10
SAFETY INSTRUCTIONS FOR WORK.....................1-12
PRECAUTIONS ....................................................1-12
INTRODUCTION TO WORKSHOP MANUAL............1-16
GENERAL .............................................................1-16
INTRODUCTION TO DESCRIPTIONS.................1-17
DEFINITION OF TERM.........................................1-20
TROUBLE SHOOTING .................................. 1-21
TROUBLESHOOTING WITH
DIAGNOSIS MONITOR ..............................................1-21
TROUBLESHOOTING PROCEDURE ..................1-21
APPARATUS FOR TROUBLE SHOOTING...........1-23
TROUBLESHOOTING WITH
COMPUTER (HINO-DX).............................................1-24
STEP OF TROUBLE SHOOTING.........................1-24
APPARATUS FOR TROUBLE SHOOTING...........1-25
GLOSSARY ................................................... 1-26
DEFINITION OF ABBREVIATION .............................1-26
LIST OF ABBREVIATION .....................................1-26
GLOSSARY OF SAE AND HINO TERMS ............1-29
1–2 GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE
HOW TO IDENTIFY VEHICLE TYPE
HOW TO IDENTIFY VEHICLE TYPE
VEHICLE TYPE
EN01H01ZZZ010102001001
Ԙ ԙ Ԛ ԛ Ԝ ԝ Ԟ ԟ Ԡ ԡ Ԣ ԣ Ԥ ԥ Ԧ
X J C 7 0 0 L H K T Q L A 3
REPORTED MODEL CLASSIFICATION
Ԙ ԙ㧦ENGINE MODEL Ԛ㧦VEHICLE MODEL ԡ㧦DECK HEIGHT
X F J05E-TP (HV) C HEAVY DUTY TRACK K HIGH FLOOR CAB
X J J05E-TP (Diesel)
ԛ Ԝ㧦CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE Ԣ㧦TRANSMISSION
CAB WIDTH DRIVE FRAME WHEEL BASE T 6AT
FORM FRAME ASSEMBLY WIDTH
840 mm {33 in.}
7 0 WIDE 2WD OPEN MEDIUM 2,900 mm {114 in.}
7 1 WIDE 2WD OPEN LONG 3,500 mm {138 in.} ԣ㧦LOADING CAPACITY, GVW, REAR TIRES
7 2 WIDE 2WD OPEN SUPER LONG 3,800 mm {150 in.} Q 6.58 t {14,500 lbs} REAR DOUBLE
7 4 WIDE 2WD OPEN SUPER LONG 4,400 mm {173 in.} 8.14 t {17,950 lbs},
T REAR DOUBLE
8.85 t {19,500 lbs}
ԝ㧦TYPE OF SUSPENSION Ԥ㧦ENGINE HORSEPOWER, FUEL
0 FRONT RIGID, REAR RIGID FUEL HORSEPOWER EXHAUST
L DIESEL OIL VERY HIGH US10
ԟ㧦STEERING WHEEL POSITION ԥ㧦DESTINATION
L LEFT HAND DRIVE
DESTINATION
A U.S., CANADA
Ԡ㧦CAB FORM, BRAKE TYPE
CAB FORM BRAKE TYPE
H SINGLE CAB VACUUM Ԧ㧦DECK FORM
Q CREW CAB VACUUM 3 CHASSIS WITH CAB
C SINGLE CAB HYDRAULIC
D CREW CAB HYDRAULIC
SHTS01ZZZ0100001
WMI VDS CD VIS
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)
J H H K D L 2 H X C K 0 0 1 0 0 1
MANUFACTURER ,TYPE SERIES CHECK DIGIT ASSEMBLY PLANT
SEQUENTIAL NUMBER
MODEL, CAB TYPE, ENGINE MODEL MAKE MODEL YEAR
WHEEL BASE,
BRAKE SYSTEM
CODE MANUFACTURER TYPE CODE YEAR CODE YEAR
JHN HINO MOTORS, LTD. INCOMPLETE VEHICLE C 2012 H 2017
HINO MOTORS D 2013 J 2018
2AY INCOMPLETE VEHICLE
CANADA, LTD. E 2014 K 2019
F 2015 L 2020
PRODUCTION BRAKE
CODE CLASS MODEL CAB TYPE WHEEL BASE
CODE SYSTEM G 2016 M 2021
HINO 195h XFC710 COE
H 5 3500mm{138 in.} HYDRAULIC For USA
HINO 195 XJC710 SINGLE CAB
CODE ASSEMBLY PLANT
COE CODE MAKE
K 5 HINO 195 XJC700 2900mm{114 in.} HYDRAULIC HINO MOTORS, LTD.
SINGLE CAB K Hamura Plant in Japan
HINO 155h XFC720 COE H HINO
L 4 3800mm{150 in.} VACUUM
HINO 155 XJC720 CREW CAB For Canada
HINO 155h XFC740 COE CODE ASSEMBLY PLANT
P 4 4400mm{173 in.} VACUUM
HINO 155 XJC740 CREW CAB
CODE SERIES GVWR
1 Canada Plant (COE)
HINO 195h XFC720 COE
R 5 3800mm{150 in.} HYDRAULIC 1 6,580 kg
HINO 195 XJC720 SINGLE CAB
{14,500 lbs.} HINO MOTORS, LTD.
HINO 195h XFC740 COE K Hamura Plant in Japan
S 5 4400mm{173 in.} HYDRAULIC 8,140 - 8,850 kg
HINO 195 XJC740 SINGLE CAB 2
{17,950 - 19,500 lbs.}
COE
T 4 HINO 155 XJC700 2900mm{114 in.} VACUUM
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE
SINGLE CAB
HINO 155h XFC710 COE
U 4 3500mm{138 in.} VACUUM
HINO 155 XJC710 SINGLE CAB
GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE
HINO 195h XFC720 COE
V 5 3800mm{150 in.} HYDRAULIC
HINO 195 XJC720 CREW CAB CODE ENGINE MODEL APPLICATION
HINO 195h XFC740 COE
W 5 4400mm{173 in.} HYDRAULIC PL J05E Hybrid
HINO 195 XJC740 CREW CAB
HINO 155h XFC740 COE DL J05E Diesel
X 4 4400mm{173 in.} VACUUM
HINO 155 XJC740 SINGLE CAB
HINO 155h XFC720 COE
Y 4 3800mm{150 in.} VACUUM
HINO 155 XJC720 SINGLE CAB
SHTS01ZZZ0100002
1–3
EN01H01ZZZ010102001002
1–4 GENERAL INTRODUCTION/APPEARANCE OF VEHICLE
APPEARANCE OF VEHICLE
APPEARANCE
APPEARANCE OF VEHICLE
EN01H01ZZZ020101003001
SHTS01ZZZ0200001
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–5
SAFETY INSTRUCTIONS AND READINESS TO WORK
WARNING
GENERAL PRECAUTIONS
EN01H01ZZZ030101001001
Some recommended and standard maintenance services for your vehicle are included in this section. When performing
maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a mal-
function of the vehicle which may result in personal injury and/or property damage. If you have any question about per-
forming maintenance, please consult your Hino dealer.
WARNING
When working on your vehicle, observe the following general precautions to prevent death, personal injury and/
or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chap-
ter.
• Always wear safety glasses or goggles to protect your eyes.
• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
• Bind long hair securely behind the head.
• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and
block the wheels.
• Always turn off the starter switch to stop the engine, unless the operation requires the engine running.
Removing the key from the switch is recommended.
• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia-
tor, muffler, exhaust pipe and tail pipe.
• Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.
• Take utmost care when working on the battery. It contains corrosive sulfuric acid.
• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
• Read carefully and observe the instructions specified on the jack before using it.
• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a
vehicle supported only by a jack.
• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly
applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.
• Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.
• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
• Be careful not to damage lines and hoses by stepping or holding your feet on them.
• Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can
cause personal injury.
1–6 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
PRECAUTIONS IN TILTING AND LOWERING THE CAB
! WARNING
Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may
result in death, serious injury and/or property damage.
• Park the vehicle on a level place and ensure ample space around the cab before tilting the cab.
• Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is
equipped with automatic transmission).
• Stop the engine and block the wheels.
• Remove any articles in or over the cab and close the doors firmly.
• Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the
cab.
• The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very
hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working
under the cab.
• Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack.
• Never put your body under the cab while raising or lowering the cab.
• Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch (E)
completely after raising the cab.
• Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the
cab.
• Make sure the handle (B) is caught by the catch after lowering the cab.
Read the Owner’s manual for details.
B E
G
SHTS01ZZZ0300001
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–7
DEFINITION OF SAFETY TERMS
Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.
Provides additional information to help you to perform the repair efficiently.
1–8 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
TOWING
• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to
protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near
the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with
the bumper.
1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle
shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle
lubricant and entry of dirt or foreign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame.
(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-
tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in
towing a vehicle trapped in a gutter.
(4) Keep the gear shift lever in Neutral.
(5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running.
(6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vac-
uum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not
running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually
hard to turn, making it impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.
2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck
designed for that purpose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect
the transmission and differential gears from being damaged. The hub openings should be covered to prevent the
loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed
for vehicles equipped with either manual or automatic transmission, and for even short distance towing. After
being towed, check and refill the rear axle housing with lubricant if necessary.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight-
ahead position.
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–9
CLEAN AIR ACT
1. Heavy-duty engine rebuilding practices.
§ 86.004-40
• The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards
and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The
process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reas-
sembly, and also may include the removal of the engine from the vehicle and other acts associated with rebuilding
an engine. Any deviation from the provisions contained in this section is a prohibited act under section 203(a) (3) of
the Clean Air Act (42 U.S.C. 7522(a) (3)).
(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical
basis for knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configura-
tion (i.e., tolerances, calibrations, specifications) and the model year(s) of the resulting engine configuration must
be identified. A reasonable basis would exist if:
a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and
function of motor vehicle engines would reasonably believe that the parts perform the same function with
respect to emissions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
• In accordance with the original engine manufacturer's instructions; or
• Where data or other reasonable technical basis exists that such parameter adjustment or design element
change, when performed on the engine or similar engines, is not expected to adversely affect in-use emis-
sions.
(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a
configuration of the same or later model year as the original engine. When an engine is being replaced, the
replacement engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the
original engine.
(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or
reset without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the sys-
tems are installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface.
Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service. Such signals
may not be rendered inoperative during the rebuilding process.
(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt
engine, all critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by para-
graphs (1) through (3) of this section must be checked and cleaned, adjusted, repaired, or replaced as neces-
sary, following manufacturer recommended practices.
(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The
records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the
engine and emissions-related control components including a listing of parts and components used, engine
parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under
paragraph (4) of this section.
a. Parties may keep records in whatever format or system they choose as long as the records are understand-
able to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an under-
standable format when requested.
b. Parties are not required to keep records of information that is not reasonably available through normal busi-
ness practices including information on activities not conducted by themselves or information that they cannot
reasonably access.
c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual
engine rebuilt in cases where those rebuild practices are followed routinely.
d. Records must be kept for a minimum of two years after the engine is rebuilt.
2. Maintenance instructions.
§ 86.010-38
(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manu-
facturer shall furnish or cause to be furnished to the ultimate purchaser a statement that
"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for
highway diesel fuel, including a 15 ppm sulfur cap)."
1–10 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
IDENTIFICATION INFORMATION
EN01H01ZZZ030101001002
1. VEHICLE IDENTIFICATION NUMBER
(1) The vehicle identification number (VIN) is stamped on the
right frame, as shown in the illustration. This number has also
been stamped on the manufacture's plate.
A: Vehicle Identification Number (VIN)
B: Manufacturer's Plate
(2) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUC-
TURE on the following page.
A
SHTS01ZZZ0300007
(3) PRODUCTION CODE AND VEHICLE COMPONENTS
MODEL (CLASS) HINO 155h (4) HINO 155 (4) HINO 195h (5) HINO 195 (5)
XJC700 XJC700
XFC710 XFC710
XJC710 XJC710
PRODUCTION CODE XFC720 XFC720
XJC720 XJC720
XFC740 XFC740
XJC740 XJC740
TRANSMISSION SERIES A465
1st 3.742
2nd 2.003
3rd 1.343
TRANSMISSION RATIO
4th 1.000
5th 0.773
6th 0.634
REAR AXLE SERIES SH13
REAR AXLE RATIO 4.333 / 4.625 / 4.875 / 5.142 / 5.571 / 5.857
SERVICE BRAKE Vacuum Hydraulic
PARKING BRAKE ACTING ON DIFFERENTIAL OUTPUT SHAFT
SUSPENSION LEAF
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–11
2. VEHICLE NOISE EMISSION CONTROL INFORMATION
• The Vehicle Noise Emission Control Information is affixed to the
FOR ALL MODELS left pillar of the cab. The name of manufacturer, production year
and month, and noise emission applicable to medium and heavy
trucks in conformity with U.S. EPA Regulations are displayed.
SHTS01ZZZ0300008
3. ENGINE SERIAL NUMBER
(1) The engine serial number is stamped on the cylinder block,
as shown in the illustration.
A: J05E
SHTS01ZZZ0300009
4. TRANSMISSION SERIAL NUMBER
(1) The transmission serial number is stamped on the transmis-
A sion, as shown in the illustration.
A: A465
SHTS01ZZZ0300010
5. CLEAN IDLE CERTIFIED LABEL FOR U.S.
• Make sure that the following clean engine idling certified label is
affixed to the outside of the left door. By the CARB below, the
label must be affixed there to prove that the new vehicle with
diesel engine manufactured from Jan., 2008 conforms to this
low.
CARB § 1956.8. Exhaust Emission Standard and Test
Procedure (a) (b) Heavy-Duty Diesel Engine Idling
Requirements
SHTS01ZZZ0300011
1–12 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
SAFETY INSTRUCTIONS FOR WORK
PRECAUTIONS
EN01H01ZZZ030101004001
1. SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS
(1) Removing the battery cable
! WARNING
• Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you disconnect
the battery terminals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the
exhaust gas after treatment after the starter key is turned to "LOCK" position. Otherwise, the vehicle data will
not be recorded on ECU properly and DCU will not complete working properly, which may result in the malfunc-
tion of DPR system and DEF-SCR system.
• The MIL (malfunction indicator light) may come on when the starter key is turned to "ON" position again, even if
you wait for at least ten minutes before disconnecting the battery terminals from the battery after the starter key
is turned to "LOCK" position. In this case, use HINO-DX to clear the DTC (P204F and P068A), to turn off the MIL
and to conduct DPR regeneration manually.
a. Before electrical system work, remove the cable from the minus terminal of the battery in order to avoid burn-
ing caused by short-circuiting.
b. To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the ter-
minal.
LOOSEN
SHTS01ZZZ0300012
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–13
(2) Handling of electronic parts
a. Never give an impact to electronic parts of a computer or relay.
b. Keep electronic parts away from high temperatures and humidity.
c. Never splash water onto electronic parts in washing the vehicle.
d. Do not remove the harness connector, electric component box, and cover except for repair and inspection.
If removal is necessary, pay attention that water and foreign matters do not attach or enter to the connector,
terminals, electric component box, and cover.
In restoration, make sure there is no attachment or entry of water and foreign matters and mount them prop-
erly, because it causes degradation of waterproof function.
INCORRECT
SHTS01ZZZ0300013
(3) Handling of wire harness
a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not
interfere with the end and acute angle section of the body and a bolt.
b. To attach a part, take care not to bite the wire harness.
INCORRECT INCORRECT
INCORRECT
SHTS01ZZZ0300014
1–14 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
(4) Handling of connectors
a. When removing a connector, hold a connector (area shown in an arrow in the figure) and then pull it off. Do not
pull wire harnesses.
b. Pull off a lockable connector after unlocking.
c. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound.
d. When inserting a test lead, insert it from the back of a connector.
e. If it is difficult to insert a test lead from the back of a connector, make and use an inspection harness.
INCORRECT
INCORRECT
CORRECT
SHTS01ZZZ0300015
(5) Installation of battery disconnect switch
! WARNING
• Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF-SCR
(DCU) may damage or result in the malfunction of DEF-SCR system.
• Be sure to read and follow the procedures and instructions on the service bulletin before the installation of the
battery disconnect switch.
(6) Handling of battery disconnect switch
! WARNING
• Wait for at least ten minute before using the battery disconnect switch after the starter key is turned to "LOCK"
position.
Otherwise, the vehicle data will not be recorded on ECU properly, which may result in the malfunction of DPR
system.
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–15
2. PRECAUTION FOR ELECTRIC WELDING
Electrical components such as the alternator and tachograph are directly connected to the battery and one
end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth
circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical
components, etc. Consequently, the following precautions are always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the
frame itself. (Do not fit the welding equipment earth to such things as the tire rims, brake pipes or fuel pipes and
leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the battery’s negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the functioning of all instruments.
COMPUTER
ALTERNATOR
etc. BATTERY
Disconnect the ground terminal for
battery at the connecting point on the
frame and disconnect the ground for
computer as well.
CHASSIS FRAME
CHASSIS FRAME
Connect the ground of the ARC welding
machine near the place on the frame to be
ARC WELDING welded but not connect it to plated parts such
MACHINE as fuel pipes, brake pipes and leaf spring.
SHTS01ZZZ0300016
(2) In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as
putting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.
1–16 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
GENERAL INFORMATION
INTRODUCTION TO WORKSHOP MANUAL
GENERAL
EN01H01ZZZ030102002001
1. SCOPE OF REPAIR DESCRIPTIONS
(1) There are three major processes in repair work: i.e. "trouble shooting", "removal/installation, replacement, over-
haul, assembly, inspection and adjustment" and "final inspection".
(2) This document covers only the first process (trouble shooting) and the second process (removal/installation,
replacement, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).
(3) The element tasks listed below are omitted from this document but must be done in actual repair work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual check
2. STANDARD VALUE
(1) Standard values, limits, required actions and tightening torques are tabulated in this document.
3. REQUIRED ITEMS
(1) Special tools, tools, instruments, oil and grease and other items to be prepared before starting work are listed in
the section titled "REQUIRED ITEMS". Note that general tools, jacks, rigid racks and other required items sup-
posedly available at a general service shop are omitted from the list.
4. REPRESENTATION OF SECTION AND TITLE
(1) Under a title containing a system name such as "ENGINE CONTROL SYSTEM", the descriptions cover
"INSPECTION", "ADJUSTMENT", "REPLACEMENT" and "OVERHAUL" of components.
(2) Under a title containing a part name such as "AIR COMPRESSOR ASSEMBLY", the descriptions cover
"REPLACEMENT" and "OVERHAUL".
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–17
INTRODUCTION TO DESCRIPTIONS
EN01H01ZZZ030102002002
1. TROUBLE SHOOTING FOR EACH TROUBLE SYMPTOM WITH REFERENCE TO THE CHART
A possible cause and remedy/prevention are indicated for
every item, respectively.
SHTS01ZZZ0300017
1–18 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
2. INTRODUCTION TO TROUBLE SHOOTING
(1) This document covers the trouble shooting steps 2 and 3 listed below.
Identify a fact through adequate hearings on the situation
(1) Hearing "Step 1"
and environment where a trouble has occurred.
Conduct a diagnosis inspection, a symptom check, a func-
(2) Prior check tional inspection and a basic inspection to identify a symp-
"Step 2"
(3) Reproducing technique tom. If a symptom check does not gain enough
reproducibility, use a reproducing technique.
(4) Trouble shooting for each
Sort the inspection results obtained from the step 2 and con-
diagnosis code
"Step 3" duct an systematized inspection in accordance with the pro-
(5) Trouble shooting for each
cedures for trouble shooting for each trouble symptom.
trouble symptom
Verify that the same trouble will not occur after trouble shoot-
ing. If a trouble is not reproducible enough, conduct a verifi-
(6) Verification test "Step 4"
cation test under the reproduced conditions and
environment.
(2) Prior check
• Take the following prior check steps.
Diagnosis inspectiondiagnosis deletiontrouble symptom verification (use a reproducing
technique if not reproducible.)diagnosis recheck
• Prior to a reproduction test, identify a system suspected to have a trouble, attach a tester and
other apparatuses and then conduct both a symptom check and an examination on a sus-
pected trouble. For a suspected cause of a trouble symptom, the trouble shooting chart.
Prior check
• Instantaneous occurrence of a trouble symptom will also trigger a failure code. If no troubles
are observed, use a reproducing technique in performing each trouble shooting activity.
• Trouble symptom verification
If not reproducible, take the steps 2, 3 and 4.
If not reproducible, use a reproducing technique (e.g. adjust external conditions and inspect
each wire harness and connector part).
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–19
3. INTRODUCTION TO TROUBLE SHOOTING FOR EACH DIAGNOSIS MONITOR CODE
(1) The "diagnosis code list" and the "trouble shooting for each code" are contained in this document to address
each system for which a diagnosis monitor code will be output. If a diagnosis monitor code is already identified,
it is possible to immediately proceed with a trouble shooting process based on the code list.
SHTS01ZZZ0300018
1–20 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
DEFINITION OF TERM
EN01H01ZZZ030102002003
DEFINITION OF TERM
Terms used in this document are defined as follows.
DIRECTION
1. CHASSIS RELATED
(1) Longitudinal direction
a. The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the
installed position in a vehicle.
(2) Rotational direction
a. The clockwise direction and the counterclockwise direction viewed from the rear side of a vehicle are defined
as right-handed and left-handed respectively.
(3) Vertical direction
a. The upward direction and the downward direction in the installed position in a vehicle are defined as an upper
side and a lower side respectively.
(4) Lateral direction
a. The leftward direction and the rightward direction viewed from the back of a vehicle are respectively defined as
a left side and a right side in the installed position in a vehicle.
2. INDIVIDUAL DEVICES
(1) Longitudinal direction
a. The input side and the output side of motive power are defined as a front side and a rear side respectively.
(2) Rotational direction
a. The clockwise direction and the counterclockwise direction viewed from the back side are defined as right-
handed and left-handed respectively.
(3) Vertical direction
a. The upward direction and the downward direction of a device in its installed position in a vehicle (chassis) are
defined as an upper side and a lower side respectively.
(4) Lateral direction
a. The leftward direction and the rightward direction as viewed from the back side are defined as a left side and a
right side respectively.
STANDARD VALUE
Represents a basic dimension (excluding a tolerance), and a clearance arising from tolerances when two parts are assem-
bled.
REPAIR LIMIT
Represents a numerical value indicating need of correction. A symbol "+" or "-" indicated next to a repair limit represents
an increase or a decrease from a standard value.
SERVICE LIMIT
Represents a numerical value indicating need of replacement. A symbol "+" or "-" indicated next to a repair limit represents
an increase or a decrease from a standard value.
GENERAL INTRODUCTION/TROUBLE SHOOTING 1–21
TROUBLE SHOOTING
TROUBLESHOOTING WITH DIAGNOSIS MONITOR
TROUBLESHOOTING PROCEDURE
EN01H01ZZZ040301002001
NOTICE
• Before reading the diagnosis code, turn the starter key to "ON"
and check that the check engine warning light comes on.
• Inspection is not available in check mode.
1. CONNECTION OF DIAGNOSIS CHECK WIRE
DLC3 (1) Turn the starter key to the "LOCK" position.
TC TS (2) Use a SST to short circuit DLC3 12(TS) or 13(TC) 4(CG)
terminals.
SST: 09843-18040
Diagnosis check wire
HINT
The terminals to be shorted vary depending on the device to be
diagnosed.
CG ! CAUTION
SHTS01ZZZ0400001
• Never fail to connect connectors to correct locations. Other
wise failure may occur.
• Use the dedicated diagnosis check wire.
1–22 GENERAL INTRODUCTION/TROUBLE SHOOTING
2. INDICATION OF DIAGNOSIS MONITOR CODE
(1) A diagnosis monitor code can be identified by viewing the
diagnosis monitor and the check engine light. The example
shown below represents how to identify diagnosis monitor
codes 32 and 21. Intervals between light flashings will iden-
tify a diagnosis monitor code. For the first code, the number
"3" in the ten's place of the first code will be represented by
three 0.5-second flashings, followed by an interval of 1.5 sec-
onds. Then, the light will flash twice. For the next code, after
an interval of 4.3 seconds, two flashings will be followed by
one flashing in the similar fashion to the first code. This flash-
ing pattern will be repeated. If no system malfunctions are
detected, the light will repeat a 0.3-second flashing pattern.
NOTICE
As individual systems have different diagnosis monitor code out-
putting patterns, follow the descriptions provided for each sys-
tem.
HINT
• This figure indicates a typical indication of diagnosis monitor
codes. For details, refer to the descriptions provided for individ-
ual systems.
• If no malfunctions are detected, the "diagnosis monitor code 1"
will be indicated.
• Malfunction codes will be repeatedly output in the ascending
order regardless of present or past malfunction codes.
INDICATION OF DIAGNOSIS MONITOR CODE (EXAMPLE)
WHEN CODES 32 AND 21 ARE INDICATED:
0.5 SECONDS 0.5 SECONDS
LIGHT ON
LIGHT OFF
4.3 SECONDS
1.5 SECONDS CODE 21
THE OPERATION IS REPEATED
CODE 32
WHEN THE SYSTEM IS NORMAL
0.3 SECONDS
LIGHT ON
LIGHT OFF
SHTS01ZZZ0400002
HINT
• If no code is indicated (light not flashing), it is suspected that
the TC or TS terminal line is broken or the computer is faulty.
• If the check engine warning light is always on, it is suspected
that the wire harness is shorted (for example, jammed) or the
computer is faulty.
• If any meaningless code is out, the computer is suspected of
being faulty.
GENERAL INTRODUCTION/TROUBLE SHOOTING 1–23
• If the check engine warning light is lit and no code is output at
1,000 r/min or more, once turn the starter key to "LOCK" and
then recheck.
(2) Release DLC3 12(TS) or 13(TS) 14(CG) terminals.
APPARATUS FOR TROUBLE SHOOTING
EN01H01ZZZ040301002002
1. TAG CODE AND SYSTEM NAME LIST FOR DEDICATED HARNESS
No. Tag name Name of system to be diagnosed
1 STD: ENG Common rail
3 STD: AIR BAG Not used
5 STD: ABS/ASR ABS
7 STD: ES START Not used
10 STD: VSC Not used
11 STD: TIRE Not used
2 OPT: RTD/4WD Not used
4 OPT: SHAKAN Not used
6 OPT: AIR SUS Not used
8 OPT: IDL STOP Not used
9 OPT: ATM Not used
12 OPT: PRO SHIFT Not used
DEDICATED HARNESS (S0963-02300) 2 1
4 3
10 6 5
8 7
12 11 9
SHTS01ZZZ0400003
1–24 GENERAL INTRODUCTION/TROUBLE SHOOTING
TROUBLESHOOTING WITH COMPUTER (HINO-DX)
STEP OF TROUBLE SHOOTING
EN01H01ZZZ040301003001
1. PREPARATION FOR CONNECTING HINO-DX
(1) The HINO-DX is a trouble shooting tool for the common rail
fuel injection system and the chassis system. For connecting
to a vehicle, the interface box (Hino-Bowie or DST-i) and the
dedicated cable will be required.
SPECIAL TOOL: Computer interface
Part name Part No.
The main body and cables
Hino-Bowie (for RS-232C and USB) 09993-E9070 *1
SHTS01ZZZ0400004 (Interface box) Cable between vehicle and Hino-Bowie
S0904-21220
DENSO DST-i Set Without Bluetooth 95171-01020
(Without LCD) With Bluetooth 95171-01040
DENSO DST-i Set Without Bluetooth 95171-0103
(With LCD) With Bluetooth 95171-01050
HINO Diagnostic eXplorer (HINO-DX)
(*1): To use Hino-Bowie (interface box) "09993-E9070",
update the hardware. For details, refer to the user's manual
in the HINO-DX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie)
using the software in the HINO-DX CD-ROM. For details,
refer to the user's manual in the HINO-DX CD-ROM.
HINT
• A cable between the Hino-Bowie and a computer is supplied
with Hino-Bowie. Use either RS-232C type or USB type.
• Install the Hino Diagnostic eXplorer (HINO-DX) software in a
computer. For detailed installation procedures, refer to the
user's manual supplied with a CD.
2. CONNECTION OF HINO-DX
(1) Connect the Hino-Bowie or DST-i to the trouble shooting con-
nector located in the electrical component box in the instru-
ment panel or located in the electrical component box behind
the rearmost seat.
(2) Connect a computer in which the HINO-DX has been
installed, to the Hino-Bowie or DST-i.
(3) Turn the starter key ON.
(4) Turn on the computer power supply to start the HINO-DX.
HINT
TROUBLE SHOOTING If the Hino-Bowie is used, connection to a vehicle will automati-
CONNECTOR cally turn the power supply ON and light the POWER light (red) on
SHTS01ZZZ0400005 the Hino-Bowie.
GENERAL INTRODUCTION/TROUBLE SHOOTING 1–25
APPARATUS FOR TROUBLE SHOOTING
EN01H01ZZZ040301003002
1. APPARATUS FOR TROUBLE SHOOTING
Part name Part No. Illustration of appearance Outline/function
Computer • Operating system (OS):
(DOS/V standard) Windows2000, Win-
dowsXP,
WindowsVista*2,
Windows7*2
— • CPU and memory:
To guarantee proper oper-
ations of the operating
systems listed above.
• Display: 800X600,
256 or more colors
Hino-Bowie 09993-E9070*1 Computer interface
(Interface box) The main body and cables
(for RS-232C and USB)
Cable between vehicle and
Hino-Bowie
S0904-21220
DENSO DST-i Set Without Bluetooth
—
(without LCD) 95171-01020
With Bluetooth
95171-01040
DENSO DST-i Set Without Bluetooth
(with LCD) 95171-01030
With Bluetooth
95171-01050
(*1): To use Hino-Bowie (interface box) "09993-E9070", update the hardware. For details, refer to the user's manual in
the HINO-DX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HINO-DX CD-ROM. For details,
refer to the user's manual in the HINO-DX CD-ROM.
(*2): When use DST-i, after HINO-DX. (Ver. 3.0.5)
1–26 GENERAL INTRODUCTION/GLOSSARY
GLOSSARY
DEFINITION OF ABBREVIATION
LIST OF ABBREVIATION
EN01H01ZZZ060102001001
Abbreviations Meaning, or Official Name
A/C Air Conditioner
ABS Anti-lock Brake System
ACC Accessory
AMT Automated Manual Transmission
ATC After Turbo Catalyst
ATF Automatic Transmission Fluid
CA Crank Angle
CAN Controller Area Network
CD-ROM Compact Disc Read Only Memory
CPU Central Processing Unit
dB Decibel
DC Direct Current
D-CAT Diesel-Clean Advanced Technology System
DC motor Direct Current Motor
DCU Dosing Control Unit
DEF Diesel Exhaust Fluid
DPR Diesel Particulate active Reduction system
DSS Driving Support System
ECU Electronic Control Unit
EEPROM Electronically Erasable and Programmable Read Only Memory
EGR Exhaust Gas Recirculation
ELR Emergency Locking Retractor
ENG Engine
ES START Easy and Smooth start system
F/A Front Axle
FCCB Fuel Control Cylinder Balance
FCV Fuel Cutoff Valve
FF shift Feather touch & Finger shift
FL Fusible link
GENERAL INTRODUCTION/GLOSSARY 1–27
Abbreviations Meaning, or Official Name
Fr Front
FRP Fiber Reinforced Plastic
FUP Front Underrun Protector
GND Ground
GVW Gross Vehicle Weight
Hi High
HINO-DX Hino Diagnostic eXplorer
HV Hybrid Vehicle
HVAC Heating, Ventilating and Air-Conditioning unit
I.S.C. Idle Speed Control
IC Integrated Circuits
ID Identification
IPD Intelligent Power Device
IS Idling Stop
ISO International Organization for Standardization
JIS Japanese Industrial Standards
LED Light Emitting Diode
LEV Low Emission Vehicle
LH Left Hand
LLC Long Life Coolant
Lo Low
MAX Maximum
MIN Minimum
MS evaporator Multi-tank and Super slim structure evaporator
MT Manual Transmission
No. Number
NOx Nitrogen Oxide
NMR No load Maximum Revolution
OHC Over Head Camshaft
PC Personal Computer
PCD Pitch Circle Diameter
PCS Pre-Crash Safety
PCV Pump Control Valve
PCV valve Positive Crankcase Ventilation valve
PM Particulate Matter
1–28 GENERAL INTRODUCTION/GLOSSARY
Abbreviations Meaning, or Official Name
PPG Glass-fiber-reinforced Polypropylene
ppm Parts Per Million
PS pump Power Steering Pump
PTO Power Take-Off
PVD Physical Vapor Deposit
PWR Power
QR code Quick Response Code
R/A Rear Axle
RH Right Hand
SCR Selective Catalytic Reduction
SST Special Service Tool
SW Switch
T/M Transmission
GENERAL INTRODUCTION/GLOSSARY 1–29
GLOSSARY OF SAE AND HINO TERMS
EN01H01ZZZ060102001002
This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation,
as well as their HINO equivalents.
SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS
A/T AUTOMATIC TRANSMISSION Automatic transmission
AAT AMBIENT AIR TEMPERATURE Ambient Air Temperature
ACL AIR CLEANER Air cleaner
ACL Element ACL (Air Cleaner) Element Air Cleaner element
ACL Element AIR CLEANER Element Air Cleaner element
ACL Housing AIR CLEANER Housing Air cleaner body assembly
ACL Housing Cover AIR CLEANER Housing Cover Air Cleaner Housing Cover
AFTER TREATMENT DIESEL EXHAUST
AFTDEF DEF
FLUID
AFTER TREATMENT DIESEL EXHAUST
AFTDEFDU DCU
FLUID DOSING UNIT
AFTER TREATMENT DIESEL OXIDATION
AFTDOC DOC (Diesel Oxidation Catalyst)
CATALYST
AFTDOS AFTER TREATMENT DOSER AFTDOS Dosing
AFTER TREATMENT DIESEL PARTICU-
AFTDPF DPR filter
LATE FILTER
AFTER TREATMENT DIESEL PARTICU-
AFTDPFDP DPR differential pressure
LATE FILTER DIFFERENTIAL PRESSURE
AFTER TREATMENT EXHAUST GAS TEM-
AFTEGT Exhaust gas temperature
PERATURE
AP ACCELERATOR PEDAL Accelerator pedal
AP Sensor ACCELERATOR PEDAL Sensor Accelerator Pedal Position Sensor
APP ACCELERATOR PEDAL POSITION Accelerator Pedal Position
CAC CHARGE AIR COOLER Intercooler
CPP Switch CLUTCH PEDAL POSITION Switch Clutch Switch
DCC DIAGNOSTIC CONNECTOR, Cab Diagnosis connector
DCU DIAGNOSTIC CONNECTOR, Under-hood Diagnosis connector
DRIVER DRIVER Driver
DTC DIAGNOSTIC TROUBLE CODE Diagnosis Trouble Code
DTM Switch DIAGNOSTIC TEST MODE Switch Diagnosis switch
EBP EXHAUST BACK PRESSURE Back pressure
EBP EXHAUST BACK PRESSURE Exhaust back pressure
EBP Sensor EXHAUST BACK PRESSURE Sensor Back Pressure Sensor
EXHAUST BACK PRESSURE REGULATOR
EBPR Valve Exhaust control valve
Valve
1–30 GENERAL INTRODUCTION/GLOSSARY
SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS
EC ENGINE CONTROL Engine control
ECT ENGINE COOLANT TEMPERATURE Coolant Temperature
ECT ENGINE COOLANT TEMPERATURE Water Temperature
EFT ENGINE FUEL TEMPERATURE Fuel temperature
EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor
EGR EXHAUST GAS RECIRCULATION EGR
EGR Valve EXHAUST GAS RECIRCULATION Valve EGR valve
EXHAUST GAS RECIRCULATION TEM-
EGRT EGR temperature
PERATURE
EXHAUST GAS RECIRCULATION TEM-
EGRT Sensor EGR exit temperature sensor
PERATURE Sensor
EGT EXHAUST GAS TEMPERATURE Exhaust gas temperature
EI ELECTRONIC IGNITION Ignition coil
EOP ENGINE OIL PRESSURE Oil Pressure
EOT ENGINE OIL TEMPERATURE Oil Temperature
FP FUEL PUMP Fuel pump
FUEL PRESSURE
FUEL PRESSURE Sensor Fuel Pressure sensor
Sensor
GLOW PLUG GLOW PLUG Glow plug
GND GROUND GROUND
IA INTAKE AIR Air Intake
IA System INTAKE AIR System Air Intake System
IAT INTAKE AIR TEMPERATURE Intake temperature
IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor
IDLE IDLE Idle
IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor
IMAT INTAKE MANIFOLD TEMPERATURE Intake manifold temperature sensor
INJ INJECTOR Injector
MAF Sensor MASS AIR FLOW Sensor Air flow sensor
MIL MALFUNCTION INDICATOR LAMP Check engine
OSS Sensor OUTPUT SHAFT SPEED Sensor Output Speed Sensor
OSS Sensor OUTPUT SHAFT SPEED Sensor Speed Sensor
PC Solenoid Valve PRESSURE CONTROL Solenoid Valve Solenoid control valves
PCV POS CRANKCASE VENTILATION PCV (Positive Crankcase Vent)
PCV Valve POS CRANKCASE VENTILATION Valve PCV (Positive Crankcase Vent) Valve
PCV Valve POS CRANKCASE VENTILATION Valve PCV Valve
GENERAL INTRODUCTION/GLOSSARY 1–31
SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS
PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve
PNP PARK/NEUTRAL POSITION Neutral position
PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch
RFP RAIL FUEL PRESSURE Common rail Pressure
RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor
SPARK PLUG SPARK PLUG Spark plug
SRI SERVICE REMINDER INDICATOR Check engine
ST SCAN TOOL Diagnostic tool
TC TURBOCHARGER Turbocharger
TCC TORQUE CONVERTER CLUTCH Torque Converter
TP Sensor THROTTLE POSITION Sensor Throttle Sensor
TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor
VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor
VLS VEHICLE LIMITING SPEED Speed Limiter Upper Limit
VSS VEHICLE SPEED SENSOR Vehicle Speed sensor
ENGINE (J05E) 2–1
ENGINE (J05E)
2
2-001
TROUBLESHOOTING ..................................... 2-4 DTC: P003A ........................................................2-126
DTC: P0045 ........................................................2-133
ENGINE ECU (J05E)....................................................2-4
DTC: P0047 ........................................................2-138
PRECAUTIONS FOR DIAGNOSIS .........................2-4
DTC: P0048 ........................................................2-143
ELECTRICAL ..........................................................2-6
DTC: P006E ........................................................2-148
PRECAUTIONS ......................................................2-7
DTC: P006F ........................................................2-153
COMPUTER (ECU) PIN ASSIGNMENT...............2-11
DTC: P007B ........................................................2-158
ENGINE ECU CONNECTOR................................2-15
DTC: P007C and P007D.....................................2-176
INSPECTION ........................................................2-19
DTC: P0088 ........................................................2-186
DIAGNOSIS USING THE PC DIAGNOSIS
DTC: P0096 ........................................................2-211
TOOL.....................................................................2-20
DTC: P0097 and P0098 ......................................2-226
DIAGNOSTIC TROUBLE CODE (DTC)
DTC: P00AF........................................................2-236
TABLE ...................................................................2-21
DTC: P0101 ........................................................2-241
GROUP SHARING THE SENSOR SUPPLY
DTC: P0104 ........................................................2-254
TERMINAL ............................................................2-42
DTC: P0106 ........................................................2-263
GROUP SHARING THE SENSOR
DTC: P0108 ........................................................2-271
GND TERMINAL ...................................................2-43
DTC: P0112 and P0113 ......................................2-279
MALFUNCTION CODES IN CASE OF
DTC: P0115 ........................................................2-289
DISRUPTION OF CAN COMMUNICATION..........2-44
DTC: P0117 and P0118 ......................................2-302
PRE-INSPECTION FOR ENGINE CAN
DTC: P011A ........................................................2-312
COMMUNICATION LINE (250 k) ..........................2-48
DTC: P011C........................................................2-324
DISCONNECTION INSPECTION FOR ENGINE
DTC: P0122 and P0123 ......................................2-332
CAN_H COMMUNICATION L LINE (250 k)
DTC: P0128 ........................................................2-343
[DIESEL] ...............................................................2-53
DTC: P0148 ........................................................2-351
DISCONNECTION INSPECTION FOR ENGINE
DTC: P016E and P016F .....................................2-369
CAN_H COMMUNICATION L LINE (250 k)
DTC: P0182 and P0183 ......................................2-395
[HYBRID]...............................................................2-62
DTC: P0191 ........................................................2-405
PRE-INSPECTION FOR ENGINE CAN
DTC: P0192 and P0193 ......................................2-429
COMMUNICATION LINE (500 k) [DIESEL] ..........2-72
DTC: P01A5 ........................................................2-441
PRE-INSPECTION FOR ENGINE CAN
DTC: P01A6 ........................................................2-450
COMMUNICATION LINE (500 k) [HYBRID]..........2-77
DTC: P0200 ........................................................2-459
DISCONNECTION INSPECTION FOR ENGINE
DTC: P0201, P0202, P0203 and P0204 .............2-462
CAN_H COMMUNICATION L LINE (500 k)
DTC: P0217 ........................................................2-469
[DIESEL] ...............................................................2-83
DTC: P0219 ........................................................2-476
DISCONNECTION INSPECTION FOR ENGINE
DTC: P0222 and P0223 ......................................2-485
CAN_H COMMUNICATION L LINE (500 k)
DTC: P0234 ........................................................2-497
[HYBRID]...............................................................2-88
DTC: P0237 ........................................................2-505
MALFUNCTION CODES FOR FAULTY ACTUATOR
DTC: P0263, P0266, P0269 and P0272 .............2-513
POWER RELAY ....................................................2-93
DTC: P026C and P026D.....................................2-529
ENG BASIC INSPECTION SHEET
DTC: P0299 ........................................................2-548
(ENGINE INSPECTION CHECK SHEET) ............2-94
DTC: P0300 ........................................................2-556
NO DTC ................................................................2-98
DTC: P0301, P0302, P0303 and P0304 .............2-566
DTC: P0005 ........................................................ 2-102
DTC: P0335 ........................................................2-578
DTC: P0006 and P0007 ...................................... 2-108
DTC: P0336 ........................................................2-587
DTC: P0016 ........................................................ 2-115
DTC: P0340 ........................................................2-597
DTC: P0027 ........................................................ 2-119
DTC: P0341 ........................................................2-603
2–2 ENGINE (J05E)
DTC: P0381.........................................................2-613 DTC: P14B2 ......................................................2-1007
DTC: P0401.........................................................2-621 DTC: P14B3 and P14B4 ...................................2-1012
DTC: P0402.........................................................2-641 DTC: P14B7 and P14B8 ...................................2-1019
DTC: P0404.........................................................2-655 DTC: P14BC and P14BD ..................................2-1026
DTC: P0405 and P0406 ......................................2-662 DTC: P14BF ......................................................2-1033
DTC: P041B ........................................................2-669 DTC: P1515.......................................................2-1040
DTC: P041C and P041D .....................................2-686 DTC: P1530.......................................................2-1047
DTC: P0420.........................................................2-696 DTC: P1601.......................................................2-1052
DTC: P0421.........................................................2-699 DTC: P200C ......................................................2-1057
DTC: P0422.........................................................2-703 DTC: P2032 and P2033 ....................................2-1069
DTC: P0489 and P0490 ......................................2-707 DTC: P203F ......................................................2-1079
DTC: P049D ........................................................2-714 DTC: P204F ......................................................2-1084
DTC: P04D5 and P04D6 .....................................2-721 DTC: P207F ......................................................2-1088
DTC: P0500 and P0501 ......................................2-731 DTC: P2080.......................................................2-1100
DTC: P0504.........................................................2-740 DTC: P2084.......................................................2-1110
DTC: P0519.........................................................2-747 DTC: P20CD .....................................................2-1120
DTC: P0521.........................................................2-752 DTC: P20CE......................................................2-1126
DTC: P0524.........................................................2-758 DTC: P20CF ......................................................2-1131
DTC: P0545 and P0546 ......................................2-765 DTC: P20D8 ......................................................2-1135
DTC: P0562 and P0563 ......................................2-775 DTC: P20DE......................................................2-1141
DTC: P05F1 ........................................................2-783 DTC: P20DF ......................................................2-1146
DTC: P0605.........................................................2-794 DTC: P20E0 ......................................................2-1154
DTC: P0606.........................................................2-797 DTC: P20EE ......................................................2-1163
DTC: P0607.........................................................2-800 DTC: P2100.......................................................2-1175
DTC: P0610.........................................................2-803 DTC: P2101.......................................................2-1183
DTC: P0611.........................................................2-807 DTC: P2103.......................................................2-1192
DTC: P0617.........................................................2-810 DTC: P2120.......................................................2-1200
DTC: P0628 and P0629 ......................................2-815 DTC: P2122 and P2123 ....................................2-1205
DTC: P062F ........................................................2-825 DTC: P2127 and P2128 ....................................2-1216
DTC: P0630.........................................................2-830 DTC: P2135.......................................................2-1226
DTC: P0642.........................................................2-835 DTC: P2138.......................................................2-1232
DTC: P0643.........................................................2-843 DTC: P2146.......................................................2-1238
DTC: P064C ........................................................2-853 DTC: P2147 and P2148 ....................................2-1247
DTC: P0652.........................................................2-860 DTC: P2149.......................................................2-1257
DTC: P0653.........................................................2-868 DTC: P2150 and P2151 ....................................2-1266
DTC: P0671 and P0672 ......................................2-877 DTC: P2184 and P2185 ....................................2-1276
DTC: P0673 and P0674 ......................................2-884 DTC: P2214.......................................................2-1286
DTC: P0683.........................................................2-891 DTC: P2227.......................................................2-1301
DTC: P0686.........................................................2-899 DTC: P2228 and P2229 ....................................2-1306
DTC: P06D3 and P06D4 .....................................2-905 DTC: P2269.......................................................2-1312
DTC: P073D ........................................................2-917 DTC: P226C ......................................................2-1319
DTC: P081A ........................................................2-922 DTC: P22D3 ......................................................2-1328
DTC: P081B ........................................................2-930 DTC: P240F ......................................................2-1333
DTC: P0A7B........................................................2-935 DTC: P2428.......................................................2-1347
DTC: P0AC4........................................................2-938 DTC: P242B ......................................................2-1353
DTC: P0CA1........................................................2-941 DTC: P242C and P242D ...................................2-1363
DTC: P1133.........................................................2-944 DTC: P244A ......................................................2-1373
DTC: P119F ........................................................2-952 DTC: P244B ......................................................2-1399
DTC: P1426.........................................................2-960 DTC: P2457.......................................................2-1422
DTC: P1427.........................................................2-969 DTC: P2458.......................................................2-1440
DTC: P1428.........................................................2-978 DTC: P2459.......................................................2-1454
DTC: P1458.........................................................2-988 DTC: P2463.......................................................2-1458
DTC: P1459.........................................................2-995 DTC: P246F ......................................................2-1469
DTC: P14B0 ......................................................2-1002 DTC: P2470 and P2471 ....................................2-1479
ENGINE (J05E) 2–3
DTC: P24A0 ...................................................... 2-1489
DTC: P24A1 ...................................................... 2-1493
DTC: P24A2 ...................................................... 2-1496
DTC: P2562 ...................................................... 2-1510
DTC: P259E ...................................................... 2-1515
DTC: P259F ...................................................... 2-1522
DTC: P2635 ...................................................... 2-1529
DTC: P268A and P2696.................................... 2-1554
DTC: P26C8...................................................... 2-1561
DTC: P2BA9...................................................... 2-1564
DTC: U0073 ...................................................... 2-1571
DTC: U010A...................................................... 2-1574
DTC: U010C...................................................... 2-1582
DTC: U010E...................................................... 2-1590
DTC: U0293 ...................................................... 2-1599
DTC: U029D (DIESEL) ..................................... 2-1606
DTC: U029D (HYBRID)..................................... 2-1614
DTC: U029E (DIESEL)...................................... 2-1622
DTC: U029E (HYBRID)..................................... 2-1630
DTC: U02A2...................................................... 2-1638
DTC: U0301 ...................................................... 2-1646
DTC: U1001 ...................................................... 2-1650
DTC: U110A...................................................... 2-1659
2–4 ENGINE (J05E)/TROUBLESHOOTING
TROUBLESHOOTING
ENGINE ECU (J05E)
PRECAUTIONS FOR DIAGNOSIS
EN01H02127030602016001
• Ensure that individual connectors are certainly connected before start of checking works.
• Make sure to set the starter key to the "LOCK" position before disconnecting a connector.
• Replace the part or the component that have a failure or trouble. Do not fix and reuse it.
• Delete the past malfunction code after recording. Then conduct a diagnosis again to check for present failures.
• Delete the past failure memory after completion of a diagnostic analysis.
ENGINE (J05E)/TROUBLESHOOTING 2–5
1. ILLUSTRATION OF CONNECTOR AND MEASUREMENT ON TERMINAL
LOCK
ILLUSTRATION OF CONNECTOR
The illustration of a connector contained in this document
represents an image of a connector with its lock positioned
on top as viewed from the connecting face.
TO BE CONNECTED
MALE FEMALE
CONNECTOR CONNECTOR
NUMBERING OF CONNECTOR TERMINALS
3 2 1 1 2 3 The terminals are symmetrically numbered (symmetrically
6 5 4 4 5 6 reversed numbering) as viewed on the connecting faces of a
pair of connectors.
The terminal #1 is located at the top right corner of a male
connector and at the top left corner of a female connector
MALE FEMALE respectively in this document.
CONNECTOR CONNECTOR
PRECAUTIONS FOR TERMINAL MEASUREMENT
Unless otherwise specified in this document, the illustration
INCORRECT of a connector represents an image of a connector as viewed
from the connecting face. A test probe must access the back
CORRECT face of a connector.
However, some types of connector do not allow a test probe
to contact with the back face such as a waterproof connector.
In such case, a test probe may be allowed to access the front
face of a connector but a special care must be used to avoid
a risk of damage in terminals.
CORRECT
As to a connector that is designed to use the signal check
harness for terminal measurement, do not place a test probe
INCORRECT directly onto the front or back face. Use a contact box of the
connected signal check harness to take measurement on
terminals.
WATERPROOF CONNECTOR
ILLUSTRATION OF CONNECTOR AND
MEASUREMENT SURFACE
A The illustration of a connector contained in this document
1 2
4 3 represents an image of a connector as viewed from the
5 6 connecting face. For example, the terminal #1 of a female
VIEW A connector is located at the top left corner of a connector as
viewed from the connecting face.
3 2
6 1 In actual measurement on the terminal #1 of a female
5 4 connector, a test probe must be placed onto the top right
corner on the back face of a connector.
VIEW B
B
SHTS021270300001
2–6 ENGINE (J05E)/TROUBLESHOOTING
ELECTRICAL
EN01H02127030602016002
Actuator relay : monitored for the OBD requirements
FUSE
: monitored for the system safety
Power source
Main relay FUSE
Key switch
Starter switch FUSE
- +
Accelerator pedal Battery
position sensor 1, 2 Battery
CAN communication
PTO accelerator sensor (Variable nozzle turbo charger, EGR valve, DEF dosing system, NOx sensor)
O
CAN communication (Diagnosis, Vehicle ECU)
Vehicle speed sensor T Vehicle ECU
Engine stop switch
H
E Diagnostic tool
Neutral switch R PC
S diagnosis
PTO switch 1
PTO switch 2
Diagnostic switch Fuel cut valve
Fuel closer
DPR regeneration switch
Starter cut relay
Stop light switch
DPR indicator light
Water in fuel switch
I Glow lamp (wait-to-start lamp)
Oil pressure switch N
P Malfunction indicator light (MIL)
U
Diagnostic lamp (Check engine light )
T
PTO cut relay
O Fuel injector drive signal
Fuel injector
U
T
DPF downstream temperature sensor Exhaust brake drive signal
P Exhaust brake magnetic valve relay
Exhaust gas temperature sensor (DOC outlet) U
Exhaust gas temperature sensor (DOC inlet) T
Barometric DC motor (for Intake throttle valve) drive signal
Differential pressure sensor pressure
sensor
Intake air temperature sensor (ECU built-in)
(intercooler outlet)
Supply pump
Intake air temperature sensor
(intake manifold) Suction control valve for fuel supply pump drive signal
Engine coolant Suction control valve for fuel supply pump drive power S/P
temperature sensor
Crankshaft position sensor Fuel temperature sensor
T
Camshaft position sensor
Boost pressure sensor Aftertreatment fuel injection line pressure sensor
P
Intake air temperature sensor
Intake throttle valve position sensor 1 Intake
Fuel rail pressure sensor
Fuel rail pressure sensor
A throttle DC
A valve motor
(Frequency-type)
Air flow sensor
(AFS built-in)
ATC downstream
temperature sensor Exhaust
aftertreatment system
(main)
(sub)
ATC
P T Fuel cut DPR DEF
T cleaner SCR
Fuel rail valve
P Frequency-type P T T
AFS T
G Engine
N
T T T EGR EGR
cooler valve Turbocharger
DC motor DC motor
EGR valve
controller Variable nozzle turbocharger (VNT)
and actuator controller and actuator
SHTS021270300002
ENGINE (J05E)/TROUBLESHOOTING 2–7
PRECAUTIONS
EN01H02127030602016003
! WARNING
Approximately 110V is generated for the injector drive actuation
system. For this reason, electrical shock may result if the injector
drive circuit is touched directly by hand. Set the starter key to the
LOCK position if it is necessary to check or repair the computer,
harnesses, or connectors.
1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE
ACTUATOR OR MAGNETIC VALVES.
2. HARNESS WIRE CONNECTOR.
(1) Multi-contact connectors suitable for the small electrical sig-
nals of electronic circuitry are used for wiring connections to
the sensors, actuator and control unit. Be very careful when
handling them.
• Before disconnecting any connectors, make sure that the
starter key is in the "LOCK" position.
• When disconnecting connectors, try to pull them out in a
straight line, disengaging the lock and holding onto the
housing.
• Do not try to disconnect connectors by gripping the wires
or twisting them, as this could bend the contacts.
• Do not disconnect connectors unnecessarily.
• When using a circuit tester, apply the tester probe to the
harness wire side only. Never stick the tester probe into the
holes on the connector terminal side, as this could cause
poor contacts when the connector is reconnected.
Correct Correct
Incorrect
Incorrect
How to use tester probe
SHTS021270300003
• Do not let water, oil or dust get on the connector when it is
disconnected, as this could cause poor contacts when the
connector is reconnected.
• Do not open the control unit cover. It could malfunction if
dust or water gets inside.
• Take care to ensure that water, oil or dust do not get on or
inside parts.
• When connecting in connectors, push them in all the way
and make sure that the lock engages.
3. ERASING THE MALFUNCTION MEMORY STORED IN THE
PAST, CHECK THE CURRENT MALFUNCTION BY PERFORM-
ING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
2–8 ENGINE (J05E)/TROUBLESHOOTING
4. AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE
THE MALFUNCTION MEMORY STORED IN THE PAST. OTHER-
WISE, THE MALFUNCTION LIGHT IN THE DISPLAY WILL
REMAIN LIT.
5. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE
SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING
LEAD FROM THE BACKSIDE.
6. USING A CIRCUIT TESTER
• Use a circuit tester with an internal resistance of 100 k or
greater in the voltage measuring range.
7. USING A SIGNAL CHECK HARNESS
• To prevent breakage of the ECU connector, connect the signal
check harness and perform measuring by bringing the test lead
into contact with the signal check harness side (contact box).
NOTICE
The terminal numbers in the text and in the illustrations corre-
spond to the table on the next page (computer pin assignment) as
shown below.
Computer (ECU) terminal signal
Computer (ECU) terminal No.
A
Main/
Exhaust brake Glow
Power supply 1 Starter cut relay Actuator power PTO cut relay -
relay (Indic
relay 1
V1 VF V2 STCR V3 MREL V4 EXB V5 PTOC V6 - V7
Vehicle speed CAN CA
Neutral switch Starter signal Starter switch 1 - communication commun
pulse converter
line lin
V11 NSW V12 STA V13 IGSW V14 SP1 V15 - V16 CANL V17
Main/
Power supply 2 - Actuator power Glow relay - - Diagnos
relay 2
V21 VF2 V22 - V23 MRL2 V24 SREL V25 - V26 - V27
Engine stop CAN CA
PTO switch 1 Starter switch 2 TACHO Pulse - communication commun
switch
line lin
V31 PTO V32 ESTP V33 IG V34 TAC V35 - V36 CANH V37
Example: V23 terminal
A
A (1 to 40)
Signal check
harness
(contact box) 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
V23
SHTS021270300004
ENGINE (J05E)/TROUBLESHOOTING 2–9
8. CONNECT THE SIGNAL CHECK HARNESS.
(1) Set the starter key to the "LOCK" position and disconnect the
connectors from the engine ECU.
(2) Connect a signal check harness to the engine sub harness
and the engine ECU.
SST: 09843-E4050
Signal check harness
Computer (engine ECU)
Connector Connector
(engine ECU side) (engine ECU side)
Engine Vehicle
side side
Connector
Connector
(engine sub
(engine sub
harness side)
harness side)
Red White
C Engine sub harness
A
Terminal Terminal
E01-E40 V01-V40
Blue D B
Black
Terminal Terminal
Test lead
E41-E80 V41-V80
Signal check Signal check
harness harness
(engine side) (vehicle side)
09843-E4060 Contact box 09843-E4020
Signal check harness assembly
09843-E4050
SHTS021270300005
2–10 ENGINE (J05E)/TROUBLESHOOTING
9. RADIO INSTALLATION
• There is a danger that the control unit might malfunction if a high
output radio transmitter (over 50W) is installed in the vehicle.
10. USING A QUICK CHARGER
• Disconnect both battery terminals before using a quick charger.
11. AIR CONDITIONER INSTALLATION
• Be careful not to scratch or damage the engine, chassis or the
harness inside the cab when installing an air conditioner. Also,
make sure to reattach afterward any connectors that were dis-
connected during the installation process.
12. PERFORMING ELECTRIC WELDING
• Disconnect the negative terminal of the battery before perform-
ing any electric welding.
13. OTHER
• Make sure to check the other connectors before connecting
them in to prevent incorrect connections.
• Be careful not to allow the connectors to become soiled with
dust, water, fuel or oil when performing inspections or removing
and replacing parts.
A
Main/ Check engine
Exhaust brake Glow pulg
Power supply 1 Starter cut relay Actuator power PTO cut relay - DPR refresh light warning light -
relay (Indicator)
relay 1
V1 VF V2 STCR V3 MREL V4 EXB V5 PTOC V6 - V7 GIND V8 W2 V9 W V10 -
CAN CAN Power supply 1
Vehicle speed Back up power
Neutral switch Starter signal Starter switch 1 - communication communication (+B) -
pulse converter supply
COMPUTER (ECU) PIN ASSIGNMENT
line line
V11 NSW V12 STA V13 IGSW V14 SP1 V15 - V16 CANL V17 CANN V18 +B V19 BATT V20 -
Main/
Power supply 2 - Actuator power Glow relay - - Diagnosis light - - Diagnosis switch
relay 2
V21 VF2 V22 - V23 MRL2 V24 SREL V25 - V26 - V27 DG V28 - V29 - V30 TC
ENGINE (J05E)/TROUBLESHOOTING
CAN CAN
Engine stop Power supply 2
PTO switch 1 Starter switch 2 TACHO Pulse - communication communication Power ground 1 Signal ground 1
switch (+B)
line line
V31 PTO V32 ESTP V33 IG V34 TAC V35 - V36 CANH V37 CANP V38 +B1 V39 E01 V40 E11
SHTS021270300006
EN01H02127030602016004
2–11
2–12
B
Exhaust gas
Accelerator Sensor power
- WIF signal - - Sensor ground 7 Sensor ground 9 - temperature sensor
sensor 1 supply 3
(DOC2 inlet)
V41 - V42 42 V43 - V44 - V45 EPA V46 46 V47 VPA V48 - V49 49 V50 VCPA
Exhaust gas
Sensor power DPR refresh temperature sensor
Power supply 3
- - - - Power ground 2 Signal ground 2
supply 4 switch (DPF outlet) (+B)
V51 VCP2 V52 - V53 - V54 - V55 - V56 RGSW V57 57 V58 +B2 V59 E02 V60 E12
PTO Exhaust gas
Accelerator DPR differential
- PTO switch 2 - - Sensor ground 8 - acceclerator temperature sensor
sensor 2 pressure sensor
sensor (DOC2 outlet)
V61 - V62 PTO2 V63 - V64 - V65 EPA2 V66 - V67 VPA2 V68 VPA1 V69 69 V70 70
ENGINE (J05E)/TROUBLESHOOTING
Sensor power Power supply 4
- - - Stop light switch - - Power ground 3 Power ground 4
supply 5 (+B)
V71 71 V72 - V73 - V74 - V75 ST1- V76 - V77 - V78 +BM V79 E03 V80 E04
SHTS021270300007
C
Intake throttle After treatment Suction control Suction control
valve motor (+) - - - - - -
fuel injector valve (Main) valve (Main)
E1 M+ E2 - E3 - E4 - E5 FIV E6 - E7 - E8 - E9 PCV+ E10 PCV-
Air flow sensor Sensor power No.1 Fuel injector No.1 Fuel injector No.4 Fuel injector No.2 Fuel injector No.3 Fuel injector No.2 Fuel injector
- -
(Power) supply 1 (Main) (Main) (Main) (Main) (Main) (Main)
E11 - E12 VAF E13 VC E14 IJ1+ E15 #1 E16 #3 E17 - E18 IJ2+ E19 #2 E20 #4
Intake throttle Suction control Suction control
valve motor (-) - - - - - - -
valve (Sub) valve (Sub)
E21 M- E22 - E23 - E24 - E25 - E26 - E27 - E28 - E29 PV+S E30 PV-S
ENGINE (J05E)/TROUBLESHOOTING
After treatment Sensor power No.4 Fuel injector No.1 Fuel injector No.4 Fuel injector No.3 Fuel injector No.3 Fuel injector No.2 Fuel injector
- -
fuel cutoff valve supply 2 (Sub) (Sub) (Sub) (Sub) (Sub) (Sub)
E31 FCV E32 - E33 VC2 E34 I1+S E35 #10 E36 #30 E37 - E38 I2+S E39 #20 E40 #40
SHTS021270300008
2–13
2–14
D
Exhaust gus Intake air
Engine oil temperature sensor Fuel temperature Fuel rail pressure
- temperature sensor - - - -
pressure switch (Air flow sensor sensor 1 (Main)
(DOC1 outlet) sensor built-in)
E41 OSW E42 - E43 THO1 E44 - E45 - E46 - E47 THA E48 THF E49 PCR1 E50 -
CAN
G sensor G sensor
- NE sensor (+) - Sensor ground 1 Sensor ground 3 Sensor ground 5 communication -
(Supply) (ground)
line
E51 - E52 NE+ E53 VCG E54 G- E55 - E56 E1 E57 E3 E58 E5 E59 CAN+ E60 -
Intake throttle Intakemanifold Coolant
Engine oil Fuel rail pressure Fuel rail pressure Boost pressure
valve position temperature temperature Fuel rail pressure - -
pressure switch sensor 2 (Main) sensor 2 (Sub) sensor
sensor 1 sensor sensor
E61 DM E62 VTA1 E63 THIA E64 PCR2 E65 PC2S E66 THW E67 PIM E68 PC1S E69 - E70 -
ENGINE (J05E)/TROUBLESHOOTING
CAN
- NE sensor (-) G sensor Air flow sensor NE sensor (SLD) Sensor ground 2 Sensor ground 4 Sensor ground 6 communication -
line
E71 - E72 NE- E73 G+ E74 VG E75 SNE E76 E2 E77 E4 E78 EVG E79 CAN- E80 -
SHTS021270300009
ENGINE (J05E)/TROUBLESHOOTING 2–15
ENGINE ECU CONNECTOR
EN01H02127030602016005
REMOVING THE ENGINE ECU CONNECTOR
NOTICE
Before replacement, wait until the engine cools down as you may
get burned. (Set the starter key to the "LOCK" position and leave it
for more than 30 minutes to cool.)
1. CLEANING THE ENGINE ECU CONNECTOR
(1) Check that the engine ECU connector is completely con-
nected to the engine ECU.
(2) Directly spray water around the engine ECU connector by
using a small spray bottle.
NOTICE
Do not remove the connector while at work.
HINT
If it is much dirty, squirt water at the connector sliding portion and
connector surface.
(3) Blow air around the engine ECU connector and engine ECU
surface to remove dirt and foreign matter.
NOTICE
• Do not remove the connector while at work.
• Blow off water with air as much as possible for drying.
(4) Using a small brush, carefully remove dirt and foreign matter
remaining at the sliding portion.
NOTICE
Do not remove the connector while at work.
(5) Using a waste cloth, wipe off around the engine ECU con-
nector and engine ECU surface.
NOTICE
• Do not remove the connector while at work.
• Wipe up water thoroughly.
Sliding
portion Lever (6) If you feel the movement of the lever un-smooth, repeat steps
SHTS021270300010 (1), (2), (3), (4) and (5).
(7) Disconnect the engine ECU connector and check it for depo-
sition of dirt and foreign matter.
a. Set the hook of the connector in the direction of the arrow
to release the lock.
Hook
SHTS021270300011
2–16 ENGINE (J05E)/TROUBLESHOOTING
b. While pushing the primary latch of the connector, move the
lever in the direction of the arrow as shown in the figure
until a "click" is heard and then detach the connector.
Primary latch
Lever
SHTS021270300012
c. Pull out the connector straight.
NOTICE
• Do not insert and remove the connector more than necessary.
• Do not give shocks to the engine ECU.
• Never detach the harness by holding and pulling or prying as it
may result in wire or terminal deformation.
• Never insert a test lead from the rear of the connector.
• Do not paint or apply grease or oil to the connector to maintain
its function and durability.
HINT
SHTS021270300013 If it cannot be pulled out with a light force, check if the lever is
fully open.
(8) If the side of the harness side connector is found dirty, wipe it
off with a moistened waste cloth while being careful not
allowing dirt and foreign matter to drop.
Wipe off NOTICE
Do not
wipe • Use a thoroughly wrung waste cloth.
• Do not wipe off the terminal opening.
• Do not directly spray water.
Harness side
connector
SHTS021270300014
(9) If the engine ECU side connector is found dirty, wipe off its
side with a moistened waste cloth.
Wipe off
NOTICE
Do not
• Use a thoroughly wrung waste cloth.
wipe • Do not wipe off the terminal opening.
• Do not directly spray water.
Engine ECU side (10) Blow air on the terminal part inside the engine ECU side con-
connector nector to remove dirt and foreign matter.
SHTS021270300015
ENGINE (J05E)/TROUBLESHOOTING 2–17
MOUNTING THE ENGINE ECU CONNECTOR
1. ATTACHING THE ENGINE ECU CONNECTOR
(1) Check that the harness side connector lever is fully open and
place it straight on the engine ECU side connector.
NOTICE
Lever At this time, check that the lever is fully open.
SHTS021270300016
HINT
Check that it is inserted along the wrong fitting prevention key-
way.
Wrong fitting
prevention keyway
SHTS021270300017
(2) Press the upper part of the harness side connector and
insert the connector uniformly.
Lever
SHTS021270300018
2–18 ENGINE (J05E)/TROUBLESHOOTING
(3) Move the lever in the direction of the arrow as shown in the
figure until a "click" is heard and attach the connector.
NOTICE
If the lever cannot move smoothly, repeat steps (1) and (2). Also
drop a few drops of water to the sliding portion to make it smooth.
Sliding
portion Lever
SHTS021270300019
(4) Move the hook in the direction of the arrow as shown in the
figure until a "click" is heard in order to lock the connector.
Hook
SHTS021270300020
ENGINE (J05E)/TROUBLESHOOTING 2–19
INSPECTION
EN01H02127030602016006
1. PRIOR CHECK
(1) Set the starter key to the "ON" position (do not start the
engine) and confirm that the check engine light in the indica-
tor area lights up.
MIL
HINT
• If the MIL (Malfunction Indicator Light) is lit, perform a system
check to see if the malfunction is of the past or present.
DIAG LAMP • In the case of the past malfunction, this light will turn off if a sta-
tus is judged to be normal in 3 times of driving.
• DTC must be cleared on the HINO-DX, after MIL comes off.
.
SHTS021270300021
(DEFINITION OF 1 TIME OF DRIVING)
a. Begins with engine start and ends with engine shut off.
b. Begins with engine start and ends after four hours of continu-
ous engine-on operation.
c. Begins at end of the previous four hours of continuous
engine-on operation and ends after four hours of continuous
engine-on operation.
d. Begins at the end of the previous four hours of continuous
engine-on operation and ends with engine shut off.
• Since the normal judgement method and time differ accord-
ing to the malfunction code, a proper definition will be
selected from the above 4 definitions.
• If the malfunction indicator light does not go out, the system is
abnormal. Check the system according to diagnosis on the fol-
lowing page.
MALFUNCTION INDICATOR LIGHT ILLUMINATION
PATTERN
Start
Starter ON
switch
Lock
Running
Engine
Stop
Malfunction ON
indicator
light OFF
TIME
SHTS021270300022
2–20 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSIS USING THE PC DIAGNOSIS
TOOL
EN01H02127030602016007
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC diagnosis
tool. By connection to the diagnosis connector, the trouble loca-
tion is indicated.
SPECIAL TOOL: Computer interface
Part name Part No.
The main body and cables
Hino-Bowie (for RS-232C and USB) 09993-E9070 *1
(Interface box) Cable between vehicle and Hino-Bowie
SHTS021270300023
S0904-21220
DENSO DST-i Set Without Bluetooth 95171-01020
(Without LCD) With Bluetooth 95171-01040
DENSO DST-i Set Without Bluetooth 95171-0103
(With LCD) With Bluetooth 95171-01050
Diagnosis software: HINO Diagnostic eXplorer (HINO-DX)
(*1): To use Hino-Bowie (interface box) "09993-E9070", update the
hardware. For details, refer to the user's manual in the HINO-DX
CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie)
using the software in the HINO-DX CD-ROM. For details, refer to
the user's manual in the HINO-DX CD-ROM.
HINT
• A cable between the Hino-Bowie and a computer is supplied
with Hino-Bowie. Use either RS-232C type or USB type.
• Install the Hino Diagnostic eXplorer (HINO-DX) software in a
computer. For detailed installation procedures, refer to the
user's manual supplied with a CD.
NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.
2. CONNECT THE PC DIAGNOSIS TOOL
(1) Set the starter key to the "LOCK" position.
(2) Connect the PC DIAGNOSIS TOOL.
SHTS021270300024
ENGINE (J05E)/TROUBLESHOOTING 2–21
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
EN01H02127030602016008
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
Light No Light P0005 Fuel Cut Valve stuck closed • Fuel cut valve
• Fuel cut valve
Light No Light P0006 Malfunction of fuel cutoff valve - low • Wire harness
• ECU (ECU connector)
• Fuel cut valve
Light No Light P0007 Malfunction of fuel cutoff valve - high • Wire harness
• ECU (ECU connector)
• Camshaft gear
• Flywheel
Crankshaft position sensor and Camshaft • Engine speed main sensor
Light No Light P0016
position sensor - rationality (crankshaft position sensor)
• Engine speed sub sensor
(camshaft position sensor)
Light No Light P0027 Exhaust Brake Performance • Exhaust brake valve
Initialization failure
Light No Light P003A • VNT controller
(VNT actuator initialize error)
DC motor open circuit • VNT actuator
Light No Light P0045
(VNT actuator motor open circuit) • VNT controller
DC motor terminal short circuit, DC motor • VNT actuator
Light No Light P0047 short circuit (Short to Battery)
(VNT actuator motor short to BATT) • VNT controller
DC motor terminal short circuit, DC motor • VNT actuator
Light No Light P0048 short circuit (Short to GND)
(VNT actuator motor short to GND) • VNT controller
Power supply failure (Out of range low)
Light No Light P006E • VNT controller
(VNT actuator power supply too low)
Power supply failure (Out of range high)
Light No Light P006F • VNT controller
(VNT actuator power supply too high)
• Intercooler outlet temperature sensor
• ECU (ECU connector)
Intake air temperature sensor • Intake air temperature sensor
Light No Light P007B
(intercooler outlet) - rationality • Boost pressure sensor
• Intake manifold temperature sensor
• Wire harness
• Intercooler outlet temperature sensor
Intake air temperature sensor (intercooler
Light No Light P007C • ECU (ECU connector)
outlet) - out of range (Out of range low)
• Wire harness
• Intercooler outlet temperature sensor
Intake air temperature sensor (intercooler
Light No Light P007D • ECU (ECU connector)
outlet) - out of range (Out of range high)
• Wire harness
2–22 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Engine
• Supply pump
• SCV
• Engine ECU
• Fuel filter
• Fuel pipe
• Breather hose
• Fuel tank feed pipe
No Light No Light P0088 Excessive common-rail pressure
• Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Bubble separator
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Intake air temperature sensor (intake
manifold)
• ECU (ECU connector)
• Intake air temperature sensor
Intake air temperature sensor (intake man- (air flow sensor built-in)
Light No Light P0096
ifold) - rationality
• Intake air temperature sensor (inter-
cooler outlet)
• Boost pressure sensor
• Wire harness
• Intake air temperature sensor (intake
Intake air temperature sensor (intake man- manifold)
Light No Light P0097
ifold) - out of range (Out of range low) • ECU (ECU connector)
• Wire harness
• Intake air temperature sensor (intake
Intake air temperature sensor (intake man- manifold)
Light No Light P0098
ifold) - out of range (Out of range high) • ECU (ECU connector)
• Wire harness
Controller error (VNT actuator CPU mal-
Light No Light P00AF • VNT controller
function)
• Air cleaner element
• Intake system
• Air flow sensor
• ECU (ECU connector)
Light No Light P0101 Air flow sensor - rationality
• Wire harness
• EGR valve
• Diesel throttle valve
• Intercooler
ENGINE (J05E)/TROUBLESHOOTING 2–23
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Air flow sensor
Light No Light P0104 Air flow sensor - out of range • ECU (ECU connector)
• Wire harness
• Boost pressure sensor
Light No Light P0106 Boost pressure sensor - rationality • ECU (ECU connector)
• Wire harness
• Boost pressure sensor
Boost pressure sensor - out of range
Light No Light P0108 • ECU (ECU connector)
(Out of range high)
• Wire harness
Intake air temperature sensor • Intake air temperature sensor
Light No Light P0112 (air flow sensor built-in) - out of range • ECU (ECU connector)
(Out of range low) • Wire harness
Intake air temperature sensor • Intake air temperature sensor
Light No Light P0113 (air flow sensor built-in) - out of range • ECU (ECU connector)
(Out of range high) • Wire harness
• Engine coolant temperature sensor 1
Malfunction of coolant temperature sensor • Engine coolant temperature sensor 2
Light No Light P0115
and intake air temperature sensor • ECU (ECU connector)
• Wire harness
• Engine coolant temperature sensor
Engine coolant temperature sensor 1 - out
Light No Light P0117 • ECU (ECU connector)
of range (Out of range low)
• Wire harness
• Engine coolant temperature sensor
Engine coolant temperature sensor 1 - out
Light No Light P0118 • ECU (ECU connector)
of range (Out of range high)
• Wire harness
• Engine coolant temperature sensor 1
Engine coolant temperature sensor - ratio- • Engine coolant temperature sensor 2
Light No Light P011A
nality • ECU (ECU connector)
• Wire harness
• Intake air temperature sensor
Intake air temperature sensor
Light No Light P011C • ECU (ECU connector)
(air flow sensor built-in) - rationality
• Wire harness
• Intake throttle valve position sensor 1
Intake throttle valve position sensor 1 - out
Light No Light P0122 • ECU (ECU connector)
of range (Out of range low)
• Wire harness
• Intake throttle valve position sensor 1
Intake throttle valve position sensor 1 - out
Light No Light P0123 • ECU (ECU connector)
of range (Out of range high)
• Wire harness
Thermostat - The coolant temperature • Engine coolant temperature sensor
Light No Light P0128
does not reach a warmed-up temperature • Thermostat
2–24 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Fuel line
• Fuel filter
No Light No Light P0148 Post injection failure • Injector
• Engine speed main sensor
(Crankshaft position sensor)
• Engine
• Supply pump
• SCV
• Engine ECU
• Fuel filter
• Fuel pipe
• Breather hose
• Fuel tank feed pipe
Light No Light P016E Fuel system pressure control - high
• Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Bubble separator
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Engine
• Supply pump
• SCV
• Engine ECU
• Fuel filter
• Fuel pipe
• Breather hose
• Fuel tank feed pipe
Light No Light P016F Fuel system pressure control - low
• Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Bubble separator
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Fuel temperature sensor
No Light Light P0182 Fuel temperature sensor Low • ECU (ECU connector)
• Wire harness
• Fuel temperature sensor
No Light Light P0183 Fuel temperature sensor High • ECU (ECU connector)
• Wire harness
ENGINE (J05E)/TROUBLESHOOTING 2–25
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Engine
• Supply pump
• SCV
• Engine ECU
• Fuel filter
• Fuel pipe
• Breather hose
Fuel rail pressure sensor (main and sub) - • Fuel tank feed pipe
Light No Light P0191
out of range • Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Bubble separator
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Common rail pressure sensor
Fuel rail pressure sensor (main) - out of
Light No Light P0192 • Wire harness
range (Out of range low)
• ECU (ECU connector)
• Common rail pressure sensor
Fuel rail pressure sensor (main) - out of
Light No Light P0193 • Wire harness
range (Out of range high)
• ECU (ECU connector)
• Common rail pressure sensor
Fuel rail pressure sensor (sub) - out of
Light No Light P01A5 • Wire harness
range (Out of range low)
• ECU (ECU connector)
• Common rail pressure sensor
Fuel rail pressure sensor (sub) - out of
Light No Light P01A6 • Wire harness
range (Out of range high)
• ECU (ECU connector)
Fuel injector driver charge circuit (circuit
Light No Light P0200 • Engine ECU
high)
• ECU (ECU connector)
• Injector
Light No Light P0201 Fuel injector - disconnection (#1cyl)
• Engine ECU
• Injector harness
• ECU (ECU connector)
• Injector
Light No Light P0202 Fuel injector - disconnection (#2cyl)
• Engine ECU
• Injector harness
• ECU (ECU connector)
• Injector
Light No Light P0203 Fuel injector - disconnection (#3cyl)
• Engine ECU
• Injector harness
2–26 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• ECU (ECU connector)
• Injector
Light No Light P0204 Fuel injector - disconnection (#4cyl)
• Engine ECU
• Injector harness
• Engine
• Cooling fan
No Light Light P0217 Engine coolant over temperature condition
• Fan clutch
• Engine coolant temperature sensor
• Engine oil level
• Main engine speed sensor
No Light No Light P0219 Engine overspeed condition
• ECU (ECU connector)
• Wire harness
• Intake throttle valve position sensor 2
Intake throttle valve position sensor 2 - out
Light No Light P0222 • ECU (ECU connector)
of range (Out of range low)
• Wire harness
• Intake throttle valve position sensor 2
Intake throttle valve position sensor 2 - out
Light No Light P0223 • ECU (ECU connector)
of range (Out of range high)
• Wire harness
• Boost pressure sensor
Light No Light P0234 Overboost • VNT controller
• EGR valve
• Boost pressure sensor
Boost pressure sensor - out of range (Out
Light No Light P0237 • ECU (ECU connector)
of range low)
• Wire harness
• Fuel line
• Fuel filter
Light No Light P0263 #1 Injection quantity and timing • Injector
• Engine speed main sensor
(Crankshaft position sensor)
• Fuel line
• Fuel filter
Light No Light P0266 #2 Injection quantity and timing • Injector
• Engine speed main sensor
(Crankshaft position sensor)
• Fuel line
• Fuel filter
Light No Light P0269 #3 Injection quantity and timing • Injector
• Engine speed main sensor
(Crankshaft position sensor)
ENGINE (J05E)/TROUBLESHOOTING 2–27
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Fuel line
• Fuel filter
All injector (#1 – #4) Injection quantity and
Light No Light P026C • Injector
timing
• Engine speed main sensor
(Crankshaft position sensor)
• Fuel line
• Fuel filter
All injector (#1 – #4) Injection quantity and
Light No Light P026D • Injector
timing
• Engine speed main sensor
(Crankshaft position sensor)
• Fuel line
• Fuel filter
Light No Light P0272 #4 Injection quantity and timing • Injector
• Engine speed main sensor
(Crankshaft position sensor)
• Boost pressure sensor
• Wire harness
Light No Light P0299 Underboost
• VNT controller
• EGR valve
• Fuel pipe
Light No Light P0300 All injector (#1 – #4) Misfire
• Injector
• Fuel injection pipe
Light No Light P0301 #1 Misfire
• Injector
• Fuel injection pipe
Light No Light P0302 #2 Misfire
• Injector
• Fuel injection pipe
Light No Light P0303 #3 Misfire
• Injector
• Fuel injection pipe
Light No Light P0304 #4 Misfire
• Injector
• Engine speed main sensor
(crankshaft position sensor)
No Light Light P0335 Crankshaft position sensor - disconnection
• ECU (ECU connector)
• Wire harness
• Engine speed main sensor
(crankshaft position sensor)
Light No Light P0336 Crankshaft position sensor - rationality
• ECU (ECU connector)
• Wire harness
• Engine speed sub sensor
(camshaft position sensor)
Light No Light P0340 Camshaft position sensor - disconnection
• ECU (ECU connector)
• Wire harness
2–28 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Engine speed sub sensor
(camshaft position sensor)
Light No Light P0341 Camshaft position sensor - rationality
• ECU (ECU connector)
• Wire harness
• Combination meter
Light No Light P0381 Glow lamp (wait-to-start lamp) - circuit • ECU (ECU connector)
• Wire harness
• Air cleaner element
• Air flow sensor
• Boost pressure sensor
• Intake air temperature sensor
Light No Light P0401 EGR low flow (intake manifold)
• EGR valve
• EGR cooler
• SCV
• Injector
• EGR valve
• VNT controller
• Air cleaner element
• Air flow sensor
Light No Light P0402 EGR high flow
• Air intake system
• Boost pressure sensor
• Intake air temperature sensor
(intake manifold)
Valve position control failure - DC motor
Light No Light P0404 out of range, functional (EGR valve stick • EGR valve
failure)
EGR valve controller position sensor sig-
Light No Light P0405 nal too low (EGR actuator position sensor • EGR valve
signal too low)
Valve position sensor magnet lost (EGR
Light No Light P0406 • EGR valve
actuator position sensor signal too high)
• EGR cooler outlet temperature sensor
• ECU (ECU connector)
• Wire harness
Light No Light P041B EGR gas temperature sensor - rationality • Intake air temperature sensor
(intake manifold)
• Intake air temperature sensor
(intercooler outlet)
• Boost pressure sensor
• EGR cooler outlet temperature sensor
EGR gas temperature sensor - out of
Light No Light P041C • ECU (ECU connector)
range (Out of range low)
• Wire harness
ENGINE (J05E)/TROUBLESHOOTING 2–29
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• EGR cooler outlet temperature sensor
EGR gas temperature sensor - out of
Light No Light P041D • ECU (ECU connector)
range (Out of range high)
• Wire harness
Tentative determination of ATC deteriora-
No Light No Light P0420 —
tion
• Fuel
Light No Light P0421 Determination of ATC deterioration • Exhaust gas temperature sensor (DPF
inlet)
• Fuel
Light No Light P0422 DOC deterioration • Exhaust gas temperature sensor (DPF
inlet)
EGR valve controller motor (open circuit)
Light No Light P0489 • EGR valve
(EGR actuator motor open circuit)
EGR valve controller motor (short circuit)
Light No Light P0490 • EGR valve
(EGR actuator motor short circuit)
• EGR valve
Light No Light P049D Position failure (EGR actuator wiping fault)
• EGR controller
• Exhaust brake magnetic valve
Light No Light P04D5 Exhaust brake - circuit (Circuit low) • Wire harness
• ECU (ECU connector)
• Exhaust brake magnetic valve
Light No Light P04D6 Exhaust brake - circuit (Circuit high) • Wire harness
• ECU (ECU connector)
• Combination meter
Light No Light P0500 Vehicle speed sensor - low • Wire harness
• ECU (ECU connector)
• Combination meter
Light No Light P0501 Vehicle speed sensor - high • Wire harness
• ECU (ECU connector)
• Brake switch
No Light No Light P0504 Brake Switch Correlation • Wire harness
• ECU (ECU connector)
• Injector
Light No Light P0519 Idle speed control system • Air compressor
• Power steering pump
• Engine oil
• Oil pressure switch
No Light Light P0521 Engine oil pressure rationality
• Wire harness
• ECU (ECU connector)
2–30 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Engine oil
• Oil pressure switch
No Light Light P0524 Engine oil pressure Too Low
• Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC1 (DOC1 inlet)
Light No Light P0545
outlet) - out of range (Out of range low) • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC1 (DOC1 inlet)
Light No Light P0546
outlet) - out of range (Out of range high) • Wire harness
• ECU (ECU connector)
• Fuse
• Fusible link
Battery voltage - out of range • Battery cable
No Light Light P0562
(Out of range low) • Alternator
• Wire harness
• ECU (ECU connector)
• Fuse
• Fusible link
Battery voltage - out of range • Battery cable
No Light Light P0563
(Out of range high) • Alternator
• Wire harness
• ECU (ECU connector)
• Air cleaner element
• Air intake system
• Air flow sensor
Crankcase ventilation system - disconnec- • Wire harness
Light No Light P05F1 tion between the CV valve and the intake
manifold • ECU (ECU connector)
• EGR valve
• Intake throttle valve
• Intercooler
Light No Light P0605 Flash ROM error —
No Light Light P0606 Control module processor —
No Light Light P0607 Control module performance —
No Light Light P0610 VIN data error —
Fuel injector driver charge circuit - circuit
Light No Light P0611 —
(circuit low)
• Starter key
• Wire harness
Light No Light P0617 Starter key - rationality
• ECU (ECU connector)
• Neutral start switch
ENGINE (J05E)/TROUBLESHOOTING 2–31
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• SCV
Suction control valve for fuel supply pump
Light No Light P0628 • Wire harness
- circuit (Circuit low)
• ECU (ECU connector)
• SCV
Suction control valve for fuel supply pump
Light No Light P0629 • Wire harness
- circuit (Circuit high)
• ECU (ECU connector)
Controller store data error
Light No Light P062F • VNT controller
(VNT actuator EEPROM error)
No Light Light P0630 VIN Not Programmed or Mismatch • Vehicle control ECU.
ECU sensor power supply 1 failure • Wire harness
No Light No Light P0642
(Out of range low) • ECU (ECU connector)
• Common rail pressure sensor 1
• Accelerator sensor 2
• Wire harness
• Boost pressure sensor
ECU sensor power supply 1 failure
No Light No Light P0643 • Intake throttle valve position sensor
(Out of range high)
• Engine speed sub sensor
(camshaft position sensor)
• Wire harness
• ECU (ECU connector)
• Fuse
Glow controller - Battery for glow plug • Fusible link
Light No Light P064C open, GND short Glow controller - Over • Glow control unit
temperature • Wire harness
• ECU (ECU connector)
ECU sensor power supply 2 failure • Wire harness
No Light No Light P0652
(Out of range low) • ECU (ECU connector)
• Common rail pressure sensor 2
• Wire harness
• Accelerator sensor 1
• DPR differential pressure sensor
ECU sensor power supply 2 failure
No Light No Light P0653 • PTO accelerator sensor
(Out of range high)
• Aftertreatment fuel injection line pres-
sure sensor
• Wire harness
• ECU (ECU connector)
• Fusible link
Glow plug (Circuit low) (#1cyl), • Glow control unit
Light No Light P0671
Glow plug (Circuit high) (#1cyl) • Wire harness
• Glow plug
2–32 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Fusible link
Glow plug (Circuit low) (#2cyl), • Glow control unit
Light No Light P0672
Glow plug (Circuit high) (#2cyl) • Wire harness
• Glow plug
• Glow control unit
Glow plug (Circuit low) (#3cyl),
Light No Light P0673 • Wire harness
Glow plug (Circuit high) (#3cyl)
• Glow plug
• Glow control unit
Glow plug (Circuit low) (#4cyl),
Light No Light P0674 • Wire harness
Glow plug (Circuit high) (#4cyl)
• Glow plug
Glow controller - Battery for glow controller • Glow control unit
open, GND short Glow controller - Glow
Light No Light P0683 • Wire harness
control signal Glow controller - Diagnosis
signal • ECU (ECU connector)
• Main relay
ECM/PCM Power Relay Control Circuit
No Light Light P0686 • Wire harness
high
• ECU (ECU connector)
• Air flow sensor
Air flow sensor power supply failure Short
No Light No Light P06D3 • Wire harness
to GND
• ECU (ECU connector)
• Air flow sensor
No Light No Light P06D4 Air flow sensor power supply failure (High) • Wire harness
• ECU (ECU connector)
Transmission information
Light No Light P073D • Neutral switch
(automatic transmission) - rationality
• Starter cut relay
No Light No Light P081A Starter Disable Circuit Low • Wire harness
• ECU (ECU connector)
• Wire harness
No Light No Light P081B Starter Disable Circuit High
• ECU (ECU connector)
Light No Light P0A7B HV BATTELY system failure —
Light No Light P0AC4 HV system failure —
Light No Light P0CA1 HV MOTOR system failure —
• PTO accelerator sensor
No Light No Light P1133 PTO accelerator sensor (Hi) • Wire harness
• ECU (ECU connector)
• Common rail pressure sensor
Light No Light P119F Fuel rail pressure sensor - rationality • Wire harness
• ECU (ECU connector)
ENGINE (J05E)/TROUBLESHOOTING 2–33
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Differential pressure hose and pipe
• Differential pressure sensor
Light No Light P1426 Differential pressure sensor - rationality
• Wire harness
• ECU (ECU connector)
• Differential pressure sensor
Differential pressure sensor - out of range
Light No Light P1427 • Wire harness
(Out of range low)
• ECU (ECU connector)
• Differential pressure sensor
Differential pressure sensor - out of range
Light No Light P1428 • Wire harness
(Out of range high)
• ECU (ECU connector)
Valve position control failure - DC motor
No Light No Light P1458 out of range, functional • EGR valve
(EGR actuator over temp warning level)
Controller high temperature
Light No Light P1459 • EGR valve
(EGR actuator over temp severe level)
Controller store data error (EGR actuator
Light No Light P14B0 • EGR valve
abnormal information reading)
EGR controller power supply open circuit
Light No Light P14B2 • EGR valve
(EGR actuator power supply open circuit)
Battery voltage (high)
Light No Light P14B3 • EGR valve
(EGR actuator power supply too high)
Battery voltage (low) (EGR actuator power
Light No Light P14B4 • EGR valve
supply too low)
EGR valve controller temperature sensor 1
Light No Light P14B7 (Signal too low) (EGR actuator temp. sen- • EGR valve
sor 1 signal too low)
EGR valve controller temperature sensor 1
Light No Light P14B8 (Signal too high) (EGR actuator temp. sen- • EGR valve
sor 1 signal too high)
EGR valve controller temperature sensor 2
Light No Light P14BC (Signal too low) (EGR actuator temp. sen- • EGR valve
sor 2 signal too low)
EGR valve controller temperature sensor 2
Light No Light P14BD (Signal too high) (EGR actuator temp. sen- • EGR valve
sor 2 signal too high)
EGR valve controller temperature sensor
Light No Light P14BF 1, 2 - rationality (EGR actuator temp. sen- • EGR valve
sor 1 performance invalid)
2–34 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Radiator curtain
• Air cleaner element
• Radiator fan
Light No Light P1515 Charge air undercooling • Fan clutch
• Intercooler
• Intercooler tube
• Radiator
• Engine stop switch
No Light No Light P1530 Engine stop switch malfunction • Wire harness
• ECU (ECU connector)
Light No Light P1601 Fuel injector adjustment data error • Injector
• Exhaust pipe
• Injector
• Engine
Light No Light P200C DPF over temperature • Exhaust gas temperature sensor
(DPF inlet)
• Exhaust gas temperature sensor
(DPF outlet)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC2 (DOC2 inlet)
Light No Light P2032
inlet) - out of range (Out of range low) • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC2 (DOC2 inlet)
Light No Light P2033
inlet) - out of range (Out of range high) • Wire harness
• ECU (ECU connector)
• DEF tank
No Light No Light P203F Empty reductant tank
• DEF tank level sensor
Light No Light
or or P204F Reductant System Performance —
No Light Light
• DEF
• Engine
• Air flow sensor
• Exhaust gas temperature sensor
Light No Light P207F Improper reductant (SCR inlet)
• DEF pipe
• DEF injector
• NOx sensor
• SCR catalyst
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC1 inlet)
Light No Light P2080
(DOC1outlet) - rationality • Wire harness
• ECU (ECU connector)
ENGINE (J05E)/TROUBLESHOOTING 2–35
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC2 (DOC2 inlet)
Light No Light P2084
inlet) - rationality • Wire harness
• ECU (ECU connector)
• Fuel dosing valve
Malfunction of fuel addition valve
Light No Light P20CD • Wire harness
[Short-circuit]
• ECU (ECU connector)
Malfunction of fuel addition valve
Light No Light P20CE • Fuel dosing valve
[+B short-circuit]
Malfunction of fuel addition valve [Leak]
Light No Light P20CF —
(Continuous injection)
• Fuel pipe (for aftertreatment)
Light No Light P20D8 Exhaust Fuel Doser open/close stuck
• Fuel dosing valve
Aftertreatment Fuel Injection Line Pres- • Aftertreatment fuel pressure sensor
Light No Light P20DE
sure Sensor Performance Invalid • Fuel pipe (for aftertreatment)
• Aftertreatment fuel injection line pres-
Aftertreatment Fuel Injection Line Pres- sure sensor
Light No Light P20DF
sure Sensor Signal Too Low • Wire harness
• ECU (ECU connector)
• Aftertreatment fuel injection line pres-
Aftertreatment Fuel Injection Line Pres- sure sensor
Light No Light P20E0
sure Sensor Signal Too High • Wire harness
• ECU (ECU connector)
• DEF solution
• Engine
• Air flow sensor
• Exhaust gas temperature sensor
NOx converting catalyst conversion effi- (SCR inlet)
Light No Light P20EE
ciency • DEF pipe
• DEF injector
• Exhaust pipe
• NOx sensor
• SCR catalyst
• Diesel throttle
DC motor for intake throttle valve - circuit
Light No Light P2100 • Wire harness
(Open circuit (circuit low))
• ECU (ECU connector)
• Air cleaner element
• Air hose
• Air pipe
Light No Light P2101 Intake throttle valve - functional
• Exhaust muffler (exhaust pipe)
• Exhaust brake valve
• Diesel throttle
2–36 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Diesel throttle
DC motor for intake throttle valve - circuit
Light No Light P2103 • Wire harness
(Short circuit (circuit high))
• ECU (ECU connector)
Throttle/Pedal Position Sensor/Switch "D"
No Light Light P2120 —
Circuit
• Accelerator sensor
Accelerator pedal position sensor 1 - out of
Light No Light P2122 • Wire harness
range (Out of range low)
• ECU (ECU connector)
• Accelerator sensor
Accelerator pedal position sensor 1 - out of
Light No Light P2123 • Wire harness
range (Out of range high)
• ECU (ECU connector)
• Accelerator sensor
Accelerator pedal position sensor 2 - out of
Light No Light P2127 • Wire harness
range (Out of range low)
• ECU (ECU connector)
• Accelerator sensor
Accelerator pedal position sensor 2 - out of
Light No Light P2128 • Wire harness
range (Out of range high)
• ECU (ECU connector)
• Intake throttle valve position sensor
Intake throttle valve position sensor - ratio-
Light No Light P2135 • Wire harness
nality
• ECU (ECU connector)
• PTO accelerator sensor
Accelerator pedal position sensor - ratio-
Light No Light P2138 • Accelerator sensor
nality
• ECU (ECU connector)
• Injector
Fuel injector driver circuit 1 - circuit (circuit
Light No Light P2146 • Wire harness
open)
• ECU (ECU connector)
Fuel injector driver circuit 1 - circuit (circuit • Injector
Light No Light P2147
low) • Wire harness
Fuel injector driver circuit 1 - circuit (circuit • Injector
Light No Light P2148
high) • Wire harness
• Injector
Fuel injector driver circuit 2 - circuit (circuit
Light No Light P2149 • Wire harness
open)
• ECU (ECU connector)
Fuel injector driver circuit 2 - circuit (circuit • Injector
Light No Light P2150
low) • Wire harness
Fuel injector driver circuit 2 - circuit (circuit • Injector
Light No Light P2151
high) • Wire harness
• Engine coolant temperature sensor 2
Engine coolant temperature sensor 2 - out
Light No Light P2184 • Wire harness
of range (Out of range low)
• ECU (ECU connector)
ENGINE (J05E)/TROUBLESHOOTING 2–37
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Engine coolant temperature sensor 2
Engine coolant temperature sensor 2 - out
Light No Light P2185 • Wire harness
of range (Out of range high)
• ECU (ECU connector)
• DEF
• Exhaust pipe
• Air flow sensor
• Exhaust gas temperature sensor
NOx sensor (SCR downstream) - Perfor- (SCR inlet)
Light No Light P2214
mance and Monitoring capability • Exhaust temperature sensor
(DPF outlet)
• Ambient air temperature sensor
• DEF injector
• NOx sensor
Light No Light P2227 Barometric pressure sensor - rationality • Boost pressure sensor
Barometric pressure sensor - out of range
Light No Light P2228 —
(out of range low)
Barometric pressure sensor - out of range
Light No Light P2229 —
(out of range high)
• Fuel filter
• Fuel filter water level sensor
No Light No Light P2269 Water in Fuel Condition
• Wire harness
• ECU (ECU connector)
• VNT controller
• EGR valve
• Air cleaner
Light No Light P226C Boost pressure slow response
• Air intake system
• Boost pressure sensor
• VNT actuator
Light No Light P22D3 Nozzle stuck (VNT stick failure) • VNT controller
• EGR valve
• VNT controller
• Air cleaner element
• Air flow sensor
Light No Light P240F EGR flow slow response
• Intake system
• Boost pressure sensor
• Intake manifold temperature sensor
• Injector
• Injector
• Pipe
No Light No Light P2428 Improper ATC temperature • Hose
• ATC
• DPR
2–38 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC (DPF inlet)
Light No Light P242B
inlet) - rationality • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC (DPF inlet)
Light No Light P242C
inlet) - out of range (Out of range low) • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC (DPF inlet)
Light No Light P242D
inlet) - out of range (Out of range high) • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
(DPF inlet)
• Differential pressure sensor
• DPR filter
• Exhaust gas temperature sensor
Light No Light P244A Filtering performance (missing substrate) (DPF outlet)
• EGR valve
• VNT controller
• Diesel throttle valve
• SCV
• Injector
• DPR
• Differential pressure sensor
• Engine
• Exhaust gas temperature sensor
(DPF inlet)
• Exhaust gas temperature sensor
(DPF outlet)
Light No Light P244B Incomplete regeneration • DPF indicator light
• DPR switch
• Neutral switch
• Accelerator switch
• PTO signal
• External accelerator signal
• Injector
• EGR cooler outlet gas temperature
sensor
• EGR cooler
Light No Light P2457 EGR cooler performance • EGR valve
• Diesel throttle valve
• SCV
• Injector
ENGINE (J05E)/TROUBLESHOOTING 2–39
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Exhaust pipe
• Exhaust brake valve
• Exhaust gas temperature sensor
(DPF inlet)
No Light Light P2458 DPR manual regeneration failure • Exhaust gas temperature sensor
(DOC1 inlet)
• DPR
• Coolant temperature sensor
• Engine
Light No Light P2459 Frequent regeneration —
• DPF indicator light
• DPR switch
• Neutral switch
Light No Light P2463 DPF clogged
• Accelerator switch
• PTO signal
• External accelerator signal
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC (DPF outlet)
Light No Light P246F
outlet) - rationality • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC (DPF outlet)
Light No Light P2470
outlet) - out of range (Out of range low) • Wire harness
• ECU (ECU connector)
• Exhaust gas temperature sensor
Exhaust gas temperature sensor (DOC (DPF outlet)
Light No Light P2471
outlet) - out of range (Out of range high) • Wire harness
• ECU (ECU connector)
Closed Loop DPF Regeneration Control At • Exhaust gas temperature sensor
Light No Light P24A0
Limit - Temperature Too Low (DPF inlet)
Closed Loop DPF Regeneration Control At
Light No Light P24A1 —
Limit - Temperature Too High
• Engine oil
• Exhaust pipe
• Injector
• Exhaust brake valve
No Light No Light P24A2 Excessive DPR fuel addition rate • EGR valve
• VNT controller
• Exhaust gas temperature sensor
(DPF inlet)
• DPR
Nozzle position sensor failure range (High • VNT controller
Light No Light P2562 level) (VNT actuator position sensor per-
formance invalid) • VNT actuator
2–40 ENGINE (J05E)/TROUBLESHOOTING
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
Nozzle operating range failure -NARROW • VNT controller
Light No Light P259E (VNT actuator wiping error (too narrow
range)) • Turbocharger
Nozzle operating range failure -WIDE
Light No Light P259F (VNT actuator wiping error (too wide • VNT controller
range))
• Engine
• Supply pump
• Fuel filter
• Engine ECU
• Fuel hose
• Fuel tank breather
• Fuel tank feed pipe
• Supply pump gauze filter
No Light No Light P2635 Fuel Pump Low Flow/Performance
• Fuel high-pressure pipe
• Bubble separator
• SCV
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Fuel pipe
Light No Light P268A Fuel injector adjustment data error • Injector
Light No Light P2696 Fuel injector adjustment data error • Injector
No Light No Light P26C8 Vehicle system failure —
• DEF
No Light No Light P2BA9 Insufficient Reagent Quality • DEF tank
• DEF quality sensor
Engine ECU CAN communication bus for
Light No Light U0073 —
Emission control system - bus off
• Connector
Engine ECU CAN communication
Light No Light U010A • Wire harness
(EGR valve control)
• EGR controller
• Connector
Light No Light U010C VNT actuator CAN communication error • Wire harness
• VNT controller
• Connector
Engine ECU CAN communication
Light No Light U010E • Wire harness
(DeNOx ECU)
• DCU
• Connector
Light No Light U0293 CAN Bus-Line Open From HV • Wire harness
• HV system
ENGINE (J05E)/TROUBLESHOOTING 2–41
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAG
MIL DTC No. DIAGNOSIS ITEM INSPECTION ITEM
LAMP
• Connector
Engine ECU CAN communication
Light No Light U029D • NOx sensor 1
(NOx sensor (SCR upstream))
• Wire harness
• Connector
Engine ECU CAN communication
Light No Light U029E • NOx sensor 2
(NOx sensor (SCR downstream))
• Wire harness
• Connector
Engine ECU CAN communication
Light No Light U02A2 • DEF sensor
(DEF tank sensor)
• Wire harness
No Light No Light U0301 Software Incompatibility With DeNOx ECU —
• Connector
Engine ECU CAN communication bus for
Light No Light U1001 • Wire harness
Vehicle control - bus off
• Vehicle control ECU
Light • Connector
Engine ECU CAN communication
or No Light U110A • Wire harness
(Vehicle ECU)
No Light • Vehicle control ECU
NOTICE
• It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service
replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at the
time of ECU service replacement, so ensure sufficient time (several minutes) is available.
• When an injector is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using
the Diagnostic tool.
2–42 ENGINE (J05E)/TROUBLESHOOTING
GROUP SHARING THE SENSOR SUPPLY TERMINAL
EN01H02127030602016009
• If one of the sensor power supplies fails, more than one malfunction codes will occur for the sensors sharing the sensor
supply terminal.
Check the sensors for short circuits and whether the sensor supply circuit is in normal condition.
ECU terminal Sensor DTC
Intake throttle valve position sensor 1 P0122
E33 Common rail pressure sensor (Main) P0193
Boost pressure sensor P0237
PTO accelerator sensor —
V71
Differential pressure sensor P1428
• If P0642 or P0652 has also occurred, the sensor supply of the ECU may be in abnormal condition or the GND may be
shorted somewhere in the following sensor group.
Group Sensor DTC
Accelerator pedal position sensor 1 P2122
P1198
Common rail pressure sensor (Sub)
P1197
P0642
P1428
Differential pressure sensor
P1427
PTO accelerator sensor P1133
Boost pressure sensor P0237
P0193
Common rail pressure sensor
P0192
P0652
Intake throttle valve position sensor 1 P0122
Accelerator pedal position sensor 1 P2127
Camshaft position sensor P0016
ENGINE (J05E)/TROUBLESHOOTING 2–43
GROUP SHARING THE SENSOR GND TERMINAL
EN01H02127030602016010
ECU terminal Sensor
Fuel temperature sensor
E76 Intake air temperature sensor (intake manifold)
Common rail pressure sensor (Main)
E77 Boost sensor
Exhaust gas temperature sensor 1
E58 Engine coolant temperature sensor
Intake air temperature sensor
Exhaust gas temperature sensor 2
Exhaust gas temperature sensor 3
V46
Exhaust gas temperature sensor 4
Differential pressure sensor
Accelerator sensor 1
V45
PTO accelerator sensor
E57 Intake throttle valve position sensor 1
E56 Common rail pressure sensor (Sub)
E65 Accelerator sensor 2
2–44 ENGINE (J05E)/TROUBLESHOOTING
MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION
EN01H02127030602016011
Since the CAN communication line is configured as described below, more than one malfunction code may occur depend-
ing on the faulty area of the circuit.
For single failure
• The system itself is suspected of being faulty due to the broken harness or connector or supply circuit failure of the CAN
communication circuit for each actuator and controller.
ENGINE EQUIPMENT/EMISSION CONTROL DEVICE CAN LINE (250 k)
<Diesel>
Engine peripherals/ Diesel aftertreatment system CAN line
CAN-TMN2 DCU
(Terminator) 6 7 J/C_ENG_CAN2 8 J/C_ENG_CAN 9 J/C_CAN_Diesel 10 J/C_DEF_Sensor 11 (Terminator)
1 2 3 4 5
VNT EGR NOx NOx DEF
Engine
Controller Controller Sensor 2 Sensor 1 sensor
ECU
<Hybrid>
Engine peripherals/ Diesel aftertreatment system CAN line
CAN-TMN2 DCU
(Terminator) 6 7 J/C_ENG_CAN2 8 J/C_ENG_CAN 9 J/C_HV2 10 J/C_HV1 11 J/C_DEF_Sensor 12 (Terminator)
1 2 3 4 5
VNT EGR NOx NOx DEF
Engine
Controller Controller Sensor 2 Sensor 1 sensor
ECU
SHTS021270300025
ENGINE (J05E)/TROUBLESHOOTING 2–45
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE
(ENGINE ECU)
Malfunction Part Case
1 U010A
2 U010C
3 U029E
4 U029D
5 U02A2
6-12 U010A, U010C, U029D, U029E, U0073, U010E, U02A2
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE
(DCU)
Malfunction Part Case
3 U029E
4 U029D
5 U02A2
6-12 U029D, U029E, U0029, U0100
2–46 ENGINE (J05E)/TROUBLESHOOTING
ENGINE CONTROL/DIAGNOSIS CAN LINE (500 k)
<Diesel>
Engine control/ Diagnosis CAN Line
CAN-TMN2 DCU
(Terminator) 4 J/C_CAN2 (22P) 5 J/C_CAN2 6 J/C_CAN1
J/C_CAN1 (10P)
(10P) 7 J/C_CAN5 8 (Terminator)
1 2 3
Engine
DLC ATM ECU VCS ECU ABS ECU
ECU
<Hybrid>
Engine control/ Diagnosis CAN Line
CAN-TMN2 DCU
(Terminator) 4 J/C_CAN1 (10P) 5 J/C_CAN2 (22P) 6 J/C_CAN2 7 J/C_CAN5 8 (Terminator)
1 2 3
Engine
ABS ECU DLC ATM ECU VCS ECU
ECU
SHTS021270300026
ENGINE (J05E)/TROUBLESHOOTING 2–47
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE
(ENGINE ECU)
Malfunction Part Case
1, 3 Communication failure of the HINO-DX
2 U1001, U110A Failure to communicate the VCU
4, 5, 6, 7, 8 U0293, U1001, U110A, Communication failure of the HINO-DX
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE
(DCU)
Malfunction Part Case
1 Communication failure of the HINO-DX
4, 5, 6, 7, 8 U0038, Communication failure of the HINO-DX
2–48 ENGINE (J05E)/TROUBLESHOOTING
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)
EN01H02127030602016012
1 Check the DTC detected [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
3. Set the starter key to the "ON" position.
4. Check that the any DTC other than CAN communication system
DTC (U****) has been detected in the [Fault Information] in HINO-
DX menu.
SHTS021270300027
Has a DTC other than CAN communication system DTC (U****) been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
ENGINE (J05E)/TROUBLESHOOTING 2–49
2 Check for +B/GND short-circuit in CAN H-line
1. Set the starter key to the "LOCK" position.
+B2 GND4 GND1
LEP LEW LET +24V CAN- TC DSW
K9G KS4 KS2 KPZ
2. Disconnect the following sensors and controllers connected to the
+B3 GND5 GND2
LEQ LEX LEU ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 Engine peripherals and after-treatment CAN line.
+B4 +B1 GND3
LER LEN LEV
• DCU(53P)
• EGR controller, VNT controller
CAH1
LF5 • NOx sensors 1 and 2, DEF sensor
CAL1
TE1B
LF6
• CAN-TMN2 (terminating resistance)
LF2
TE1A CAH0
LF1 LEY
TE2B
LF4
CAL0
LEZ
3. Use the electrical tester to check the continuity between the follow-
TE2A
LF3
ing terminals.
(1) Between the CAH0 terminal in the DCU (53P) vehicle side
connector and the 16th terminal in the DLC (16P).
ISGW
LES
(2) Between the CAH0 terminal in the DCU (53P) vehicle side
connector and the 4th terminal in the DLC (16P).
Measurement Tester
Standard values
conditions connections
SHTS021270300028
DCU vehicle-side
connector –
Diagnostic con-
Starter key: LOCK No Continuity
nector
CAH0 – 16th
CAH0 – 4th
Do the measurements meet the standard value?
YES NO
Go to step 3. Refer to "DISCONNECTION INSPECTION
FOR ENGINE CAN_H COMMUNICATION L
LINE (250 k)" and check the CAN bus line.
2–50 ENGINE (J05E)/TROUBLESHOOTING
3 Check for +B/GND short-circuit in CAN L-line
1. Use the electrical tester to check the continuity between the follow-
ing terminals.
+B2 GND4 GND1
LEP LEW LET +24V CAN- TC DSW
K9G KS4 KS2 KPZ
+B3 GND5 GND2
ISOK CAN+ SGND CGFR +
(1) Between the CAL0 terminal in the DCU (53P) vehicle side
LEQ LEX LEU
K9E KS3 K9H L30 KE4
connector and the 16th terminal in the DLC(16P).
+B4 +B1 GND3
LER LEN LEV
(2) Between the CAL0 terminal in the DCU (53P) vehicle side
connector and the 4th terminal in the DLC(16P).
CAH1
LF5
Measurement Tester
CAL1
LF6 Standard values
TE1B
LF2
conditions connections
TE1A CAH0
LF1 LEY
TE2B
LF4
CAL0
LEZ
DCU vehicle-side
TE2A
LF3
connector –
Diagnostic con-
Starter key: LOCK No Continuity
nector
ISGW
LES CAL0 – 16th
CAL0 – 4th
SHTS021270300029
Do the measurements meet the standard value?
YES NO
Go to step 4. Refer to "DISCONNECTION INSPECTION
FOR ENGINE CAN_H COMMUNICATION L
LINE (250 k)" and check the CAN bus line.
ENGINE (J05E)/TROUBLESHOOTING 2–51
4 Check the terminating resistance
1. Use the electrical tester to check the continuity between the follow-
ing terminals.
(1) Between the CAH0 terminal and CAL0 terminal in the DCU
(53P).
(2) Between the CANP terminal and CANN terminal in CAN-
ISGW
LES
TMN2.
CAH0 Measurement Tester
Standard values
TE2A
LF3 conditions connections
TE2B CAH0
LF4 LEY
TE1A
LF1
CAL0
LEZ DCU (53P):
TE1B
CAH0 – CAL0
120 10
LF2
CAL1 Starter key: ON
LF6
CAL0 CAN-TMN2:
CANP – CANN
CAH1
LF5
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2
LEQ LEX LEU
+B2 GND4 GND1
LEP LEW LET
CANP CANN
SHTS021270300030
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the faulty part.
After replacing the part, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–52 ENGINE (J05E)/TROUBLESHOOTING
5 Check the resistance
1. Use the electrical tester to check the continuity between the follow-
ing terminals.
(1) Between the CAH0 terminal and CAL0 terminal in the DCU
(53P).
ISGW Measurement Tester
LES
Standard values
conditions connections
CAH0
DCU (53P):
45 – 75
TE2A
LF3
Starter key: ON
TE2B
LF4
CAH0
LEY
CAH0 – CAL0
TE1A CAL0
LF1 LEZ
TE1B
LF2
CAL1
LF6
CAH1
CAL0
LF5
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2
LEQ LEX LEU
+B2 GND4 GND1
LEP LEW LET
SHTS021270300031
Do the measurements meet the standard value?
YES NO
Procedure completed. Refer to "DISCONNECTION INSPECTION
CAN bus line (main line and trunk lines) FOR ENGINE CAN_H COMMUNICATION L
between terminating resistances is normal. LINE (250 k)" and check the CAN bus line.
Go to the diagnostic procedure for the
detected DTC.
ENGINE (J05E)/TROUBLESHOOTING 2–53
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L
LINE (250 k) [DIESEL]
EN01H02127030602016013
1 Check harness in CAN bus line between J/C DEF SSR and DCU (Failure Site 11)
1. Set the starter key to the "LOCK" position.
2. Disconnect the following sensors and controllers connected to the
Engine peripherals and aftertreatment CAN line. (Leave the DCU,
engine ECU, and CAN-TMN2 connected.)
• EGR controller, VNT controller
• NOx sensor 1 and 2, DEF sensor
3. Disconnect the J/C DEF SSR connector.
4. Use electrical tester to measure the resistance between No.5
SHTS021270300032 (CANH) terminal and No.10 (CANL) terminal at the J/C DEF SSR
connector.
Measurement Tester
Standard values
conditions connections
J/C DEF SSR con-
nector
Starter key: LOCK 110 – 130
No.5 (CANH) –
No.10 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C DEF SSR connector, and go CAN bus line disconnection between J/C
to step 2. DEF SSR and the DCU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–54 ENGINE (J05E)/TROUBLESHOOTING
2 Check harness in CAN bus line between J/C_CAN_Diesel and J/C DEF SSR (Failure Site 10)
1. Disconnect the J/C_CAN_Diesel connector.
2. Use electrical tester to measure the resistance between No.5
(CANH) terminal and No.8 (CANL) terminal at the J/
C_CAN_Diesel connector.
Measurement Tester
Standard values
conditions connections
J/C_CAN_Diesel
connector
Starter key: LOCK 110 – 130
No.5 (CANH) –
SHTS021270300033 No.8 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN_Diesel connector, and CAN bus line disconnection between J/
go to step 3. C_CAN_Diesel and the J/C DEF SSR
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–55
3 Check harness in CAN bus line between J/C_ENG_CAN and J/C_CAN_Diesel (Failure Site 9)
1. Disconnect the J/C_ENG_CAN connector.
2. Use electrical tester to measure the resistance between No.6
(CANH) terminal and No.8 (CANL) terminal at the J/C_ENG_CAN
connector.
Measurement Tester
Standard values
conditions connections
J/C_ENG_CAN
connector
Starter key: LOCK 110 – 130
No.6 (CANH) –
SHTS021270300034 No.8 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_ENG_CAN connector, and CAN bus line disconnection between J/
go to step 4. C_ENG_CAN and the J/C_CAN_Diesel
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–56 ENGINE (J05E)/TROUBLESHOOTING
4 Check harness in CAN bus line between J/C_ENG_CAN2 and J/C_ENG_CAN (Failure Site 8)
1. Disconnect the J/C_ENG_CAN2 connector.
2. Use electrical tester to measure the resistance between No.5
1 2 3 4
%KH %KF %KE %KG (CANH) terminal and No.8 (CANL) terminal at the J/
6 7
%KM %KL
C_ENG_CAN2 connector.
Measurement Tester
Standard values
conditions connections
J/C_ENG_CAN2
connector
Starter key: LOCK 110 – 130
No.5 (CANH) –
SHTS021270300035 No.8 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_ENG_CAN2 connector, and CAN bus line disconnection between J/
go to step 5. C_ENG_CAN2 and the J/C_ENG_CAN
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–57
5 Check harness in CAN bus line between engine ECU and J/C_ENG_CAN2 (Failure Site 7)
1. Disconnect the engine ECU connector (both 2 connectors).
D E59
2. Connect the signal check harness to the engine ECU vehicle-side
E79
connector. (Do not connect harness to the ECU)
3. Use electrical tester to measure the resistance between (CANH)
terminal and (CANL) terminal at the ECU check harness. These
circuits are identified as terminal E59 and terminal E79 on the
ECU check harness D.
Measurement Tester
Standard values
conditions connections
SHTS021270300036
Signal check har-
ness (Engine ECU)
Starter key: LOCK 110 – 130
E59 (CANH) –
E79 (CANL)
Do the measurements meet the standard value?
YES NO
Go to step 6. CAN bus line disconnection between engine
ECU and J/C_ENG_CAN2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–58 ENGINE (J05E)/TROUBLESHOOTING
6 Check harness in CAN bus line between engine ECU and CAN-TMN2 (terminating resistance)
(Failure Site 6)
1. Use electrical tester to measure the resistance between (CANN)
terminal and (CANH) terminal at the ECU check harness. These
A V17 circuits are identified as terminal V17 and terminal V37 on the
V37 ECU check harness A.
Measurement Tester
Standard values
conditions connections
Signal check har-
ness (Engine ECU)
Starter key: LOCK 110 – 130
V17 (CANN) –
V37 (CANP)
SHTS021270300037
Do the measurements meet the standard value?
YES NO
Disconnect ECU Check Harness. CAN bus line disconnection between engine
Go to step 7. ECU and CAN-TMN2 (terminating resistance)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–59
7 Inspect the EGR controller [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the connector of the engine ECU.
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Erase the malfunction history and set the starter key to the
"LOCK" position.
6. Connect the EGR controller connector.
SHTS021270300038
7. Set the starter key to the "ON" position.
8. Check that the EGR controller communication failure (U010A) is
not detected in the [Fault Information] in HINO-DX menu.
Did the EGR controller communication failure (U010A) disappear?
YES NO
Go to step 8. Replace the EGR controller.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–60 ENGINE (J05E)/TROUBLESHOOTING
8 Inspect the VNT controller [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Connect the VNT controller connector.
3. Set the starter key to the "ON" position.
4. Check that the VNT controller communication failure (U010C) is
not detected in the [Fault Information] in HINO-DX menu.
SHTS021270300039
Did the VNT controller communication failure (U010C) disappear?
YES NO
Go to step 9. Replace the VNT controller.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
9 NOx sensor 1 [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Connect the NOx sensor 1 connector.
3. Set the starter key to the "ON" position.
4. Check that the NOx sensor 1 communication failure (U029D) is not
detected in the [Fault Information] in HINO-DX menu.
SHTS021270300040
Did the NOx sensor 1 communication failure (U029D) disappear?
YES NO
Go to step 10. Replace the NOx sensor 1.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–61
10 Inspect the NOx sensor 2 [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Connect the NOx sensor 2 connector.
3. Set the starter key to the "ON" position.
4. Check that the NOx sensor 2 communication failure (U029E) is not
detected in the [Fault Information] in HINO-DX menu.
SHTS021270300041
Did the NOx sensor 2 communication failure (U029E) disappear?
YES NO
Go to step 11. Replace the NOx sensor 2.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
11 Check the DEF sensor [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Disconnect the DEF sensor connector.
3. Set the starter key to the "ON" position.
4. Check that the DEF sensor communication failure (U02A2) is not
detected in the [Fault Information] in HINO-DX menu.
SHTS021270300042
Did the DEF sensor communication failure (U02A2) disappear?
YES NO
Procedure completed. Replace the DEF sensor.
If another CAN communication system DTC Perform After-inspection work. (Clear all past
is detected, go to the diagnostic procedure DTC. Check no DTC is stored after test
for the detected DTC. drive.)
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–62 ENGINE (J05E)/TROUBLESHOOTING
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L
LINE (250 k) [HYBRID]
EN01H02127030602016014
1 Check harness in CAN bus line between J/C DEF SSR and DCU (Failure Site 12)
1. Set the starter key to the "LOCK" position.
2. Disconnect the following sensors and controllers connected to the
Engine peripherals and after-treatment CAN line. (Leave the DCU,
engine ECU, and CAN-TMN2 connected.)
• EGR controller, VNT controller
• NOx sensor 1 and 2, DEF sensor
3. Disconnect the J/C DEF SSR connector.
4. Use electrical tester to measure the resistance between No.5
SHTS021270300043 (CANH) terminal and No.10 (CANL) terminal at the J/C DEF SSR
connector.
Measurement Tester
Standard values
conditions connections
J/C DEF SSR con-
nector
Starter key: LOCK 110 – 130
No.5 (CANH) –
No.10 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C DEF SSR connector, and go CAN bus line disconnection between J/C
to step 2. DEF SSR and the DCU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–63
2 Check harness in CAN bus line between J/C_HV1 and J/C DEF SSR (Failure Site 11)
1. Disconnect the J/C_HV1 connector.
2. Use electrical tester to measure the resistance between No.4
(CANH) terminal and No.9 (CANL) terminal at the J/C_HV1 con-
nector.
Measurement Tester
Standard values
conditions connections
J/C_HV1 connec-
tor
Starter key: LOCK 110 – 130
No.4 (CANH) –
SHTS021270300044 No.9 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_HV1 connector, and go to CAN bus line disconnection between J/
step 3. C_HV1 and the J/C DEF SSR
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–64 ENGINE (J05E)/TROUBLESHOOTING
3 Check harness in CAN bus line between J/C_HV2 and J/C_HV1 (Failure Site 10)
1. Disconnect the J/C_HV2 connector.
2. Use electrical tester to measure the resistance between No.3
(CANH) terminal and No.8 (CANL) terminal at the J/C_HV2 con-
nector.
Measurement Tester
Standard values
conditions connections
J/C_HV2 connec-
tor
Starter key: LOCK 110 – 130
No.3 (CANH) –
SHTS021270300045 No.8 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_HV2 connector, and go to CAN bus line disconnection between J/
step 4. C_HV2 and the J/C_HV1
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–65
4 Check harness in CAN bus line between J/C_ENG_CAN and J/C_HV2 (Failure Site 9)
1. Disconnect the J/C_ENG_CAN connector.
2. Use electrical tester to measure the resistance between No.6
(CANH) terminal and No.8 (CANL) terminal at the CAN_J/C1 con-
nector.
Measurement Tester
Standard values
conditions connections
J/C_ENG_CAN
connector
Starter key: LOCK 110 – 130
No.6 (CANH) –
SHTS021270300046 No.8 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_ENG_CAN connector, and CAN bus line disconnection between J/
go to step 5. C_ENG_CAN and the J/C_HV2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–66 ENGINE (J05E)/TROUBLESHOOTING
5 Check harness in CAN bus line between J/C_ENG_CAN2 and J/C_ENG_CAN (Failure Site 8)
1. Disconnect the J/C_ENG_CAN2 connector.
2. Use electrical tester to measure the resistance between No.5
K6W LEZ K6V L4R
%J1 %J6 %J4 %J8 (CANH) terminal and No.8 (CANL) terminal at the J/
L48 KV9 KV8 LEV
%J5 %J2 %J3 %J7
C_ENG_CAN2 connector.
Measurement Tester
Standard values
conditions connections
J/C_ENG_CAN2
connector
Starter key: LOCK 110 – 130
No.5 (CANH) –
SHTS021270300047 No.8 (CANL)
Do the measurements meet the standard value?
YES NO
Connect the J/C_ENG_CAN2 connector, and CAN bus line disconnection between J/
go to step 6. C_ENG_CAN2 and the J/C_ENG_CAN
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–67
6 Check harness in CAN bus line between engine ECU and J/C_ENG_CAN2 (Failure Site 7)
1. Disconnect the engine ECU connector (both 2 connectors).
D E59
2. Connect the signal check harness to the engine ECU vehicle-side
E79
connector. (Do not connect harness to the ECU)
HINT
Refer to "PRECAUTIONS".
3. Use electrical tester to measure the resistance between (CANH)
terminal and (CANL) terminal at the ECU check harness. These
circuits are identified as terminal E59 and terminal E79 on the
ECU check harness D.
SHTS021270300048
Measurement Tester
Standard values
conditions connections
Signal check har-
ness (Engine ECU)
Starter key: LOCK 110 – 130
E59 (CANH) –
E79 (CANL)
Do the measurements meet the standard value?
YES NO
Go to step 7. CAN bus line disconnection between engine
ECU and J/C_ENG_CAN2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–68 ENGINE (J05E)/TROUBLESHOOTING
7 Check harness in CAN bus line between engine ECU and CAN-TMN2 (terminating resistance)
(Failure Site 6)
1. Use electrical tester to measure the resistance between (CANP)
terminal and (CANH) terminal at the ECU check harness. These
A V17 circuits are identified as terminal V17 and terminal V37 on the
V37 ECU check harness A.
Measurement Tester
Standard values
conditions connections
Signal check har-
ness (Engine ECU)
Starter key: LOCK 110 – 130
V17 (CANN) –
V37 (CANP)
SHTS021270300049
Do the measurements meet the standard value?
YES NO
Disconnect ECU Check Harness. CAN bus line disconnection between engine
Go to step 8. ECU and CAN-TMN2 (terminating resistance)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–69
8 Inspect the EGR controller [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the connector of the engine ECU.
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Erase the malfunction history and set the starter key to the
"LOCK" position.
6. Connect the EGR controller connector.
SHTS021270300050
7. Set the starter key to the "ON" position.
8. Check that the EGR controller communication failure (U010A) is
not detected in the [Fault Information] in HINO-DX menu.
Did the EGR controller communication failure (U010A) disappear?
YES NO
Go to step 9. Replace the EGR controller.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–70 ENGINE (J05E)/TROUBLESHOOTING
9 Inspect the VNT controller [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Connect the VNT controller connector.
3. Set the starter key to the "ON" position.
4. Check that the VNT controller communication failure (U010C) is
not detected in the [Fault Information] in HINO-DX menu.
SHTS021270300051
Did the VNT controller communication failure (U010C) disappear?
YES NO
Go to step 10. Replace the VNT controller.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
10 NOx sensor 1 [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Connect the NOx sensor 1 connector.
3. Set the starter key to the "ON" position.
4. Check that the NOx sensor 1 communication failure (U029D) is not
detected in the [Fault Information] in HINO-DX menu.
SHTS021270300052
Did the NOx sensor 1 communication failure (U029D) disappear?
YES NO
Go to step 11. Replace the NOx sensor 1.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–71
11 Inspect the NOx sensor 2 [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Connect the NOx sensor 2 connector.
3. Set the starter key to the "ON" position.
4. Check that the NOx sensor 2 communication failure (U029E) is not
detected in the [Fault Information] in HINO-DX menu.
SHTS021270300053
Did the NOx sensor 2 communication failure (U029E) disappear?
YES NO
Go to step 12. Replace the NOx sensor 2.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
12 Check the DEF sensor [HINO-DX]
1. Erase the trouble history and set the starter key to the "LOCK"
position.
2. Disconnect the DEF sensor connector.
3. Set the starter key to the "ON" position.
4. Check that the DEF sensor communication failure (U02A2) is not
detected in the [Fault Information] in HINO-DX menu.
SHTS021270300054
Did the DEF sensor communication failure (U02A2) disappear?
YES NO
Procedure completed. Replace the DEF sensor.
If another CAN communication system DTC Perform After-inspection work. (Clear all past
is detected, go to the diagnostic procedure DTC. Check no DTC is stored after test
for the detected DTC. drive.)
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–72 ENGINE (J05E)/TROUBLESHOOTING
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k)
[DIESEL]
EN01H02127030602016015
1 Check the DTC detected Engine ECU
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
3. Set the starter key to the "ON" position.
4. Check that any DTC other than CAN communication system DTC
(U****) has been detected in the [Fault Information] in HINO-DX
menu.
SHTS021270300055
Has a DTC other than CAN communication system DTC (U****) been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
ENGINE (J05E)/TROUBLESHOOTING 2–73
2 Check for +B/GND short-circuit in CAN H-line
1. Set the starter key to the "LOCK" position.
+B2 GND4 GND1
LEP LEW LET +24V CAN- TC DSW
K9G KS4 KS2 KPZ
2. Disconnect the following sensors and controllers connected to the
+B3 GND5 GND2
LEQ LEX LEU ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 Engine_control/Diagnosis_CAN line.
+B4 +B1 GND3
LER LEN LEV
• DCU(53P), engine ECU, AT ECU, ABS ECU, vehicle control ECU,
CAN-TMN
CAH1
LF5
CAL1
LF6
3. Use the electrical tester to check the continuity between the CAH1
TE1B
LF2
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
TE1A
LF1
CAH0
LEY
minal and 16th terminal in the diagnostic connector (16P).
TE2B CAL0
LF4 LEZ
TE2A
LF3
Measurement Tester
Standard values
conditions connections
ISGW
LES
DCU vehicle-side
connector – Diag-
Starter key: LOCK nostic connector No Continuity
CAH1 – 4th
CAH1 – 16th
SHTS021270300056
Do the measurements meet the standard value?
YES NO
Go to step 3. Refer to "DISCONNECTION INSPECTION
FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
2–74 ENGINE (J05E)/TROUBLESHOOTING
3 Check for +B/GND short-circuit in CAN L-line
1. Use the electrical tester to check the continuity between the CAL1
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
+B2 GND4 GND1
LEP LEW LET +24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ minal and 16th terminal in the diagnostic connector (16P).
+B3 GND5 GND2
LEQ LEX LEU ISOK CAN+ SGND CGFR +
K9E KS3 K9H L30 KE4
+B4 +B1 GND3 Measurement Tester
LER LEN LEV
Standard values
conditions connections
CAH1
LF5
DCU vehicle-side
CAL1
LF6
connector – Diag-
TE1B
LF2 Starter key: LOCK nostic connector No Continuity
TE1A
LF1
CAH0
LEY CAL1 – 4th
TE2B
LF4
CAL0
LEZ
CAL1 – 16th
TE2A
LF3
ISGW
LES
SHTS021270300057
Do the measurements meet the standard value?
YES NO
Go to step 4. Refer to "DISCONNECTION INSPECTION
FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
ENGINE (J05E)/TROUBLESHOOTING 2–75
4 Check the terminating resistance
1. Use the electrical tester to check the continuity between the follow-
ing terminals.
(1) Between the CAH1 terminal and CAL1 terminal in the DCU
(53P).
(2) Between the 1st terminal and 2nd terminal in the CAN_TMN.
ISGW
LES
Measurement Tester
Standard values
TE2A
conditions connections
LF3
TE2B CAL0
LF4 LEZ
DCU (53P):
TE1A CAH0
CAL1
LF1 LEY
CAH1 – CAL1
TE1B
LF2 Starter key: ON 120 10
CAL1
CAN_TMN:
1st – 2nd
LF6
CAH1
LF5
CAH1
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2
LEQ LEX LEU
+B2 GND4 GND1
LEP LEW LET
SHTS021270300058
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the faulty part.
After replacing the part, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–76 ENGINE (J05E)/TROUBLESHOOTING
5 Check the resistance
1. Connect the DCU (53P) connector and CAN-TMN connector.
2. Use the electrical tester to measure the terminating resistance of
DCU (53P).
ISGW
LES
Measurement Tester
Standard values
conditions connections
TE2A
DCU (53P):
LF3
TE2B CAL0
Starter key: ON 45 – 75
CAH1 – CAL1
LF4 LEZ
TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2
CAL1
LF6
CAH1
LF5
CAH1
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2
LEQ LEX LEU
+B2 GND4 GND1
LEP LEW LET
SHTS021270300059
Do the measurements meet the standard value?
YES NO
Procedure completed. Refer to "DISCONNECTION INSPECTION
CAN bus line (main line and trunk lines) FOR ENGINE CAN_H COMMUNICATION L
between terminating resistances is normal. LINE (500 k)" and check the CAN bus line.
Go to the diagnostic procedure for the
detected DTC.
ENGINE (J05E)/TROUBLESHOOTING 2–77
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k)
[HYBRID]
EN01H02127030602016016
1 Check the DTC detected Engine ECU
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
3. Set the starter key to the "ON" position.
4. Check that any DTC other than CAN communication system DTC
(U****) has been detected in the [Fault Information] in HINO-DX
menu.
SHTS021270300060
Has a DTC other than CAN communication system DTC (U****) been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2–78 ENGINE (J05E)/TROUBLESHOOTING
2 Check for +B/GND short-circuit in CAN H-line
1. Set the starter key to the "LOCK" position.
+B2 GND4 GND1
LEP LEW LET +24V CAN- TC DSW
K9G KS4 KS2 KPZ
2. Disconnect the following sensors and controllers connected to the
+B3 GND5 GND2
LEQ LEX LEU ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 Engine_control/Diagnosis_CAN line.
+B4 +B1 GND3
LER LEN LEV
• DCU(53P), engine ECU, AT ECU, ABS ECU, vehicle control ECU,
HV PCU
CAH1
LF5
CAL1
LF6
3. Use the electrical tester to check the continuity between the CAH1
TE1B
LF2
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
TE1A
LF1
CAH0
LEY
minal and 16th terminal in the diagnostic connector (16P).
TE2B CAL0
LF4 LEZ
TE2A
LF3
Measurement Tester
Standard values
conditions connections
ISGW
LES
DCU vehicle-side
connector – Diag-
Starter key: LOCK nostic connector No Continuity
CAH1 – 4th
CAH1 – 16th
SHTS021270300061
Do the measurements meet the standard value?
YES NO
Go to step 3. Refer to "DISCONNECTION INSPECTION
FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
ENGINE (J05E)/TROUBLESHOOTING 2–79
3 Check for +B/GND short-circuit in CAN L-line
1. Use the electrical tester to check the continuity between the CAL1
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
+B2 GND4 GND1
LEP LEW LET +24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ minal and 16th terminal in the diagnostic connector (16P).
+B3 GND5 GND2
LEQ LEX LEU ISOK CAN+ SGND CGFR +
K9E KS3 K9H L30 KE4
+B4 +B1 GND3 Measurement Tester
LER LEN LEV
Standard values
conditions connections
CAH1
LF5
DCU vehicle-side
CAL1
LF6
connector – Diag-
TE1B
LF2 Starter key: LOCK nostic connector No Continuity
TE1A
LF1
CAH0
LEY CAL1 – 4th
TE2B
LF4
CAL0
LEZ
CAL1 – 16th
TE2A
LF3
ISGW
LES
SHTS021270300062
Do the measurements meet the standard value?
YES NO
Go to step 4. Refer to "DISCONNECTION INSPECTION
FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
2–80 ENGINE (J05E)/TROUBLESHOOTING
4 Check the DCU (terminating resistance)
1. Use the electrical tester to measure the terminating resistance of
DCU (53P).
Measurement Tester
Standard values
conditions connections
ISGW
LES
DCU (53P):
Starter key: ON 120 10
CAH1 – CAL1
TE2A
LF3
TE2B CAL0
LF4 LEZ
TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2
CAL1
LF6
CAH1
LF5
CAH1
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2
LEQ LEX LEU
+B2 GND4 GND1
LEP LEW LET
SHTS021270300063
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the DCU.
After replacing the DCU, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–81
5 Check the HV ECU (terminating resistance)
1. Use the electrical tester to measure the terminating resistance of
the HV ECU.
Measurement Tester
Standard values
conditions connections
HV ECU
Starter key: ON 120 10
21st – 22nd
SHTS021270300064
Do the measurements meet the standard value?
YES NO
Go to step 6. Replace the HV ECU.
After replacing the ECU, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–82 ENGINE (J05E)/TROUBLESHOOTING
6 Check the resistance
1. Connect the DCU (53P) connector and HV PCU connector.
2. Use the electrical tester to measure the terminating resistance of
DCU (53P).
ISGW
LES
Measurement Tester
Standard values
conditions connections
TE2A
DCU (53P):
LF3
TE2B CAL0
Starter key: ON 45 – 75
CAH1 – CAL1
LF4 LEZ
TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2
CAL1
LF6
CAH1
LF5
CAH1
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2
LEQ LEX LEU
+B2 GND4 GND1
LEP LEW LET
SHTS021270300065
Do the measurements meet the standard value?
YES NO
Procedure completed. Replace the DCU.
CAN bus line (main line and trunk lines) Refer to "DISCONNECTION INSPECTION
between terminating resistances is normal. FOR ENGINE CAN_H COMMUNICATION L
Go to the diagnostic procedure for the LINE (500 k)" and check the CAN bus line.
detected DTC.
ENGINE (J05E)/TROUBLESHOOTING 2–83
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k) [DIESEL]
EN01H02127030602016017
1 Check harness in CAN bus line between J/C_CAN5 and DCU (Failure Site 8)
1. Set the starter key to the "LOCK" position.
2. Disconnect the following controller connectors connected to the
Engine_control/Diagnosis_CAN line.
• Engine ECU, AT ECU, ABS ECU, vehicle control ECU
3. Disconnect the J/C_CAN5 connector.
4. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the DCU side, viewed
from J/C_CAN5.
SHTS021270300066
Measurement Tester
Standard values
conditions connections
J/C_CAN5:
Starter key: LOCK 110 – 130
5th – 10th
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN5 connector, and go to CAN bus line disconnection between J/
step 2. C_CAN5 and the DCU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–84 ENGINE (J05E)/TROUBLESHOOTING
2 Check harness in CAN bus line between J/C_CAN1 (10P) and J/C_CAN5 (Failure Site 7)
1. Disconnect the J/C_CAN1 (10P) connector.
2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the J/C_CAN5 side,
viewed from J/C_CAN1 (10P).
Measurement Tester
Standard values
conditions connections
J/C_CAN1 (10P):
Starter key: LOCK 110 – 130
5th – 10th
SHTS021270300067
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN1 (10P) connector, and CAN bus line disconnection between J/
go to step 3. C_CAN1 (10P) and J/C_CAN5
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
3 Check harness in CAN bus line between J/C_CAN2 and J/C_CAN1 (10P) (Failure Site 6)
1. Disconnect the J/C_CAN2 connector.
2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the J/C_CAN1 (10P)
side, viewed from J/C_CAN2.
Measurement Tester
Standard values
conditions connections
J/C_CAN2:
Starter key: LOCK 110 – 130
6th – 17th
SHTS021270300068
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN2 connector, and go to CAN bus line disconnection between J/
step 4. C_CAN2 and J/C_CAN1 (10P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–85
4 Check harness in CAN bus line between J/C_CAN1 (22P) and J/C_CAN2 (Failure Site 5)
1. Disconnect the J/C_CAN1 (22P) connector.
2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the J/C_CAN2 side,
viewed from J/C_CAN1 (22P).
Measurement Tester
Standard values
conditions connections
J/C_CAN1 (22P):
Starter key: LOCK 110 – 130
6th – 17th
SHTS021270300069
Do the measurements meet the standard value?
YES NO
Go to step 5. CAN bus line disconnection between J/
C_CAN1 (22P) and J/C_CAN2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
5 Check harness in CAN bus line between CAN_TMN and J/C_CAN1 (22P) (Failure Site 4)
1. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the J/C_CAN1 (22P)
side, viewed from CAN_TMN.
Measurement Tester
Standard values
conditions connections
J/C_CAN1 (22P):
Starter key: LOCK 110 – 130
5th – 16th
SHTS021270300070
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN1 (22P) connector, and CAN bus line disconnection between
go to step 6. CAN_TMN and J/C_CAN1 (22P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–86 ENGINE (J05E)/TROUBLESHOOTING
6 Check harness in CAN bus line between DLC and J/C_CAN1 (22P) (Failure Site 1)
1. Use the electrical tester to measure the resistance between the
DLC CAN H line terminal and L line terminal.
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
Measurement Tester
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 Standard values
conditions connections
Starter key: LOCK DLC: 6th – 14th 45 – 75
SHTS021270300071
Do the measurements meet the standard value?
YES NO
Go to step 7. CAN bus line disconnection between DLC
and J/C_CAN1 (22P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–87
7 Check harness in CAN bus line between engine ECU and J/C_CAN5 (Failure Site 3)
1. Disconnect the J/C_CAN1 (10P) connector.
A V16
2. Connect the signal check harness to the engine ECU vehicle-side
V36
connector. (Do not connect harness to the ECU)
3. Use electrical tester to measure the resistance between (CANL)
terminal and (CANH) terminal at the ECU check harness. These
circuits are identified as terminal V16 and terminal V36 on the
ECU check harness A.
Measurement Tester
Standard values
conditions connections
SHTS021270300072
Signal check har-
ness (Engine ECU)
Starter key: LOCK 110 – 130
V16 (CANL) –
V36 (CANH)
Do the measurements meet the standard value?
YES NO
Procedure completed. CAN bus line disconnection between engine
If another CAN communication system DTC ECU and J/C_CAN5
is detected, go to the diagnostic procedure Repair or replace the harness.
for the detected DTC. Perform After-inspection work. (Clear all past
Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test
DTC. Check no DTC is stored after test drive.)
drive.)
2–88 ENGINE (J05E)/TROUBLESHOOTING
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k) [HYBRID]
EN01H02127030602016018
1 Check harness in CAN bus line between J/C_CAN5 and DCU (Failure Site 8)
1. Set the starter key to the "LOCK" position.
2. Disconnect the following controller connectors connected to the
Engine_control/Diagnosis_CAN line.
• Engine ECU, AT ECU, ABS ECU, vehicle control ECU
3. Disconnect the J/C_CAN5 connector.
4. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the DCU side, viewed
from J/C_CAN5.
SHTS021270300073
Measurement Tester
Standard values
conditions connections
J/C_CAN5:
Starter key: LOCK 110 – 130
5th – 10th
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN5 connector, and go to CAN bus line disconnection between J/
step 2. C_CAN5 and the DCU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–89
2 Check harness in CAN bus line between J/C_CAN2 and J/C_CAN5 (Failure Site 7)
1. Disconnect the J/C_CAN2 connector.
2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the J/C_CAN5 side,
viewed from J/C_CAN2.
Measurement Tester
Standard values
conditions connections
J/C_CAN2:
Starter key: LOCK 110 – 130
6th – 17th
SHTS021270300074
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN2 connector, and go to CAN bus line disconnection between J/
step 3. C_CAN2 and J/C_CAN5
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
3 Check harness in CAN bus line between J/C_CAN1 (22P) and J/C_CAN2 (Failure Sites 2 & 6)
1. Disconnect the J/C_CAN1 (22P) connector.
2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the J/C_CAN2 side,
viewed from J/C_CAN1 (22P).
Measurement Tester
Standard values
conditions connections
J/C_CAN1 (22P):
Starter key: LOCK 110 – 130
6th – 17th
SHTS021270300075
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN1 (22P) connector, and CAN bus line disconnection between J/
go to step 4. C_CAN1 (22P) and J/C_CAN2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–90 ENGINE (J05E)/TROUBLESHOOTING
4 Check harness in CAN bus line between J/C_CAN1 (10P) and J/C_CAN1 (22P) (Failure Site 5)
1. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on J/C_CAN1 (22P) side,
viewed from J/C_CAN1 (10P).
Measurement Tester
Standard values
conditions connections
J/C_CAN1 (10P):
Starter key: LOCK 110 – 130
3rd – 8th
SHTS021270300076
Do the measurements meet the standard value?
YES NO
Go to step 5. CAN bus line disconnection between CAN_J/
C2 and vehicle control ECU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
5 Check harness in CAN bus line between HV PCU and J/C_CAN1 (10P) (Failure Site 4)
1. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on J/C_CAN1 (10P) side,
viewed from HV PCU.
Measurement Tester
Standard values
conditions connections
J/C_CAN1 (10P):
Starter key: LOCK 110 – 130
5th – 10th
SHTS021270300077
Do the measurements meet the standard value?
YES NO
Connect the J/C_CAN1 (10P) connector, and CAN bus line disconnection between HV
go to step 6. PCU and J/C_CAN1 (10P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–91
6 Check harness in CAN bus line between DLC and J/C_CAN1 (22P) (Failure Site 1)
1. Use the electrical tester to measure the resistance between the
DLC CAN H line terminal and L line terminal.
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 Measurement Tester
Standard values
conditions connections
Starter key: LOCK DLC: 6th – 14th 45 – 75
SHTS021270300078
Do the measurements meet the standard value?
YES NO
Go to step 7. CAN bus line disconnection between DLC
and J/C_CAN1 (22P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–92 ENGINE (J05E)/TROUBLESHOOTING
7 Check harness in CAN bus line between engine ECU and J/C_CAN5 (Failure Site 3)
1. Disconnect the J/C_CAN2 connector.
A V16
2. Connect the signal check harness to the engine ECU vehicle-side
V36
connector. (Do not connect harness to the ECU)
3. Use electrical tester to measure the resistance between (CANL)
terminal and (CANH) terminal at the ECU check harness. These
circuits are identified as terminal V16 and terminal V36 on the
ECU check harness A.
Measurement Tester
Standard values
conditions connections
SHTS021270300079
Signal check har-
ness (Engine ECU)
Starter key: LOCK 110 – 130
V16 (CANL) –
V36 (CANH)
Do the measurements meet the standard value?
YES NO
Procedure completed. CAN bus line disconnection between engine
If another CAN communication system DTC ECU and No. J/C_CAN5
is detected, go to the diagnostic procedure Repair or replace the harness.
for the detected DTC. Perform After-inspection work. (Clear all past
Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test
DTC. Check no DTC is stored after test drive.)
drive.)
ENGINE (J05E)/TROUBLESHOOTING 2–93
MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY
EN01H02127030602016019
Since the following actuators and switches are connected in the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.
Sensor Case
Neutral switch P0850
Brake switch P0504
EGR actuator U1122
VNT actuator U1123
DPR regeneration switch Manual regeneration failure of DPR
Exhaust brake
Functional failure
Cruise
Aftertreatment fuel injector P20CD
2–94 ENGINE (J05E)/TROUBLESHOOTING
ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)
EN01H02127030602016020
* After inspection, indicate a check mark in the boxes below.
Inspec-
1 2 3 4 5 6 7 8 9
tion steps
Exhaust
Air intake
Inspec- Engine/ Fuel tank, Sensor system/ VN turbo- EGR valve/ Supply
system Injector
tion area ECU filter system exhaust charger cooler pump
parts
brake
Checking Inspect Inspect Damage Gas leak Follow Follow Inspect Inspect
the diag- the fuel the air in the sen- from tight- ability dur- ability dur- the injec- the power
nosis tank. cleaner. sor har- ened and ing ing tor drive supply.
code. Low- Fouled ness fastened inspec- inspec- wiring. Actuation
grade element Poor fit of areas tion (Devi- tion (Devi- and wir-
fuel, con- the sensor ation 8% ation 5% ing of
taminants coupler or under) or under) main relay
or mois-
ture inclu-
sion
Check the Inspect Inspect Inspect Inspect Clogged Inspect Inspect
program the fuel the air the rota- actuation cooler the com- SCV
part No. hose. flow meter tion sig- of the pression. resis-
Break- for any nal exhaust tance.
Inspection age, crush degrada- system. brake.
items or clog- tion/dete- NE or G
ging rioration. active flag
Fouling and pulsar
and damage
assembly
direction
Check the Inspect Inspect Inspect Check a Inspect Inspect
injector the fuel the air the accel- valve gap. appear- SCV
calibra- pipe. hose. erator ance of amper-
tion data. Connec- Loose- sensor. the injec- age dur-
tion to IN/ ness, 0 to 100% tor. ing idling.
OUT and crush and voltage Presence Variance
wrong loose of deposit in amper-
assembly clamp at the end age ( 40
mA)
ENGINE (J05E)/TROUBLESHOOTING 2–95
Inspec-
1 2 3 4 5 6 7 8 9
tion steps
Exhaust
Air intake
Inspec- Engine/ Fuel tank, Sensor system/ VN turbo- EGR valve/ Supply
system Injector
tion area ECU filter system exhaust charger cooler pump
parts
brake
Check the Inspect Inspect Engine Injection Inspect
supply the fuel fil- the boost coolant quantity the set
pump ter. sensor. tempera- compen- timing.
specifica- Element, Inspect ture sen- sation Check
tion learn- separator the sen- sor between gear
ing and gauze sors and Output cylinders phases.
filter check the voltage Check
hoses for and resis- through
clogging. tance data mon-
itoring.
Check for Inspect air Inter- Common Inspect a
free inclusion. cooler rail pres- compen-
smoke. Priming body and sure sen- sated
operation Damage sor injection
and air in hoses Inspect quantity.
bleeding HINO-DX Check
fuel leak- writing.
age and
Inspection check fol-
items low ability
to actual
level.
ECU data External Inspect an
monitor fuel leak- injection
(Check age quantity.
HINO-DX Check 1. Idling
reports.) pipes and speed
hoses for 2. Mid
leakage. speed
Internal
fuel leak-
age
Presence
of an
increase
in engine
oil
2–96 ENGINE (J05E)/TROUBLESHOOTING
Inspec-
1 2 3 4 5 6 7 8 9
tion steps
Exhaust
Air intake
Inspec- Engine/ Fuel tank, Sensor system/ VN turbo- EGR valve/ Supply
system Injector
tion area ECU filter system exhaust charger cooler pump
parts
brake
- Check -Remove -Replace - Re-fit - Retighten. - Inspect - Clean or - Check - Inspect
parts contami- the ele- and repair or replace replace for discon- the relay
based on nants and ment. damaged the turbo the valve. nection. upstream
each diag- fouling parts. charger. fuse.
nosis and
code. replace
low-grade
fuel.
- Repro- - Replace - Clean or - Replace - Check - Inspect - Clean - Clean
gram with deformed replace the sen- air leak- or replace the cooler. the end of
the latest parts. the air sor. age and the turbo the noz-
part No. flow exhaust charger. zle nee-
meter. brake dle.
magnetic
valve
operation.
- Write a - Correct - Replace - Adjust a - Standard
correct wrong the hose gap. 5q
calibra- assembly and
tion data. to proper retighten
assembly. the clamp.
Actions to
be taken - Perform - Replace - Replace
upon "fail" the sup- the ele- the sen-
judgment ply pump ment. sor.
specifica-
tion learn-
ing again.
- Free - Air - Replace
accelera- bleeding the hose
tion and
method retighten
smoke the clamp.
test
Standard:
10 % or
less with-
out muf-
fler.
- Clear - Inspect
data after for fuel
outputting leakage
a HINO- (check
DX report. connec-
tions and
pipings).
ENGINE (J05E)/TROUBLESHOOTING 2–97
Standard injection quantity
J05E
r/min 750
Idling (normal)
Injection quantity (mm3/st) 7 – 16
r/min 1,500
Mid-speed inspection point
Injection quantity (mm3/st) 10 or more (AT)
r/min 2,800
Standard DPR filter differential pressure
Differential pressure 1.5 kPa or under
2–98 ENGINE (J05E)/TROUBLESHOOTING
NO DTC
EN01H02127030602016021
ENGINE LOW POWER, MISS-FIRE, HESITATION, KNOCKING, RUNNING ROUGH
Check
No Parts Check contents Judgement If fail
(Pass/Fail)
Injection quantity at 1,500r/min No load 10 (mm3/st) or Injector
1 Injector
Coolant temp. more than 80 C {176 F} more Replace
Cylinder cut out test Find knocking Injector
2 Injector
(Detail on next page A) cylinder Replace
Check restriction or contamination of the
No restriction Filter
3 Air filter air cleaner element
Genuine parts Replace
(Detail on next page B)
Visually check No bending
4 Air hoses Fix Replace
(Detail on next page C) No leaking
No excessive dirt
Visually check
inside
5 Intake throttle Activation test by HINO-DX Drill holes
Drilled 3 holes
(Detail on next page D)
Following target
Difference
Mass air flow test at 100% Free accelera- between old and MAF
6 Mass air flow sensor
tion (Detail on next page E) new sensor less Replace
than 10%
Visually check Exhaust
No sticking
7 Exhaust Brake Open and close butterfly valve brake
No seizing
(Detail on next page F) Replace
8 Engine Compression test More than 340psi Overhaul
ENGINE (J05E)/TROUBLESHOOTING 2–99
Cylinder cut out test
System fix 1. Park vehicle with parking brake set,
and chock whiles.
Check function 2. Set engine speed at 1,500r/min by
A cruse control switch.
Activation test 3. Check each cylinder for decreased
level of knock. If the knock
Cylinder cut out decreases during cut out test, that
cylinder should be considered
Start abnormal fueling injector
Air Filter Visually check
(Single cab) (Single cab)
CHECK NO RESTRICTION CHECK INDICATOR
AND GENUINE PARTS
B
(Crew cab) (Crew cab)
CHECK INDICATOR
CHECK NO RESTRICTION
AND GENUINE PARTS
Air hoses Visually check
CHECK TIGHTNESS, NO BENDING CHECK TIGHTNESS, NO CHECK TIGHTNESS, NO
BENDING AND NO LEAK BENDING AND NO LEAK
C
2–100 ENGINE (J05E)/TROUBLESHOOTING
Intake throttle Visually check
No excessive dirt inside of throttle
body and no movement between but-
terfly valve and shaft
D
Intake throttle activation test
1. Park vehicle with parking brake set,
and chock whiles.
System fix 2. When click [Intake throttle UP/
Intake throttle DOWN] button, the
Check function directed Intake throttle valve posi-
tion changes from 0% to 90% by
Intake throttle valve check 10% step.
Confirm actual intake throttle valve
position is followed directed intake
throttle valve.
Mass air flow sensor check
1. Park vehicle with parking brake set,
and chock whiles.
2. Make accelerator 100% when park-
ing.
Coolant temp must be more than
System fix 80C {176F}
E
Check function 3. Click keep and white down the
value. (A)
Suction air volume check 4. Replace initial MAF to bran new
one.
5. Do again (2) and (3). (B)
Calculation form: {(B)-(A)} / (B) x 100
< 10
ENGINE (J05E)/TROUBLESHOOTING 2–101
Exhaust Brake valve check
DPR NORMAL MANUAL REGENERATION IS NOT COMPLETE
Check
No Parts Check contents Judgement If fail
(Pass/Fail)
Check carbon of fuel addition valve nozzle No carbon Cleaning
1 Fuel addition valve
and folder deposited carbon
2–102 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0005
EN01H02127030602016022
P0005: Fuel Cut Valve stuck closed
INFORMATION
Engine ECU
Fuel cut valve
EBP TYP 0.7A EB4 (FCV)
FCV
(FCV)
SHTS021270300094
1. Technical description
• The engine ECU monitors the pressure in the DPR fuel pipe based on the value of the DPR fuel pressure sensor.
<Description of malfunction>
• Sticking of the fuel cut valve (FCV) was detected.
2. DTC set condition
(1) DTC detection condition
• The engine revolution is 700 r/min or more.
• The difference between the actual fuel pressure and the target fuel pressure is 7.8 MPa/sec or less.
(2) Judgement criteria
• The pressure in the DPR fuel pipe is 0 MPa or less when the engine revolution is 750 r/min, and remains at 0.2
MPa or less for 30 seconds even when the engine revolution becomes 1000 r/min or more.
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• DPR automatic regeneration may not be performed properly.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Power supply for fuel cut valve.
• Fuel leakage (loose joint bolt), clogging, crush, and wrong assembly in fuel pipe.
• Defect of fuel cut valve.
ENGINE (J05E)/TROUBLESHOOTING 2–103
INSPECTION PROCEDURE: P0005
1 Check the DTC detected [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the diagnostic system (HINO-DX) to the vehicle.
Select
3. Set the starter key to the "ON" position.
Engine
4. On the screen of the diagnostic system, select [Engine], and check
[Fault Information] for any DTC listed below other than P0005.-
P0006, P0007, P016F
SHTS021270300095
Is any DTC other than P0005 detected?
YES NO
Go to the relevant DTC-specific trouble- Go to step 2.
shooting.
2 Inspect the power supply for the fuel cut valve
1. Set the starter key to the "LOCK" position.
BODY GND 2. Disconnect the connector from the fuel cut valve.
3. Set the starter key to the "ON" position.
4. Using the electrical tester, measure the pressure between the fuel
cut valve vehicle side connector FCV terminal and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300096 Fuel cut valve
vehicle side con-
Starter key: LOCK 8 V or more
nector FCV termi-
nal –Ground
Do the measurements meet the standard value?
YES NO
Go to step 3. Inspect the power supply circuit of the
engine ECU.
2–104 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the fuel cut valve downstream pipe 1
1. Check if any of the following defects is found in the pipe between
the fuel cut valve and the fuel dosing valve.
• Fuel leakage (loose joint bolt)
• Crush
• Wrong assembly
Was any failure found?
YES NO
Repair or replace the defective part.After Go to step 4.
repair or replacement, bleed air from the
pipe.
4 Inspect the fuel cut valve downstream pipe 2
1. Bleed air from the fuel cut valve downstream pipe and also check
that there is no clogging in the pipe.
<Inspection procedure>
- Set the starter key to the "ON" position.
- Loosen the downstream side joint bolt.
- Slowly push the feed pump on the fuel pump until fuel comes out.
! CAUTION
Use care, as a large amount of fuel may come out if the feed pump
is pushed excessively.
Is fuel drained? Is bleeding air completed?
YES NO
Replace the fuel cut valve. Go to step 5.
ENGINE (J05E)/TROUBLESHOOTING 2–105
5 Inspect the fuel cut valve upstream pipe 1
1. Check if any of the following defects is found in the pipe between
the fuel pump and the fuel cut valve.
(1) Fuel leakage (loose joint bolt)
(2) Crush
(3) Wrong assembly
Was any failure found?
YES NO
Repair or replace the defective part.After Go to step 6.
repair or replacement, bleed air from the
pipe.
6 Inspect the fuel cut valve upstream pipe 2
1. Bleed air from the fuel cut valve upstream pipe and also check that
there is no clogging in the pipe.
<Inspection procedure>
- Set the starter key to the "ON" position.
- Loosen the upstream side joint bolt.
- Slowly push the feed pump on the fuel pump until fuel comes out.
! CAUTION
Use care, as a large amount of fuel may come out if the feed pump
is pushed excessively.
Is fuel drained? Is bleeding air completed?
YES NO
Replace the fuel cut valve. Clean or replace the fuel cut valve upstream
pipe.
2–106 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0005
DTC: P0005 Fuel Cut Valve stuck closed Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Set the starter key to the
"LOCK" position.
DTC other
2. Connect the diagnostic system
than P0005
(HINO-DX) to the vehicle.
has been Go to the rele-
Check the 3. Set the starter key to the "ON" detected: Go vant DTC-spe-
1 DTC detected position. to YES. cific Go to step 2.
[HINO-DX] 4. On the screen of the diagnostic troubleshoot-
system, select [Engine], and No DTC has ing.
check [Fault Information] for been detected:
any DTC listed below other Go to NO.
than P0005.- P0006, P0007,
P016F
1. Set the starter key to the
"LOCK" position.
2. Disconnect the connector from
the fuel cut valve. The measure-
3. Set the starter key to the "ON" ments meet
position. the standard
value: Go to
Inspect the 4. Using the electrical tester, mea- Inspect the
YES.
power supply sure the pressure between the power supply
2 Go to step 3.
for the fuel cut fuel cut valve vehicle side con- circuit of the
The measure-
valve nector FCV terminal and engine ECU.
ments do not
ground.
meet the stan-
<Tester connections>
dard value: Go
Fuel cut valve vehicle side con-
to NO.
nector
FCV – Ground
<Standard values>
8 V or more
1. Check if any of the following Repair or
defects is found in the pipe Failure found: replace the
Inspect the between the fuel cut valve and Go to YES. defective
fuel cut valve the fuel dosing valve. part.After
3 Go to step 4.
downstream • Fuel leakage No failure repair or
pipe 1 (loose joint bolt) found: Go to replacement,
• Crush NO. bleed air from
the pipe.
• Wrong assembly
ENGINE (J05E)/TROUBLESHOOTING 2–107
DTC: P0005 Fuel Cut Valve stuck closed Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Bleed air from the fuel cut valve
downstream pipe and also
check that there is no clogging
in the pipe.
Fuel is
drained, bleed-
<Inspection procedure>
ing air is com-
- Set the starter key to the pleted: Go to
Inspect the "ON" position. YES.
fuel cut valve Replace the
4 - Loosen the downstream side Go to step 5.
downstream fuel cut valve.
joint bolt. Fuel is not
pipe 2
- Slowly push the feed pump drained, bleed-
on the fuel pump until fuel ing air is not
comes out. completed: Go
to NO.
! CAUTION
Use care, as a large amount of
fuel may come out if the feed
pump is pushed excessively.
1. Check if any of the following Repair or
defects is found in the pipe Failure found: replace the
Inspect the between the fuel pump and the Go to YES. defective
fuel cut valve fuel cut valve. part.After
5 Go to step 6.
upstream pipe (1) Fuel leakage No failure repair or
1 (loose joint bolt) found: Go to replacement,
(2) Crush NO. bleed air from
(3) Wrong assembly the pipe.
1. Bleed air from the fuel cut valve
upstream pipe and also check
that there is no clogging in the
pipe.
Fuel is
drained, bleed-
<Inspection procedure>
ing air is com-
- Set the starter key to the pleted: Go to
Inspect the "ON" position. Clean or
YES.
fuel cut valve Replace the replace the
6 - Loosen the upstream side
upstream pipe fuel cut valve. fuel cut valve
joint bolt. Fuel is not
2 upstream pipe.
- Slowly push the feed pump drained, bleed-
on the fuel pump until fuel ing air is not
comes out. completed: Go
to NO.
! CAUTION
Use care, as a large amount of
fuel may come out if the feed
pump is pushed excessively.
2–108 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0006 and P0007
EN01H02127030602016023
P0006: Malfunction of fuel cut valve (Low)
INFORMATION
Engine ECU
Fuel cut valve
EBP TYP 0.7A EB4 (FCV)
FCV
(FCV)
SHTS021270300097
1. Technical description
• –
<Description of malfunction>
• Fuel cut valve is not working properly.
• Possible magnetic valve failure or harness GND short-circuit
2. DTC set condition
(1) DTC detection condition
• Fuel cut valve inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• The condition that the fuel cut valve circuit voltage is 2.8 V or less remains for 3 seconds or more.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• DPR automatic regeneration may not be performed properly.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• GND short-circuit in fuel cut valve signal line
• Malfunction of fuel cut valve
• Malfunction of engine ECU
ENGINE (J05E)/TROUBLESHOOTING 2–109
P0007: Malfunction of fuel cut valve (High)
INFORMATION
Engine ECU
Fuel cut valve
EBP TYP 0.7A EB4 (FCV)
FCV
(FCV)
SHTS021270300098
1. Technical description
• –
<Description of malfunction>
• Fuel cut valve is not working properly.
• Possible magnetic valve failure or +B short-circuit or disconnection
2. DTC set condition
(1) DTC detection condition
• Fuel cut valve inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• The condition that the fuel cut valve circuit voltage is 3 V or more remains for 3 seconds or more.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• DPR automatic regeneration may not be performed properly.
6. Pre-inspection work
• Check the battery voltage and make sure it is okay.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• +B short-circuit or disconnection in exhaust brake drive signal line.
• Malfunction of exhaust brake magnetic valve.
• Malfunction of engine ECU.
2–110 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0006 and P0007
1 Inspect the fuel cut valve connector
1. Check the connection of the fuel cut valve connector (looseness
and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the fuel cut valve
1. Check the installation of the fuel cut valve.
Was any failure found?
YES NO
Install the fuel cut valve correctly. Go to step 3.
Replace the fuel cut valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–111
3 Inspect the fuel cut valve unit
1. Set the starter key to the "LOCK" position.
FCV 2. Disconnect the fuel cut valve connector.
BODY GND
3. Use the electrical tester to measure the resistance between the
terminals of the fuel cut valve FCV and ground.
Measurement Tester
Standard values
conditions connections
Fuel cut valve 20 C {68 F}:
Starter key: LOCK
FCV – Ground 8.0 – 9.2
SHTS021270300099
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the fuel cut valve.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect for short-circuit of the fuel cut valve harness
1. Connect the signal check harness to the engine ECU (Do not con-
nect the harness to the ECU).
C
BODY GND 2. Use the electrical tester to measure the resistance between the
E31 terminals of the engine ECU (signal check harness) FCV (E31)
terminal and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
SHTS021270300100 Starter key: LOCK ness)
FCV (E31) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–112 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect disconnection of the fuel cut valve harness
1. Use the electrical tester to measure the resistance between the
terminals of the fuel cut valve vehicle side connector and the
C engine ECU.
FCV
E31 Measurement Tester
Standard values
conditions connections
Fuel cut valve
vehicle side con-
nector –
Starter key: LOCK Engine ECU 2 or less
(signal check har-
SHTS021270300101 ness)
FCV – FCV (E31)
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Check the DTC detected (Engine ECU)
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
3. Select [Engine] and check if the DTC (P0006 or P0007) has been
Engine
detected in [Fault Information].
SHTS021270300102
Has DTC (P0006 or P0007) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–113
CHECKLIST: P0006 and P0007
DTC: P0006 Malfunction of fuel cut valve (Low)
Inspection procedure
DTC: P0007 Malfunction of fuel cut valve (High)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Go to YES.
Inspect the Check the connection of the fuel needed.
1 fuel cut valve cut valve connector (looseness Perform "After- Go to step 2.
No failure
connector and poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Install the
valve correctly.
Failure found: Replace the
Go to YES. fuel cut valve if
Inspect the Check the installation of the fuel it is damaged.
2 Go to step 3.
fuel cut valve cut valve. No failure Perform "After-
found: Go to inspection
NO. work" of
INFORMA-
TION section.
The measure-
Disconnect the fuel cut valve con- ments meet
nector and measure the resis- the standard Replace the
tance between the terminals of value: Go to valve.
Inspect the the fuel cut valve. YES. Perform "After-
3 fuel cut valve <Tester connections> Go to step 4. inspection
unit Fuel cut valve The measure- work" of
FCV – Ground ments do not INFORMA-
<Standard values> meet the stan- TION section.
20 C {68 F}: 8.0 – 9.2 dard value: Go
to NO.
Connect the signal check harness
to the engine ECU (Do not con- The measure-
nect the harness to the ECU) and ments meet
Repair or
measure the resistance between the standard
replace the
the exhaust brake magnetic valve value: Go to
Inspect for harness.
vehicle side connector terminals YES.
short-circuit of Perform "After-
4 and ground. Go to step 5.
the fuel cut inspection
<Tester connections> The measure-
valve harness work" of
Engine ECU ments do not
INFORMA-
(signal check harness) meet the stan-
TION section.
FCV (E31) – Ground dard value: Go
<Standard values> to NO.
2–114 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0006 Malfunction of fuel cut valve (Low)
Inspection procedure
DTC: P0007 Malfunction of fuel cut valve (High)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check harness
to the engine ECU and measure The measure-
the resistance between the termi- ments meet
Repair or
nals of the fuel cut valve vehicle the standard
replace the
side connector and the engine value: Go to
Inspect dis- harness.
ECU. YES.
connection of Perform "After-
5 <Tester connections> Go to step 6.
the fuel cut inspection
Fuel cut valve vehicle side con- The measure-
valve harness work" of
nector – Engine ECU ments do not
INFORMA-
(signal check harness) meet the stan-
TION section.
FCV – FCV (E31) dard value: Go
<Standard values> to NO.
2 or less
DTC (P0006
Replace the Procedure
or P0007) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0006 or Perform "After- Perform "After-
Go to YES.
6 DTC detected P0007) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–115
DTC: P0016
EN01H02127030602016024
P0016: Crankshaft position sensor and Camshaft position sensor - rationality
INFORMATION
Engine ECU
(G-) N44 15mA X4Z (G-)
Engine speed main sensor (G1) N43 5mA XZA (G+)
(VG) N45 15mA EB5 (VCG)
ZTZ
(SNE)
Engine speed sub sensor (NE-) J0J 1mA X3F (NE-)
(NE+) J0H 1mA XK4 (NE+)
SHTS021270300103
1. Technical description
• A phase difference (deviation) between the engine speed main sensor (crankshaft position sensor) and engine
speed sub sensor (camshaft position sensor) is diagnosed.
<Description of malfunction>
• Detect the phase difference between engine speed main sensor (crankshaft position sensor) pulse and engine
speed sub sensor (camshaft position sensor) pulse.
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
• Engine speed is in the range from 700 to 1,000 r/min.
• Engine coolant temperature is 60 C {140 F} or higher.
• A difference between an actual engine speed and a target engine speed is 20 r/min or less.
(2) Judgement criteria
• A phase difference between the engine speed main sensor (crankshaft position sensor) pulse and engine
speed sub sensor (camshaft position sensor) pulse remains 15.5 C {59.9 F} or less or 26.5 C {79.7 F} or
greater for 1 second or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–116 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
Camshaft gear: Check assembly.
Flywheel: Check for miss assembly.
Engine speed main sensor (crankshaft position sensor): Check the installation position.
Engine speed sub sensor (camshaft position sensor): Check the installation position.
ENGINE (J05E)/TROUBLESHOOTING 2–117
INSPECTION PROCEDURE: P0016
1 Inspect the camshaft gear
1. Check that the camshaft gear is properly assembled.
Was any failure found?
YES NO
Assemble the camshaft gear properly. Go to step 2.
2 Inspect the flywheel
1. Check that the flywheel is properly assembled.
Was any failure found?
YES NO
Assemble the flywheel normally. Go to step 3.
3 Inspect engine speed main sensor (crankshaft position sensor) engine speed sub sensor
(camshaft position sensor)
1. Check that the engine speed main sensor (crankshaft position
sensor) engine speed sub sensor (camshaft position sensor) are
installed to the proper position.
Was any failure found?
YES NO
Install the engine speed main sensor (crank- Procedure completed.
shaft position sensor) and the engine speed Perform "After-inspection work" of INFOR-
sub sensor (camshaft position sensor) in MATION section.
proper locations.
2–118 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0016
Crankshaft position sensor and
DTC: P0016 Inspection procedure
Camshaft position sensor - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES.
Assemble the
Inspect the Check that the camshaft gear is
1 camshaft gear Go to step 2.
camshaft gear properly assembled. No failure
properly.
found: Go to
NO.
Failure found:
Go to YES.
Assemble the
Inspect the fly- Check that the flywheel is prop-
2 flywheel nor- Go to step 3.
wheel erly assembled. No failure
mally.
found: Go to
NO.
Inspect engine
speed main
sensor (crank- Failure found:
Check that the engine speed
shaft position Go to YES.
main sensor (crankshaft position Install the sen-
sensor) Procedure
3 sensor) engine speed sub sensor sor in proper
engine speed No failure completed.
(camshaft position sensor) are locations.
sub sensor found: Go to
installed to the proper position.
(camshaft NO.
position sen-
sor)
ENGINE (J05E)/TROUBLESHOOTING 2–119
DTC: P0027
EN01H02127030602016025
P0027: Exhaust Brake Performance
INFORMATION
1. Technical description
<Description of malfunction>
• The engine ECU detected sticking of the exhaust brake valve.
2. DTC set condition
(1) DTC detection condition
• DPR regeneration is in process.
• The vehicle speed is 0 km/h.
• The time of 60 seconds has elapsed after the exhaust brake was actuated.
(2) Judgement criteria
• The difference between the fuel injection quantity while the exhaust brake is working and the fuel injection
quantity when the exhaust brake is not actuated is 5 mm3/st or less.And also, the difference between the air
flow while the exhaust brake is working and the air flow when the exhaust brake is not actuated is -50 mg/cyl
or more.
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• The exhaust brake does not work.
• DPR regeneration is not terminated successfully.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Abnormality in characteristics of air flow sensor
• Diesel throttle sticking
• Bend, clogging, and crack of piping and hose
• Improper adjustment of exhaust brake valve
• Malfunction of exhaust brake valve
2–120 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0027
1 Check the DTC detected 1 [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
3. Set the starter key to the "ON" position.
Select
Engine
4. On the screen of the diagnostic system, select [Engine], and check
[Fault Information] for any DTC listed below other than P0027.-
P0101, P04D5, P2101, P2526
SHTS021270300104
Has a DTC other than P0027 been detected?
YES NO
Perform the relevant DTC-specific trouble- Go to step 2.
shooting.
2 Inspect the exhaust brake valve piping and hose
1. Check the piping and hose, connected to the exhaust brake valve,
for bend, clogging, and crack.
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
ENGINE (J05E)/TROUBLESHOOTING 2–121
3 Inspect the exhaust brake valve
1. Check the exhaust brake valve for unease and sticking.
SHTS021270300105
Was any failure found?
YES NO
Clean the exhaust brake valve.Replace if Go to step 5.
necessary.After clearing or replacement, go
to Step 4.
4 Check the DTC detected 2 [HINO-DX]
1. Perform a DPR forced regeneration.
2. After completion of regeneration, on the screen of the diagnostic
system, select [Engine] and read the detected DTCs in [Fault Infor-
mation].
Select
Engine
SHTS021270300106
Has DTC P0027 been detected?
YES NO
Go to step 5. Procedure completed.
2–122 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect the exhaust brake valve
1. Warm up the engine. (Coolant temperature: 80 C {176 F} or
more)
2. Turn OFF the devices that place load on the engine, such as the
Select air conditioner and PTO.
Engine
<Inspection procedure>
- Adjust the engine revolution to 980 r/min by using the idling volume.
(For vehicles without the idling volume, adjust the engine revolution
to 980 r/min by using [Activation Test] for the diagnostic system.)
- Select [Engine] on the screen of the diagnostic system.
SHTS021270300107 - Select [Injection quantity] from [Data Monitor].
- Turn ON/OFF the exhaust brake switch, and check the difference
between the injection quantity of the injector while the exhaust brake
is working and the injection quantity when the exhaust brake is not
actuated.
Measurement conditions Standard values
• Engine revolution: 980 r/
min
• Engine coolant tempera-
ture:
80 C {176 F} or more 10 – 18 mm3/st
• Turn OFF the air condi-
tioner, PTO, and other
devices that place load on
the engine.
Is the measured value within the standard values? (There shall be a change in the injection quan-
tity between while the exhaust brake is working and when it is not actuated.)
YES NO
Go to step 6. Adjust the butterfly opening of the exhaust
brake. (Refer to the service manual.)
ENGINE (J05E)/TROUBLESHOOTING 2–123
6 Check the DTC detected [HINO-DX]
1. Perform a DPR forced regeneration.
2. After regeneration, on the screen of the diagnostic system, select
[Engine] and check the detected DTCs in [Fault Information].
Select
Engine
SHTS021270300108
Has DTC P0027 been detected?
YES NO
Replace the engine ECU. Procedure completed.
2–124 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0027
DTC: P0027 Exhaust Brake Performance Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Set the starter key to the
"LOCK" position.
DTC other
2. Connect the vehicle to HINO-
than P0027
DX.
has been
3. Set the starter key to the "ON" Perform the
Check the detected: Go
position. relevant DTC-
1 DTC detected to YES. Go to step 2.
specific trou-
1 [HINO-DX] 4. On the screen of the diagnostic
bleshooting.
system, select [Engine], and No DTC has
check [Fault Information] for been detected:
any DTC listed below other Go to NO.
than P0027.- P0101, P04D5,
P2101, P2526
Failure found:
Inspect the Go to YES. Connect
Check the piping and hose, con-
exhaust brake securely,
2 nected to the exhaust brake valve, Go to step 3.
valve piping No failure repair if
for bend, clogging, and crack.
and hose found: Go to needed.
NO.
Clean the
Failure found: exhaust brake
Go to YES. valve.Replace
Inspect the
Check the exhaust brake valve for if neces-
3 exhaust brake Go to step 5.
unease and sticking. No failure sary.After
valve
found: Go to clearing or
NO. replacement,
go to Step 4.
DTC P0027
1. Perform a DPR forced regener-
has been
ation.
detected: Go
Check the 2. After completion of regenera- to YES. Procedure
4 DTC detected tion, on the screen of the diag- Go to step 5.
completed.
2 [HINO-DX] nostic system, select [Engine] No DTC has
and read the detected DTCs in been detected:
[Fault Information]. Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–125
DTC: P0027 Exhaust Brake Performance Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Warm up the engine. (Coolant
temperature: 80 C {176 F} or
more)
2. Turn OFF the devices that
place load on the engine, such The measure-
as the air conditioner and PTO. ments meet
the standard
<Inspection procedure> value (There
- Adjust the engine revolution to shall be a
980 r/min by using the idling change in the
volume. (For vehicles without injection quan-
the idling volume, adjust the tity between Adjust the but-
engine revolution to 980 r/min while the terfly opening
Inspect the
by using [Activation Test] for the exhaust brake of the exhaust
5 exhaust brake Go to step 6.
diagnostic system.) is working and brake. (Refer
valve
- Select [Engine] on the screen when it is not to the service
of the diagnostic system. actuated.): Go manual.)
to YES.
- Select [Injection quantity] from
[Data Monitor].
The measure-
- Turn ON/OFF the exhaust ments do not
brake switch, and check the dif- meet the stan-
ference between the injection dard value: Go
quantity of the injector while the to NO.
exhaust brake is working and
the injection quantity when the
exhaust brake is not actuated.
<Standard value>
10 – 18 mm3/st
DTC P0027
1. Perform a DPR forced regener-
has been
ation.
detected: Go
Check the 2. After regeneration, on the to YES. Replace the Procedure
6 DTC detected screen of the diagnostic sys- engine ECU. completed.
[HINO-DX] tem, select [Engine] and check No DTC has
the detected DTCs in [Fault been detected:
Information]. Go to NO.
2–126 ENGINE (J05E)/TROUBLESHOOTING
DTC: P003A
EN01H02127030602016026
P003A: Initialization failure (VNT actuator initialize error)
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300109
1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
Item Details (Reference)
When the amount of operation after power has been turned ON is larger than HI
1. Initialization failure range, or when the Hall IC output does not become constant after 5 seconds
has elapsed
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
ENGINE (J05E)/TROUBLESHOOTING 2–127
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• VNT link is stuck or cannot operate due to rust, etc.
• External link is disconnected.
2–128 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P003A
1 Check the DTC detected 1 [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
3. Select [Engine] and check if any DTC other than P003A (for exam-
Engine
ple, U010C) has been detected in [Fault Information].
SHTS021270300110
Has a DTC other than P003A been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 3.
After repairing, go to step 2.
2 Check the DTC detected 2 [HINO-DX]
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P003A has been detected in [Fault
Information].
Select
Engine
SHTS021270300111
Has DTC P003A been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–129
3 Inspect the operation of the VNT controller [HINO-DX]
1. Set the starter key to the "ON" position.
2. Erase the trouble history using HINO-DX.
Select
3. Set the starter key to the "LOCK" position.
Engine
4. Set the starter key to the "ON" position again.
5. Select [Engine] and check if P003A has been detected in [Fault
Information].
HINT
Turn the key LOCK and ON verifies the wiping operation of the
SHTS021270300112
VNT actuator (DC motor).
Standard values
Starter key: LOCK ON
Has DTC P003A been detected?
YES NO
Replace the turbocharger. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
2–130 ENGINE (J05E)/TROUBLESHOOTING
4 Check the response delay of the VNT controller
1. Select [Check functions] [VNT check] from the menu, and inspect
the response delay at the Target VNT position and Actual VNT
(1)
position.
! CAUTION
(2) Perform the inspection while the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [VNT check].
(3) Select [Start].
(3) (4) Select [VNT opening UP].
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT opening DOWN].
(4) (5) • Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of 10% per step between 0 –
90%.
SHTS021270300113 Standard values
The response delay should be less than 3 seconds.
Are the measurements within standard value?
YES NO
Procedure completed. Replace the turbocharger.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–131
CHECKLIST: P003A
Initialization failure
DTC: P003A Inspection procedure
(VNT actuator initialize error)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P003A Go to diagno-
has been sis procedure
Check the Check if any DTC other than detected: Go of a related
1 DTC detected P003A (for example U010C) have to YES. DTC. Go to step 3.
1 [HINO-DX] been detected in [Engine]. After replace-
No DTC has ment, go to
been detected: step 2.
Go to NO.
DTC P003A
Procedure
has been
completed.
detected: Go
Check the Perform "After-
Check if P003A has been to YES.
2 DTC detected Go to step 3. inspection
detected in [Engine].
2 [HINO-DX] work" of
No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
Erase the malfunction history, set
the starter key to the "LOCK"
position. Turn again the starter DTC P003A
Replace the
key to the "ON", and check if has been
Check the turbocharger.
P003A has been detected in detected: Go
operation of Perform "After-
[Engine]. to YES.
3 the VNT con- inspection Go to step 4.
troller [HINO- HINT work" of
No DTC has
DX] Turning the starter key "LOCK" INFORMA-
been detected:
and "ON" verifies the wiping TION section.
Go to NO.
operation of the VNT actuator
(DC motor).
2–132 ENGINE (J05E)/TROUBLESHOOTING
Initialization failure
DTC: P003A Inspection procedure
(VNT actuator initialize error)
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Check functions] [VNT
check] from the menu, and
inspect the response delay at the
Target VNT position and Actual
VNT position.
! CAUTION
Perform the inspection while
the engine is stopped to avoid
engine damages.
<Inspection procedure>
The measure-
(1) Select [Check functions].
ments meet
(2) Select [VNT check].
the standard Procedure Replace the
(3) Select [Start].
Check the value: Go to completed. turbocharger.
(4) Select [VNT opening UP]:
response YES. Perform "After- Perform "After-
4 delay of the • Inspect the response delay at inspection inspection
VNT controller each step of the Target VNT The measure- work" of work" of
[HINO-DX] position and Actual VNT posi- ments do not INFORMA- INFORMA-
tion from 0 to 90%. meet the stan- TION section. TION section.
(5) Select [VNT opening DOWN]: dard value: Go
• Inspect the response delay at to NO.
each step of the Target VNT
position and Actual VNT posi-
tion from 90 to 0%.
HINT
The VNT opening position
changes of 10% per step
between 0 – 90%.
<Standard values>
The response delay should be
less than 3 seconds.
ENGINE (J05E)/TROUBLESHOOTING 2–133
DTC: P0045
EN01H02127030602016027
P0045: DC motor terminal open circuit or DC motor coil open circuit
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300114
1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the target and actual value of the
nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
<Description of malfunction>
• –
2–134 ENGINE (J05E)/TROUBLESHOOTING
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• DTC P259F detected.
• Battery voltage is in the range of 10 V to 16 V
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
Item Details (Reference)
When 1st, 2nd and 3rd conditions simultaneously form in the following matrix:
1st 2nd 3rd
Terminal U Output Batt. Voltage ≤ 1 V (Condition (c)) ≤ 1 V (Condition (e))
Motor terminal or
coil disconnection Terminal V ≤ 1 V (Condition (a)) Output Batt. Voltage ≤ 1 V (Condition (f))
Terminal W ≤ 1 V (Condition (b)) ≤ 1 V (Condition (d)) Output Batt. Voltage
Condition of motor
(a) or (b) (c) or (d) (e) or (f)
open circuit
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Faulty contact in VNT controller connector
• LEA internal disconnection
• Controller internal disconnection
ENGINE (J05E)/TROUBLESHOOTING 2–135
INSPECTION PROCEDURE: P0045
1 Check the DTC detected 1 [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select 3. Select [Engine] and check if any DTC other than P0045 (for exam-
Engine ple U010C) has been detected in [Fault Information].
SHTS021270300115
Has DTC other than P0045 (for example U010C) been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 3.
Go to step 2 after repair.
2 Check the DTC detected 2 [HINO-DX]
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P0045 has been detected in [Fault
Information].
Select
Engine
SHTS021270300116
Has DTC P0045 been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–136 ENGINE (J05E)/TROUBLESHOOTING
3 Check the connector connection [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Disconnect the VNT actuator and VNT controller connector and
connect properly again.
3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0045 has been detected in [Fault
Information].
VNT controller
SHTS021270300117
Has DTC P0045 been detected?
YES NO
Go to step 4. Procedure completed.
(Connector connection is faulty.)
Perform "After-inspection work" of INFOR-
MATION section.
4 Check the operation of the VNT controller [HINO-DX]
1. Set the starter key to the "ON" position.
2. Erase the trouble history using HINO-DX.
Select 3. Set the starter key to the "LOCK" position.
Engine
4. Set the starter key to the "ON" position again.
5. Select [Engine] and check if P0045 has been detected in [Fault
Information].
HINT
Turning the switch OFF and ON verifies the wiping operation of
SHTS021270300118
the VNT actuator (DC motor).
Measurement conditions
Starter key: LOCK ON
Has DTC P0045 been detected?
YES NO
Replace the VNT controller. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–137
CHECKLIST: P0045
DC motor terminal open circuit
DTC: P0045 Inspection procedure
or DC motor coil open circuit
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0045
(for example Go to diagno-
U010C) has sis procedure
Check the Check if any DTC other than
been detected: of a related
1 DTC detected P0045 (for example U010C) have Go to step 3.
Go to YES. DTC.
1 [HINO-DX] been detected in [Engine].
Go to step 2
No DTC has after repair.
been detected:
Go to NO.
DTC P0045
Procedure
has been
completed.
detected: Go
Check the Perform "After-
Check if P0045 has been to YES.
2 DTC detected Go to step 3. inspection
detected in [Engine].
2 [HINO-DX] work" of
No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
Procedure
DTC P0045 completed.
has been (Connector
1. Disconnect the VNT actuator
Check the detected: Go connection is
and VNT controller connector
connector con- to YES. faulty.)
3 and connect properly again. Go to step 4.
nection [HINO- Perform "After-
DX] 2. Check if P0045 has been No DTC has inspection
detected in [Engine]. been detected: work" of
Go to NO. INFORMA-
TION section.
DTC P0045
1. Erase the trouble history using Replace the Procedure
has been
Check the HINO-DX and set the starter VNT controller. completed.
detected: Go
operation of key to the "LOCK" position and Perform "After- Perform "After-
to YES.
4 the VNT con- set the starter key to the "ON" inspection inspection
troller [HINO- position again. work" of work" of
No DTC has
DX] 2. Check if P0045 has been INFORMA- INFORMA-
been detected:
detected in [Engine]. TION section. TION section.
Go to NO.
2–138 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0047
EN01H02127030602016028
P0047: DC motor terminal short circuit, DC motor short circuit
(Short to Battery) (VNT actuator motor short to BATT)
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300119
1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
Item Details (Reference)
1. Motor short-circuit When LO-side current of at least 20.7 A is detected 3 times.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
ENGINE (J05E)/TROUBLESHOOTING 2–139
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Short-circuit in VNT actuator motor coil.
• VNT controller internal short.
2–140 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0047
1 Check the DTC detected (Engine ECU)
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
3. Select [Engine] and check if any DTC other than P0047 (for exam-
Engine
ple U010C) has been detected in [Fault Information].
HINT
Due to CAN communication failure P0047 may have been
detected.
SHTS021270300120
Has DTC U010C been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 3.
Go to step 2 after repair.
2 Check the DTC detected (Engine ECU)
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P0047 has been detected in [Fault
Information].
Select
Engine
SHTS021270300121
Has DTC P0047 been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–141
3 Check the connector connection [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Disconnect the VNT actuator and VNT controller connector and
connect properly again.
3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0047 has been detected in [Fault
Information].
Has DTC P0047 been detected?
YES NO
Go to step 4. Procedure completed.
(Connector connection is faulty.)
Perform "After-inspection work" of INFOR-
MATION section.
4 Check the operation of the VNT controller [HINO-DX]
1. Set the starter key to the "ON" position.
2. Erase the trouble history using HINO-DX.
Select
3. Set the starter key to the "LOCK" position.
Engine
4. Set the starter key to the "ON" position again.
5. Select [Engine] and check if P0047 has been detected in [Fault
Information].
HINT
Turning the switch LOCK and ON verifies the wiping operation of
SHTS021270300122
the VNT actuator (DC motor).
Measurement conditions
Starter key: LOCK ON
Has DTC P0047 been detected?
YES NO
Replace the VNT controller. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–142 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0047
DC motor terminal short-circuit, DC motor
DTC: P0047 short-circuit (Short to Battery) Inspection procedure
(VNT actuator motor short to BATT)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0047
Check if any DTC other than (for example Go to diagno-
P0047 (for example U010C) has U010C) has sis procedure
Check the
been detected in [Engine]. been detected: of a related
1 DTC detected Go to step 3.
HINT Go to YES. DTC.
(Engine ECU)
Due to CAN communication Go to step 2
failure may have been detected. No DTC has after repair.
been detected.
Go to NO.
DTC P0047
Procedure
has been
completed.
detected: Go
Check the Perform "After-
Check if P0047 has been to YES.
2 DTC detected Go to step 3. inspection
detected in [Engine].
(Engine ECU) work" of
No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
Procedure
DTC P0047 completed.
has been (Connector
Disconnect the VNT actuator and
Check the detected: Go connection is
VNT controller connector and
connector con- to YES. faulty.)
3 connect properly again. Go to step 4.
nection [HINO- Perform "After-
Check if P0047 has been
DX] No DTC has inspection
detected in [Engine].
been detected: work" of
Go to NO. INFORMA-
TION section.
Erase the trouble history and set
the starter key to the "LOCK"
position and set the starter key to DTC P0047
Replace the Procedure
the "ON" position again and has been
Check the VNT controller. completed.
check if P0047 has been detected detected: Go
operation of Perform "After- Perform "After-
in [Engine]. to YES.
4 the VNT con- inspection inspection
troller [HINO- HINT work" of work" of
No DTC has
DX] Turning the switch LOCK and INFORMA- INFORMA-
been detected:
ON verifies the wiping opera- TION section. TION section.
Go to NO.
tion of the VNT actuator (DC
motor).
ENGINE (J05E)/TROUBLESHOOTING 2–143
DTC: P0048
EN01H02127030602016029
P0048: DC motor terminal short circuit, DC motor short circuit
(Short to GND) (VNT actuator motor short to GND)
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300123
1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• While the engine is in operation: Always
• While the engine is stopped: During wiping operation
(2) Judgement criteria
Item Details (Reference)
1. Motor circuit short When LO-side current of at least 20.7 A is detected 3 times.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
2–144 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• VNT actuator motor coil disconnection.
• VNT controller internal disconnection.
ENGINE (J05E)/TROUBLESHOOTING 2–145
INSPECTION PROCEDURE: P0048
1 Check the DTC detected (Engine ECU)
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
3. Select [Engine] and check if any DTC other than P0048 (for exam-
Engine
ple U010C) has been detected in [Fault Information].
HINT
Due to CAN communication failure P0048 may have been
detected.
SHTS021270300124
Has DTC U010C been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 3.
Go to step 2 after repair.
2 Check the DTC detected (Engine ECU)
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P0048 has been detected in [Fault
Information].
Select
Engine
SHTS021270300125
Has DTC P0048 been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–146 ENGINE (J05E)/TROUBLESHOOTING
3 Check the connector connection [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Disconnect the VNT actuator and VNT controller connector and
connect properly again.
3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0048 has been detected in [Fault
Information].
Has DTC P0048 been detected?
YES NO
Go to step 4. Procedure completed.
(Connector connection is faulty.)
Perform "After-inspection work" of INFOR-
MATION section.
4 Check the operation of the VNT controller [HINO-DX]
1. Set the starter key to the "ON" position.
2. Erase the trouble history using HINO-DX.
Select
3. Set the starter key to the "LOCK" position.
Engine
4. Set the starter key to the "ON" position again.
5. Select [Engine] and check if P0048 has been detected in [Fault
Information].
HINT
Turn the switch LOCK and ON verifies the wiping operation of the
SHTS021270300126
VNT actuator (DC motor).
Measurement conditions
Starter key: LOCK ON
Has DTC P0048 been detected?
YES NO
Replace the VNT controller. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–147
CHECKLIST: P0048
DC motor terminal short circuit,
DTC: P0048 DC motor short circuit (Short to GND) Inspection procedure
(VNT actuator motor short to GND)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0048
Check if any DTC other than (for example Go to diagno-
P0048 (for example U010C) have U010C) has sis procedure
Check the
been detected in [Engine]. been detected: of a related
1 DTC detected Go to step 3.
HINT Go to YES. DTC.
(Engine ECU)
Due to CAN communication Go to step 2
failure may have been detected. No DTC has after repair.
been detected:
Go to NO.
DTC P0048
Procedure
has been
completed.
detected: Go
Check the Select [Engine] from the menu, Perform "After-
to YES.
2 DTC detected and check if P0048 has been Go to step 3. inspection
(Engine ECU) detected in [Engine]. work" of
No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
Procedure
DTC P0048 completed.
1. Disconnect the VNT actuator has been (Connector
Check the and VNT controller connector detected: Go connection is
connector con- and connect properly again. to YES. faulty.)
3 Go to step 4.
nection [HINO- 2. Select [Engine] and check if Perform "After-
DX] P0048 has been detected in No DTC has inspection
[Engine]. been detected: work" of
Go to NO. INFORMA-
TION section.
1. Set the starter key to the "ON"
position.
2. Erase the trouble history using
HINO-DX.
DTC P0048
3. Set the starter key to the Replace the Procedure
has been
"LOCK" position. VNT controller. completed.
Check opera- detected: Go
4. Set the starter key to the "ON" Perform "After- Perform "After-
tion of the VNT to YES.
4 position again. inspection inspection
controller
work" of work" of
[HINO-DX] 5. Check if P0048 has been No DTC has
INFORMA- INFORMA-
detected in [Engine]. been detected:
TION section. TION section.
HINT Go to NO.
Turning the switch LOCK and
ON verifies the wiping opera-
tion of the VNT actuator (DC
motor).
2–148 ENGINE (J05E)/TROUBLESHOOTING
DTC: P006E
EN01H02127030602016030
P006E: Power supply failure (Out of range low) (VNT actuator power supply too low)
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300127
1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
Item Details (Reference)
Power supply voltage failure (Low) Power supply voltage is 8 V or less for at least 6 seconds.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
ENGINE (J05E)/TROUBLESHOOTING 2–149
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Failure in alternator, regulator, or other part of the power supply system
• Battery is depleted.
2–150 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P006E
1 Check the DTC detected 1 (Engine ECU)
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
3. Select [Engine] and check if any DTC other than P006E (U010C)
Engine
has been detected in [Fault Information].
HINT
Due to CAN communication failure P006E may have been
detected.
SHTS021270300128
Has DTC U010C been detected?
YES NO
Go to diagnosis procedure of the related Go to step 3.
DTC.
After repair, go to step 2.
2 Check the DTC detected 2 (Engine ECU)
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P006E has been detected in [Fault
Information].
Select
Engine
SHTS021270300129
Has DTC P006E been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–151
3 Check the VNT controller power supply circuit
1. Set the starter key to the "LOCK" position.
GND
+B 2. Disconnect the VNT controller connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the VNT controller vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300130 VNT controller
vehicle side con-
Starter key: ON 8 V or more
nector
+B – GND
Do the measurements meet the standard value?
YES NO
Procedure completed. Check the VNT controller power supply cir-
Perform "After-inspection work" of INFOR- cuit.
MATION section. Perform "After-inspection work" of INFOR-
MATION section.
2–152 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P006E
Power supply failure (Out of range low)
DTC: P006E Inspection procedure
(VNT actuator power supply too low)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P006E
Go to diagno-
has been
Check the sis procedure
Check if any DTC other than detected: Go
DTC detected of the related
1 P006E (U010C) have been to YES. Go to step 3.
1 (Engine DTC.
detected in [Engine].
ECU) After repair, go
No DTC has
to step 2.
been detected:
Go to NO.
DTC P006E
Procedure
has been
completed.
Check the detected: Go
Perform "After-
DTC detected Check if P006E has been to YES.
2 Go to step 3. inspection
2 (Engine detected in [Engine].
work" of
ECU) No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
The measure-
ments meet Check the
Disconnect the VNT controller the standard Procedure VNT controller
connector and measure the volt- value: Go to completed. power supply
Check the
age between the terminals (+B – YES. Perform "After- circuit.
VNT controller
3 GND) of the VNT controller vehi- inspection Perform "After-
power supply
cle side connector. The measure- work" of inspection
circuit
<Standard values> ments do not INFORMA- work" of
8 V or more meet the stan- TION section. INFORMA-
dard value: Go TION section.
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–153
DTC: P006F
EN01H02127030602016031
P006F: Power supply voltage failure
(Out of range high) (VNT actuator power supply too high)
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300131
1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
Item Details (Reference)
Power supply voltage failure (High) Power supply voltage is 18 V or higher for at least 6 seconds.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
2–154 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Failure in alternator, regulator, or other part of the power supply system
ENGINE (J05E)/TROUBLESHOOTING 2–155
INSPECTION PROCEDURE: P006F
1 Check the DTC detected 1 (Engine ECU)
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
3. Select [Engine] and check if any DTC other than P006F (U010C)
Engine
has been detected in [Fault Information].
SHTS021270300132
Has DTC U010C been detected?
YES NO
Go to diagnosis procedure of the related Go to step 3.
DTC.
After repair, go to step 2.
2 Check the DTC detected 2 (Engine ECU)
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P006F has been detected in [Fault
Information].
Select
Engine
SHTS021270300133
Has DTC P006F been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–156 ENGINE (J05E)/TROUBLESHOOTING
3 Check the VNT controller power supply circuit
1. Set the starter key to the "LOCK" position.
GND
+B 2. Disconnect the VNT controller connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the VNT controller vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300134 VNT controller
vehicle side con-
Starter key: ON 8 V or more
nector
+B – GND
Do the measurements meet the standard value?
YES NO
Procedure completed. Check the VNT controller power supply cir-
Perform "After-inspection work" of INFOR- cuit.
MATION section. Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–157
CHECKLIST: P006F
Power supply failure (Out of range high)
DTC: P006F Inspection procedure
(VNT actuator power supply too high)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC U010C
has been Go to diagno-
Check the detected: Go sis procedure
Check if any DTC other than
DTC detected to YES. of the related
1 P006F (for example U010C) have Go to step 3.
1 (Engine DTC.
been detected in [Engine].
ECU) No DTC has After repair,
been detected. Go to step 2.
Go to NO.
DTC P006F
Procedure
has been
completed.
Check the detected: Go
Perform "After-
DTC detected Check if P006F has been to YES.
2 Go to step 3. inspection
2 (Engine detected in [Engine].
work" of
ECU) No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
The measure-
ments meet Check the
Disconnect the VNT controller the standard Procedure VNT controller
connector and measure the volt- value: Go to completed. power supply
Check the
age between the terminals of the YES. Perform "After- circuit.
VNT controller
3 VNT controller vehicle side con- inspection Perform "After-
power supply
nector. The measure- work" of inspection
circuit
<Standard values> ments do not INFORMA- work" of
8 V or more meet the stan- TION section. INFORMA-
dard value: Go TION section.
to NO.
2–158 ENGINE (J05E)/TROUBLESHOOTING
DTC: P007B
EN01H02127030602016032
P007B: Intake air temperature sensor (intercooler outlet) - rationality
INFORMATION [at Engine Startup]
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
15mA
(VC) J0M
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300135
1. Technical description
• The intercooler outlet temperature sensor, which is installed downstream of the boost pressure sensor, constantly
measures the intake temperature at the intercooler outlet.
<Description of malfunction>
• The intake temperature at the intercooler outlet cannot be correctly recognized.
ENGINE (J05E)/TROUBLESHOOTING 2–159
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• The engine speed is 1000 r/min or less.
• Engine coolant temperature is in the range of -30 to 55 C {-22 to 131 F}.
• The battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the average temperature of the air intake temperature sensor (built in the air flow sensor) and
the intercooler outlet temperature sensor is 30 C {86 F} or more while the average temperature of the inter-
cooler outlet temperature sensor and the intake manifold temperature sensor is 30 C {86 F} or more.
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Intercooler outlet temperature sensor malfunction:
• Failure of intake air temperature sensor (with built-in air flow sensor):
• Intake air temperature sensor malfunction:
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• ECU sensor power supply failure
2–160 ENGINE (J05E)/TROUBLESHOOTING
P007B: Intake air temperature sensor (intercooler outlet) - rationality
INFORMATION [while Driving (1)]
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
15mA
(VC) J0M
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300136
1. Technical description
• The intercooler outlet temperature sensor, which is installed downstream of the boost pressure sensor, constantly
measures the intake temperature at the intercooler outlet.
<Description of malfunction>
• The intake temperature at the intercooler outlet cannot be correctly recognized.
ENGINE (J05E)/TROUBLESHOOTING 2–161
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 11 seconds or more.
• The battery voltage is in the range of 10 V to 16 V.
• The engine speed remains at 500 r/min or more for 5 seconds or more.
The conditions described below remain for 40 seconds or more.
• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st.cyl or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl. sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mph or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow sensor) is -10 C {14 F} or more.
• DPR is not actuated.
(2) Judgement criteria
• The calculated intercooler efficiency, which is derived from the intake temperature sensor, boost pressure sen-
sor, intercooler outlet temperature sensor, and atmospheric pressure sensor, is greater than 140%.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Intercooler outlet temperature sensor malfunction:
• Failure of intake air temperature sensor (with built-in air flow sensor):
• Boost pressure sensor:
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• ECU sensor power supply failure
2–162 ENGINE (J05E)/TROUBLESHOOTING
P007B: Intake air temperature sensor (intercooler outlet) - rationality
INFORMATION [while Driving (2)]
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
15mA
(VC) J0M
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300137
1. Technical description
• The intercooler outlet temperature sensor, which is installed downstream of the boost pressure sensor, constantly
measures the intake temperature at the intercooler outlet.
<Description of malfunction>
• The intake temperature at the intercooler outlet cannot be correctly recognized.
ENGINE (J05E)/TROUBLESHOOTING 2–163
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 11 seconds or more.
• The battery voltage is in the range of 10 V to 16 V.
• The engine speed remains at 500 r/min or more for 5 seconds or more.
The conditions described below remain for 40 seconds or more.
• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st.cyl or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl.sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mile/h or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow sensor) is -10 C {14 F} or more.
• Exhaust brake and DPR are not actuated.
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency is less than 65%,
• the difference between the intake manifold air take temperature and the actual intake air temperature is lower
than the specified value (less than 10 C {50 F} when the EGR rate is 0%, less than 17 C {62.6 F} when the
EGR rate is 20% and less than 60 C {140 F} when the EGR rate is 60%), and
• the calculated intercooler efficiency is lower than the specified value (less than 45% when the vehicle speed is
13 mile/h or less than 65% when the vehicle speed is 25 mile/h).
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
2–164 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Intercooler outlet temperature sensor malfunction:
• Failure of intake air temperature sensor (with built-in air flow sensor):
• Intake manifold temperature sensor malfunction:
• Boost pressure sensor
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• ECU sensor power supply failure
ENGINE (J05E)/TROUBLESHOOTING 2–165
INSPECTION PROCEDURE: P007B
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] from the menu, and check if any DTC other than
P007B (for example, P0401, P0402, P0404, P0234, P0299,
P22D3, or turbocharger/EGR system DTC) has been detected in
[Fault Information].
HINT
Intercooler outlet temperature sensor characteristic abnormality
SHTS021270300138
judgement is performed based on the boost pressure and EGR
rate data.
If EGR system or Turbo DTC are detected, perform another failure
diagnosis starting from the first DTC associated with the malfunc-
tion.
Has a DTC other than P007B been detected?
(P0401, P0402, P0404, P0234, P0299, P22D3, or turbocharger/EGR system DTC)
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2 Inspect intercooler outlet temperature sensor connector
1. Check the connection of the intercooler outlet temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–166 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the intercooler outlet temperature sensor
1. Check the installation of the intercooler outlet temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intercooler outlet temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the intercooler outlet temperature sensor unit
1. Set the starter key to the "LOCK" position.
THG E2 2. Disconnect the intercooler outlet temperature sensor connector.
3. Measure the resistance between the terminals of the intercooler
outlet temperature sensor using the electrical tester.
Measurement Tester
Standard values
conditions connections
Intercooler outlet 20 C {68 F}:
temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300139 sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the intercooler outlet temperature
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–167
5 Inspect the intercooler outlet temperature sensor power supply
1. Set the starter key to the "ON" position.
E2 THG 2. Use the electrical tester to measure the voltage between the termi-
nals of the intercooler outlet temperature sensor vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Intercooler outlet
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300140 connector
THG – E2
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
6 Inspect for short-circuit in wire harness of intercooler outlet temperature sensor
1. Set the starter key to the "LOCK" position.
E44 D
E77 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between each
terminal in the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300141 nal check har-
ness)
Starter key: LOCK
THA0 (E44) –
Ground
E4 (E77) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–168 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect for disconnection in wire harness of intercooler outlet temperature sensor
1. Connect the intercooler outlet temperature sensor connector.
E44 D 2. Measure the resistance between the terminals of engine ECU (sig-
E77
nal check harness) using the electrical tester.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
THA0 (E44) –
2.435 – 1.994 k
SHTS021270300142 E4 (E77)
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
8 Inspect the intake air temperature sensor
1. Check the installation of the intake air temperature sensor (air flow
sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 9.
If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–169
9 Inspect the intake air temperature sensor unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake air temperature sensor (air flow sensor) con-
nector.
3. Measure the resistance between the terminals of the intake tem-
perature sensor using the electrical tester.
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
intake tempera-
SHTS021270300143 2.69 – 2.21 k
Starter key: LOCK ture sensor
60 C {140 F}:
THA – E2
0.667 – 0.493 k
Do the measurements meet the standard value?
YES NO
Go to step 10. Replace the intake air temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the boost pressure sensor hose
1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.
2. Make sure the pipe on the intake manifold side is not clogged.
Was any failure found?
YES NO
1. Replace the boost pressure sensor hose. Go to step 11.
2. Clean the intake manifold pipes
Perform "After-inspection work" of INFOR-
MATION section.
2–170 ENGINE (J05E)/TROUBLESHOOTING
11 Inspect the boost pressure sensor power supply system
1. Set the starter key to the "LOCK" position.
E VC
2. Disconnect the boost pressure sensor connector.
3. Set the starter key to the "ON" position.
4. Measure the voltage between the terminals of the boost pressure
sensor vehicle side connector using the electrical tester.
Measurement Tester
Standard values
conditions connections
Boost pressure
SHTS021270300144
sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 12. Inspect the wire harness and engine ECU
sensor power supply output value.
Perform "After-inspection work" of INFOR-
MATION section.
12 Inspect the intake manifold temperature sensor
1. Check the installation of the intake manifold temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 13.
If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–171
13 Inspect the intake manifold temperature sensor unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake manifold temperature sensor connector.
3. Measure the resistance between the terminals of the sensor using
the electrical tester.
Measurement Tester
Standard values
conditions connections
Intake manifold 20 C {68 F}:
temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300145 sor 50 C {122 F}:
THA – E2 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 14. Replace the intake manifold temperature
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
14 Check the DTC detected (Engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P007B has been detected in [Fault
Information].
SHTS021270300146
Has DTC P007B been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–172 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P007B
Intake air temperature sensor
DTC: P007B Inspection procedure
(intercooler outlet) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P007B
(like P0401,
P0402, P0404,
Check if any DTC other than P0234, P0299,
P007B (for example, P0401, P22D3) or the Go to diagno-
Check the
P0402, P0404, P0234, P0299, EGR turbo sis procedure
1 DTC detected Go to step 2.
P22D3, or turbocharger/EGR sys- system have of a related
(Engine ECU)
tem DTC) has been detected in been detected: DTC.
[Engine]. Go to YES.
Have not been
detected: Go
to NO.
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the inter- Go to YES.
intercooler needed.
cooler outlet temperature sensor
2 outlet temper- Perform "After- Go to step 3.
connector (looseness and poor No failure
ature sensor inspection
contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and connect
1. Check the installation of the
Failure found: securely.
intercooler outlet temperature
Inspect the Go to YES. If damaged,
sensor connector.
intercooler replace the
3 2. Make sure there is no dirt, Go to step 4.
outlet temper- No failure sensor.
ature sensor damage or clogging in the found: Go to Perform "After-
sensing unit of intercooler out- NO. inspection
let temperature sensor. work" of
INFORMA-
TION section.
Measure the resistance between The measure-
the terminals of the intercooler ments meet
outlet temperature sensor. the standard Replace the
Inspect the <Tester connections> value: Go to sensor.
intercooler Intercooler outlet temperature YES. Perform "After-
4 outlet temper- sensor Go to step 5. inspection
ature sensor THG – E2 The measure- work" of
unit <Standard values> ments do not INFORMA-
20 C {68 F}: 7.336 – 5.794 k meet the stan- TION section.
50 C {122 F}: 2.435 – 1.994 k dard value: Go
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–173
Intake air temperature sensor
DTC: P007B Inspection procedure
(intercooler outlet) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the voltage between the
ments meet
terminals of the intercooler outlet
the standard
temperature sensor vehicle side
Inspect the value: Go to
connector.
intercooler YES.
<Tester connections>
5 outlet temper- Go to step 8. Go to step 6.
Intercooler outlet temperature
ature sensor The measure-
sensor vehicle side connector
power supply ments do not
THG – E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
Connect the signal check harness
The measure-
and measure the resistance
ments meet
between each terminal in the Repair or
the standard
Inspect for engine ECU (signal check har- replace the
value: Go to
short-circuit in ness) and ground. harness.
YES.
wire harness <Tester connections> Perform "After-
6 Go to step 7.
of intercooler Engine ECU inspection
The measure-
outlet temper- (signal check harness) work" of
ments do not
ature sensor THA0 (E44) – Ground INFORMA-
meet the stan-
E4 (E77) – Ground TION section.
dard value: Go
<Standard values>
to NO.
1. Connect the intercooler outlet
temperature sensor connector. The measure-
2. Measure the resistance ments meet
Repair or
between the terminals of the the standard
Inspect for dis- replace the
engine ECU (signal check har- value: Go to
connection in harness.
ness). YES.
wire harness Perform "After-
7 <Tester connections> Go to step 8.
of intercooler inspection
Engine ECU The measure-
outlet temper- work" of
(signal check harness) ments do not
ature sensor INFORMA-
THA0 (E44) – E4 (E77) meet the stan-
TION section.
<Standard values> dard value: Go
20 C {68 F}: 7.336 – 5.794 k to NO.
50 C {122 F}: 2.435 – 1.994 k
Clean the
sensing unit
and connect
1. Check the installation of the Failure found: securely.
Inspect the intake air temperature sensor. Go to YES. If damaged,
intake air tem- 2. Make sure there is no dirt, replace the
8 Go to step 9.
perature sen- damage or clogging in the No failure sensor.
sor sensing unit of intake air tem- found: Go to Perform "After-
perature sensor. NO. inspection
work" of
INFORMA-
TION section.
2–174 ENGINE (J05E)/TROUBLESHOOTING
Intake air temperature sensor
DTC: P007B Inspection procedure
(intercooler outlet) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance of the ments meet
intake air temperature sensor ter- the standard Replace the
minals. value: Go to sensor.
Inspect the
<Tester connections> YES. Perform "After-
intake air tem-
9 Intake air temperature sensor Go to step 10. inspection
perature sen-
THA – E2 The measure- work" of
sor unit
<Standard values> ments do not INFORMA-
20 C {68 F}: 2.69 – 2.21 k meet the stan- TION section.
60 C {140 F}: 0.667 – 0.493 k dard value: Go
to NO.
Replace the
hose.
Failure found:
1. Make sure that the boost pres- Clean the
Go to YES.
Inspect the sure hose sensor has no clog- pipe.
10 boost pressure ging, punctures, or cracks. Perform "After- Go to step 11.
No failure
sensor hose 2. Make sure there is no clogging inspection
found: Go to
in the intake manifold side pipe. NO. work" of
INFORMA-
TION section.
The measure- Inspect the
Measure the voltage of the boost ments meet wire harness
pressure sensor vehicle side con- the standard and engine
nector terminals. value: Go to ECU sensor
Inspect the
<Tester connections> YES. power supply
boost pressure
11 Boost pressure sensor vehicle Go to step 12. output value.
sensor power
side connector The measure- Perform "After-
supply system
VC – E ments do not inspection
<Standard values> meet the stan- work" of
4.75 – 5.25 V dard value: Go INFORMA-
to NO. TION section.
Clean the
sensing unit
and connect
1. Check the installation of the
Failure found: securely.
intake manifold temperature
Insect the Go to YES. If damaged,
sensor.
intake mani- replace the
12 2. Make sure there is no dirt, Go to step 13.
fold tempera- No failure sensor.
ture sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the intake mani- NO. inspection
fold temperature sensor work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–175
Intake air temperature sensor
DTC: P007B Inspection procedure
(intercooler outlet) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance of the
ments meet
intake manifold temperature sen-
the standard Replace the
sor terminals.
Insect the value: Go to sensor.
<Tester connections>
intake mani- YES. Perform "After-
Intake manifold temperature sen-
13 fold tempera- Go to step 14. inspection
sor
ture sensor The measure- work" of
THA – E2
unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k
dard value: Go
50 C {122 F}: 2.435 – 2.41 k
to NO.
DTC P007B
Replace the Procedure
has been
engine ECU. completed.
Warm up the engine (engine cool- detected: Go
Check the Perform "After- Perform "After-
ant temperature: 80 C {176 F} to YES.
14 DTC detected inspection inspection
or more) and check if P007B has
(Engine ECU) work" of work" of
been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–176 ENGINE (J05E)/TROUBLESHOOTING
DTC: P007C and P007D
EN01H02127030602016033
P007C: Intake air temperature sensor (intercooler outlet) - out of range (Out of range low)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA X4A (THG)
Exhaust gas (THG) X7U
temperature sensor (E2) Z2N 10mA
J0M 15mA
(VC)
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
SHTS021270300147
1. Technical description
• The intake air temperature sensor (intercooler outlet) installed to the downstream of the boost pressure sensor con-
sistently measures temperature at the outlet of the intercooler.
<Description of malfunction>
• The intake air temperature at the intercooler outlet cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the intake air temperature sensor (intercooler outlet) remains at 0.06 V (200 C {392 F})or less for 3
seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
ENGINE (J05E)/TROUBLESHOOTING 2–177
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Disconnection or short-circuit in sensor harness
• Faulty connector contact or fit
• Intercooler outlet temperature sensor failure
- Abnormal resistance
- Internal short
• Failure in engine ECU sensor power supply or internal circuit
2–178 ENGINE (J05E)/TROUBLESHOOTING
P007D: Intake air temperature sensor (intercooler outlet) - out of range (Out of range high)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA X4A (THG)
Exhaust gas (THG) X7U
temperature sensor (E2) Z2N 10mA
J0M 15mA
(VC)
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
SHTS021270300148
1. Technical description
• The intake air temperature sensor (intercooler outlet) installed to the downstream of the boost pressure sensor con-
sistently measures temperature at the outlet of the intercooler.
<Description of malfunction>
• The intake air temperature at the intercooler outlet cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• Intake air temperature is -20 C {-4 F} or more.
(2) Judgement criteria
• Output of the intake air temperature sensor (intercooler outlet) remains at 4.87 V (-35 C {-31 F}) or higher for
3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
ENGINE (J05E)/TROUBLESHOOTING 2–179
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Disconnection or short-circuit in sensor harness
• Faulty connector contact or fit
• Intercooler outlet temperature sensor failure
- Abnormal resistance
- Internal short
• Failure in engine ECU sensor power supply or internal circuit
2–180 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P007C and P007D
1 Inspect the intercooler outlet temperature sensor connector
1. Check the connection of the intercooler outlet temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the intercooler outlet temperature sensor
1. Check the installation of the intercooler outlet temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intercooler outlet temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–181
3 Inspect the intercooler outlet temperature sensor unit
1. Set the starter key to the "LOCK" position.
THG E2 2. Disconnect the intercooler outlet temperature sensor connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intercooler outlet temperature sensor.
Measurement Tester
Standard values
conditions connections
Intercooler outlet 20 C {68 F}:
temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300149 sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the intercooler outlet temperature
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–182 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect for short-circuit in wire harness of intercooler outlet temperature sensor
1. Set the starter key to the "LOCK" position.
E44 D
E77
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) terminals and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300150 nal check har-
ness)
Starter key: LOCK
THA0 (E44) –
Ground
E4 (E77) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
5 Inspect for disconnection in wire harness of intercooler outlet temperature sensor
1. Connect the intercooler outlet temperature sensor connector.
E44 D 2. Use the electrical tester to measure the resistance between the
E77
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
THA0 (E44) –
2.435 – 1.994 k
SHTS021270300151 E4 (E77)
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–183
6 Inspect the intercooler outlet temperature sensor power supply
1. Disconnect the intercooler outlet temperature sensor connector.
E44 D
E77
2. Connect the signal check harness to the engine ECU.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the
engine ECU (signal check harness) terminals.
Measurement Tester
Standard values
conditions connections
SHTS021270300152 Engine ECU (sig-
nal check har-
Starter key: ON ness) 4.5 – 5.5 V
THA0 (E44) –
E4 (E77)
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
7 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P007C or P007D) has been
detected in [Fault Information].
SHTS021270300153
Has DTC (P007C or P007D) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–184 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P007C and P007D
Intake air temperature sensor
DTC: P007C (intercooler outlet) - out of range
(Out of range low)
Inspection procedure
Intake air temperature sensor
DTC: P007D (intercooler outlet) - out of range
(Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the inter- Go to YES.
intercooler needed.
cooler outlet temperature sensor
1 outlet temper- Perform "After- Go to step 2.
connector (looseness and poor No failure
ature sensor inspection
contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
intercooler outlet temperature
Inspect the Go to YES. If damaged,
sensor.
intercooler replace the
2 2. Make sure there is no dirt, Go to step 3.
outlet temper- No failure sensor.
ature sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the intercooler NO. inspection
outlet temperature sensor. work" of
INFORMA-
TION section.
Disconnect the intercooler outlet
The measure-
temperature sensor connector,
ments meet
and measure the resistance
the standard Replace the
between the terminals of the
Inspect the value: Go to sensor.
intercooler outlet temperature
intercooler YES. Perform "After-
sensor.
3 outlet temper- Go to step 4. inspection
<Tester connections>
ature sensor The measure- work" of
Intercooler outlet temperature
unit ments do not INFORMA-
sensor THG – E2
meet the stan- TION section.
<Standard values>
dard value: Go
20 C {68 F}: 7.336 – 5.794 k
to NO.
50 C {122 F}: 2.435 – 1.994 k
Connect the signal check harness
to the engine ECU vehicle side
The measure-
harness (Do not connect harness
ments meet
to the ECU.), and measure the Repair or
the standard
Inspect for resistance between the engine replace the
value: Go to
short-circuit in ECU (signal check harness) ter- harness.
YES.
wire harness minals and ground. Perform "After-
4 Go to step 5.
of intercooler <Tester connections> inspection
The measure-
outlet temper- Engine ECU work" of
ments do not
ature sensor (signal check harness) INFORMA-
meet the stan-
E44 (THA0) – Ground TION section.
dard value: Go
E77 (E4) – Ground
to NO.
<Standard values>
ENGINE (J05E)/TROUBLESHOOTING 2–185
Intake air temperature sensor
DTC: P007C (intercooler outlet) - out of range
(Out of range low)
Inspection procedure
Intake air temperature sensor
DTC: P007D (intercooler outlet) - out of range
(Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the intercooler outlet
temperature sensor connector, The measure-
and measure the resistance ments meet
Repair or
between the terminals of the the standard
Inspect for dis- replace the
engine ECU (signal check har- value: Go to
connection in harness.
ness). YES.
wire harness Perform "After-
5 <Tester connections> Go to step 6.
of intercooler inspection
Engine ECU The measure-
outlet temper- work" of
(signal check harness) ments do not
ature sensor INFORMA-
E44 (THA0) – E77 (E4) meet the stan-
TION section.
<Standard values> dard value: Go
20 C {68 F}: 7.336 – 5.794 k to NO.
50 C {122 F}: 2.435 – 1.994 k
Disconnect the intercooler outlet
The measure-
temperature sensor connector,
ments meet
connect the signal check to the Repair or
the standard
engine ECU, and measure the replace the
Inspect the value: Go to
voltage between the engine ECU harness.
intercooler YES.
(signal check harness) terminals. Perform "After-
6 outlet temper- Go to step 7.
<Tester connections> inspection
ature sensor The measure-
Engine ECU work" of
power supply ments do not
(signal check harness) INFORMA-
meet the stan-
E44 (THA0) – E77 (E4) TION section.
dard value: Go
<Standard values>
to NO.
4.5 – 5.5 V
DTC (P007C
Replace the Procedure
or P007D) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P007C or Perform "After- Perform "After-
Go to YES.
7 DTC detected P007D) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–186 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0088
EN01H02127030602016034
P0088: Fuel system pressure - High
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
SHTS021270300154
1. Technical description
• Common rail pressure is controlled by a discharge rate of the supply pump.
• Discharge rate of the supply pump is adjusted by the SCV (suction control valve).
<Description of malfunction>
• Abnormally high fuel pressure inside common rail is detected.
2. DTC set condition
(1) DTC detection condition
• Common rail pressure is normal.
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• A calculated value of (actual common rail pressure reading – Target common rail pressure.) remains at 232
MPa or greater for 1 seconds.
3. Reset condition
• After restoration to normal condition and starter key "ON"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: OFF
• Cruise control function is not available.
ENGINE (J05E)/TROUBLESHOOTING 2–187
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Fuel filter: Clogging
• Common rail pressure sensor: Irregular contact (fault in power supply, fault in GND), fault in sensor
• Supply pump: Fault in SCV, fault in learned value
• Common rail: Pressure limiter opening valve
• Harness related: Irregular contact of crankshaft position sensor and camshaft position sensor, misconnection
2–188 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0088
1 Inspect the start of the engine
1. Inspect the start of the engine.
Does the engine start?
YES NO
Go to step 4. Go to step 2.
2 Inspect the supply pump
1. Check if fuel is leaking or seeping out of the supply pump.
SUPPLY PUMP
SHTS021270300155
Was any failure found?
YES NO
Replace the supply pump, and go to step 4. Go to step 3.
ENGINE (J05E)/TROUBLESHOOTING 2–189
3 Function check of supply pump [HINO-DX]
1. Connect the vehicle to HINO-DX.
Actual common rail pressure
Specified common rail pressure
2. Set the starter key to the "ON" position.
222MP䌡
Common rail pressure
The pressure limiter is 3. Select [Engine].
open reducing the pressure.
4. Select [Actual common rail pressure] and [Target common rail
Idling pressure] in [Data Monitor].
5. Start the engine while checking the common rail pressure.
Starter 䌏䌎 (Engine starting) Hour
Standard values
SHTS021270300156
The actual common rail pressure rises and stabilizes at a
constant value.
Was any failure found?
YES NO
Replace the supply pump, go to step 4. Contact the TSM.
4 SCV free acceleration test [HINO-DX]
1. In the screen of the diagnostic tool, select [Freeze Frame] of DTC
P0088 in [Fault Information] to check the freeze frame data.
2. Perform an SCV test to check the current data.
Select • For detailed procedures, refer to the attachment "SCV free accelera-
Engine tion test".
HINT
The data obtained in this procedure is used as the comparison
data for later procedures.
3. Check the engine ECU software part number (ECU part number)
SHTS021270300157
by HINO-DX.
(Select [About System] in the [View] menu.)
Confirm the latest part number with Hino national service man-
ager.
Does the engine ECU have the latest product number?
YES NO
Go to step 5. Reprogram the engine ECU and then go to
step 5.
2–190 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect the fuel filter
1. Check the fuel filter.
FUEL FILTER • Has the replacement period expired?
• Is it dirty, damaged, or clogged?
• Is it a genuine Hino part?
2. Check if the fuel inside the fuel filter is within the standard value.
Measurement conditions Standard values
• At least 25.4 mm {1 in.}
above collar and below the
SHTS021270300158 element upper level.
While engine is running • High-sped idle ≥ wide
open throttle
Fuel level does not con-
tinue to drop during wide
open throttle.
Was any failure found?
YES NO
Replace the fuel filter element, and go to step Go to step 11.
6.
6 Inspect the fuel pipe
1. Check if the fuel pipe and hose between the fuel tank and fuel filter
are clogged, punctured, or bent.
2. Make sure the fuel pipe joint bolts are not loose.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 7.
step 7.
ENGINE (J05E)/TROUBLESHOOTING 2–191
7 Inspect the fuel tank breather
1. Check if the breather hose is clogged, punctured, or bent.
2. Make sure the check valve is functioning normally.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 8.
step 8.
8 Inspect the fuel tank feed pipe
1. Make sure the fuel tank feed pipe is not clogging.
Was any failure found?
YES NO
Repair or replace the faulty part and, go to Go to step 9.
step 9.
9 Inspect the fuel tank
1. Drain fuel out of the fuel tank and check if there are foreign objects
inside the tank.
Was any failure found?
YES NO
Remove the foreign object and clean the fuel Go to step 10.
tank.
Then go to step 10.
2–192 ENGINE (J05E)/TROUBLESHOOTING
10 Inspect the supply pump gauze filter
1. Make sure the gauze filter (built into the supply pump) is not
clogged.
Was any failure found?
YES NO
Clean the gauze filter, and go to step 11. Go to step 11.
11 Inspect the fuel high-pressure pipe
1. Make sure the fuel high-pressure pipe is not leaking fuel.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 12.
step 12.
12 Inspect the bubble separator
1. Make sure the bubble separator is not clogging.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to If failure was found in steps 6 – 11:
step 13. Go to step 13.
If failure was not found in steps 6 – 11:
Go to step 14.
ENGINE (J05E)/TROUBLESHOOTING 2–193
13 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select 2. Compare the results with those obtained in step 4 and check if
Engine they improved.
SHTS021270300159
Did the test results improve?
YES NO
Procedure completed. Go to step 14.
Perform "After-inspection work" of INFOR-
MATION section.
14 Inspect the SCV connector
1. Check the connection of the SCV connector (looseness and poor
contact).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 15.
step 15.
2–194 ENGINE (J05E)/TROUBLESHOOTING
15 Inspect the common rail pressure sensor connector
1. Check the connection of the common rail pressure sensor connec-
tor (looseness and poor contact).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 16.
step 16.
16 Inspect the common rail pressure sensor power supply
1. Disconnect the common rail pressure sensor connector.
VC2 E2
2. Set the starter key to the "ON" position.
3. Use the electrical tester to measure the voltage between the termi-
nals of the common rail pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300160 cle side connector
VC2 – E2
Do the measurements meet the standard value?
YES NO
Go to step 17. Replace the common rail pressure sensor
and then go to step 17.
ENGINE (J05E)/TROUBLESHOOTING 2–195
17 Inspect the engine speed main sensor (crankshaft position sensor)
1. Set the starter key to the "ON" position.
2. Select [Engine].
Select 3. Select [NE sensor active flag], [G sensor active flag] in [Data Mon-
Engine itor].
4. Start the engine and confirm that the engine main speed sensor
(NE) and sub speed sensor (G) operate (stay ON) continuously.
SHTS021270300161
Was any failure found?
YES NO
Check the faulty the engine speed main sen- Go to step 18.
sor (crankshaft position sensor) and repair
or replace it as needed.
After inspection, go to step 18.
18 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select 2. Compare the test results with those obtained in step 4 and check if
Engine they improved.
SHTS021270300162
Did the test results improve?
YES NO
Procedure completed. Go to step 19.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–196 ENGINE (J05E)/TROUBLESHOOTING
19 SCV free acceleration test [HINO-DX]
1. Check that the malfunction pattern from the malfunction reproduc-
tion test carried out in step 18, and replace the pertinent part.
<Reproduction test results>
Select - a, g: Replace the supply pump.
Engine - b, c, d, h, i, j: Replace the SCV.
- e: Replace the common rail.
- f: Check the fuel return pipe/hose.
2. After replacing the part, perform the SCV test and malfunction
reproduction test again.
SHTS021270300163
3. Compare the test results with those obtained in step 4 and check if
they improved.
Did the test results improve?
YES NO
Procedure completed. Go to step 20.
20 Inspect the fuel return pipe and hose
1. Check if the fuel return pipe and hose are clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 21.
step 21.
ENGINE (J05E)/TROUBLESHOOTING 2–197
21 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select 2. Compare the test results with those obtained in step 4 and check if
Engine they improved.
SHTS021270300164
Did the test results improve?
YES NO
Procedure completed. Go to step 22.
22 Check again the fuel pipe
1. Check the fuel pipe again (steps 6 – 12).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 23.
step 23.
2–198 ENGINE (J05E)/TROUBLESHOOTING
23 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select 2. Compare the test results with those obtained in step 4 and check if
Engine they improved.
SHTS021270300165
Did the test results improve?
YES NO
Procedure completed. Go to step 24.
24 Check again the sensor system
1. Check the sensor system again (steps 14 – 17).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 25.
step 25.
ENGINE (J05E)/TROUBLESHOOTING 2–199
25 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For detailed procedures, refer to the attachment "SCV free accelera-
tion test".
Select 2. Compare the test results with those obtained in step 4 and check if
Engine they improved.
SHTS021270300166
Did the test results improve?
YES NO
Procedure completed. Report the TSM.
2–200 ENGINE (J05E)/TROUBLESHOOTING
SCV FREE ACCELERATION TEST
1 Test method
<Engine speed pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Control the engine revolution by means of operating Cruise Control
system.
Engine speed pattern
2500 r/min - Measure each engine
Engine speed
speed for 20 seconds.
2000 r/min
1500 r/min
1000 r/min
750r/min
Time
SHTS021270300167
<Acceleration pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Check that actual common rail pressure following target.
Acceleration pattern
At least three times, repeating the Wide-Open Throttle
100%
opening
Throttle
20sec 20sec
0%
Time
SHTS021270300168
ENGINE (J05E)/TROUBLESHOOTING 2–201
2 Types of HINO-DX data to be measured
SHTS021270300169
2–202 ENGINE (J05E)/TROUBLESHOOTING
3 If the following symptoms occur, FAIL. If not, OK.
a. Pressure is reduced by 5 MPa or more continually for 5 seconds or
more. Replace the supply pump.
Engine speed pattern
Common rail pressure
Actual common rail pressure
a: Pressure is reduced by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300170
b. Pressure is increased by 5 MPa or more continually for 5 seconds or
more. Replace the SCV.
Engine speed pattern
Common rail pressure
Actual common rail pressure
Pressure is increased by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300171
c. The maximum common rail pressure exceeds 222 MPa for even a
moment during pressure increase. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300172
ENGINE (J05E)/TROUBLESHOOTING 2–203
d. After the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300173
e. Before the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure rapidly. Replace the common rail.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300174
f. The maximum common rail pressure exceeds 222 MPa during pres-
sure drop. Check the return pipe.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300175
2–204 ENGINE (J05E)/TROUBLESHOOTING
g. The pressure is disturbed at a given speed and the pressure
decreases at higher speed. Replace the supply pump.
Engine speed pattern
Common rail pressure
The pressure is disturbed
at a given speed and the Actual common rail pressure
10 MPa or more pressure decreases at
higher speed. Target common rail pressure
Remains for 5 seconds or longer.
Time
SHTS021270300176
h. Hunting remains within 10 MPa or more for more than 5 seconds.
Replace the SCV.
Engine speed pattern
Common rail pressure
㪩㪸㫅㪾㪼㩷㫉㪼㫄㪸㫀㫅㫊㩷㫎㫀㫋㪿㫀㫅㩷㪈㪇 Actual common rail pressure
10 MPa or more 㪤㪧㪸㩷㫆㫉㩷㫄㫆㫉㪼㩷㪽㫆㫉㩷㫄㫆㫉㪼
Target common rail pressure
㫋㪿㪸㫅㩷㪌㩷㫊㪼㪺㫆㫅㪻㫊㪅
Remains for 5 seconds or longer.
Time
SHTS021270300177
i. The engine stops during pressure relief. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300178
ENGINE (J05E)/TROUBLESHOOTING 2–205
j. Target common rail pressure during idling deviates from the standard
value. Replace the SCV.
.
<FINAL VALUE OF PUMP CURRENT TARGET test>
1. After engine has reached operating temperature. (more than 82 C
{179.6 F})
2. After air compressor has completed building pressure.
3. A/C, Head lights are off.
4. All other devices turned off. (PTO, Refrigeration compressor. etc)
5. Engine speed: 750 r/min
Criteria
Average current
FINAL VALUE OF 1740 80 mA
value
PUMP CURRENT
TARGET Fluctuation in cur-
< 80 mA
rent value
Current value [mA]
Target current value
Average current value (30sec)
Fluctuation in current value
Time [sec]
SHTS021270300179
2–206 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0088
DTC: P0088 Fuel system pressure control - High Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
The engine
can be started:
Inspect the Go to YES.
1 start of the Inspect the start of the engine. Go to step 4. Go to step 2.
engine Cannot be
started: Go to
NO.
Failure found:
Go to YES. Replace the
Inspect the Check if fuel is leaking or seeping supply pump,
2 Go to step 3.
supply pump out of the supply pump. No failure and go to step
found: Go to 4.
NO.
Select [Actual common rail pres-
sure] from [Data Monitor] in
Failure found:
[Engine] of HINO-DX menu and,
Function Go to YES. Replace the
start the engine while checking
check of sup- supply pump, Contact the
3 the common rail pressure.
ply pump No failure and go to step TSM.
<Standard values>
[HINO-DX] found: Go to 4.
The actual common rail pressure
NO.
rises and stabilizes at a constant
value.
1. Select [Freeze Frame] of the
DTC (P016E or P016F) in
[Fault Information] in HINO-DX
menu, and confirm the freeze-
frame data.
It is the latest
2. Conduct an SCV test and con- product num-
firm the existing data. ber: Go to
SCV free Reprogram the
• For a detailed procedure, YES.
acceleration engine ECU
4 refer to the separate "SCV Go to step 5.
test [HINO- and then go to
free acceleration test". It is not the lat-
DX] step 5.
HINT est product
The data obtained in this proce- number: Go to
dure will serve as comparison NO.
data in subsequent proce-
dures.
3. Check the engine ECU product
number.
ENGINE (J05E)/TROUBLESHOOTING 2–207
DTC: P0088 Fuel system pressure control - High Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Inspect the fuel filter.
• Has the replacement period
expired?
• Is it dirty, damaged, or
clogged?
• Is it a genuine Hino part? Failure found:
2. Check if the fuel inside the fuel Go to YES. Replace the
Inspect the filter is within the standard fuel filter ele-
5 value. Go to step 11.
fuel filter No failure ment, and go
<Measurement conditions> found: Go to to step 6.
While engine is running NO.
<Standard values>
• At least 25.4 mm {1 in.} above
collar and below the element
upper level.
• Fuel level does not continue to
drop during high-speed idle.
1. Check if the fuel pipe and hose Failure found:
between the fuel tank and fuel Go to YES. Repair or
Inspect the filter are clogged, punctured, or replace the
6 Go to step 7.
fuel pipe bent. No failure faulty part, and
2. Make sure the fuel pipe joint found: Go to go to step 7.
bolts are not loose. NO.
Failure found:
1. Check if the breather hose is Go to YES. Repair or
Inspect the
clogged, punctured, or bent. replace the
7 fuel tank Go to step 8.
2. Make sure the check valve is No failure faulty part, and
breather
functioning normally. found: Go to go to step 8.
NO.
Failure found:
Go to YES. Repair or
Inspect the
Make sure the fuel tank feed pipe replace the
8 fuel tank feed Go to step 9.
is not clogged. No failure faulty part, and
pipe
found: Go to go to step 9.
NO.
Failure found:
Remove the
Go to YES.
Drain fuel out of the fuel tank and foreign objects
Inspect the
9 check if there are foreign objects and clean the Go to step 10.
fuel tank No failure
inside the tank. fuel tank. Then
found: Go to
go to step 10.
NO.
Failure found:
Go to YES. Clean the
Inspect the
Make sure the gauze filter (built gauze filter,
10 fuel pump Go to step 11.
into the fuel pump) is not clogged. No failure and go to step
gauze filter
found: Go to 11.
NO.
2–208 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0088 Fuel system pressure control - High Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES. Repair or
Inspect the
Make sure the fuel high-pressure replace the
11 fuel high-pres- Go to step 12.
pipe is not leaking fuel. No failure faulty part, and
sure pipe.
found: Go to go to step 12.
NO.
If failure was
Failure found: found in steps
Go to YES. Repair or 6 – 11: Go to
Inspect the
Make sure the bubble separator is replace the step 13.
12 bubble separa-
not clogged. No failure faulty part, and If failure was
tor
found: Go to go to step 13. not found in
NO. steps 6 – 11:
Go to step 14.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
13 inspection Go to step 14.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the results with those not improve: INFORMA-
obtained in step 4 and check if Go to NO. TION section.
they improved.
Failure found:
Go to YES. Repair or
Inspect the Check the connection of the SCV
replace the
14 SCV connec- connector (looseness and poor Go to step 15.
No failure faulty part, and
tor contact).
found: Go to go to step 15.
NO.
Failure found:
Inspect the Go to YES. Repair or
Check the connection of the com-
common rail replace the
15 mon rail pressure sensor connec- Go to step 16.
pressure sen- No failure faulty part, and
tor (looseness and poor contact).
sor connector found: Go to go to step 16.
NO.
1. Disconnect the common rail The measure-
pressure sensor connector and ments meet
measure the voltage between the standard
Inspect the the terminals of the common value: Go to
rail pressure sensor vehicle Repair the
common rail YES.
side connector sensor and
16 pressure sen- Go to step 17.
<Tester connections> then go to step
sor power sup- The measure-
common rail pressure sensor 17.
ply ments do not
vehicle side connector meet the stan-
VC2 – E2 dard value: Go
<Standard values> to NO.
4.5 – 5.5 V
ENGINE (J05E)/TROUBLESHOOTING 2–209
DTC: P0088 Fuel system pressure control - High Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Check any
Select [NE Active identification],
Inspect the Failure found: faulty sensor
[G Active identification] in [Data
engine speed Go to YES. and repair or
Monitor].
main sensor replace it as
17 Start the engine and confirm that Go to step 18.
(crankshaft No failure needed.
the engine main speed sensor
position sen- found: Go to After inspec-
(NE) and sub speed sensor (G)
sor) NO. tion, go to step
operate (stay ON) continuously.
18.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
18 inspection Go to step 19.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
1. Check that the malfunction pat-
tern from the malfunction repro-
duction test carried out in step
18, and replace the pertinent
part.
<Reproduction test results>
The results Procedure
- a, g: Replace the fuel pump. improved: Go completed.
SCV free - b, c, d, h, i, j: Replace the to YES. Perform "After-
acceleration SCV.
19 inspection Go to step 20.
test [HINO-
- e: Replace the common rail. The results did work" of
DX]
- f: Check the fuel return pipe/ not improve: INFORMA-
hose. Go to NO. TION section.
2. After replacing the part, per-
form the SCV test and malfunc-
tion reproduction test again.
3. Compare the test results with
those obtained in step 4 and
check if they improved.
Failure found:
Go to YES. Repair or
Inspect the
Check if the fuel return pipe and replace the
20 fuel return Go to step 21.
hose are clogged. No failure faulty part, and
pipe and hose
found: Go to go to step 21.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
21 inspection Go to step 22.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
2–210 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0088 Fuel system pressure control - High Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES. Repair or
Check again Check the fuel pipe again (steps 6 replace the
22 Go to step 23.
the fuel pipe – 12). No failure faulty part, and
found: Go to go to step 23.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
23 inspection Go to step 24.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
Failure found:
Go to YES. Repair or
Check again
Check the sensor system again replace the
24 the sensor Go to step 25.
(steps 14 – 17). No failure faulty part, and
system
found: Go to go to step 25.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV Contact the
25 inspection
test [HINO- free acceleration test". TSM.
The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
ENGINE (J05E)/TROUBLESHOOTING 2–211
DTC: P0096
EN01H02127030602016035
P0096: Intake air temperature sensor (intake manifold) - rationality
INFORMATION [at engine start]
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
15mA
(VC) J0M
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300180
1. Technical description
• The intake air temperature sensor (intake manifold) installed to the intake manifold consistently measures intake
manifold temperature.
<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.
2–212 ENGINE (J05E)/TROUBLESHOOTING
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 20 seconds or more.
• Starter key "ON".
• The engine speed is 1000 r/min or less.
• Fuel injection quantity is 35 mm3/st. cyl or less.
• Engine coolant temperature is in the range of -30 to 60 C {-22 to 140 F}.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the average temperature difference between the intake manifold temperature sensor and the
intake air temperature sensor (built-in air flow sensor) is 30 C {86 F} or more while the average temperature
difference between the intake manifold temperature sensor and the intercooler outlet temperature sensor is 30
C {86 F} or more.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Failure of intercooler outlet temperature sensor:
• Failure of intake air temperature sensor (with built-in air flow sensor):
• Failure of intake manifold temperature sensor:
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• Malfunction of ECU sensor power supply
ENGINE (J05E)/TROUBLESHOOTING 2–213
P0096: Intake air temperature sensor (intake manifold) - rationality
INFORMATION [at engine running]
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
15mA
(VC) J0M
5mA X0G (PIM)
Boost pressure sensor (PIM) J0L
15mA
(E) Z6R ZJP
(E4)
Intercooler outlet 10mA
(E2) E7Q
temperature sensor
(THG) E7P 10mA XSW
(THAO)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300181
1. Technical description
• The intake air temperature sensor (intake manifold) installed to the intake manifold consistently measures intake
manifold temperature.
<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.
2–214 ENGINE (J05E)/TROUBLESHOOTING
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 11 seconds or more.
• The battery voltage is in the range of 10 to 16 V.
• The condition that the engine speed remains at 500 r/min or more for 5 seconds or more.
The conditions described below remain for 40 seconds or more.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The engine speed is 1000 r/min or less.
• Fuel injection quantity is 35 mm3/st.cyl or less.
• Engine coolant temperature is in the range of -30 to 60 C {-22 to 140 F}.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency is greater than 65%,
• the difference between the calculated intake manifold air intake temperature and the actual intake air is higher
than 60 C {140 F} or less than -60 C {-76 F}, and
• the calculated intercooler efficiency is higher than the specified value (30% or more when the vehicle speed is
13 mile/h, 50% or more when the vehicle speed is 25 mile/h).
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Failure of intercooler outlet temperature sensor:
• Failure of intake air temperature sensor (with built-in air flow sensor):
• Failure of intake manifold temperature sensor:
• Failure of boost pressure sensor:
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• Malfunction of ECU sensor power supply
ENGINE (J05E)/TROUBLESHOOTING 2–215
INSPECTION PROCEDURE: P0096
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than P0096 (for exam-
ple, P0401, P0402, P0404, P0234, P0299, P22D3, turbo, EGR
DTC) has been detected in [Fault Information].
HINT
Intercooler outlet temperature sensor characteristic abnormality
judgement is performed based on the boost pressure and EGR
SHTS021270300182
rate data.
If EGR system or Turbo DTC are detected, perform another failure
diagnosis starting from the first DTC associated with the malfunc-
tion.
Has a DTC other than P0096 been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
2 Inspect the intake air temperature sensor (intake manifold) connector
1. Check the connection of the intake air temperature sensor (intake
manifold) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–216 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the intake air temperature sensor (intake manifold)
1. Check the installation of the intake air temperature sensor (intake
manifold).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intake manifold).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If damaged, replace the intake air tempera-
ture sensor (intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the intake air temperature sensor (intake manifold) unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake air temperature sensor (intake manifold)
connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intake manifold).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
SHTS021270300183 ture sensor (intake 7.336 – 5.794 k
Starter key: LOCK
manifold) 50 C {122 F}:
THA – E2 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the intake air temperature sensor
(intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–217
5 Inspect the intake air temperature sensor (intake manifold) power supply
1. Set the starter key to the "ON" position.
THA E2
2. Use the electrical tester to measure the voltage between the termi-
nals of the intake air temperature sensor (intake manifold) vehicle
side connector.
Measurement Tester
Standard values
conditions connections
Intake air tempera-
ture sensor (intake
Starter key: ON manifold) vehicle 4.5 – 5.5 V
SHTS021270300184 side connector
THA – E2
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
6 Inspect for short-circuit of the intake air temperature sensor (intake manifold) harness
1. Set the starter key to the "LOCK" position.
D E76
E63 2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300185 nal check har-
ness)
Starter key: LOCK
THIA (E63) –
Ground
E2 (E76) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–218 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect disconnection of the intake air temperature sensor (intake manifold) harness
1. Connect the intake air temperature sensor (intake manifold) con-
nector.
D E76
E63 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
ATIA (E63) –
SHTS021270300186
2.435 – 2.41 k
E2 (E76)
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
8 Inspect the intake air temperature sensor (air flow sensor built-in)
1. Check the installation of the intake air temperature sensor (air flow
sensor built-in).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (air flow sensor built-in).
Was any failure found?
YES NO
If the sensing part is dirty, clogged, or dam- Go to step 9.
aged, replace the air flow sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–219
9 Inspect the intake air temperature sensor (air flow sensor built-in) unit
1. Set the starter key to the "LOCK" position.
E2 THA
2. Disconnect the intake air temperature sensor (air flow sensor built-
in) connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (air flow sensor
built-in).
Measurement Tester
Standard values
conditions connections
Intake air tempera-
SHTS021270300187
20 C {68 F}:
ture sensor (air
2.69 – 2.21 k
Starter key: LOCK flow sensor built-
60 C {140 F}:
in)
0.667 – 0.493 k
THA – E2
Do the measurements meet the standard value?
YES NO
Go to step 10. Replace the intake air temperature sensor
(air flow sensor built-in).
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the intake air temperature sensor (intercooler outlet)
1. Check the installation of the intake air temperature sensor (inter-
cooler outlet).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intercooler outlet).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 11.
If damaged, replace the intake air tempera-
ture sensor (intercooler outlet)
Perform "After-inspection work" of INFOR-
MATION section.
2–220 ENGINE (J05E)/TROUBLESHOOTING
11 Inspect the intake air temperature sensor (intercooler outlet) unit
1. Set the starter key to the "LOCK" position.
THG E2 2. Disconnect the intake air temperature sensor (intercooler outlet)
connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intercooler outlet).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
SHTS021270300188 ture sensor (inter- 7.336 – 5.794 k
Starter key: LOCK
cooler outlet) 50 C {122 F}:
THG – E2 2.435 – 1.994 k
Do the measurements meet the standard value?
YES NO
Go to step 12. Replace the intake air temperature sensor
(intercooler outlet).
Perform "After-inspection work" of INFOR-
MATION section.
12 Inspect the boost pressure sensor hose.
1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.
2. Make sure the pipe on the intake manifold side is not clogged.
Was any failure found?
YES NO
1. Replace the boost pressure sensor hose. Go to step 13.
2. Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–221
13 Inspect the boost pressure sensor power supply system
1. Set the starter key to the "LOCK" position.
E
2. Disconnect the boost pressure sensor connector.
VC
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300189 Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 14. Inspect the wire harness and engine ECU
sensor power supply output valve.
Perform "After-inspection work" of INFOR-
MATION section.
14 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0096 has been detected in [Fault
Information].
SHTS021270300190
Has DTC P0096 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–222 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0096
Intake air temperature sensor
DTC: P0096 Inspection procedure
(intake manifold) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0096
1. Set the starter key to the (P0401,
"LOCK" position. P0402, P0404,
2. Connect the vehicle to HINO- P0234, P0299,
DX. P22D3, etc.
3. Set the starter key to the "ON" have been Go to diagno-
Check the
position. detected in the sis procedure
1 DTC detected Go to step 2.
turbo EGR of a related
(Engine ECU) 4. Check if any DTC other than
system. Turbo DTC.
P0096 (for example, P0401,
EGR DTC
P0402, P0404, P0234, P0299,
detected: Go
P22D3, or turbocharger/EGR
to YES.
system DTC) has been
detected in [Engine].
Not detected:
Go to NO.
Connect
securely and
Inspect the Failure found:
repair if
intake mani- Check the connection of the Go to YES.
needed.
fold tempera- intake manifold temperature sen-
2 Perform "After- Go to step 3.
ture sensor sor connector. (looseness and No failure
inspection
(intake mani- poor contact) found: Go to
work" of
fold) connector NO.
INFORMA-
TION section.
Clean the
sensing unit
and connect
1. Check the installation of the
securely.
intake manifold temperature Failure found:
Inspect the Replace the
sensor (intake manifold). Go to YES.
intake air tem- sensor if dam-
3 perature sen- 2. Make sure there is no dirt, age was Go to step 4.
damage or clogging in the No failure
sor (intake found.
manifold) sensing unit of the intake mani- found: Go to Perform "After-
fold temperature sensor (intake NO. inspection
manifold). work" of
INFORMA-
TION section.
The measure-
Measure the resistance of the
ments meet
intake manifold temperature sen-
the standard Replace the
sor terminals.
Inspect the value: Go to sensor.
<Tester connections>
intake air tem- YES. Perform "After-
Intake manifold temperature sen-
4 perature sen- Go to step 5. inspection
sor
sor (intake The measure- work" of
THA – E2
manifold) unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k
dard value: Go
50 C {122 F}: 2.435 – 2.41 k
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–223
Intake air temperature sensor
DTC: P0096 Inspection procedure
(intake manifold) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the voltage of the intake ments meet
manifold temperature sensor the standard
Inspect the
vehicle side connector terminals. value: Go to
intake air tem-
<Tester connections> YES.
perature sen-
5 Intake manifold temperature sen- Go to step 8. Go to step 6.
sor (intake
sor vehicle side connector The measure-
manifold)
THA – E2 ments do not
power supply
<Standard values> meet the stan-
4.5 – 5.5 V dard value: Go
to NO.
Connect the signal check harness
The measure-
and measure the resistance
ments meet
between the engine ECU (signal Repair or
Inspect for the standard
check harness) terminals and replace the
short-circuits value: Go to
ground harness.
of the intake YES.
<Tester connections> Perform "After-
6 air tempera- Go to step 7.
Engine ECU inspection
ture sensor The measure-
(signal check harness) work" of
(intake mani- ments do not
ATIA (E63) – Ground INFORMA-
fold) harness meet the stan-
E2 (E76) – Ground TION section.
dard value: Go
<Standard values>
to NO.
1. Connect the intake manifold
The measure-
temperature sensor connector.
ments meet
2. Measure the resistance of the Repair or
Inspect for dis- the standard Replace the
engine ECU (signal check har- replace the
connection of value: Go to engine ECU.
ness) terminal. harness.
the intake air YES. Perform "After-
<Tester connections> Perform "After-
7 temperature inspection
Engine ECU inspection
sensor (intake The measure- work" of
(signal check harness) work" of
manifold) har- ments do not INFORMA-
ATIA (E63) – E2 (E76) INFORMA-
ness meet the stan- TION section.
<Standard values> TION section.
dard value: Go
20 C {68 F}: 7.336 – 5.794 k to NO.
50 C {122 F}: 2.435 – 2.41 k
If the sensing
unit is dirty, or
there was
1. Check the installation of the clogging, or it
Failure found:
Inspect the intake air temperature sensor was dam-
Go to YES.
Intake air tem- (air flow sensor). aged, replace
8 perature sen- 2. Make sure there is no dirt, the air flow Go to step 9.
No failure
sor (air flow damage or clogging in the sensor.
found: Go to
sensor built-in) sensing unit of the intake air Perform "After-
NO.
temperature sensor. inspection
work" of
INFORMA-
TION section.
2–224 ENGINE (J05E)/TROUBLESHOOTING
Intake air temperature sensor
DTC: P0096 Inspection procedure
(intake manifold) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Replace the
Measure the resistance of the ments meet
intake air tem-
intake air temperature sensor ter- the standard
Inspect the perature sen-
minals. value: Go to
Intake air tem- sor (Air flow
<Tester connections> YES.
perature sen- sensor).
9 Intake air temperature sensor Go to step 10.
sor (air flow Perform "After-
THA – E2 The measure-
sensor built-in) inspection
<Standard values> ments do not
unit work" of
20 C {68 F}: 2.69 – 2.21 k meet the stan-
INFORMA-
60 C {140 F}: 0.667 – 0.493 k dard value: Go
TION section.
to NO.
Clean the
sensing unit
and connect
1. Check the installation of the securely.
Inspect the Failure found:
intercooler outlet temperature Replace the
intake air tem- Go to YES.
sensor. sensor if dam-
perature sen-
10 2. Make sure there is no dirt, age was Go to step 11.
sor No failure
damage or clogging in the found.
(intercooler found: Go to
sensing unit of the intercooler Perform "After-
outlet) NO.
outlet temperature sensor. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the resistance of the
ments meet
intercooler outlet temperature
the standard Replace the
Inspect the sensor terminals.
value: Go to sensor.
intake air tem- <Tester connections>
YES. Perform "After-
perature sen- Intercooler outlet temperature
11 Go to step 12. inspection
sor sensor
The measure- work" of
(intercooler THG – E2
ments do not INFORMA-
outlet) unit <Standard values>
meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k
dard value: Go
50 C {122 F}: 2.435 – 1.994 k
to NO.
Replace the
boost pressure
sensor hose.
1. Make sure the sensor boost Failure found:
Clean the
pressure hose is not clogged, Go to YES.
Inspect the intake mani-
crushed and that there is no
12 boost pressure fold pipe.
cracks. No failure
sensor hose Perform "After-
2. Make sure there is no clogging found: Go to
inspection
in the intake manifold side pipe. NO.
work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–225
Intake air temperature sensor
DTC: P0096 Inspection procedure
(intake manifold) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure- Inspect the
Measure the voltage of the boost ments meet wire harness
pressure sensor vehicle side con- the standard and the engine
nector terminals. value: Go to ECU sensor
Inspect the
<Tester connections> YES. supply output
boost pressure
13 Boost pressure sensor vehicle Go to step 14. value.
sensor power
side connector The measure- Perform "After-
supply system
VC – E ments do not inspection
<Standard values> meet the stan- work" of
4.75 – 5.25 V dard value: Go INFORMA-
to NO. TION section.
DTC P0096
Replace the Procedure
has been
1. Warm up the engine (engine engine ECU. completed.
detected: Go
Check the coolant temperature: 80 C Perform "After- Perform "After-
to YES.
14 DTC detected {176 F} or more). inspection inspection
(Engine ECU) 2. Check if P0096 has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–226 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0097 and P0098
EN01H02127030602016036
P0097: Intake air temperature sensor (intake manifold) - out of range (Out of range low)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
SHTS021270300191
1. Technical description
• The intake air temperature sensor installed to the intake manifold consistently measures intake manifold tempera-
ture.
<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Intake manifold temperature sensor output ≤ 0.06 V (200 C {392 F}) for at least 3 seconds.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
ENGINE (J05E)/TROUBLESHOOTING 2–227
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Disconnection or short-circuit in sensor harness
• Poor connector contact or faulty connector fit.
• Intake air temperature sensor (intake manifold):
- Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
- Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply, malfunction of internal circuit.
2–228 ENGINE (J05E)/TROUBLESHOOTING
P0098: Intake air temperature sensor (intake manifold) - out of range (Out of range high)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70
E1 (E1)
2mA XZG (PCR1)
PCR1 EBJ
15mA X85 (VC)
Common rail VC1 EBH
15mA Z72 (E2)
pressure sensor E2 EBN
2mA XZH
PCR2 EBM (PCR2)
15mA XG2
VC2 EBL (VC2)
$XW
(PC2S)
10mA
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q 10mA XZJ (THIA)
SHTS021270300192
1. Technical description
• The intake air temperature sensor (intake manifold) installed to the intake manifold consistently measures intake
manifold temperature.
<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Intake manifold temperature sensor output remains less than 4.87 V (-35 C {-31 F}) for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
ENGINE (J05E)/TROUBLESHOOTING 2–229
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Disconnection or short-circuit in sensor harness
• Irregular contact, improper engagement
• Intake air temperature sensor (intake manifold):
- Abnormality in resistance of sensor
- Internal short-circuit
• Failure in engine ECU sensor power supply, malfunction of internal circuit
2–230 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0097 and P0098
1 Inspect the intake air temperature sensor (intake manifold) connector
1. Check the connection of the intake air temperature sensor (intake
manifold) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the intake air temperature sensor (intake manifold)
1. Check the installation of the intake air temperature sensor (intake
manifold).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intake manifold).
Was any failure found?
YES NO
Remove all contaminants and clogging. Go to step 3.
Replace if damaged.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–231
3 Inspect the intake air temperature sensor (intake manifold) unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake air temperature sensor (intake manifold)
connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intake manifold).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
SHTS021270300193 ture sensor (intake 7.336 – 5.794 k
Starter key: LOCK
manifold) 50 C {122 F}:
E2 – THA 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the intake air temperature sensor
(intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
2–232 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect for short-circuit of the intake air temperature sensor (intake manifold) harness
1. Set the starter key to the "LOCK" position.
D E76
E63 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300194 nal check har-
ness)
Starter key: LOCK
THIA (E63) –
Ground
E2 (E76) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect disconnection of the intake air temperature sensor (intake manifold) harness
1. Connect the intake air temperature sensor (intake manifold) con-
nector.
D E76
E63
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
THIA (E63) –
SHTS021270300195
2.435 – 2.41 k
E2 (E76)
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–233
6 Inspect the sensor power supply
1. Connect the signal check harness to the engine ECU.
D E76 2. Set the starter key to the "ON" position.
E63
3. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
SHTS021270300196 Starter key: ON ness) 4.5 – 5.5 V
THIA (E63) –
E2 (E76)
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the engine ECU.
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0097 or P0098) has been
detected in [Fault Information].
SHTS021270300197
Has DTC (P0097 or P0098) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–234 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0097 and P0098
Intake air temperature sensor (intake manifold)
DTC: P0097
- out of range (Out of range low)
Inspection procedure
Intake air temperature sensor (intake manifold)
DTC: P0098
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Inspect the Failure found:
repair if
intake air tem- Check the connection of the Go to YES.
needed.
perature sen- intake air temperature sensor
1 Perform "After- Go to step 2.
sor (intake (intake manifold) connector No failure
inspection
manifold) con- (looseness and poor contact). found: Go to
work" of
nector NO.
INFORMA-
TION section.
Clean the
sensing unit,
1. Check the installation of the and install it
intake air temperature sensor Failure found: properly. If
Inspect the
(intake manifold). Go to YES. damaged,
intake air tem-
2. Make sure there is no dirt, replace the
2 perature sen- Go to step 3.
damage or clogging in the No failure sensor.
sor (intake
sensing unit of the intake air found: Go to Perform "After-
manifold)
temperature sensor (intake NO. inspection
manifold). work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet
the terminals of the intake air tem-
the standard Replace the
perature sensor (intake manifold)
Inspect the value: Go to sensor.
<Tester connections>
intake air tem- YES. Perform "After-
intake air temperature sensor
3 perature sen- Go to step 4. inspection
(intake manifold)
sor (intake The measure- work" of
THG – E2
manifold) unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k
dard value: Go
50 C {122 F}: 2.435 – 2.41k
to NO.
Measure the resistance between
The measure-
the terminals of the engine ECU
ments meet
(signal check harness) and Repair or
Inspect for the standard
ground replace the
short-circuit of value: Go to
<Tester connections> harness.
the intake air YES.
Engine ECU Perform "After-
4 temperature Go to step 5.
(signal check harness) inspection
sensor (intake The measure-
THIA (E63) – Ground work" of
manifold) har- ments do not
E2 (E76) – Ground INFORMA-
ness meet the stan-
<Standard values> TION section.
dard value: Go
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–235
Intake air temperature sensor (intake manifold)
DTC: P0097
- out of range (Out of range low)
Inspection procedure
Intake air temperature sensor (intake manifold)
DTC: P0098
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance of the
ments meet
engine ECU (signal check har- Repair or
Inspect dis- the standard
ness) terminal. replace the
connection of value: Go to
<Tester connections> harness.
the intake air YES.
Engine ECU Perform "After-
5 temperature Go to step 6.
(signal check harness) inspection
sensor (intake The measure-
THIA (E63) – E2 (E76) work" of
manifold) har- ments do not
<Standard values> INFORMA-
ness meet the stan-
20 C {68 F}: 7.336 – 5.794 k TION section.
dard value: Go
50 C {122 F}: 2.435 – 2.41 k
to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the intake air temper-
the standard
ature sensor (intake manifold)
value: Go to
vehicle side connector.
Inspect the YES.
<Tester connections> Replace the
6 sensor power Go to step 7.
Engine ECU engine ECU.
supply The measure-
(signal check harness)
ments do not
THIA (E63) – E2 (E76)
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
DTC (P0097
Replace the Procedure
or P0098) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0097 or Perform "After- Perform "After-
Go to YES.
7 DTC detected P0098) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–236 ENGINE (J05E)/TROUBLESHOOTING
DTC: P00AF
EN01H02127030602016037
P00AF: Controller error (VNT actuator CPU malfunction)
INFORMATION
LEA
POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block
Target position Over current Position sensor
information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)
P/S (GND)
SHTS021270300198
1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
Item Details (Reference)
1. ROM failure ROM readout data differ from previous data.
2. RAM failure RAM write data and read data do not match.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
ENGINE (J05E)/TROUBLESHOOTING 2–237
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• CPU failure inside VNT controller
2–238 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P00AF
1 Check the DTC detected (Engine ECU) 1
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select 3. Select [Engine] and check if P00AF (for example, U010C) has
Engine been detected in [Fault Information].
SHTS021270300199
Has a DTC other than P00AF been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 3.
DTC.
After the repair, go to step 2.
2 Check the DTC detected (Engine ECU) 2
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if P00AF has been detected in [Fault
Information].
Select
Engine
SHTS021270300200
Has DTC P00AF been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–239
3 Check the operation of the VNT controller [HINO-DX]
1. Set the starter key to the "ON" position.
2. Erase the trouble history using HINO-DX.
Select 3. Set the starter key to the "OFF" position.
Engine
4. Set the starter key to the "ON" position again.
5. Select [Engine] and check if P00AF has been detected in [Fault
Information].
HINT
SHTS021270300201 Turning the starter key "LOCK" and "ON" verifies the wiping oper-
ation of the VNT actuator (DC motor).
Measurement conditions
Starter key: LOCK ON
Has DTC P00AF been detected?
YES NO
Replace the VNT controller. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–240 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P00AF
Controller error
DTC: P00AF Inspection procedure
(VNT actuator CPU malfunction)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P00AF Go to diagno-
(U010C) has sis procedure
Check the Check if any DTC other than been detected. of a related
1 DTC detected P00AF (for example U010C) has Go to YES. DTC. Go to step 2.
(ECU) 1 been detected in [Engine]. Go to step 2
No DTC has after replace-
been detected. ment.
Go to NO.
DTC P00AF
Procedure
has been
completed.
detected: Go
Check the Perform "After-
Check if P00AF has been to YES.
2 DTC detected Go to step 3. inspection
detected in [Engine].
(ECU) 2 work" of
No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
1. Erase the trouble history and
set the starter key to the "OFF"
DTC P00AF
position and set the starter key Replace the Procedure
has been
Check the to the "ON" position again. VNT controller. completed.
detected: Go
operation of 2. Check if P00AF has been Perform "After- Perform "After-
to YES.
3 the VNT con- detected in [Engine]. inspection inspection
troller [HINO- HINT work" of work" of
No DTC has
DX] Turning the starter key "LOCK" INFORMA- INFORMA-
been detected:
and "ON" verifies the wiping TION section. TION section.
Go to NO.
operation of the VNT actuator
(DC motor).
ENGINE (J05E)/TROUBLESHOOTING 2–241
DTC: P0101
EN01H02127030602016038
P0101: Air flow sensor - rationality
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300202
1. Technical description
• The air flow sensor mounted on the air cleaner constantly measures the intake air quantity.
<Description of malfunction>
• Air flow sensor value cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Engine speed is between 700 r/min and 980 r/min.
• Engine speed variation is 234.4 r/min/sec or less.
• Fuel injection rate is between 0 mm3/st. cyl. sec and 35 mm3/st. cyl.
• Fuel injection rate variation is 78.1 mm3/st. cyl sec. or less.
• Engine coolant temperature is 55 C {131 F} or less.
• EGR valve opening is 0% or less (EGR-cut status)
• Exhaust brake is not actuated.
(2) Judgement criteria
• Theoretical air quantity calculated from boost pressure and atmospheric pressure and actual air quantity are
compared for at least 10 seconds, and the ratio of theoretical air quantity to actual air quantity is at least 1.12
or no greater than 0.85. And:
• Difference between DCY value prior to above result and current DCY value is 0.10 or less; and
• The condition "(Average boost pressure minus average atmospheric pressure) was ≥18 kPa" when the starter
key turned off and engine was stopped after previous DCY is not continued for more than 3 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
2–242 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• EGR valve is fully closed.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
• EGR valve malfunction
• Diesel throttle valve malfunction
• Intercooler failure (due to dirt, clogging, etc.)
• Engine ECU sensor power supply (air flow sensor dedicated 12 V power supply) failure or internal circuit failure
ENGINE (J05E)/TROUBLESHOOTING 2–243
INSPECTION PROCEDURE: P0101
1 Inspect the air cleaner element
1. Check the air cleaner element is dirty, clogged or damaged.
2. Make sure the element is a Hino genuine part.
Was any failure found?
YES NO
Clean or replace the air cleaner element. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Check the intake system
1. Check the intake hose and verify that there are no disconnections,
clogging, punctures, or cracks.
2. Check the breather hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.
3. Check the intercooler hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.
Was any failure found?
YES NO
Repair or replace the intake system hoses. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–244 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the air flow sensor
1. Check the installation of the air flow sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the air flow sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If dirt, clogging or damage was found,
replace the air flow sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect for short-circuits in wire harness of air flow sensor
1. Set the starter key to the "LOCK" position.
C D
E12 2. Disconnect the air flow sensor connector.
3. Connect the signal check harness to the engine ECU vehicle side
E74 E78 harness. (Do not connect harness to the ECU.)
4. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) terminals and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300203
Engine ECU (sig-
nal check har-
ness)
VAF (E12) –
Starter key: LOCK
Ground
VG (E74) – Ground
EVG (E78) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–245
5 Inspect for disconnection in wire harness of air flow sensor
1. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) terminal and the air flow sen-
C sor vehicle side connector terminal.
E12
Measurement Tester
Standard values
conditions connections
+B E29 Engine ECU (sig-
D
FC nal check har-
ness) – air flow
sensor vehicle
E74 E78
Starter key: LOCK 1 or less
side connector
VAF (E12) – +B
VG (E74) – FC
EVG (E78) – E29
SHTS021270300204
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Replace the air flow sensor.
1. Set the starter key to the "LOCK" position.
2. Replace the air flow sensor with a new one.
3. Start the engine.
Select
Engine
4. After thirty seconds, stop the engine and set the starter key to the
"LOCK" position.
5. Set the starter key to the "ON" position.
6. Select [Engine] and check if P0101 has been detected in [Fault
SHTS021270300205
Information].
Has DTC P0101 been detected?
YES NO
Go to step 7. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–246 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect the EGR valve
1. Check the EGR valve for damage due to foreign substances.
2. Check if there is soot obstructing the exhaust gas passageway
inlet or outlet.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 7.
valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–247
8 Check the response delay of the EGR valve
1. Set the starter key to the "ON" position.
(1)
2. Check the time lag (following characteristics) of the target EGR
valve opening and actual EGR valve opening.
(2)
! CAUTION
Perform the inspection while the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Select [Start].
(3)
(4) Select [EGR opening UP]:
• Check each step from 0% – 90% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
(4) (5)
(5) Select [EGR opening DOWN]:
• Check each step from 90% – 0% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
HINT
In EGR openings from 0% – 90%, 1 step corresponds to a 10%
SHTS021270300206 change.
Standard values
The response delay should be less than 5 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 9. Replace the EGR valve.
Perform "After-inspection work" of INFOR-
MATION section.
2–248 ENGINE (J05E)/TROUBLESHOOTING
9 Inspect the diesel throttle valve
1. Stop the engine.
2. Check the operating status of the diesel throttle valve (for incorrect
opening or sticky valve).
Was any failure found?
YES NO
Replace the diesel throttle valve. Go to step 10.
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the intercooler
1. Check if there is an obstruction due to clogging inside the inter-
cooler.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 11.
intercooler.
Replace the intercooler if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–249
11 Check the DTC detected
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if P0101 has been detected in [Fault
Information].
SHTS021270300207
Has DTC P0101 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–250 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0101
DTC: P0101 Air flow sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Clean or
replace the air
Failure found:
cleaner ele-
1. Check the air cleaner element Go to YES.
Inspect the air ment.
is dirty, clogged or damaged.
1 cleaner ele- Perform "After- Go to step 2.
2. Make sure the element is a No failure
ment inspection
Hino genuine part. found: Go to
work" of
NO.
INFORMA-
TION section.
1. Check the intake hose and ver-
ify that there are no disconnec-
tions, clogging, punctures, or Repair or
cracks. replace the
Failure found:
intake system
2. Check the breather hose and Go to YES.
hoses.
Check the verify that there are no discon-
2 Perform "After- Go to step 3.
intake system nections, clogging, punctures, No failure
inspection
or cracks. found: Go to
work" of
3. Check the intercooler hose and NO.
INFORMA-
verify that there are no discon- TION section.
nections, clogging, punctures,
or cracks.
Clean the
sensing unit
and install it
properly.
1. Check the installation of the air Failure found: If dirt, clog-
flow sensor. Go to YES. ging or dam-
Inspect the air 2. Make sure there is no dirt, age was
3 Go to step 4.
flow sensor damage or clogging in the No failure found, replace
sensing unit of the air flow sen- found: Go to the sensor.
sor. NO. Perform "After-
inspection
work" of
INFORMA-
TION section.
Connect the signal check harness
to the engine ECU vehicle side The measure-
harness. (Do not connect harness ments meet
Repair or
to the ECU.) the standard
replace the
Inspect for Measure the resistance between value: Go to
harness.
short-circuits the engine ECU (signal check YES.
Perform "After-
4 in wire har- harness) terminals and ground. Go to step 5.
inspection
ness of air flow <Tester connections> The measure-
work" of
sensor VAF (E12) – Ground ments do not
INFORMA-
VG (E74) – Ground meet the stan-
TION section.
EVG (E78) – Ground dard value: Go
<Standard values> to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–251
DTC: P0101 Air flow sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Measure the resistance between The measure-
the engine ECU (signal check ments meet
Repair or
harness) terminal and the air flow the standard
replace the
Inspect for dis- sensor vehicle side connector ter- value: Go to
harness.
connection in minal. YES.
Perform "After-
5 wire harness <Tester connections> Go to step 6.
inspection
of air flow sen- VAF (E12) – +B The measure-
work" of
sor VG (E74) – FC ments do not
INFORMA-
EVG (E78) – E29 meet the stan-
TION section.
<Standard values> dard value: Go
1 or less to NO.
1. Replace the air flow sensor
with a new one. DTC P0101
2. Start the engine. Procedure
has been
completed.
3. After thirty seconds, stop the detected: Go
Replace the Perform "After-
engine and set the starter key to YES.
6 air flow sen- Go to step 7. inspection
sor [HINO-DX] to the "LOCK" position. work" of
4. Set the starter key to the "ON" No DTC has
INFORMA-
position. been detected:
TION section.
Go to NO.
5. Check if P0101 has been
detected in [Engine].
Remove for-
eign matter
and clean.
1. Check that there are no foreign Failure found:
If damaged,
objects caught in the EGR Go to YES.
replace the
Inspect the valve.
7 EGR valve. Go to step 8.
EGR valve 2. Inspect the exhaust gas inlet No failure
Perform "After-
and outlet passage for soot found: Go to
inspection
clogging. NO.
work" of
INFORMA-
TION section.
2–252 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0101 Air flow sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Check the time lag (following
characteristics) of the target
EGR valve opening and actual
EGR valve opening.
! CAUTION
Perform the inspection while
the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check]. The measure-
(3) Select [Start]. ments meet
(4) Select [EGR opening UP]: the standard Replace the
• Check each step from 90% – value: Go to EGR valve.
Check the
0% of the time lag (following YES. Perform "After-
response
8 characteristics) of the target Go to step 9. inspection
delay of the
EGR valve opening and actual The measure- work" of
EGR valve
EGR valve opening. ments do not INFORMA-
(5) Select [EGR opening DOWN]: meet the stan- TION section.
dard value: Go
• Check each step from 90% –
to NO.
0% of the time lag (following
characteristics) of the target
EGR valve opening and actual
EGR valve opening.
HINT
In EGR openings from 0% –
90%, 1 step corresponds to a
10% change.
<Standard values>
The response delay should be
less than 5 seconds.
Replace the
Failure found: intake throttle
Go to YES. valve.
Inspect the Check the operating status of the
Perform "After-
9 intake throttle diesel throttle valve (for incorrect Go to step 10.
No failure inspection
valve opening or sticky valve).
found: Go to work" of
NO. INFORMA-
TION section.
Remove for-
eign sub-
stances and
clean the inter-
Failure found: cooler.
Check if there is an obstruction Go to YES. Replace the
Inspect the
10 due to clogging inside the inter- intercooler if it Go to step 11.
intercooler
cooler. Failure found: is damaged.
Go to YES. Perform "After-
inspection
work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–253
DTC: P0101 Air flow sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC P0101
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
11 DTC detected inspection inspection
F} or more), and check if P0101
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–254 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0104
EN01H02127030602016039
P0104: Air flow sensor - out of range
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300208
1. Technical description
• The air flow sensor installed to the air cleaner consistently measures an intake air volume.
<Description of malfunction>
• The air flow sensor value cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the output of the air flow sensor is less than 0.85 kHz (-5.5 kg/h) remains for 2 seconds or
more, or the condition that the output of the air flow sensor is greater than 9.8 kHz (1632 kg/h) remains for 2
seconds or more.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
ENGINE (J05E)/TROUBLESHOOTING 2–255
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Sensor disconnected from the measured part or sensing unit malfunctioning (due to dirt, clogging, damage, etc.
• Engine ECU sensor power supply (air flow sensor dedicated 12 V power supply) malfunction or internal circuit mal-
function
• Sensor harness disconnection, short-circuit
• Poor connector contact or faulty connector fit
• Sensor harness high frequency noise
2–256 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0104
1 Check the DTC detected (Engine ECU) 1
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if P0104 (for example, P0642, P0643,
P0652, P0653) has been detected in [Fault Information].
SHTS021270300209
Has a DTC (for example, P0642, P0643, P0652, P0653) other than P0104 been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
2 Inspect the air flow sensor connector
1. Check the connection of the air flow sensor connector (looseness
and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–257
3 Inspect the air flow sensor
1. Check the installation of the air flow sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the air flow sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If damaged, replace the air flow sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect for short-circuit of the air flow sensor harness
1. Set the starter key to the "LOCK" position.
C D
E12 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
E74 E78 3. Disconnect the air flow sensor connector.
4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300210
Engine ECU (sig-
nal check har-
ness)
VG (E74) – Ground
Starter key: LOCK
EVG (E78) –
Ground
VAF (E12) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–258 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect disconnection of the air flow sensor harness
1. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and air flow
C sensor vehicle side connector.
E12
Measurement Tester
Standard values
conditions connections
+B E2G Engine ECU (sig-
D
FC nal check har-
ness) – Air flow
sensor vehicle
E74 E78
Starter key: LOCK 1 or less
side connector
VG (E74) – FC
EVG (E78) – E2G
VAF (E12) – +B
SHTS021270300211
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–259
6 Inspect the air flow sensor power supply
1. Connect the signal check harness to the engine ECU.
+B E2G
2. Set the starter key to the "ON" position.
3. Use the electrical tester to measure the voltage between the termi-
nals of the air flow sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Air flow sensor
vehicle side con-
Starter key: ON 10 – 16 V
SHTS021270300212 nector
+B – E2G
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
2–260 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect the air flow sensor signal
1. Set the starter key to the "LOCK" position.
E74 E78
D 2. Connect the air flow sensor connector.
3. Start the engine.
4. Use the oscilloscope to measure the signal voltage between the
terminals in the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
SHTS021270300213 Engine ECU (sig-
After engine warm nal check har-
up, with engine ness) 5 – 6 kHz
idling AFSI (E74) –
AGD6 (E78)
Do the measurements meet the standard value?
YES NO
Go to step 8. Replace the air flow sensor.
Perform "After-inspection work" of INFOR-
MATION section.
8 Check the DTC detected (Engine ECU) 2
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if P0104 has been detected in [Fault
Information].
SHTS021270300214
Has DTC P0104 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–261
CHECKLIST: P0104
DTC: P0104 Air flow sensor - out of range Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0104
(P0642,
P0643. P0652,
Check the Check if any DTC other than Go to diagno-
P0653) are
DTC detected P0104 (for example, P0642, sis procedure
1 detected: Go Go to step 2.
(Engine ECU) P0643, P0652, P0653) has been of a related
to YES.
1 detected in [Engine]. DTC.
Are not
detected: Go
to NO.
Connect
securely and
Failure found:
repair if
Go to YES.
Inspect the air Check the connection of the air needed.
2 flow sensor flow sensor connector (loose- Perform "After- Go to step 3.
No failure
connector ness and poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit,
and install it
1. Check the installation of the air Failure found: properly. If
flow sensor. Go to YES. damaged,
Inspect the air 2. Make sure there is no dirt, replace the air
3 Go to step 4
flow sensor damage or clogging in the No failure flow sensor.
sensing unit of the air flow sen- found: Go to Perform "After-
sor. NO. inspection
work" of
INFORMA-
TION section.
Connect the signal check harness
to engine ECU and measure the The measure-
resistance between the engine ments meet
Repair or
ECU (signal check harness) ter- the standard
replace the
Inspect for minals and ground. value: Go to
harness.
short-circuit of <Tester connections> YES.
Perform "After-
4 the air flow Engine ECU Go to step 5.
inspection
sensor har- (signal check harness) The measure-
work" of
ness VG (E74) – Ground ments do not
INFORMA-
EVG (E78) – Ground meet the stan-
TION section.
VAF (E12) – Ground dard value: Go
<Standard values> to NO.
2–262 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0104 Air flow sensor - out of range Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Measure the resistance between
the engine ECU (signal check The measure-
harness) and the air flow sensor ments meet
Repair or
vehicle side connector terminals. the standard
replace the
Inspect dis- <Tester connections> value: Go to
harness.
connection of Engine ECU (signal check har- YES.
Perform "After-
5 the air flow ness – Air flow sensor vehicle Go to step 6.
inspection
sensor har- side connector The measure-
work" of
ness VG (E74) – FC ments do not
INFORMA-
EVG (E78) – E2G meet the stan-
TION section.
VAF (E12) – +B dard value: Go
<Standard values> to NO.
1 or less
The measure-
ments meet
Measure the voltage of the air
the standard Replace the
flow sensor vehicle side connec-
value: Go to engine ECU.
tor terminals.
Inspect the air YES. Perform "After-
<Tester connections>
6 flow sensor Go to step 7. inspection
Air flow vehicle side connector
power supply The measure- work" of
+B – E2G
ments do not INFORMA-
<Standard values>
meet the stan- TION section.
10 – 16 V
dard value: Go
to NO.
Use an oscilloscope to measure
the signal voltage between the The measure-
terminals in the engine ECU (sig- ments meet
nal check harness). the standard Replace the
<Measurement conditions> value: Go to sensor.
Inspect the air After engine warm up, with engine YES. Perform "After-
7 flow sensor idling Go to step 8. inspection
signal <Tester connections> The measure- work" of
Engine ECU ments do not INFORMA-
(signal check harness) meet the stan- TION section.
AFSI (E74) – AGD6 (E78) dard value: Go
<Standard values> to NO.
5 – 6 kHz
DTC P0104
Replace the Procedure
has been
1. Warm up the engine engine ECU. completed.
Check the detected: Go
(engine coolant temperature: Perform "After- Perform "After-
DTC detected to YES.
8 80 C {176 F} or more) inspection inspection
(Engine ECU)
2. Check if P0104 had been work" of work" of
2 No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–263
DTC: P0106
EN01H02127030602016040
P0106: Boost pressure sensor - rationality
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
SHTS021270300215
1. Technical description
• The boost pressure sensor mounted on the diesel throttle outlet constantly measures the boost pressure.
<Description of malfunction>
• Boost pressure cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Engine speed is between 700 r/min and 980 r/min.
• Engine speed variation is 234.4 r/min/sec or less.
• Fuel injection rate is between 0 mm3/st. cyl and 35 mm3/st. cyl.
• Fuel injection rate variation is 78.1 mm3/st. cyl or less.
• Engine coolant temperature is 55 C {131 F} or less.
• EGR valve opening is 0% or less (EGR-cut status)
• Exhaust brake is not actuated
(2) Judgement criteria
• Theoretical air quantity calculated from boost pressure and atmospheric pressure and actual air quantity are
compared for at least 10 seconds, and the ratio of theoretical air quantity to actual air quantity is at least 1.12
or no greater than 0.85.
• And: Difference between DCY value prior to above result and current DCY value is 0.10 or less; and
• When prior DCY starter key is turned "LOCK" and engine is stopped, (Average boost pressure – average
atmospheric pressure) is ≥ 18 kPa, and this condition continues for at least 3 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
2–264 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• EGR valve is fully closed.
• DPR filter auto regeneration control is stopped.
<Symptoms on the vehicle due to malfunction>
• Engine output is insufficient.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
• Abnormal sensor resistance (stuck sensor)
• Engine ECU sensor power supply failure, internal circuit failure
ENGINE (J05E)/TROUBLESHOOTING 2–265
INSPECTION PROCEDURE: P0106
1 Inspect the boost pressure sensor connector
1. Check the connection of the boost pressure sensor connector
(looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the boost pressure sensor.
3. Make sure there is no dirt, damage or clogging in the pipes or
hoses unit of the boost pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If dirt, clogging or damage was found,
replace the boost pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–266 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect for short-circuits in wire harness of boost pressure sensor
1. Set the starter key to the "LOCK" position.
C E67 D
E77 2. Disconnect the boost pressure sensor connector.
E33
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)
4. Use the electrical tester to measure the resistance between each
terminal in the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300216
Engine ECU (sig-
nal check har-
ness)
VC2 (E33) –
Starter key: LOCK
Ground
PIM (E67) –
Ground
E4 (E77) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 4. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–267
4 Inspect for disconnection in wire harness of boost pressure sensor
1. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) and boost pressure sensor
C vehicle side connector terminals.
E33
PIM Measurement Tester
E
Standard values
VC conditions connections
D Engine ECU (sig-
E67
nal check har-
E77
ness) – boost
pressure sensor
Starter key: LOCK vehicle side con-
nector
VC2 (E33) – VC
PIM (E67) – PIM
E4 (E77) – E
SHTS021270300217
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–268 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect the boost pressure sensor power supply
1. Connect the engine ECU vehicle side harness to the engine ECU.
E
2. Set the starter key to the "ON" position.
VC
3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300218 side connector
VC – E
Do the measurements meet the standard value?
YES NO
Replace the boost pressure sensor. Replace the engine ECU.
Go to step 6 after replacement. Perform "After-inspection work" of INFOR-
MATION section.
6 Check the DTC detected (Engine ECU)
1. Warm up the engine (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0106 has been detected in [Fault
Information].
SHTS021270300219
Has DTC P0106 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–269
CHECKLIST: P0106
DTC: P0106 Boost pressure sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the boost needed.
boost pressure
1 pressure sensor connector. Perform "After- Go to step 2.
sensor con- No failure
(looseness and poor contact) inspection
nector. found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
1. Check the installation of the sensing unit
boost pressure sensor. and install it
2. Make sure there is no dirt, Failure found: properly.
damage or clogging in the Go to YES. If damaged,
Inspect the
sensing unit of the boost pres- replace the
2 boost pressure Go to step 3.
sure sensor. No failure sensor.
sensor
3. Make sure there is no dirt, found: Go to Perform "After-
damage or clogging in the NO. inspection
pipes or hoses unit of the boost work" of
pressure sensor. INFORMA-
TION section.
Connect the signal check harness
to engine ECU and measure the The measure-
resistance between the engine ments meet
Repair or
ECU (signal check harness) ter- the standard
Inspect for replace the
minals and ground. value: Go to
short-circuits harness.
<Tester connections> YES.
in wire har- Perform "After-
3 Engine ECU Go to step 4.
ness of boost inspection
(signal check harness) The measure-
pressure sen- work" of
VC2 (E33) – Ground ments do not
sor INFORMA-
PIM (E67) – Ground meet the stan-
TION section.
E4 (E77) – Ground dard value: Go
<Standard values> to NO.
Measure the resistance between
the engine ECU (signal check
The measure-
harness) and the boost pressure
ments meet
sensor vehicle side connector ter- Repair or
the standard
minals. replace the
Inspect for dis- value: Go to
<Tester connections> harness.
connection in YES.
Engine ECU (signal check har- Perform "After-
4 wire harness Go to step 5.
ness) – Boost pressure sensor inspection
of boost pres- The measure-
vehicle side connector work" of
sure sensor ments do not
VC2 (E33) – VC INFORMA-
meet the stan-
PIM (E67) – PIM TION section.
dard value: Go
E4 (E77) – E
to NO.
<Standard values>
1
2–270 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0106 Boost pressure sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
1. Connect the engine ECU vehi-
ments meet
cle side harness to engine
the standard Replace the
ECU.
value: Go to Replace the engine ECU.
Inspect the 2. Measure the voltage of the YES. sensor. Perform "After-
boost pressure boost pressure sensor termi-
5 Go to step 6 inspection
sensor power nals. The measure- after replace- work" of
supply <Tester connections> ments do not ment. INFORMA-
VC – E meet the stan- TION section.
<Standard values> dard value: Go
4.75 – 5.25 V to NO.
Replace the Procedure
DTC P0106
1. Warm up the engine (engine engine ECU. completed.
has been
Check the coolant temperature: 80 C Perform "After- Perform "After-
detected: Go
6 DTC detected {176 F} or more). inspection inspection
to YES.
(Engine ECU) 2. Check if P0106 has been work" of work" of
detected in [Engine]. INFORMA- INFORMA-
TION section. TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–271
DTC: P0108
EN01H02127030602016041
P0108: Boost pressure sensor - out of range (Out of range high)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
SHTS021270300220
1. Technical description
• The boost pressure sensor installed at the outlet of the Diesel throttle (intake throttle valve) consistently measures
boost pressure.
<Description of malfunction>
• The boost pressure cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the boost pressure sensor remains greater than 3.67 V (327.4 kPa) for 3 seconds or longer.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–272 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Short-circuit in the sensor
ENGINE (J05E)/TROUBLESHOOTING 2–273
INSPECTION PROCEDURE: P0108
1 Inspect the boost pressure sensor connector
1. Check the connection of the boost pressure sensor connector
(looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the boost pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–274 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect for short-circuit of the boost pressure sensor harness
1. Set the starter key to the "LOCK" position.
C D E67 2. Disconnect the boost pressure connector.
E33 E77
3. Connect the signal check harness to the engine ECU vehicle side
connector. (Do not connect the harness to the ECU.)
4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300221
Engine ECU (sig-
nal check har-
ness)
VC2 (E33) –
Starter key: LOCK
Ground
PIM (E67) –
Ground
E4 (E77) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 4. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–275
4 Inspect disconnection of the boost pressure sensor harness
1. Connect the boost pressure sensor connector.
C 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and the boost pressure sensor vehi-
E33 E PIM cle side connector (signal check harness).
VC
Measurement Tester
D Standard values
conditions connections
Engine ECU (sig-
nal check har-
E77
E67 ness) – Boost
pressure sensor
Starter key: LOCK vehicle side con- 1
nector
VC2 (E33) – VC
PIM (E67) – PIM
E4 (E77) – E
SHTS021270300222
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect the boost pressure sensor power supply
1. Connect the vehicle side harness connect to the engine ECU.
E
2. Set the starter key to the "ON" position.
VC
3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300223 side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 6. Replace the engine ECU.
2–276 ENGINE (J05E)/TROUBLESHOOTING
6 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0108 has been detected in [Fault
Information].
SHTS021270300224
Has DTC P0108 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–277
CHECKLIST: P0108
Boost pressure sensor - out of range
DTC: P0108 Inspection procedure
(Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the boost needed.
boost pressure
1 pressure sensor connector. Perform "After- Go to step 2.
sensor con- No failure
(looseness and poor contact) inspection
nector found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
boost pressure sensor connec-
Go to YES. If damaged,
Inspect the tor.
replace the
2 boost pressure 2. Make sure there is no dirt, Go to step 3.
No failure sensor.
sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the boost pres- NO. inspection
sure sensor. work" of
INFORMA-
TION section.
1. Connect the signal check har-
ness to the engine ECU. (Do
not connect harness to the
The measure-
ECU.)
ments meet
2. Measure the resistance Repair or
the standard
between the terminals of the replace the
Inspect for value: Go to
engine ECU (signal check har- harness.
short-circuit of YES.
ness) and ground. Perform "After-
3 the boost pres- Go to step 4.
<Tester connections> inspection
sure sensor The measure-
Engine ECU work" of
harness ments do not
(signal check harness) INFORMA-
meet the stan-
VC2 (E33) – Ground TION section.
dard value: Go
PIM (E67) – Ground to NO.
E4 (E77) – Ground
<Standard values>
2–278 ENGINE (J05E)/TROUBLESHOOTING
Boost pressure sensor - out of range
DTC: P0108 Inspection procedure
(Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Connect the boost pressure
sensor connector.
2. Measure the resistance The measure-
between the terminals of the ments meet
Repair or
engine ECU (signal check har- the standard
replace the
Inspect dis- ness) and the boost pressure value: Go to
harness.
connection of sensor vehicle side connector. YES.
Perform "After-
4 the boost pres- <Tester connections> Go to step 8.
inspection
sure sensor Engine ECU (signal check har- The measure-
work" of
harness ness) – Boost pressure sensor ments do not
INFORMA-
vehicle side connector meet the stan-
TION section.
VC2 (E33) – VC dard value: Go
PIM (E67) – PIM to NO.
<Standard values>
1
The measure-
Measure the voltage between the ments meet
terminals of the boost pressure the standard
sensor vehicle side connector. value: Go to
Inspect the
<Tester connections> YES.
boost pressure Replace the
5 Boost pressure sensor vehicle Go to step 6.
sensor power engine ECU.
side connector The measure-
supply
VC – E ments do not
<Standard values> meet the stan-
4.75 – 5.25 V dard value: Go
to NO.
DTC P0108
Replace the Procedure
has been
1. Perform engine warm up. engine ECU. completed.
detected: Go
Check the (engine coolant temperature: Perform "After- Perform "After-
to YES.
6 DTC detected 80 C {176 F} or more) inspection inspection
(Engine ECU) 2. Check if P0108 has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–279
DTC: P0112 and P0113
EN01H02127030602016042
P0112: Intake air temperature sensor (air flow sensor built-in) - out of range
(Out of range low)
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300225
1. Technical description
• The intake air temperature sensor built in the air flow sensor consistently measures intake air temperature.
<Description of malfunction>
• The intake air temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the intake air temperature sensor (built in air flow sensor) remains less than 0.09 V (90 C {194 F})
for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–280 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact
ENGINE (J05E)/TROUBLESHOOTING 2–281
P0113: Intake air temperature sensor (air flow sensor built-in) - out of range
(Out of range high)
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300226
1. Technical description
• The intake air temperature sensor built in the air flow sensor consistently measures intake air temperature.
<Description of malfunction>
• The intake air temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5seconds or more.
(2) Judgement criteria
• Output of the intake air temperature sensor (built in air flow sensor) remains less than 4.17 V (-42 C {-43.6
F}) for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–282 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact
• Short-circuit in the sensor
ENGINE (J05E)/TROUBLESHOOTING 2–283
INSPECTION PROCEDURE: P0112 and P0113
1 Inspect the intake air temperature sensor connector
1. Check the connection of the intake air temperature sensor (air flow
sensor) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the intake air temperature sensor
1. Check the installation of the intake air temperature sensor (air flow
sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the intake air tempera-
ture sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–284 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the intake air temperature sensor unit
1. Set the starter key to the "LOCK" position.
E2 THA
2. Disconnect the connector of intake air temperature sensor (air flow
sensor built-in).
3. Measure the resistance between the terminals of the intake air
temperature sensor (built-in air flow sensor).
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
Intake air tempera-
SHTS021270300227 2.69 – 2.21 k
Starter key: LOCK ture sensor
60 C {140 F}:
THA – E2
0.667 – 0.493 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the intake air temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–285
4 Inspect the intake air temperature sensor power supply
1. Set the starter key to the "ON" position.
THA E2
2. Measure the voltage between the terminals of the intake air tem-
perature sensor (built-in air flow sensor) (engine sub harness
side).
Measurement Tester
Standard values
conditions connections
Intake air tempera-
ture sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
SHTS021270300228 THA – E2
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
5 Inspect for short-circuit in wire harness of intake air temperature sensor
1. Set the starter key to the "LOCK" position.
E47
D E58 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between each
terminal in the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300229 nal check har-
ness)
Starter key: LOCK
THA (E47) –
Ground
E5 (E58) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–286 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect for disconnection in wire harness of intake air temperature sensor
1. Connect the intake air temperature sensor connector.
E47
D E58 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.69 – 2.21 k
Starter key: LOCK ness)
60 C {140 F}:
THA (E47) –
0.667 – 0.493 k
SHTS021270300230 E5 (E58)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
7 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0112 or P0113) has been
detected in [Fault Information].
SHTS021270300231
Has DTC (P0112 or P0113) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–287
CHECKLIST: P0112 and P0113
Intake air temperature sensor (air flow sensor
DTC: P0112
built-in) - out of range (Out of range low)
Inspection procedure
Intake air temperature sensor (air flow sensor
DTC: P0113
built-in) - out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Check the connection of the Go to YES.
needed.
intake air tem- intake air temperature sensor (air
1 Perform "After- Go to step 2.
perature sen- flow sensor) connector (loose- No failure
inspection
sor connector ness and poor contact). found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
intake air temperature sensor
Inspect the Go to YES. If damaged,
(air flow sensor).
intake air tem- replace the
2 2. Make sure there is no dirt, Go to step 3.
perature sen- No failure sensor.
sor damage or clogging in the found: Go to Perform "After-
sensing unit of the intake air NO. inspection
temperature sensor. work" of
INFORMA-
TION section.
The measure-
Measure the resistance between ments meet
the terminals of the intake air tem- the standard Replace the
perature sensor (air flow sensor value: Go to sensor.
Inspect the
built-in). YES. Perform "After-
intake air tem-
3 <Tester connections> Go to step 4. inspection
perature sen-
THA – E2 The measure- work" of
sor unit
<Standard values> ments do not INFORMA-
20 C {68 F}: 2.69 – 2.21 k meet the stan- TION section.
60 C {140 F}: 0.667 – 0.493 k dard value: Go
to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the intake air temper-
the standard
ature sensor vehicle side connec-
Inspect the value: Go to
tor.
intake air tem- YES.
<Tester connections>
4 perature sen- Go to step 7. Go to step 5.
Intake air temperature sensor
sor power The measure-
vehicle side connector
supply ments do not
THA – E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
2–288 ENGINE (J05E)/TROUBLESHOOTING
Intake air temperature sensor (air flow sensor
DTC: P0112
built-in) - out of range (Out of range low)
Inspection procedure
Intake air temperature sensor (air flow sensor
DTC: P0113
built-in) - out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check har-
The measure-
ness, and measure the resistance
ments meet
between the terminals of the Repair or
the standard
Inspect for engine ECU and ground. replace the
value: Go to
short-circuit in <Tester connections> harness.
YES.
wire harness Engine ECU Perform "After-
5 Go to step 6.
of intake air (signal check harness) inspection
The measure-
temperature THA (E47) – Ground work" of
ments do not
sensor E5 (E58) – Ground INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
to NO.
Connect the intake air tempera- The measure-
ture sensor connector, and mea- ments meet
Repair or
sure the resistance between the the standard
Inspect for dis- replace the
terminals of the engine ECU. value: Go to
connection in harness.
<Tester connections> YES.
wire harness Perform "After-
6 Engine ECU Go to step 7.
of intake air inspection
(signal check harness) The measure-
temperature work" of
THA (E47) – E5 (E58) ments do not
sensor INFORMA-
<Standard values> meet the stan-
TION section.
20 C {68 F}: 2.69 – 2.21 k dard value: Go
60 C {140 F}: 0.667 – 0.493 k to NO.
DTC (P0112
Replace the Procedure
or P0113) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0112 or Perform "After- Perform "After-
Go to YES.
7 DTC detected P0113) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–289
DTC: P0115
EN01H02127030602016043
P0115: Malfunction of coolant temperature sensor and intake air temperature sensor
INFORMATION
Coolant temperature
sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth Z5G (E) 10mA ZJQ (E5)
Coolant temperature
sensor 2
X3Q (SL)
XS1 (THW2) 10mA XDN (THWO)
Body earth ZKP (E22) 10mA ZD6 (E3)
SHTS021270300232
1. Technical description
• Two engine coolant temperature sensors are installed in thermostat case and constantly measure the engine cool-
ant temperature.
• Although some exhaust gas components operate after the engine coolant temperature has risen to some degree
(engine warm up), when an engine coolant temperature sensor reads a value lower than the actual temperature, it
means it is not working properly. Diagnosis is therefore required to detect if there is something wrong with the char-
acteristics of the engine coolant temperature sensor.
<Description of malfunction>
• Failure of both engine coolant temperature sensors is detected.
2. DTC set condition
(1) DTC detection condition
• Engine speed is at least 500 r/min or engine is stopped.
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• When it is deemed that both engine coolant temperature sensors are malfunctioning.
3. Reset condition
• Problem does not recur in the same driving cycle.
• Normal operation is restored when in subsequent driving cycles, readings are in the normal range within the above
detection conditions.
• Three driving cycles must be deemed normal for MIL to be OFF.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• EGR valve is fully closed.
<Symptoms on the vehicle due to malfunction>
• –
2–290 ENGINE (J05E)/TROUBLESHOOTING
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Abnormal resistance of the engine coolant temperature sensor.
• Engine ECU sensor power supply failure.
ENGINE (J05E)/TROUBLESHOOTING 2–291
INSPECTION PROCEDURE: P0115
1 Inspect the engine coolant temperature sensor 1 connector
1. Check the connection of the engine coolant temperature sensor 1
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine coolant temperature sensor 1
1. Check the installation of the engine coolant temperature sensor 1.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of engine coolant temperature sensor 1.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine coolant tem-
perature sensor 1.
Perform "After-inspection work" of INFOR-
MATION section.
2–292 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the engine coolant temperature sensor 1 unit
1. Set the starter key to the "LOCK" position.
E THW
2. Disconnect the engine coolant temperature sensor 1.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor 1.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300233 sor 1 80 C {176 F}:
THW – E 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the engine coolant temperature sen-
sor 1.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the engine coolant temperature sensor 1 power supply
1. Set the starter key to the "ON" position.
THW E
2. Use the electrical tester to measure the voltage between the termi-
nals of the engine coolant temperature sensor 1 vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Engine coolant
temperature sen-
Starter key: ON sor 1 vehicle side 4.5 – 5.5 V
SHTS021270300234 connector
THW – E
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
ENGINE (J05E)/TROUBLESHOOTING 2–293
5 Check for short-circuit in wire harness of engine coolant temperature sensor 1
1. Set the starter key to the "LOCK" position.
E66 D E58 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between each
terminal in the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300235 nal check har-
ness)
Starter key: LOCK
THW (E66) –
Ground
E5 (E58) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Check for disconnection in wire harness of engine coolant temperature sensor 1
1. Connect the engine coolant temperature sensor 1 connector.
E66 D E58 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW (E66) –
0.326 – 0.310 k
SHTS021270300236 E5 (E58)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–294 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect the engine coolant temperature sensor 2 connector
1. Check the connection of the engine coolant temperature sensor 2
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 8.
Perform "After-inspection work" of INFOR-
MATION section.
8 Inspect the engine coolant temperature sensor 2
1. Check the installation of the engine coolant temperature sensor 2.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine coolant temperature sensor 2.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 9.
If damaged, replace the engine coolant tem-
perature sensor 2.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–295
9 Inspect the engine coolant temperature sensor 2 unit
1. Set the starter key to the "LOCK" position.
E22 THW2
2. Disconnect the engine coolant temperature sensor 2 connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor 2.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300237 sor 2 80 C {176 F}:
THW2 – E22 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 10. Replace the engine coolant temperature sen-
sor 2.
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the engine coolant temperature sensor 2 power supply
1. Set the starter key to the "ON" position.
THW2 E22
2. Use the electrical tester to measure the voltage between the termi-
nals of the engine coolant temperature sensor 2.
Measurement Tester
Standard values
conditions connections
Engine coolant
temperature sen-
Starter key: ON sor 2 vehicle side 4.5 – 5.5 V
connector
SHTS021270300238 THW2 – E22
Do the measurements meet the standard value?
YES NO
Go to step 13. Go to step 11.
2–296 ENGINE (J05E)/TROUBLESHOOTING
11 Check for short-circuit in wire harness of engine coolant temperature sensor 2
1. Set the starter key to the "LOCK" position.
E57 D 2. Connect the signal check harness to the engine ECU vehicle side
E69
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between each
terminal in the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300239 nal check har-
ness)
Starter key: LOCK
THW2 (E69) –
Ground
E3 (E57) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 12. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
12 Check for disconnection in wire harness of engine coolant temperature sensor 2
1. Connect the engine coolant temperature sensor 2 connector.
E57 D E69
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW2 (E69) –
0.326 – 0.310 k
SHTS021270300240 E3 (E57)
Do the measurements meet the standard value?
YES NO
Go to step 13. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–297
13 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0115 has been detected in [Fault
Information].
SHTS021270300241
Has DTC P0115 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–298 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0115
Malfunction of coolant temperature sensor and
DTC: P0115 Inspection procedure
intake air temperature sensor
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
engine cool- needed.
engine coolant temperature sen-
1 ant tempera- Perform "After- Go to step 2.
sor 1 connector (looseness and No failure
ture sensor 1 inspection
poor contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
engine coolant temperature
Inspect the Go to YES. If damaged,
sensor 1.
engine cool- replace the
2 2. Make sure there is no dirt, Go to step 3.
ant tempera- No failure sensor.
ture sensor 1 damage or clogging in the found: Go to Perform "After-
sensing unit of engine coolant NO. inspection
temperature sensor 1. work" of
INFORMA-
TION section.
Disconnect the engine coolant The measure-
temperature sensor 1 and mea- ments meet
sure the resistance between the the standard Replace the
Inspect the terminals of the sensor. value: Go to sensor.
engine cool- <Tester connections> YES. Perform "After-
3 ant tempera- Engine coolant temperature sen- Go to step 4. inspection
ture sensor 1 sor 1 The measure- work" of
unit THW – E ments do not INFORMA-
<Standard values> meet the stan- TION section.
20 C {68 F}: 2.59 – 2.32 k dard value: Go
80 C {176 F}: 0.326 – 0.310 k to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the engine coolant
the standard
temperature sensor 1 vehicle side
Inspect the value: Go to
connector.
engine cool- YES.
<Tester connections>
4 ant tempera- Go to step 7. Go to step 5.
Engine coolant temperature sen-
ture sensor 1 The measure-
sor 1 vehicle side connector
power supply ments do not
THW – E
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–299
Malfunction of coolant temperature sensor and
DTC: P0115 Inspection procedure
intake air temperature sensor
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check harness
The measure-
and measure the resistance
ments meet
between each terminal in the Repair or
the standard
Check for engine ECU (signal check har- replace the
value: Go to
short-circuit in ness) and ground. harness.
YES.
wire harness <Tester connections> Perform "After-
5 Go to step 6.
of engine cool- Engine ECU inspection
The measure-
ant tempera- (signal check harness) work" of
ments do not
ture sensor THW (E66) – Ground INFORMA-
meet the stan-
E5 (E58) – Ground TION section.
dard value: Go
<Standard values>
to NO.
Connect the engine coolant tem-
The measure-
perature sensor 1 connector and
ments meet
measure the resistance between Repair or
the standard
Check for dis- the terminals of the engine ECU replace the
value: Go to
connection in (signal check harness). harness.
YES.
wire harness <Tester connections> Perform "After-
6 Go to step 7.
of engine cool- Engine ECU inspection
The measure-
ant tempera- (signal check harness) work" of
ments do not
ture sensor 1 THW (E66) – E5 (E58) INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
20 C {68 F}: 2.59 – 2.32 k
to NO.
80 C {176 F}: 0.326 – 0.310 k
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
engine cool- needed.
engine coolant temperature sen-
7 ant tempera- Perform "After- Go to step 8.
sor 2 connector (looseness and No failure
ture sensor 2 inspection
poor contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
engine coolant temperature
Inspect the Go to YES. If damaged,
sensor 2.
engine cool- replace the
8 2. Make sure there is no dirt, Go to step 9.
ant tempera- No failure sensor.
ture sensor 2 damage or clogging in the found: Go to Perform "After-
sensing unit of the engine cool- NO. inspection
ant temperature sensor 2. work" of
INFORMA-
TION section.
2–300 ENGINE (J05E)/TROUBLESHOOTING
Malfunction of coolant temperature sensor and
DTC: P0115 Inspection procedure
intake air temperature sensor
Check
Step Action Description Judgement Yes No
(Yes/No)
Disconnect the engine coolant
The measure-
temperature sensor 2 connector
ments meet
and measure the resistance
the standard Replace the
between the terminals of the sen-
value: Go to sensor.
Inspect the sor.
YES. Perform "After-
coolant tem- <Tester connections>
9 Go to step 10. inspection
perature sen- Engine coolant temperature sen-
The measure- work" of
sor 2 unit sor 2
ments do not INFORMA-
THW2 – E22
meet the stan- TION section.
<Standard values>
dard value: Go
20 C {68 F}: 2.59 – 2.32 k
to NO.
80 C {176 F}: 0.326 – 0.310 k
The measure-
Measure the voltage between the ments meet
terminals of the engine coolant the standard
Inspect the temperature sensor 2. value: Go to
engine cool- <Tester connections> YES.
10 ant tempera- Engine coolant temperature sen- Go to step 13. Go to step 11.
ture sensor 2 sor 2 vehicle side connector The measure-
power supply THW2 – E22 ments do not
<Standard values> meet the stan-
4.5 – 5.5 V dard value: Go
to NO.
Connect the signal check harness
The measure-
and measure the resistance
ments meet
between each terminal in the Repair or
the standard
Check for engine ECU (signal check har- replace the
value: Go to
short-circuit in ness) and ground. harness.
YES.
wire harness <Tester connections> Perform "After-
11 Go to step 12.
of engine cool- Engine ECU inspection
The measure-
ant tempera- (signal check harness) work" of
ments do not
ture sensor 2 THW2 (E69) – Ground INFORMA-
meet the stan-
E3 (E57) – Ground TION section.
dard value: Go
<Standard values>
to NO.
Connect the engine coolant tem-
The measure-
perature sensor 2 connector and
ments meet
measure the resistance between Repair or
the standard
Check for dis- the terminals of the engine ECU replace the
value: Go to
connection in (signal check harness). harness.
YES.
wire harness <Tester connections> Perform "After-
12 Go to step 13.
of engine cool- Engine ECU inspection
The measure-
ant tempera- (signal check harness) work" of
ments do not
ture sensor 2 THW2 (E69) – E3 (E57) INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
20 C {68 F}: 2.59 – 2.32 k
to NO.
80 C {176 F}: 0.326 – 0.310 k
ENGINE (J05E)/TROUBLESHOOTING 2–301
Malfunction of coolant temperature sensor and
DTC: P0115 Inspection procedure
intake air temperature sensor
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC P0115
Replace the Procedure
has been
engine ECU. completed.
Warm up the engine. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
13 DTC detected inspection inspection
F} or more) and check if P0115
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–302 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0117 and P0118
EN01H02127030602016044
P0117: Engine coolant temperature sensor 1 - out of range (Out of range low)
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300242
1. Technical description
• The engine coolant temperature sensor installed to the thermostat case consistently measures the engine coolant
temperature.
<Description of malfunction>
• The engine coolant temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.2 V (122 C {251.6 F}) or less for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
ENGINE (J05E)/TROUBLESHOOTING 2–303
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
Engine coolant temperature sensor:
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Abnormal resistance of the engine coolant temperature sensor
• Engine ECU sensor power supply failure or internal circuit failure
• Disconnection or short-circuit in sensor harness
• Irregular contact
2–304 ENGINE (J05E)/TROUBLESHOOTING
P0118: Engine coolant temperature sensor 1 - out of range (Out of range high)
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300243
1. Technical description
• The engine coolant temperature sensor installed to the thermostat case consistently measures the engine coolant
temperature.
<Description of malfunction>
• The engine coolant temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Intake air temperature is -20 C {-4 F} or higher.
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 4.77 V (-37 C {-34.6 F}) or greater for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
ENGINE (J05E)/TROUBLESHOOTING 2–305
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
Engine coolant temperature sensor:
• Short-circuit in the sensor
• Abnormal resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact
2–306 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0117 and P0118
1 Inspect the engine coolant temperature sensor connector
1. Check the connection of the engine coolant temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine coolant temperature sensor
1. Check the installation of the engine coolant temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine coolant temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine coolant tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–307
3 Inspect the engine coolant temperature sensor unit
1. Set the starter key to the "LOCK" position.
E THW
2. Disconnect the engine coolant temperature sensor connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300244 sor 80 C {176 F}:
THW – E 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the engine coolant temperature sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the actuation power supply wire harness of the engine coolant temperature sensor
1. Set the starter key to the "ON" position.
THW E
2. Use the electrical tester to measure the voltage between the termi-
nals of the engine coolant temperature sensor vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Engine coolant
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300245 connector
THW – E
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
2–308 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect for short-circuit of the engine coolant temperature sensor harness
1. Set the starter key to the "LOCK" position.
E66 D E58 2. Connect the signal check harness to the engine ECU. (Do not con-
nect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300246 nal check har-
ness)
Starter key: LOCK
THW (E66) –
Ground
E5 (E58) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect disconnection of the engine coolant temperature sensor harness
1. Connect the engine coolant temperature sensor connector.
E66 D E58 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW (E66) –
0.326 – 0.310 k
SHTS021270300247 E5 (E58)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–309
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0117 or P0118) has been
detected in [Fault Information].
SHTS021270300248
Has DTC (P0117 or P0118) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–310 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0117 and P0118
Engine coolant temperature sensor 1
DTC: P0117
- out of range (Out of range low)
Inspection procedure
Engine coolant temperature sensor 1
DTC: P0118
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
engine cool- needed.
engine coolant temperature sen-
1 ant tempera- Perform "After- Go to step 2.
sor connector (looseness and No failure
ture sensor inspection
poor contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
engine coolant temperature
Inspect the Go to YES. If damaged,
sensor.
engine cool- replace the
2 2. Make sure there is no dirt, Go to step 3.
ant tempera- No failure sensor.
ture sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the engine cool- NO. inspection
ant temperature sensor. work" of
INFORMA-
TION section.
Disconnect the engine coolant
The measure-
temperature sensor connector
ments meet
and measure the resistance
the standard Replace the
between the terminals of the sen-
Inspect the value: Go to sensor.
sor.
engine cool- YES. Perform "After-
<Tester connections>
3 ant tempera- Go to step 4. inspection
Engine coolant temperature sen-
ture sensor The measure- work" of
sor
unit ments do not INFORMA-
THW – E
meet the stan- TION section.
<Standard values>
dard value: Go
20 C {68 F}: 2.59 – 2.32 k
to NO.
80 C {176 F}: 0.326 – 0.310 k
The measure-
Measure the voltage between the
ments meet
Inspect the terminals of the engine coolant
the standard
actuation temperature sensor vehicle side
value: Go to
power supply connector.
YES.
wire harness <Tester connections>
4 Go to step 7. Go to step 5.
of the engine Engine coolant temperature sen-
The measure-
coolant tem- sor vehicle side connector
ments do not
perature sen- THW – E
meet the stan-
sor <Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–311
Engine coolant temperature sensor 1
DTC: P0117
- out of range (Out of range low)
Inspection procedure
Engine coolant temperature sensor 1
DTC: P0118
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Connect the signal check har-
ness to the engine ECU. (Do
not connect harness to the The measure-
ECU.) ments meet
Repair or
2. Measure the resistance the standard
Inspect for replace the
between the terminals of the value: Go to
short-circuit of harness.
engine ECU (signal check har- YES.
the engine Perform "After-
5 ness) and ground. Go to step 6.
coolant tem- inspection
<Tester connections> The measure-
perature sen- work" of
Engine ECU ments do not
sor harness INFORMA-
(signal check harness) meet the stan-
TION section.
THW (E66) – Ground dard value: Go
E5 (E58) – Ground to NO.
<Standard values>
Connect the engine coolant tem-
The measure-
perature sensor connector and
ments meet
measure the resistance between Repair or
the standard
Inspect dis- the terminals of the engine ECU replace the
value: Go to
connection of (signal check harness). harness.
YES.
the engine <Tester connections> Perform "After-
6 Go to step 7.
coolant tem- Engine ECU inspection
The measure-
perature sen- (signal check harness) work" of
ments do not
sor harness THW+(E66) – AGD5(E58) INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
20 C {68 F}: 2.59 – 2.32 k
to NO.
80 C {176 F}: 0.326 – 0.310 k
DTC (P0117
Replace the Procedure
or P0118) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0117 or Perform "After- Perform "After-
Go to YES.
7 DTC detected P0118) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–312 ENGINE (J05E)/TROUBLESHOOTING
DTC: P011A
EN01H02127030602016045
P011A: Engine coolant temperature sensor - rationality
INFORMATION
Coolant temperature
sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth Z5G (E) 10mA ZJQ (E5)
Coolant temperature
sensor 2
X3Q (SL)
XS1 (THW2) 10mA XDN (THWO)
Body earth ZKP (E22) 10mA ZD6 (E3)
SHTS021270300249
1. Technical description
• Two engine coolant temperature sensors are installed in thermostat case and constantly measure the engine cool-
ant temperature.
• Although some exhaust gas components operate after the engine coolant temperature has risen to some degree
(engine warm up), when an engine coolant temperature sensor reads a value lower than the actual temperature, it
means it is not working properly. Diagnosis is therefore required to detect if there is something wrong with the char-
acteristics of the engine coolant temperature sensor.
<Description of malfunction>
• Incompatible readings from the 2 engine coolant temperature sensors are detected.
2. DTC set condition
(1) DTC detection condition
• Engine speed is at least 500 r/min or engine is stopped.
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• Difference between the 2 engine coolant temperature sensors is at least 15 C {59 F}.
3. Reset condition
• Problem does not recur in the same driving cycle.
• Normal operation is restored when in subsequent driving cycles, readings are in the normal range within the above
detection conditions.
• Three driving cycles must be deemed normal for MIL to be OFF.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• EGR valve is fully closed.
<Symptoms on the vehicle due to malfunction>
• –
ENGINE (J05E)/TROUBLESHOOTING 2–313
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Abnormal resistance of the engine coolant temperature sensor
• Failure in engine ECU sensor power supply
2–314 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P011A
1 Inspect the engine coolant temperature sensor 1 connector
1. Check the connection of the engine coolant temperature sensor 1
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine coolant temperature sensor 1
1. Check the installation of the engine coolant temperature sensor 1.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine coolant temperature sensor 1.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine coolant tem-
perature sensor 1.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–315
3 Inspect the engine coolant temperature sensor 1 unit
1. Set the starter key to the "LOCK" position.
E THW
2. Disconnect the engine coolant temperature sensor 1 connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor 1.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300250 sor 1 80 C {176 F}:
THW – E 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the engine coolant temperature sen-
sor 1.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the engine coolant temperature sensor 1 power supply
1. Set the starter key to the "ON" position.
THW E
2. Use the electrical tester to measure the voltage between the termi-
nals of the engine coolant temperature sensor 1 vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Engine coolant
temperature sen-
Starter key: ON sor 1 vehicle side 4.5 – 5.5 V
SHTS021270300251 connector
THW – E
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
2–316 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect for short-circuit of the engine coolant temperature sensor 1 harness
1. Set the starter key to the "LOCK" position.
E66 D E58 2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the engine ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300252 nal check har-
ness)
Starter key: LOCK
THW (E66) –
Ground
E5 (E58) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect disconnection of the engine coolant temperature sensor 1 harness
1. Connect the engine coolant temperature sensor 1 connector.
E66 D E58 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW (E66) –
0.326 – 0.310 k
SHTS021270300253 E5 (E58)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–317
7 Inspect the engine coolant temperature sensor 2 connector
1. Check the connection of the engine coolant temperature sensor 2
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 8.
Perform "After-inspection work" of INFOR-
MATION section.
8 Inspect the engine coolant temperature sensor 2
1. Check the installation of the engine coolant temperature sensor 2.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine coolant temperature sensor 2.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 9.
If damaged, replace the engine coolant tem-
perature sensor 2.
Perform "After-inspection work" of INFOR-
MATION section.
2–318 ENGINE (J05E)/TROUBLESHOOTING
9 Inspect the engine coolant temperature sensor 2 unit
1. Set the starter key to the "LOCK" position.
E22 THW2
2. Disconnect the engine coolant temperature sensor 2 connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor 2.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300254 sor 2 80 C {176 F}:
E22 – THW2 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 10. Replace the engine coolant temperature sen-
sor 2.
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the engine coolant temperature sensor 2 power supply
1. Set the starter key to the "ON" position.
THW2 E22
2. Use the electrical tester to measure the voltage between the termi-
nals of the engine coolant temperature sensor 2 vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Engine coolant
temperature sen-
Starter key: ON sor 2 vehicle side 4.5 – 5.5 V
SHTS021270300255 connector
THW2 – E22
Do the measurements meet the standard value?
YES NO
Go to step 13. Go to step 11.
ENGINE (J05E)/TROUBLESHOOTING 2–319
11 Inspect for short-circuit of the engine coolant temperature sensor 2 harness
1. Set the starter key to the "LOCK" position.
E57 D 2. Connect the signal check harness to the engine ECU. (Do not con-
E69 nect harness to the engine ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300256 nal check har-
ness)
Starter key: LOCK
THW2 (E69) –
Ground
E3 (E57) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 12. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
12 Inspect disconnection of the engine coolant temperature sensor 2 harness
1. Connect the engine coolant temperature sensor 2 connector.
E57 D E69
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW2 (E69) –
0.326 – 0.310 k
SHTS021270300257 E3 (E57)
Do the measurements meet the standard value?
YES NO
Go to step 13. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–320 ENGINE (J05E)/TROUBLESHOOTING
13 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P011A has been detected in [Fault
Information].
SHTS021270300258
Has DTC P011A been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–321
CHECKLIST: P011A
Engine coolant temperature sensor
DTC: P011A Inspection procedure
- rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the installation of the Go to YES.
engine cool- needed.
engine coolant temperature sen-
1 ant tempera- Perform "After- Go to step 2.
sor connector (looseness and No failure
ture sensor 1 inspection
poor contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
engine coolant temperature
Inspect the Go to YES. If damaged,
sensor 1.
engine cool- replace the
2 2. Make sure there is no dirt, Go to step 3.
ant tempera- No failure sensor.
ture sensor 1 damage or clogging in the found: Go to Perform "After-
sensing unit of the engine cool- NO. inspection
ant temperature sensor 1. work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet
the terminals of the engine cool-
the standard Replace the
ant temperature sensor 1.
Inspect the value: Go to sensor.
<Tester connections>
engine cool- YES. Perform "After-
Engine coolant temperature sen-
3 ant tempera- Go to step 4. inspection
sor 1
ture sensor 1 The measure- work" of
THW – E
unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 2.59 – 2.32 k
dard value: Go
80 C {176 F}: 0.326 – 0.310 k
to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the engine coolant
the standard
temperature sensor 1 vehicle side
Inspect the value: Go to
connector.
engine cool- YES.
<Tester connections>
4 ant tempera- Go to step 7. Go to step 5
Engine coolant temperature sen-
ture sensor 1 The measure-
sor vehicle side connector
power supply ments do not
THW – E
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
2–322 ENGINE (J05E)/TROUBLESHOOTING
Engine coolant temperature sensor
DTC: P011A Inspection procedure
- rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check har-
The measure-
ness, and measure the resistance
ments meet
between the terminals of the Repair or
the standard
Inspect for engine ECU and ground. replace the
value: Go to
short-circuit of <Tester connections> harness.
YES.
the engine Engine ECU Perform "After-
5 Go to step 6.
coolant tem- (signal check harness) inspection
The measure-
perature sen- THW (E66) – Ground work" of
ments do not
sor 1 harness E5 (E58) – Ground INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
to NO.
The measure-
Measure the resistance between
ments meet
the terminals of the engine ECU Repair or
the standard
Inspect dis- (signal check harness). replace the
value: Go to
connection of <Tester connections> harness.
YES.
the engine Engine ECU Perform "After-
6 Go to step 7.
coolant tem- (signal check harness) inspection
The measure-
perature sen- THW (E66) – E5 (E58) work" of
ments do not
sor 1 harness <Standard values> INFORMA-
meet the stan-
20 C {68 F}: 2.59 – 2.32 k TION section.
dard value: Go
80 C {176 F}: 0.326 – 0.310 k
to NO.
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
engine cool- needed.
engine coolant temperature sen-
7 ant tempera- Perform "After- Go to step 8.
sor 2 connector (looseness and No failure
ture sensor 2 inspection
poor contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
engine coolant temperature
Inspect the Go to YES. If damaged,
sensor 2.
engine cool- replace the
8 2. Make sure there is no dirt, Go to step 9.
ant tempera- No failure sensor.
ture sensor 2 damage or clogging in the found: Go to Perform "After-
sensing unit of the engine cool- NO. inspection
ant temperature sensor 2. work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–323
Engine coolant temperature sensor
DTC: P011A Inspection procedure
- rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals of the engine cool-
the standard Replace the
ant temperature sensor 2.
Inspect the value: Go to sensor.
<Tester connections>
engine cool- YES. Perform "After-
Engine coolant temperature sen-
9 ant tempera- Go to step 10. inspection
sor 2
ture sensor 2 The measure- work" of
E22 – THW2
unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 2.59 – 2.32 k
dard value: Go
80 C {176 F}: 0.326 – 0.310 k
to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the engine coolant
the standard
temperature sensor 2 vehicle side
Inspect the value: Go to
connector.
engine cool- YES.
<Tester connections>
10 ant tempera- Go to step 13. Go to step 11.
Engine coolant temperature sen-
ture sensor 2 The measure-
sor 2 vehicle side connector
power supply ments do not
THW2 – E22
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
Connect the signal check har- The measure-
ness, and measure the resistance ments meet
Repair or
between the terminals of the the standard
Inspect for replace the
engine ECU and ground. value: Go to
short-circuit of harness.
<Tester connections> YES.
the engine Perform "After-
11 Engine ECU Go to step 12.
coolant tem- inspection
(signal check harness) The measure-
perature sen- work" of
THW2 (E69) – Ground ments do not
sor 2 harness INFORMA-
E3 (E57) – Ground meet the stan-
TION section.
<Standard values> dard value: Go
to NO.
The measure-
Measure the resistance between
ments meet
the terminals of the engine ECU Repair or
the standard
Inspect dis- (signal check harness). replace the
value: Go to
connection of <Tester connections> harness.
YES.
the engine Engine ECU Perform "After-
12 Go to step 13.
coolant tem- (signal check harness) inspection
The measure-
perature sen- THW2 (E69) – E3 (E57) work" of
ments do not
sor 2 harness <Standard values> INFORMA-
meet the stan-
20 C {68 F}: 2.59 – 2.32 k TION section.
dard value: Go
80 C {176 F}: 0.326 – 0.310 k
to NO.
DTC P011A
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
13 DTC detected inspection inspection
F} or more), and check if P011A
(ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–324 ENGINE (J05E)/TROUBLESHOOTING
DTC: P011C
EN01H02127030602016046
P011C: Intake air temperature sensor (air flow sensor built-in) - rationality
INFORMATION
Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth
Z5G (E) 10mA ZJQ
(E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor XCT 200mA X2U (VAF)
(+B)
(air flow sensor built in) Z65 10mA
(E2)
X72 10mA X82 (THA)
(THA)
SHTS021270300259
1. Technical description
• The intake air temperature sensor with built-in air flow sensor constantly measures the intake air temperature.
<Description of malfunction>
• Intake air temperature is not correctly recognized.
2. DTC set condition
(1) DTC detection condition
The following conditions continue for at least 20 seconds:
• Engine speed is 1,000 r/min or less.
• Fuel injection rate is at least 35 mm3/st. cyl or less.
• Engine coolant temperature is between -30 C {-22 F} to 55 C {131 F}.
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
The following conditions continue for at least 3 seconds:
• Difference between intake air temperature (air flow sensor) and intercooler outlet temperature is at least 30 C
{86 F}, and difference between intake air temperature (air flow sensor) and intake manifold air temperature is
at least 30 C {86 F}.
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
ENGINE (J05E)/TROUBLESHOOTING 2–325
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.).
• Faulty resistance (due to sticking).
• Engine ECU sensor power supply or internal circuit failure.
2–326 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P011C
1 Inspect the intake air temperature sensor connector
1. Check the connection of the intake air temperature sensor (air flow
sensor) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the intake air temperature sensor
1. Check the installation of the intake air temperature sensor (air flow
sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damage was found, replace the air flow
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–327
3 Inspect the intake air temperature sensor unit
1. Set the starter key to the "LOCK" position.
E2 THA
2. Disconnect the intake air temperature sensor (air flow sensor) con-
nector.
3. Measure the resistance between the terminals of the sensor using
the electrical tester.
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
Intake air tempera-
SHTS021270300260 2.69 – 2.21 k
Starter key: LOCK ture sensor
60 C {140 F}:
THA – E2
0.667 – 0.493 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the intake air temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the intake air temperature sensor power supply
1. Set the starter key to the "ON" position.
THA E2
2. Measure the voltage between the terminals of the intake air tem-
perature sensor vehicle side connector using the electrical tester.
Measurement Tester
Standard values
conditions connections
Intake air tempera-
ture sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
THA – E2
SHTS021270300261
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
2–328 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect for short-circuits in wire harness of intake air temperature sensor
1. Set the starter key to the "LOCK" position.
D E47 2. Connect the signal check harness to the engine ECU vehicle side
E58
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between each
terminal in the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300262 nal check har-
ness)
Starter key: LOCK
THA (E47) –
Ground
E5 (E58) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect for disconnection in wire harness of intake air temperature sensor
1. Connect the intake air temperature sensor connector.
E47
2. Use the electrical tester to measure the resistance between the
D E58
terminals in the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.69 – 2.21 k
Starter key: LOCK ness)
60 C {140 F}:
THA+ (E47) –
0.667 – 0.493 k
SHTS021270300263 E5 (E58)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–329
7 Check the DTC detected (Engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P011C has been detected in [Fault
Information].
SHTS021270300264
Has DTC P011C detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–330 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P011C
Intake air temperature sensor
DTC: P011C Inspection procedure
(air flow sensor built-in) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Check the connection of the Go to YES.
needed.
intake air tem- intake air temperature sensor (air
1 Perform "After- Go to step 2.
perature sen- flow sensor) connector (loose- No failure
inspection
sor connector ness and poor contact). found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
properly.
1. Check the installation of the Failure found:
If damage was
Inspect the intake air temperature sensor Go to YES.
found, replace
intake air tem- (air flow sensor).
2 the air flow Go to step 3.
perature sen- 2. Make sure there is no dirt, No failure
sensor.
sor damage or clogging in the found: Go to
Perform "After-
sensing unit of the sensor. NO.
inspection
work" of
INFORMA-
TION section.
Disconnect the intake air temper- The measure-
ature sensor (air flow sensor) ments meet
connector and measure the resis- the standard Replace the
tance between the terminals of value: Go to sensor.
Inspect the
the sensor. YES. Perform "After-
intake air tem-
3 <Tester connections> Go to step 4. inspection
perature sen-
Intake air temperature sensor The measure- work" of
sor unit
THA – E2 ments do not INFORMA-
<Standard values> meet the stan- TION section.
20 C {68 F}: 2.69 – 2.21 k dard value: Go
60 C {140 F}: 0.667 – 0.493 k to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the intake air temper-
the standard
ature sensor vehicle side connec-
Inspect the value: Go to
tor.
intake air tem- YES.
<Tester connections>
4 perature sen- Go to step 7. Go to step 5.
Intake air temperature sensor
sor power The measure-
vehicle side connector
supply ments do not
THA– E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–331
Intake air temperature sensor
DTC: P011C Inspection procedure
(air flow sensor built-in) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check harness The measure-
to the engine ECU vehicle side ments meet
Repair or
harness and measure the resis- the standard
Inspect for replace the
tance between each terminal in value: Go to
short-circuits harness.
the engine ECU (signal check YES.
in wire har- Perform "After-
5 harness) and ground. Go to step 6.
ness of intake inspection
<Tester connections> The measure-
air tempera- work" of
THA (E47) – Ground ments do not
ture sensor INFORMA-
E5 (E58) – Ground meet the stan-
TION section.
<Standard values> dard value: Go
to NO.
Connect the intake air tempera-
The measure-
ture sensor connector.
ments meet
Measure the resistance between Repair or
the standard
Inspect for dis- the terminals in the engine ECU replace the
value: Go to
connection in (signal check harness). harness.
YES.
wire harness <Tester connections> Perform "After-
6 Go to step 7.
of intake air Engine ECU inspection
The measure-
temperature (signal check harness) work" of
ments do not
sensor THA (E47) – E5 (E58) INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
20 C {68 F}: 2.69 – 2.21 k
to NO.
60 C {140 F}: 0.667 – 0.493 k
DTC P011C
Replace the Procedure
has been
Warm up the engine (engine cool- engine ECU. completed.
detected: Go
Check the ant temperature: 80 C {176 F} Perform "After- Perform "After-
to YES.
7 DTC detected or more) inspection inspection
(Engine ECU) Check if P011C has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–332 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0122 and P0123
EN01H02127030602016047
P0122: Intake throttle valve position sensor 1 - out of range (Out of range low)
INFORMATION
Engine ECU
(E2R) XFD TYP 0.2A XQT (M-)
(VCR) XFC TYP 1A XQS (M+)
(E2) Z6P TYP 1A ZD6 (E3)
Diesel throttle XSR TYP 0.2A X3V
(VTA2) (VTA2)
(VC) X0N TYP 0.2A XG2 (VC2)
(VTA) X3U TYP 0.2A XK3 (VTA1)
SHTS021270300265
1. Technical description
• The diesel throttle controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle, a sensor designed to detect a travel of the valve consistently monitors a measurement
reading and an actual opening.
<Description of malfunction>
• Low voltage failure of diesel throttle (intake throttle valve) position sensor is detected.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Diesel throttle position sensor remains at 0.2 V (5 C {41 F}) or less for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
ENGINE (J05E)/TROUBLESHOOTING 2–333
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Engine ECU sensor power supply failure or internal circuit failure
• Disconnection or short-circuit in sensor harness
• Irregular contact
2–334 ENGINE (J05E)/TROUBLESHOOTING
P0123: Intake throttle valve position sensor 1 - out of range (Out of range high)
INFORMATION
Engine ECU
(E2R) XFD TYP 0.2A XQT (M-)
(VCR) XFC TYP 1A XQS (M+)
(E2) Z6P TYP 1A ZD6 (E3)
Diesel throttle XSR TYP 0.2A X3V
(VTA2) (VTA2)
(VC) X0N TYP 0.2A XG2 (VC2)
(VTA) X3U TYP 0.2A XK3 (VTA1)
SHTS021270300266
1. Technical description
• The diesel throttle controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle, a sensor designed to detect a travel of the valve consistently monitors a measurement
reading and an actual opening.
<Description of malfunction>
• High voltage failure of diesel throttle (intake throttle valve) position sensor is detected.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 4.8 V (120 C {248 F}) or less for 3 seconds or longer.
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Engine ECU internal circuit failure
• Sensor power supply short-circuit in sensor harness
• Sensor internal short
ENGINE (J05E)/TROUBLESHOOTING 2–335
INSPECTION PROCEDURE: P0122 and P0123
1 Inspect the intake throttle valve position sensor 1 connector
1. Check the connection of the intake throttle valve position sensor 1
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the intake throttle valve position sensor 1
1. Check the installation of the intake throttle valve position sensor 1.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake throttle valve position sensor 1.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the intake throttle valve
position sensor 1.
Perform "After-inspection work" of INFOR-
MATION section.
2–336 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the intake throttle valve position sensor 1 unit
1. Set the starter key to the "LOCK" position.
VTA VC 2. Disconnect the connector of the intake throttle valve position sen-
sor 1 connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake throttle valve position sensor 1 connector.
Measurement Tester
Standard values
conditions connections
Intake throttle
valve position
VC E2 (1) 180
sensor 1
Starter key: LOCK (2) 3 k
(1) VTA – VC
(3) 3 k
(2) VC – E2
(3) VTA – E2
VTA E2
SHTS021270300267
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the intake throttle valve position
sensor 1.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–337
4 Inspect the intake throttle valve position sensor 1 power supply
1. Set the starter key to the "ON" position.
2. Use the electrical tester to measure the voltage between the termi-
E2 VC nals of the intake throttle valve position sensor 1 vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Intake throttle
valve position
Starter key: ON sensor 1 vehicle 4.5 – 5.5 V
SHTS021270300268 side connector
VC – E2
Do the measurements meet the standard value?
YES NO
Go to step 5. Go to step 6.
5 Inspect the diesel throttle (intake throttle valve) position sensor 1 ground circuit
1. Set the starter key to the "LOCK" position.
E2 VTA
2. Use the electrical tester to measure the resistance between the
terminals of the diesel throttle (intake throttle valve) position sen-
sor 1 vehicle side connector.
Measurement Tester
Standard values
conditions connections
Intake throttle
valve position
Starter key: LOCK sensor 1 vehicle 25 – 35 k
SHTS021270300269 side connector
VTA – E2
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
2–338 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect for short-circuits in the wire harness of the diesel throttle (intake throttle valve) posi-
tion sensor 1
1. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
C
E33 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
VC2 (E33) –
Starter key: LOCK
Ground
D E57 VTA1 (E62) –
E62 Ground
E3 (E57) – Ground
SHTS021270300270
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–339
7 Inspect for disconnection in the wire harness of the diesel throttle (intake throttle valve) posi-
tion sensor 1
1. Connect the intake throttle valve position sensor 1 connector.
C D E62
2. Use the electrical tester to measure the resistance between the
E33
terminal of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
(1) VC2 (E33) – (1) 2 or more
Starter key: LOCK VTA1 (E62) (2) 3 k
C D E57
(2) VC2 (E33) – (3)
E33 E3 (E57)
(3) VTA1 (E62) –
E3 (E57)
D E57
E62
SHTS021270300271
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–340 ENGINE (J05E)/TROUBLESHOOTING
8 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0122 or P0123) has been
detected in [Fault Information].
SHTS021270300272
Has DTC (P0122 or P0123) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–341
CHECKLIST: P0122 and P0123
Intake throttle valve position sensor 1
DTC: P0122
- out of range (Out of range low)
Inspection procedure
Intake throttle valve position sensor 1 - out of
DTC: P0123
range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
intake throttle needed.
intake throttle valve position sen-
1 valve position Perform "After- Go to step 2.
sor connector (looseness and No failure
sensor 1 con- inspection
poor contact). found: Go to
nector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
intake throttle valve position
Inspect the Go to YES. If damaged,
sensor 1.
intake throttle replace the
2 2. Make sure there is no dirt, Go to step 3.
valve position No failure sensor.
sensor 1 damage or clogging in the found: Go to Perform "After-
sensing unit of the intake throt- NO. inspection
tle valve position sensor 1. work" of
INFORMA-
TION section.
Disconnect the intake throttle
valve position sensor 1 connector
and measure the resistance
The measure-
between the terminals of the
ments meet
intake throttle valve position sen-
the standard Replace the
sor 1.
value: Go to sensor.
Inspect the <Tester connections>
YES. Perform "After-
intake throttle Intake throttle valve position sen-
3 Go to step 4. inspection
valve position sor 1
The measure- work" of
sensor 1 unit (1) VTA – VC
ments do not INFORMA-
(2) VC – E2
meet the stan- TION section.
(3) VTA – E2
dard value: Go
<Standard values>
to NO.
(1) 180
(2) 3 k
(3) 3 k
The measure-
Measure the voltage between the
ments meet
terminals of the intake throttle
the standard
valve position sensor 1 vehicle
Inspect the value: Go to
side connector.
intake throttle YES.
<Tester connections>
4 valve position Go to step 5. Go to step 6.
Intake throttle valve position sen-
sensor 1 The measure-
sor 1 vehicle side connector
power supply ments meet
VC – E2
the standard
<Standard values>
value: Go to
4.5 – 5.5 V
YES.
2–342 ENGINE (J05E)/TROUBLESHOOTING
Intake throttle valve position sensor 1
DTC: P0122
- out of range (Out of range low)
Inspection procedure
Intake throttle valve position sensor 1 - out of
DTC: P0123
range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals of the intake throttle
the standard
Inspect the valve position sensor 1 vehicle
value: Go to
diesel throttle side connector.
YES.
(intake throttle <Tester connections>
5 Go to step 8. Go to step 6.
valve) position Intake throttle valve position sen-
The measure-
sensor 1 sor 1 vehicle side connector
ments do not
ground circuit VTA – E2
meet the stan-
<Standard values>
dard value: Go
25 – 35 k
to NO.
Connect the signal check harness
to the engine ECU (Do not con-
nect harness to the ECU.) and The measure-
measure the resistance between ments meet
Inspect for Repair or
the terminals of the engine ECU the standard
short-circuits replace the
(signal check harness) and value: Go to
in the wire har- harness.
ground. YES.
ness of the Perform "After-
6 <Tester connections> Go to step 7.
diesel throttle inspection
Engine ECU The measure-
(intake throttle work" of
(signal check harness) ments do not
valve) position INFORMA-
VC2 (E33) – Ground meet the stan-
sensor 1 TION section.
VTA1 (E62) – Ground dard value: Go
E3 (E57) – Ground to NO.
<Standard values>
Connect the intake throttle valve
position sensor 1 connector and
measure the resistance between The measure-
the terminals of the engine ECU ments meet
Inspect for dis- Repair or
(signal check harness). the standard
connection in replace the
<Tester connections> value: Go to
the wire har- harness.
Engine ECU YES.
ness of the Perform "After-
7 (signal check harness) Go to step 8.
diesel throttle inspection
(1) VC2 (E33) – VTA1 (E62) The measure-
(intake throttle work" of
(2) VC2 (E33) – E3 (E57) ments do not
valve) position INFORMA-
(3) VTA1 (E62) – E3 (E57) meet the stan-
sensor 1 TION section.
<Standard values> dard value: Go
(1) 2 or more to NO.
(2) 3 k
(3)
DTC (P0122
Warm up the engine. Replace the Procedure
or P0123) has
(engine coolant temperature: engine ECU. completed.
been detected:
Check the 80 C {176 F} or more) Perform "After- Perform "After-
Go to YES.
8 DTC detected Check if the DTC (P0122 or inspection inspection
(Engine ECU) P0123) has been detected in work" of work" of
No DTC has
[Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–343
DTC: P0128
EN01H02127030602016048
P0128: Thermostat - The coolant temperature does not reach a warmed-up temperature
INFORMATION
Engine coolant
temperature sensor
Intercooler
Radiator
Thermostat
X66 (THW) 10mA X28 (THW)
Body earth 10mA
Z5G (E) ZJQ (E5)
Coolant temperature sensor Engine ECU
SHTS021270300273
1. Technical description
• The thermostat prevents coolant from flowing into the radiator when the engine coolant temperature is less than 82
C {179.6 F}, in order to secure the engine warm up function. When the temperature rises above 82 C {179.6 F},
the valve opens and allows coolant to flow into the radiator, thereby preventing the engine from overheating.
• If the thermostat fails and the valve stays open, it is difficult for the engine coolant temperature to rise, so the
exhaust components that work after the engine coolant temperature has reached a certain value (warm up) will not
operate for a long time. The thermostat must therefore be diagnosed to see if it is working properly.
<Description of malfunction>
• In order to detect a malfunction of the thermostat, the above failure is determined when the actual engine coolant
temperature is a certain amount lower than the predicted temperature.
2. DTC set condition
(1) DTC detection condition
• Engine speed ≥ 700 r/min
• Engine coolant temperature at engine start-up ≤ 52 C {125.6 F}.
• Engine coolant temperature is 76 C {168.8 F} or more after running the engine for 60 seconds or more.
(2) Judgement criteria
• The condition that the actual engine coolant temperature is less than 65 C {149 F} remains for 5 seconds or
more.
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
2–344 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
- Inclusion of foreign matters in the thermostat
- Damaged spring in the thermostat
- Engine coolant temperature sensor failure
ENGINE (J05E)/TROUBLESHOOTING 2–345
INSPECTION PROCEDURE: P0128
1 Inspect the engine coolant temperature sensor connector
1. Check the connection of the engine coolant temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine coolant temperature sensor
1. Check the installation of the engine coolant temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine coolant temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine coolant tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–346 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the engine coolant temperature sensor unit
1. Set the starter key to the "LOCK" position.
E THW
2. Disconnect the engine coolant temperature sensor connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300274 sor 80 C {176 F}:
THW – E 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the engine coolant temperature sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the thermostat
1. Check if the thermostat is damaged due to the incursion of foreign
substances or if the spring is damaged.
Was any failure found?
YES NO
Replace the thermostat. Go to step 5.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–347
5 Inspect the thermostat valve-opening temperature
1. Check valve opening temperature.
Submerge in hot water (95 C {203 F}) and check if the valve lift is
13 mm {0.512 in.} or greater.
Was any failure found?
YES NO
Replace the thermostat. Go to step 6.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect the thermostat valve-open time
1. Check valve opening time.
After taking out from hot water, submerge in water and check that
the valve closes within 5 minutes.
Was any failure found?
YES NO
Replace the thermostat. Go to step 7.
Perform "After-inspection work" of INFOR-
MATION section.
2–348 ENGINE (J05E)/TROUBLESHOOTING
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0128 has been detected in [Fault
Information].
SHTS021270300275
Has DTC P0128 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–349
CHECKLIST: P0128
Thermostat - The coolant temperature does not
DTC: P0128 Inspection procedure
reach a warmed-up temperature
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
engine cool- needed.
engine coolant temperature sen-
1 ant tempera- Perform "After- Go to step 2.
sor connector (looseness and No failure
ture sensor inspection
poor contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
1. Check the installation of the and install it
engine coolant temperature Failure found: properly.
Inspect the sensor. Go to YES. If damaged,
engine cool- 2. Make sure there is no dirt, replace the
2 Go to step 3.
ant tempera- damage or clogging in the No failure sensor.
ture sensor sensing unit of the engine cool- found: Go to Perform "After-
ant temperature sensor. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet
the terminals of the engine cool-
the standard Replace the
ant temperature sensor.
Inspect the value: Go to sensor.
<Tester connections>
engine cool- YES. Perform "After-
Engine coolant temperature sen-
3 ant tempera- Go to step 4. inspection
sor
ture sensor The measure- work" of
THW – E
unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 2.59 – 2.32 k
dard value: Go
80 C {176 F}: 0.326 – 0.310 k
to NO.
Replace the
Failure found:
thermostat.
Check if the thermostat is dam- Go to YES.
Perform "After-
Inspect the aged due to the incursion of for-
4 inspection Go to step 5.
thermostat eign substances or if the spring is No failure
work" of
damaged. found: Go to
INFORMA-
NO.
TION section.
Replace the
Check valve opening tempera- Failure found:
thermostat.
Inspect the ture. Go to YES.
Perform "After-
thermostat Submerge in hot water of 95 C
5 inspection Go to step 6.
valve-opening {203 F} and check whether a 13 No failure
work" of
temperature mm {0.512 in.} or greater lift is found: Go to
INFORMA-
reached. NO.
TION section.
2–350 ENGINE (J05E)/TROUBLESHOOTING
Thermostat - The coolant temperature does not
DTC: P0128 Inspection procedure
reach a warmed-up temperature
Check
Step Action Description Judgement Yes No
(Yes/No)
Replace the
Failure found:
thermostat.
Inspect the Check valve opening time. Go to YES.
Perform "After-
thermostat After taking out from hot water,
6 inspection Go to step 7.
valve-open submerge in water and check that No failure
work" of
time the valve closes within 5 minutes. found: Go to
INFORMA-
NO.
TION section.
DTC P0128
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
7 DTC detected inspection inspection
F} or more), and check if P0128
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–351
DTC: P0148
EN01H02127030602016049
P0148: Abnormality in post injection
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
Engine ECU
X49 (#4) $XY (II+5)
Injector 4 X6Y (#40) X2X (#3)
X1Z (#30)
X47 (#3) $XX (12+5)
Injector 3 X6X (#30) X2W (#2)
X20 (#20)
X45 (#2) %X2 (IJ2+)
Injector 2 X0B (#20) X01 (#4)
X3L (#40)
X42 (#1) %X1 (IJ1+)
Injector 1 X43 (#10) X2V (#1)
X19 (#10)
SHTS021270300276
1. Technical description
<Description of malfunction>
• The engine ECU detected abnormality in post injection.
2–352 ENGINE (J05E)/TROUBLESHOOTING
2. DTC set condition
(1) DTC detection condition
• The vehicle speed is 0 km/h.
• A change in the engine revolution is 312 r/min/sec or less.
• A change in the fuel injection quantity is 312 mm3/st/sec or less.
• A change in the fuel pressure is 93.7 MPa/sec or less.
• The target operating current of the fuel pump is not less than 1500 mA but not more than 1800 mA.
(2) Judgement criteria
• A change in the operating current of the fuel pump upon post injection falls below the specified value.
• Malfunction determination time: 10 seconds
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Fuel injection pipe: Breakage, crack, fuel leakage
• Cylinder: Compression leakage
• Common rail: Malfunction of flow damper
• Injector: Clogging, keeping injecting
ENGINE (J05E)/TROUBLESHOOTING 2–353
INSPECTION PROCEDURE: P0148
1 Check the DTC detected 1 [HINO-DX]
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. On the screen of the diagnostic system, select [Engine] and check
[Fault Information] for DTC P0148 detected as present malfunc-
tion.
SHTS021270300277
Is DTC P0148 detected as present malfunction?
YES NO
Go to step 2 (It is detected as present mal- Go to step 9. (It is recorded as past malfunc-
function) tion)
2 Check the DTC detected 2 [HINO-DX]
1. Check if the following DTC are not detected at the same time in the
results of step 1.
• P0263, P0266, P0269, P0272
Select
Engine
SHTS021270300278
Has a DTC other than P0263, P0266, P0269 and P0272 been detected?
YES NO
Go to diagnosis procedure of the related Go to step 3.
DTC.
2–354 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the fuel line
1. Check that the fuel line has no leaks or clogging.
<Main inspection locations>
- Entry of foreign matter into the fuel tank
- Fuel hose breakage, collapsing, looseness
- High-pressure pipe breakage, collapsing, looseness
A return line from the fuel filter
Fuel filter
Common rail
Injector
Pre fuel
filter
Supply pump
Suction line
Positive pressure line
Fuel tank
High pressure line
Return line
SHTS021270300279
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 4.
Go to step 4 after repair or replacement.
ENGINE (J05E)/TROUBLESHOOTING 2–355
4 Inspect the fuel filter
1. Check that the fuel filter is not dirty or clogged or damaged.
Was any failure found?
YES NO
Replace the fuel filter. Go to step 5.
Go to step 5 after replacement
5 Check the DTC detected 3 [HINO-DX]
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if the DTC (P0148) has been detected
in [Fault Information].
SHTS021270300280
Has DTC (P0148) been detected?
YES NO
Go to step 6. Procedure completed.
2–356 ENGINE (J05E)/TROUBLESHOOTING
6 Perform the cylinder cut-off test (HINO-DX)
1. Start the engine and maintain the engine revolution at 1,500 r/min
using the cruise function.
2. Check the engine sound before the test (during normal operation).
Select 3. On the screen of the diagnostic system, select [Engine], and per-
Engine
form [Cut off test] in [Activation Test].
• For the detailed procedure, refer to the separate sheet "Cut off test".
<Cylinder cut-off test>
- Test to determine cylinder combustion abnormality of the engine usu-
SHTS021270300281
ally operated by four cylinders, according to the sound difference
when the fuel injection from any one of the cylinders is stopped.
Did you find the engine sound different?
YES NO
<One of the sounds A to D is always larger <No clear difference> Go to step 8.
than others or same as α> Replace the defec-
tive injector.After replacement, go to step 7.
7 Check the DTC detected 4 [HINO-DX]
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if the DTC (P0148) has been detected
in [Fault Information].
SHTS021270300282
Has DTC (P1048) been detected?
YES NO
Go to step 8. Procedure completed.
ENGINE (J05E)/TROUBLESHOOTING 2–357
8 Replace the common rail assembly [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Replace common rail assembly.
3. Perform the engine warm up. (engine coolant temperature: 80 C
Select {176 F} or more)
Engine
4. Stop the engine.
5. Set the starter key to the "ON" position.
6. Select [Engine] and check if the DTC (P0148) has been detected
SHTS021270300283
in [Fault Information].
Has DTC (P0148) been detected?
YES NO
Go to step 9. Procedure completed.
2–358 ENGINE (J05E)/TROUBLESHOOTING
9 Inspect the injector
Check the injection quantity.
1. Start the engine
Select 2. Select [Injection quantity] from the [Data Monitor] menu, and mea-
Engine sure the amount of fuel injection.
SHTS021270300284
3. Select [Engine speed] from the [Data Monitor] menu, and measure
the engine speed.
NE Engine speed
@1,500 r/min (measurement by HINO-DX) Measurement conditions
Engine speed: 1,500 r/min No-load,
Ne (r/min)
T/M shift lever: Neutral position,
A/C off and Air compressor un-operating.
Engine coolant temperature: more than 80 C {176 F}
Engine
Standard values
SHTS021270300285
Type of Q (mm3/st)
AT 5.0q
Do the measurements meet the standard value?
(Both the injection quantity and the engine speed are within the standard values)
YES NO
If DTC P0148 is the present malfunction: Go Replace the injector.
to step 10.
If DTC P0148 is the past malfunction: End of
inspection
ENGINE (J05E)/TROUBLESHOOTING 2–359
10 Check the injector clamp
1. Check that the injector clamp is not loose.
2. Check that there is no "insufficient engagement" of the injector
BOLT clamp claw.
INJECTOR
INJECTION PIPE
INJECTOR
CLAMP
INJECTION
PIPE OIL SEAL
O-RING
SHTS021270300287
Was any failure found?
YES NO
Repair or replace the faulty parts. Go to step 11.
2–360 ENGINE (J05E)/TROUBLESHOOTING
11 Check the valve clearance
1. Check that the valve clearance of each cylinder is within the stan-
dard values. (Check all the valves.)
Rocker arm
Feeler gauge
Measurement conditions Standard values
Cold engine Intake valve:
0.30 mm (0.0118 in.)
Cross head Exhaust valve:
0.45 mm (0.0177 in.)
SHTS021270300288
Cylinder number 1 2 3 4
Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No.1 cylinder at the compres-
sion stroke top dead center
No.4 cylinder at the compres-
Δ Δ Δ Δ
sion stroke top dead center
Do the measurements meet the standard value?
YES NO
Go to step 12. Adjust the valve clearance.
ENGINE (J05E)/TROUBLESHOOTING 2–361
12 Check the engine compression pressure
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
3. Remove the all injectors.
SST 4. Set the special service tool (SST) and measure the compression.
To
engine Measurement
Standard values
conditions
SHTS021270300289 Standard values:
Engine revolution: 150 r/min 3.2-3.4 MPa {33-35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}
Do the measurements meet the standard value?
YES NO
Go to step 13. Engine overhaul.
13 Inspect the engine speed main sensor (Crankshaft position sensor)
1. Inspect the condition of engine speed main sensor (crankshaft
Engine speed main sensor (Crankshaft position sensor) position sensor) connector (looseness or poor contact).
2. Check the installation of the engine speed main sensor. (Crank-
shaft position sensor)
Connector
Flywheel housing
SHTS021270300290
Was any failure found?
YES NO
Repair or replace the faulty parts. Go to step 14.
2–362 ENGINE (J05E)/TROUBLESHOOTING
14 Check the DTC detected 5 [HINO-DX]
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine
Select 3. Set the starter key to the "ON" position.
Engine
4. On the screen of the diagnostic system, check [Fault Information]
for DTC P0148.
SHTS021270300291
Has DTC (P0148) been detected?
YES NO
Inspect the crankshaft, connecting rods, fly- Procedure completed.
wheel, and other parts of the drive system.
ENGINE (J05E)/TROUBLESHOOTING 2–363
Cylinder cut off test
<Cylinder cut-off test>
Test to determine cylinder combustion abnormality of the engine usually operated by four cylinders, according to the sound
difference when the fuel injection from any one of the cylinders is stopped
<Purpose>
To determine combustion abnormality of the arbitrary cylinder according to sound difference.
<Know-how & examples>
Combustion abnormality of the arbitrary cylinder is determined according to sound difference to take proper measures.
1 Cylinder cut-off test
1. Start the engine and maintain the engine revolution at 1,500 r/min
using the cruise function.
2. Check the engine sound before the test (during normal operation).
(Assume α as the sound.)
3. On the screen of the diagnostic system, select [Engine], and per-
form [Cut off test] in [Activation Test].
SHTS021270300292
2–364 ENGINE (J05E)/TROUBLESHOOTING
4. Stop the fuel injection of the cylinder #1 to check the engine
sound. (Assume A as the sound.) -> After checking, stop the test.
(2) Execution
HINT
Because the engine maintains the rotation condition by three-cyl-
inder fuel injection instead of four-cylinder fuel injection during
(1) Select the cylinder to deactivate. the test, the sound A becomes larger than α. (This is not abnor-
mal.)
5. As the cylinder #1, stop the fuel injection of the cylinders #2, #3,
and #4 in this order.
(Assume B, C, and D as the measured sounds respectively.)
HINT
• If sound abnormality is not clear, repeat the steps 4 and 5.
• If any of the sounds A to D is same as α, make sure to check for
(3) Injection is stopped when OK is selected.
communication abnormality.
SHTS021270300293
Can engine sound difference be identified?
YES NO
<One of the sounds A to D is always larger <No clear difference>
than others or same as α. > Go to inspection.
Replace the defective injector.
ENGINE (J05E)/TROUBLESHOOTING 2–365
CHECKLIST: P0148
DTC: P0148 Abnormality in post injection Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Perform the engine warm up.
(engine coolant temperature:
80 C {176 F} or more) DTC P0148 is
2. Stop the engine and set the detected as
starter key to the "LOCK" posi- present mal-
tion. function: Go to
Go to step 2 (It Go to step 9.
Check the 3. Connect the vehicle to HINO- YES.
is detected as (It is recorded
1 DTC detected DX. present mal- as past mal-
1 [HINO-DX] 4. Set the starter key to the "ON" DTC P0148 is
function) function)
position. not detected
as present
5. On the screen of the diagnostic malfunction:
system, select [Engine] and Go to NO.
check [Fault Information] for
DTC P0148 detected as pres-
ent malfunction.
DTC other
than P0263,
P0266, P0269
Check if the following DTC are not and P0272
Go to diagno-
Check the detected at the same time in the has been
sis procedure
2 DTC detected results of step 1. detected: Go Go to step 3.
of the related
2 [HINO-DX] to YES.
• P026C, P026D, P0269, P0272 DTC.
No DTC has
been detected:
Go to NO.
Check that the fuel line has no
leaks or clogging.
Failure found: Repair of
<Main inspection locations> Go to YES. replace the
Inspect the - Entry of foreign matter into the faulty part.
3 fuel tank Go to step 4
fuel line No failure Go to step 4
- Fuel hose breakage, collaps- found: Go to after repair or
ing, looseness NO. replacement
- High-pressure pipe breakage,
collapsing, looseness
Failure found:
Replace the
Go to YES.
fuel filter.
Inspect the Check that the fuel filter is not
4 Go to step 5 Go to step 5
fuel filter dirty or clogged or damaged. No failure
after replace-
found: Go to
ment
NO.
2–366 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0148 Abnormality in post injection Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Perform the engine warm up.
(engine coolant temperature: DTC P0148
80 C {176 F} or more) have been
detected: Go
Check the 2. Stop the engine.
to YES. Procedure
5 DTC detected 3. Set the starter key to the "ON" Go to step 6.
completed.
3 [HINO-DX] position. No DTC has
4. Select [Engine] and check if the been detected:
DTC (P0148) has been Go to NO.
detected in [Fault Information].
1. Start the engine and maintain
the engine revolution at 1,500 r/
min using the cruise function.
2. Check the engine sound before
the test (during normal opera-
tion).
3. On the screen of the diagnostic <One of the
system, select [Engine], and The engine sounds A to D
perform [Cut off test] in [Activa- sound was dif- is always
Perform the tion Test]. ferent: Go to larger than
<No clear dif-
cylinder cut-off – For the detailed procedure, YES. others or same
6 ference> Go to
test [HINO- refer to the separate sheet "Cut as α> Replace
step 8.
DX] off test". There was no the defective
clear differ- injector.After
<Cylinder cut-off test> ence: NO replacement,
go to step 7.
- Test to determine cylinder com-
bustion abnormality of the
engine usually operated by four
cylinders, according to the
sound difference when the fuel
injection from any one of the
cylinders is stopped.
1. Perform the engine warm up.
(engine coolant temperature: DTC (P0148)
80 C {176 F} or more) has been
detected: Go
Check the 2. Stop the engine.
to YES. Procedure
7 DTC detected 3. Set the starter key to the "ON" Go to step 8.
completed.
4 [HINO-DX] position. No DTC has
4. Select [Engine] and check if the been detected:
DTC (P0148) has been Go to NO.
detected in [Fault Information].
ENGINE (J05E)/TROUBLESHOOTING 2–367
DTC: P0148 Abnormality in post injection Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Set the starter key to the
"LOCK" position.
2. Replace common rail assem-
bly. DTC (P0148)
has been
3. Perform the engine warm up.
Replace the detected: Go
(engine coolant temperature:
common rail to YES. Procedure
8 80 C {176 F} or more) Go to step 9.
assembly completed.
[HINO-DX] 4. Stop the engine. No DTC has
5. Set the starter key to the "ON" been detected:
position. Go to NO.
6. Select [Engine] and check if the
DTC (P0148) has been
detected in [Fault Information].
Check the injection quantity.
1. Start the engine.
2. Select [Injection quantity] from Both the injec-
the [Data Monitor] menu, and tion quantity
measure the amount of fuel and the engine
If DTC P0148
injection. speed are
is the present
3. Select [Engine speed] from the within the malfunction:
[Data Monitor] menu, and mea- standard val- Go to step 10.
Inspect the sure the rotational fluctuation. ues: Go to Replace the
9 If DTC P0148
injector <Measurement conditions> YES. injector.
is the past
Engine speed: 1,500 r/min malfunction:
No-load, Neutral, A/C off and Air The measure-
End of inspec-
compressor un-operating ment do not
tion
Engine coolant temperature: meet the stan-
more than 80 C {176 F} dard value: Go
<Standard values> to NO.
3/st):
Injection quantity (mm
5.0q or more for AT vehicles.
Failure found:
1. Check that the injector clamp is
Go to YES.
not loose. Repair or
Check the
10 2. Check that there is no "insuffi- replace the Go to step 11
injector clamp No failure
cient engagement" of the injec- faulty parts.
found: Go to
tor clamp claw. NO.
The measure-
Check that the valve clearance of ments meet
each cylinder is within the stan- the standard
dard values. (Check all the value: Go to
Check the valves.) YES. Adjust the
11 valve clear- when engine is cold Go to step 12 valve clear-
ance <Standard values> The measure- ance.
Intake valve: 0.3mm (0.0118 in) ments do not
Exhaust valve: meet the stan-
0.45mm (0.0177 in) dard value: Go
to NO.
2–368 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0148 Abnormality in post injection Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Perform an engine warm up.
(engine coolant temperature: The measure-
80 C {176 F} or more) ments meet
the standard
2. Stop the engine.
value: Go to
Check the 3. Remove the all injectors YES.
engine com- Engine over-
12 4. Set the special service tool Go to step 13
pression pres- haul.
(SST) and measure the com- The measure-
sure
pression. ments do not
Engine revolution: 150 r/min meet the stan-
<Standard values> dard value: Go
3.2 – 3.4 MPa {33 - 35 kgf/cm2} to NO.
Limit: 2.3 MPa {24 kgf/cm2}
1. Inspect the condition of engine
Inspect the Failure found:
speed main sensor (crankshaft
engine speed Go to YES.
position sensor) connector Repair or
main sensor
13 (looseness or poor contact). replace the Go to step 14
(Crankshaft No failure
2. Check the installation of the faulty parts.
position sen- found: Go to
sor) engine speed main sensor. NO.
(Crankshaft position sensor)
1. Perform an engine warm up.
(engine coolant temperature: DTC (P0148)
Inspect the
80 C {176 F} or more) has been
crankshaft,
detected: Go
Check the 2. Stop the engine connecting
to YES. Procedure
14 DTC detected 3. Set the starter key to the "ON" rods, flywheel,
completed.
5 [HINO-DX] position. and other
No DTC has
parts of the
4. On the screen of the diagnostic been detected:
drive system.
system, check [Fault Informa- Go to NO.
tion] for DTC P0148.
ENGINE (J05E)/TROUBLESHOOTING 2–369
DTC: P016E and P016F
EN01H02127030602016050
P016E: Fuel system pressure control - high
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
SHTS021270300294
1. Technical description
• The common rail pressure is controlled by the discharge of the supply pump.
• The supply pump discharge rate is adjusted by the SCV (suction control valve).
<Description of malfunction>
• Abnormally high fuel pressure inside common rail is detected.
2. DTC set condition
(1) DTC detection condition
• Engine speed ≥ 700 r/min.
• Fuel injection rate ≥ 5 mm3/st. cyl.
• Fuel injection rate fluctuation < -26.6 mm3/st. cyl.
• Target current value of SCV ≤ 1,500 mA.
(2) Judgement criteria
• (Actual common rail pressure – target common rail pressure) ≥ 15 MPa for 15 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
2–370 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Fuel filter: clogged
• Common rail pressure sensor: faulty contact (power supply fault or GND fault), sensor failure
• Supply pump: SCV fault, learning value fault
• Common rail: pressure limiter valve open
• Harness-related malfunction: faulty contact or wrong connection in engine speed main sensor or engine speed sub
sensor
ENGINE (J05E)/TROUBLESHOOTING 2–371
P016F: Fuel system pressure control - low
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
SHTS021270300295
1. Technical description
• The common rail pressure is controlled by the discharge of the fuel pump.
• The fuel pump discharge rate is adjusted by the SCV (suction control valve).
<Description of malfunction>
• Abnormally high fuel pressure inside common rail is detected.
2. DTC set condition
(1) DTC detection condition
• Engine speed ≥ 700 r/min.
• Fuel injection rate ≥ 5 mm3/st. cyl.
• Fuel injection rate fluctuation < 40.6 mm3/st. cyl.
• Target current value of SCV ≤ 1250 mA.
(2) Judgement criteria
• (Actual common rail pressure – target common rail pressure) ≥ 15 MPa for 15 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
2–372 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Fuel filter: clogged
• Common rail pressure sensor: faulty contact (power supply fault or GND fault), sensor failure
• Supply pump: SCV fault, learning value fault
• Common rail: pressure limiter valve open
• Harness-related malfunction: faulty contact or wrong connection in engine speed main sensor or engine speed sub
sensor
ENGINE (J05E)/TROUBLESHOOTING 2–373
INSPECTION PROCEDURE: P016E and P016F
1 Inspect the start of the engine
1. Inspect the start of the engine.
Does the engine start?
YES NO
Go to step 4. Go to step 2.
2 Inspect the supply pump
1. Check if fuel is leaking or seeping out of the supply pump.
Was any failure found?
YES NO
Replace the supply pump, and go to step 4. Go to step 3.
3 Function check of supply pump [HINO-DX]
1. Connect the vehicle to HINO-DX.
Actual common rail pressure
Specified common rail pressure
2. Set the starter key to the "ON" position.
222MP
Common rail pressure
The pressure limiter is 3. Select [Engine].
open reducing the pressure.
4. Select [Actual common rail pressure] from the [Data Monitor]
Idling menu.
5. Start the engine while checking the common rail pressure.
Starter (Engine starting) Hour
Standard values
SHTS021270300296
The actual common rail pressure rises and stabilizes at a
constant value.
Was any failure found?
YES NO
Replace the supply pump, and go to step 4. Contact the Hino national service manager.
2–374 ENGINE (J05E)/TROUBLESHOOTING
4 SCV free acceleration test [HINO-DX]
1. Select [Freeze Frame] of the DTC (P016E or P016F) from [Fault
Information] in HINO-DX menu, and confirm the freeze-frame
data.
2. Conduct an SCV test and confirm the existing data.
Select
Engine
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
HINT
The data obtained in this procedure will serve as comparison data
in subsequent procedures.
SHTS021270300297
3. Check the engine ECU product number.
Does the engine ECU have the latest product number?
YES NO
Go to step 5. Reprogram the engine ECU and then go to
step 5.
(Refer to "DIAGNOSIS USING THE PC DAI-
GNOSIS TOOL".)
ENGINE (J05E)/TROUBLESHOOTING 2–375
5 Inspect the fuel filter
1. Inspect the fuel filter.
• Has the replacement period expired?
• Is it dirty, damaged, or clogged?
• Is it a genuine Hino part?
2. Check if the fuel inside the fuel filter is within the standard value.
Measurement conditions Standard values
• At least 25.4 mm {1 in.}
above collar and below the
element upper level.
While engine is running
• Fuel level does not con-
tinue to drop during high-
speed idle.
Was any failure found?
YES NO
Replace the fuel filter element, and go to step Go to step 11.
6.
6 Inspect the fuel pipe
1. Check if the fuel pipe and hose between the fuel tank and fuel filter
are clogged, punctured, or bent.
2. Make sure the fuel pipe joint bolts are not loose.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 7.
step 7.
2–376 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect the fuel tank breather
1. Check if the breather hose is clogged, punctured, or bent.
2. Make sure the check valve is functioning normally.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 8.
step 8.
8 Inspect the fuel tank feed pipe
1. Make sure the fuel tank feed pipe is not clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 9.
step 9.
9 Inspect the fuel tank
1. Drain fuel out of the fuel tank and check if there are foreign objects
inside the tank.
Was any failure found?
YES NO
Remove the foreign objects and clean the Go to step 10.
fuel tank.
Then go to step 10.
ENGINE (J05E)/TROUBLESHOOTING 2–377
10 Inspect the supply pump gauze filter
1. Make sure the gauze filter (built into the supply pump) is not
clogged.
Was any failure found?
YES NO
Clean the gauze filter, and go to step 11. Go to step 11.
11 Inspect the fuel high-pressure pipe.
1. Make sure the fuel high-pressure pipe is not leaking fuel.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 12.
step 12.
12 Inspect the bubble separator
1. Make sure the bubble separator is not clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to If failure was found in steps 6 – 11: Go to
step 13. step 13.
If failure was not found in steps 6 – 11: Go to
step 14.
2–378 ENGINE (J05E)/TROUBLESHOOTING
13 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
2. Compare the results with those obtained in step 4 and check if
Select
Engine
they improved.
SHTS021270300298
Did the test results improve?
YES NO
Procedure completed. Go to step 14.
Perform "After-inspection work" of INFOR-
MATION section.
14 Inspect the SCV connector
1. Check the connection of the SCV connector (looseness and poor
contact).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 15.
step 15.
15 Inspect the common rail pressure sensor connector
1. Check the connection of the common rail pressure sensor connec-
tor (looseness and poor contact).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 16.
step 16.
ENGINE (J05E)/TROUBLESHOOTING 2–379
16 Inspect the common rail pressure sensor power supply
1. Disconnect the common rail pressure sensor connector.
VC2 GND
2. Set the starter key to the "ON" position.
3. Use the electrical tester to measure the voltage between the termi-
nals of the common rail pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300299 cle side connector
VC2 – GND
Do the measurements meet the standard value?
YES NO
Go to step 17. Repair the common rail pressure sensor and
then go to step 17.
17 Inspect the engine speed main sensor (crankshaft position sensor)
1. Set the starter key to the "ON" position.
2. Select [Engine].
3. Select [NE sensor active flag], [G sensor active flag] from the [Data
Select Monitor] menu.
Engine
4. Start the engine and confirm that the engine main speed sensor
(NE) and sub speed sensor (G) operate (stay ON) continuously.
SHTS021270300300
Was any failure found?
YES NO
Check any faulty sensor and repair or Go to step 18.
replace it as needed.
After inspection, go to step 18.
2–380 ENGINE (J05E)/TROUBLESHOOTING
18 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
2. Compare the test results with those obtained in step 4 and check if
Select
Engine
they improved.
SHTS021270300301
Did the test results improve?
YES NO
Procedure completed. Go to step 19.
Perform "After-inspection work" of INFOR-
MATION section.
19 SCV free acceleration test [HINO-DX]
1. Check that the malfunction pattern from the malfunction reproduc-
tion test carried out in step 18, and replace the pertinent part.
<Reproduction test results>
- a, g: Replace the supply pump.
Select
Engine - b, c, d, h, i, j: Replace the SCV.
- e: Replace the common rail.
- f: Check the fuel return pipe/hose.
2. After replacing the part, perform the SCV test and malfunction
reproduction test again.
SHTS021270300302
3. Compare the test results with those obtained in step 4 and check if
they improved.
Did the test results improve?
YES NO
Procedure completed. Go to step 20.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–381
20 Inspect the fuel return pipe and hose
1. Check if the fuel return pipe and hose are clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 21.
step 21.
21 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
2. Compare the test results with those obtained in step 4 and check if
Select
Engine
they improved.
SHTS021270300303
Did the test results improve?
YES NO
Procedure completed. Go to step 22.
Perform "After-inspection work" of INFOR-
MATION section.
22 Check again the fuel pipe
1. Check the fuel pipe again (steps 6 – 12).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 23.
step 23.
2–382 ENGINE (J05E)/TROUBLESHOOTING
23 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
2. Compare the test results with those obtained in step 4 and check if
Select
Engine
they improved.
SHTS021270300304
Did the test results improve?
YES NO
Procedure completed. Go to step 24.
Perform "After-inspection work" of INFOR-
MATION section.
24 Check again the sensor system
1. Check the sensor system again (steps 14 – 17).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 25.
step 25.
ENGINE (J05E)/TROUBLESHOOTING 2–383
25 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
2. Compare the test results with those obtained in step 4 and check if
Select
Engine
they improved.
SHTS021270300305
Did the test results improve?
YES NO
Procedure completed. Contact the Hino national service manager.
Perform "After-inspection work" of INFOR-
MATION section.
2–384 ENGINE (J05E)/TROUBLESHOOTING
SCV FREE ACCELERATION TEST
1 Test method
<Engine speed pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Control the engine revolution by means of operating Cruise Control
system.
Engine speed pattern
2500 r/min - Measure each engine
Engine speed
speed for 20 seconds.
2000 r/min
1500 r/min
1000 r/min
750r/min
Time
SHTS021270300306
<Acceleration pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Check that actual common rail pressure following target.
Acceleration pattern
At least three times, repeating the Wide-Open Throttle
100%
opening
Throttle
20sec 20sec
0%
Time
SHTS021270300307
ENGINE (J05E)/TROUBLESHOOTING 2–385
2 Types of HINO-DX data to be measured
SHTS021270300308
2–386 ENGINE (J05E)/TROUBLESHOOTING
3 If the following symptoms occur, FAIL. If not, OK.
a. Pressure is reduced by 5 MPa or more continually for 5 seconds or
more. Replace the supply pump.
Engine speed pattern
Common rail pressure
Actual common rail pressure
a: Pressure is reduced by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300309
b. Pressure is increased by 5 MPa or more continually for 5 seconds or
more. Replace the SCV.
Engine speed pattern
Common rail pressure
Actual common rail pressure
Pressure is increased by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300310
c. The maximum common rail pressure exceeds 222 MPa for even a
moment during pressure increase. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300311
ENGINE (J05E)/TROUBLESHOOTING 2–387
d. After the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300312
e. Before the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure rapidly. Replace the common rail.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300313
f. The maximum common rail pressure exceeds 222 MPa during pres-
sure drop. Check the return pipe.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300314
g. The pressure is disturbed at a given speed and the pressure
decreases at higher speed. Replace the supply pump.
Engine speed pattern
Common rail pressure
The pressure is disturbed
at a given speed and the Actual common rail pressure
10 MPa or more pressure decreases at
higher speed. Target common rail pressure
Remains for 5 seconds or longer.
Time
SHTS021270300315
2–388 ENGINE (J05E)/TROUBLESHOOTING
h. Hunting remains within 10 MPa or more for more than 5 seconds.
Replace the SCV.
Engine speed pattern
Common rail pressure
Actual common rail pressure
10 MPa or more
Target common rail pressure
Remains for 5 seconds or longer.
Time
SHTS021270300316
i. The engine stops during pressure relief. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300317
ENGINE (J05E)/TROUBLESHOOTING 2–389
j. Target common rail pressure during idling deviates from the standard
value. Replace the SCV.
.
<FINAL VALUE OF PUMP CURRENT TARGET test>
1. After engine has reached operating temperature. (more than 82 C
{179.6 F})
2. After air compressor has completed building pressure.
3. A/C, Head lights are off.
4. All other devices turned off. (PTO, Refrigeration compressor. etc)
5. Engine speed: 750 r/min
Criteria
Average current
FINAL VALUE OF 1740 80 mA
value
PUMP CURRENT
TARGET Fluctuation in cur-
< 80 mA
rent value
Current value [mA]
Target current value
Average current value (30sec)
Fluctuation in current value
Time [sec]
SHTS021270300318
2–390 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P016E and P016F
DTC: P016E Fuel system pressure control - high
Inspection procedure
DTC: P016F Fuel system pressure control - low
Check
Step Action Description Judgement Yes No
(Yes/No)
The engine
can be started:
Inspect the Go to YES.
1 start of the Inspect the start of the engine. Go to step 4. Go to step 2.
engine Cannot be
started: Go to
NO.
Failure found:
Go to YES. Replace the
Inspect the Check if fuel is leaking or seeping supply pump,
2 Go to step 3.
supply pump out of the supply pump. No failure and go to step
found: Go to 4.
NO.
Select [Actual common rail pres-
sure] from [Data Monitor] in
Failure found:
[Engine] of HINO-DX menu and,
Function Go to YES. Replace the Contact the
start the engine while checking
check of sup- supply pump, Hino national
3 the common rail pressure.
ply pump No failure and go to step service man-
<Standard values>
[HINO-DX] found: Go to 4. ager.
The actual common rail pressure
NO.
rises and stabilizes at a constant
value.
1. Select [Freeze Frame] of the
DTC (P016E or P016F) in
[Fault Information] in HINO-DX
menu, and confirm the freeze-
frame data.
It is the latest
2. Conduct an SCV test and con- product num-
firm the existing data. ber: Go to
SCV free Reprogram the
• For a detailed procedure, YES.
acceleration engine ECU
4 refer to the separate "SCV Go to step 5.
test [HINO- and then go to
free acceleration test". It is not the lat-
DX] step 5.
HINT est product
The data obtained in this proce- number: Go to
dure will serve as comparison NO.
data in subsequent proce-
dures.
3. Check the engine ECU product
number.
ENGINE (J05E)/TROUBLESHOOTING 2–391
DTC: P016E Fuel system pressure control - high
Inspection procedure
DTC: P016F Fuel system pressure control - low
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Inspect the fuel filter.
• Has the replacement period
expired?
• Is it dirty, damaged, or
clogged?
• Is it a genuine Hino part? Failure found:
2. Check if the fuel inside the fuel Go to YES. Replace the
Inspect the filter is within the standard fuel filter ele-
5 value. Go to step 11.
fuel filter No failure ment, and go
<Measurement conditions> found: Go to to step 6.
While engine is running NO.
<Standard values>
• At least 25.4 mm {1 in.} above
collar and below the element
upper level.
• Fuel level does not continue to
drop during high-speed idle.
1. Check if the fuel pipe and hose Failure found:
between the fuel tank and fuel Go to YES. Repair or
Inspect the filter are clogged, punctured, or replace the
6 Go to step 7.
fuel pipe bent. No failure faulty part, and
2. Make sure the fuel pipe joint found: Go to go to step 7.
bolts are not loose. NO.
Failure found:
1. Check if the breather hose is Go to YES. Repair or
Inspect the
clogged, punctured, or bent. replace the
7 fuel tank Go to step 8.
2. Make sure the check valve is No failure faulty part, and
breather
functioning normally. found: Go to go to step 8.
NO.
Failure found:
Go to YES. Repair or
Inspect the
Make sure the fuel tank feed pipe replace the
8 fuel tank feed Go to step 9.
is not clogged. No failure faulty part, and
pipe
found: Go to go to step 9.
NO.
Failure found:
Remove the
Go to YES.
Drain fuel out of the fuel tank and foreign objects
Inspect the
9 check if there are foreign objects and clean the Go to step 10.
fuel tank No failure
inside the tank. fuel tank. Then
found: Go to
go to step 10.
NO.
Failure found:
Go to YES. Clean the
Inspect the
Make sure the gauze filter (built gauze filter,
10 fuel pump Go to step 11.
into the fuel pump) is not clogged. No failure and go to step
gauze filter
found: Go to 11.
NO.
2–392 ENGINE (J05E)/TROUBLESHOOTING
DTC: P016E Fuel system pressure control - high
Inspection procedure
DTC: P016F Fuel system pressure control - low
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES. Repair or
Inspect the
Make sure the fuel high-pressure replace the
11 fuel high-pres- Go to step 12.
pipe is not leaking fuel. No failure faulty part, and
sure pipe.
found: Go to go to step 12.
NO.
If failure was
Failure found: found in steps
Go to YES. Repair or 6 – 11: Go to
Inspect the
Make sure the bubble separator is replace the step 13.
12 bubble separa-
not clogged. No failure faulty part, and If failure was
tor
found: Go to go to step 13. not found in
NO. steps 6 – 11:
Go to step 14.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
13 inspection Go to step 14.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the results with those not improve: INFORMA-
obtained in step 4 and check if Go to NO. TION section.
they improved.
Failure found:
Go to YES. Repair or
Inspect the Check the connection of the SCV
replace the
14 SCV connec- connector (looseness and poor Go to step 15.
No failure faulty part, and
tor contact).
found: Go to go to step 15.
NO.
Failure found:
Inspect the Go to YES. Repair or
Check the connection of the com-
common rail replace the
15 mon rail pressure sensor connec- Go to step 16.
pressure sen- No failure faulty part, and
tor (looseness and poor contact).
sor connector found: Go to go to step 16.
NO.
1. Disconnect the common rail The measure-
pressure sensor connector and ments meet
measure the voltage between the standard
Inspect the the terminals of the common value: Go to
rail pressure sensor vehicle Repair the
common rail YES.
side connector sensor and
16 pressure sen- Go to step 17.
<Tester connections> then go to step
sor power sup- The measure-
common rail pressure sensor 17.
ply ments do not
vehicle side connector meet the stan-
VC2 – GND dard value: Go
<Standard values> to NO.
4.5 – 5.5 V
ENGINE (J05E)/TROUBLESHOOTING 2–393
DTC: P016E Fuel system pressure control - high
Inspection procedure
DTC: P016F Fuel system pressure control - low
Check
Step Action Description Judgement Yes No
(Yes/No)
Check any
Select [NE sensor active flag], [G
Inspect the Failure found: faulty sensor
sensor active flag] in [Data Moni-
engine speed Go to YES. and repair or
tor].
main sensor replace it as
17 Start the engine and confirm that Go to step 18.
(crankshaft No failure needed.
the engine main speed sensor
position sen- found: Go to After inspec-
(NE) and sub speed sensor (G)
sor) NO. tion, go to step
operate (stay ON) continuously.
18.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
18 inspection Go to step 19.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
1. Check that the malfunction pat-
tern from the malfunction repro-
duction test carried out in step
18, and replace the pertinent
part.
<Reproduction test results>
The results Procedure
- a, g: Replace the fuel pump. improved: Go completed.
SCV free - b, c, d, h, i, j: Replace the to YES. Perform "After-
acceleration SCV.
19 inspection Go to step 20.
test [HINO-
- e: Replace the common rail. The results did work" of
DX]
- f: Check the fuel return pipe/ not improve: INFORMA-
hose. Go to NO. TION section.
2. After replacing the part, per-
form the SCV test and malfunc-
tion reproduction test again.
3. Compare the test results with
those obtained in step 4 and
check if they improved.
Failure found:
Go to YES. Repair or
Inspect the
Check if the fuel return pipe and replace the
20 fuel return Go to step 21.
hose are clogged. No failure faulty part, and
pipe and hose
found: Go to go to step 21.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
21 inspection Go to step 22.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
2–394 ENGINE (J05E)/TROUBLESHOOTING
DTC: P016E Fuel system pressure control - high
Inspection procedure
DTC: P016F Fuel system pressure control - low
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES. Repair or
Check again Check the fuel pipe again (steps 6 replace the
22 Go to step 23.
the fuel pipe – 12). No failure faulty part, and
found: Go to go to step 23.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
23 inspection Go to step 24.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
Failure found:
Go to YES. Repair or
Check again
Check the sensor system again replace the
24 the sensor Go to step 25.
(steps 14 – 17). No failure faulty part, and
system
found: Go to go to step 25.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, Contact the
to YES. Perform "After-
acceleration refer to the separate "SCV Hino national
25 inspection
test [HINO- free acceleration test". service man-
The results did work" of
DX] 2. Compare the test results with ager.
not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
ENGINE (J05E)/TROUBLESHOOTING 2–395
DTC: P0182 and P0183
EN01H02127030602016051
P0182: Fuel temperature sensor Low
INFORMATION
Engine ECU
Y57 (THF) 2mA JSR (THF)
Fuel temperature sensor ZDQ (E2) 10mA
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail pressure sensor EBN 15mA Z72
(E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300319
1. Technical description
• The fuel temperature sensor consistently measures fuel temperature.
• The fuel temperature sensor is installed to the supply pump.
<Description of malfunction>
• The fuel temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
• Output of the fuel temperature sensor remains at 0.1 V or less for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–396 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Irregular contact (wet of connector)
• Abnormal resistance of sensor
• Harness disconnection or short-circuit
• Engine ECU sensor power supply failure or internal circuit failure
• Faulty connector contact or fit
ENGINE (J05E)/TROUBLESHOOTING 2–397
P0183: Fuel temperature sensor High
INFORMATION
Engine ECU
Y57 (THF) 2mA JSR (THF)
Fuel temperature sensor ZDQ (E2) 10mA
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail pressure sensor EBN 15mA Z72
(E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300320
1. Technical description
• The fuel temperature sensor consistently measures fuel temperature.
• The fuel temperature sensor is installed to the supply pump.
<Description of malfunction>
• The fuel temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
• Output of the fuel temperature sensor remains at 4.85 V or greater for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–398 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Irregular contact (disconnection or poor fit)
• Abnormal resistance of sensor
• Harness disconnection or short-circuit
• Engine ECU sensor power supply failure or internal circuit failure
• Faulty connector contact or fit
ENGINE (J05E)/TROUBLESHOOTING 2–399
INSPECTION PROCEDURE: P0182 and P0183
1 Inspect the fuel temperature sensor connector
1. Check the connection of the fuel temperature sensor connector
(looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the fuel temperature sensor
1. Check the installation of the fuel temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the fuel temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the fuel temperature sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–400 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the fuel temperature sensor unit
1. Set the starter key to the "LOCK" position.
E2 THF 2. Disconnect the connector of the fuel temperature sensor connec-
tor.
3. Use the electrical tester to measure the resistance between the
terminals of the fuel temperature sensor connector.
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
Fuel temperature
SHTS021270300321 2.32 – 2.59 k
Starter key: LOCK sensor
80 C {176 F}:
THF – E2
0.310 – 0.326 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the fuel temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the fuel temperature sensor power supply
1. Set the starter key to the "ON" position.
THF E2
2. Use the electrical tester to measure the voltage between the termi-
nals of the fuel temperature sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Fuel temperature
sensor vehicle
Starter key: ON 4.5 – 5.5 V
side connector
THF – E2
SHTS021270300322
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
ENGINE (J05E)/TROUBLESHOOTING 2–401
5 Inspect for short-circuits in wire harness of fuel temperature sensor
1. Set the starter key to the "LOCK" position.
E76 D E48
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminal of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300323 nal check har-
ness)
Starter key: LOCK
THF (E48) –
Ground
E2 (E76) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect disconnection of the fuel temperature sensor harness
1. Connect the connector of the fuel temperature sensor.
E76 D E48 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
20 C {68 F}:
nal check har-
2.32 – 2.59 k
Starter key: LOCK ness)
80 C {176 F}:
THF (E48) –
0.310 – 0.326 k
SHTS021270300324 E2 (E76)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–402 ENGINE (J05E)/TROUBLESHOOTING
7 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0182 or P0183) has been
detected in [Fault Information].
SHTS021270300325
Has DTC (P0182 or P0183) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–403
CHECKLIST: P0182 and P0183
DTC: P0182 Fuel temperature sensor Low
Inspection procedure
DTC: P0183 Fuel temperature sensor High
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the fuel needed.
fuel tempera-
1 temperature sensor connector Perform "After- Go to step 2.
ture sensor No failure
(looseness and poor contact). inspection
connector found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
fuel temperature sensor con-
Go to YES. If damaged,
Inspect the nector.
replace the
2 fuel tempera- 2. Make sure there is no dirt, Go to step 3.
No failure sensor.
ture sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the fuel temper- NO. inspection
ature sensor. work" of
INFORMA-
TION section.
Disconnect the fuel temperature
sensor connector and measure
the resistance between the termi- Replace the
Failure found:
nals of the fuel temperature sen- sensor.
Inspect the Go to YES.
sor. Perform "After-
fuel tempera-
3 <Tester connections> Go to step 4. inspection
ture sensor No failure
Fuel temperature sensor work" of
unit found: Go to
THF – E2 INFORMA-
NO.
<Standard values> TION section.
20 C {68 F}: 2.32 – 2.59 k
80 C {176 F}: 0.310 – 0.326 k
The measure-
Measure the voltage between the
ments meet
terminals of the fuel temperature
the standard
sensor vehicle side sensor con-
value: Go to
Inspect the nector.
YES.
fuel tempera- <Tester connections>
4 Go to step 7. Go to step 5.
ture sensor Fuel temperature sensor vehicle
The measure-
power supply side connector
ments do not
THF – E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
2–404 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0182 Fuel temperature sensor Low
Inspection procedure
DTC: P0183 Fuel temperature sensor High
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check har-
The measure-
ness, and measure the resistance
ments meet
between the terminals of the Repair or
the standard
Inspect for engine ECU (signal check har- replace the
value: Go to
short-circuits ness) and ground. harness.
YES.
in wire har- <Tester connections> Perform "After-
5 Go to step 6.
ness of fuel Engine ECU inspection
The measure-
temperature (signal check harness) work" of
ments do not
sensor THF (E48) – Ground INFORMA-
meet the stan-
E2 (E76) – Ground TION section.
dard value: Go
<Standard values>
to NO.
Connect the fuel temperature
The measure-
sensor connector, and measure
ments meet
the resistance between the termi- Repair or
the standard
nals of the engine ECU (signal replace the
Inspect dis- value: Go to
check harness). harness.
connection of YES.
<Tester connections> Perform "After-
6 the fuel tem- Go to step 7.
Engine ECU inspection
perature sen- The measure-
(signal check harness) work" of
sor harness ments do not
THF (E48) – E2 (E76) INFORMA-
meet the stan-
<Standard values> TION section.
dard value: Go
20 C {68 F}: 2.32 – 2.59 k
to NO.
80 C {176 F}: 0.310 – 0.326 k
DTC (P0182
Replace the Procedure
or P0183) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0182 or Perform "After- Perform "After-
Go to YES.
7 DTC detected P0183) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–405
DTC: P0191
EN01H02127030602016052
P0191: Fuel rail pressure sensor (main and sub) - out of range
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300326
1. Technical description
• The common rail pressure is controlled by the discharge of the supply pump.
• The supply pump discharge rate is adjusted by the SCV (suction control valve).
<Description of malfunction>
• Abnormally low fuel pressure inside common rail is detected.
2. DTC set condition
(1) DTC detection condition
• Engine speed ≥ 700 r/min.
• Fuel injection rate ≥ 10 mm3/st. cyl.
• Fuel injection rate fluctuation ≤ 2.6 mm3/st. cyl. sec.
• Target current value of SCV ≤ 1,250 mA.
• No supply pump-related DTC is detected.
(2) Judgement criteria
• (Actual common rail pressure – target common rail pressure) ≤ -15 MPa for 15 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: OFF
• Engine output is restricted.
• Cruise control function is not available.
• Idling stop system is not available.
• Vehicle start control is not available.
2–406 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• Cruise control does not work.
• Idling stop system does not work.
• Vehicle start control does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Fuel filter: clogged
• Common rail pressure sensor: faulty contact (power supply fault or GND fault), sensor failure
• Supply pump: SCV fault, learning value fault
• Common rail: pressure limiter valve open
• Harness-related malfunction: faulty contact or wrong connection in engine speed main sensor or engine speed sub
sensor
ENGINE (J05E)/TROUBLESHOOTING 2–407
INSPECTION PROCEDURE: P0191
1 Inspect the start of the engine
1. Inspect the start of the engine.
Does the engine start?
YES NO
Go to step 4. Go to step 2.
2 Inspect the supply pump
1. Check if fuel is leaking or seeping out of the supply pump.
Was any failure found?
YES NO
Replace the supply pump, and go to step 4. Go to step 3.
3 Function check of supply pump [HINO-DX]
1. Connect the vehicle to HINO-DX.
Actual common rail pressure
Specified common rail pressure
2. Set the starter key to the "ON" position.
222MP
Common rail pressure
The pressure limiter is 3. Select [Engine].
open reducing the pressure.
4. Select [Actual common rail pressure] from the [Data Monitor]
Idling menu.
5. Start the engine while checking the common rail pressure.
Starter (Engine starting) Hour
Standard values
SHTS021270300327
The actual common rail pressure rises and stabilizes at a
constant value.
Was any failure found?
YES NO
Replace the supply pump, and go to step 4. Contact the Hino national service manager.
2–408 ENGINE (J05E)/TROUBLESHOOTING
4 SCV free acceleration test [HINO-DX]
1. Select [Freeze Frame] of DTC P0191 from [Fault Information] in
HINO-DX menu, and confirm the freeze-frame data.
2. Conduct an SCV test and confirm the existing data.
Select
Engine • For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
HINT
The data obtained in this procedure will serve as comparison data
in subsequent procedures.
3. Check the engine ECU product number.
SHTS021270300328
Does the engine ECU have the latest product number?
YES NO
Go to step 5. Reprogram the engine ECU and then go to
step 5.
(Refer to "DIAGNOSIS USING THE PC DAI-
GNOSIS TOOL".)
5 Inspect the fuel filter
1. Inspect the fuel filter.
• Has the replacement period expired?
• Is it dirty, damaged, or clogged?
• Is it a genuine Hino part?
2. Check if the fuel inside the fuel filter is within the standard value.
Measurement conditions Standard values
• At least 25.4 mm {1 in.}
above collar and below the
element upper level.
While engine is running
• Fuel level does not con-
tinue to drop during high-
speed idle.
Was any failure found?
YES NO
Replace the fuel filter element, and go to step Go to step 11.
6.
ENGINE (J05E)/TROUBLESHOOTING 2–409
6 Inspect the fuel pipe
1. Check if the fuel pipe and hose between the fuel tank and fuel filter
are clogged, punctured, or bent.
2. Make sure the fuel pipe joint bolts are not loose.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 7.
step 7.
7 Inspect the fuel tank breather
1. Check if the breather hose is clogged, punctured, or bent.
2. Make sure the check valve is functioning normally.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 8.
step 8.
2–410 ENGINE (J05E)/TROUBLESHOOTING
8 Inspect the fuel tank feed pipe
1. Make sure the fuel tank feed pipe is not clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 9.
step 9.
9 Inspect the fuel tank
1. Drain fuel out of the fuel tank and check if there are foreign objects
inside the tank.
Was any failure found?
YES NO
Remove the foreign objects and clean the Go to step 10.
fuel tank.
Then go to step 10.
10 Inspect the supply pump gauze filter
1. Make sure the gauze filter (built into the supply pump) is not
clogged.
Was any failure found?
YES NO
Clean the gauze filter, and go to step 11. Go to step 11.
ENGINE (J05E)/TROUBLESHOOTING 2–411
11 Inspect the fuel high-pressure pipe.
1. Make sure the fuel high-pressure pipe is not leaking fuel.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 12.
step 12.
12 Inspect the bubble separator
1. Make sure the bubble separator is not clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to If failure was found in steps 6 – 11: Go to
step 13. step 13.
If failure was not found in steps 6 – 11: Go to
step 14.
13 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select
Engine 2. Compare the results with those obtained in step 4 and check if
they improved.
SHTS021270300329
Did the test results improve?
YES NO
Procedure completed. Go to step 14.
Perform "After-inspection work" of INFOR-
MATION section.
2–412 ENGINE (J05E)/TROUBLESHOOTING
14 Inspect the SCV connector
1. Check the connection of the SCV connector (looseness and poor
contact).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 15.
step 15.
15 Inspect the common rail pressure sensor connector
1. Check the connection of the common rail pressure sensor connec-
tor (looseness and poor contact).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 16.
step 16.
ENGINE (J05E)/TROUBLESHOOTING 2–413
16 Inspect the common rail pressure sensor power supply
1. Disconnect the common rail pressure sensor connector.
VC2 E2
2. Set the starter key to the "ON" position.
3. Use the electrical tester to measure the voltage between the termi-
nals of the common rail pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300330 cle side connector
VC2 – E2
Do the measurements meet the standard value?
YES NO
Go to step 17. Repair the common rail pressure sensor and
then go to step 17.
17 Inspect the engine speed main sensor (crankshaft position sensor)
1. Set the starter key to the "ON" position.
2. Select [Engine].
Select
3. Select [NE Active identification], [G Active identification] in [Data
Engine
Monitor].
4. Start the engine and confirm that the engine main speed sensor
(NE) and sub speed sensor (G) operate (stay ON) continuously.
SHTS021270300331
Was any failure found?
YES NO
Check any faulty sensor and repair or Go to step 18.
replace it as needed.
After inspection, go to step 18.
2–414 ENGINE (J05E)/TROUBLESHOOTING
18 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select
Engine 2. Compare the test results with those obtained in step 4 and check if
they improved.
SHTS021270300332
Did the test results improve?
YES NO
Procedure completed. Go to step 19.
Perform "After-inspection work" of INFOR-
MATION section.
19 SCV free acceleration test [HINO-DX]
1. Check that the malfunction pattern from the malfunction reproduc-
tion test carried out in step 18, and replace the pertinent part.
<Reproduction test results>
Select
Engine - a, g: Replace the supply pump.
- b, c, d, h, i, j: Replace the SCV.
- e: Replace the common rail.
- f: Check the fuel return pipe/hose.
2. After replacing the part, perform the SCV test and malfunction
reproduction test again.
SHTS021270300333
3. Compare the test results with those obtained in step 4 and check if
they improved.
Did the test results improve?
YES NO
Procedure completed. Go to step 20.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–415
20 Inspect the fuel return pipe and hose
1. Check if the fuel return pipe and hose are clogged.
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 21.
step 21.
21 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select
Engine 2. Compare the test results with those obtained in step 4 and check if
they improved.
SHTS021270300334
Did the test results improve?
YES NO
Procedure completed. Go to step 22.
Perform "After-inspection work" of INFOR-
MATION section.
22 Check again the fuel pipe
1. Check the fuel pipe again (steps 6 – 12).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 23.
step 23.
2–416 ENGINE (J05E)/TROUBLESHOOTING
23 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select
Engine 2. Compare the test results with those obtained in step 4 and check if
they improved.
SHTS021270300335
Did the test results improve?
YES NO
Procedure completed. Go to step 24.
Perform "After-inspection work" of INFOR-
MATION section.
24 Check again the sensor system
1. Check the sensor system again (steps 14 – 17).
Was any failure found?
YES NO
Repair or replace the faulty part, and go to Go to step 25.
step 25.
ENGINE (J05E)/TROUBLESHOOTING 2–417
25 SCV free acceleration test [HINO-DX]
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Select
Engine 2. Compare the test results with those obtained in step 4 and check if
they improved.
SHTS021270300336
Did the test results improve?
YES NO
Procedure completed. Contact the Hino national service manager.
Perform "After-inspection work" of INFOR-
MATION section.
2–418 ENGINE (J05E)/TROUBLESHOOTING
SCV FREE ACCELERATION TEST
1 Test method
<Engine speed pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Control the engine revolution by means of operating Cruise Control
system.
Engine speed pattern
2500 r/min. - Measure each engine
Engine speed
speed for 20 seconds.
2000 r/min.
1500 r/min.
1000 r/min.
750r/min.
Time
SHTS021270300337
<Acceleration pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Check that actual common rail pressure following target.
Acceleration pattern
At least three times, repeating the Wide-Open Throttle
100%
opening
Throttle
20sec 20sec
0%
Time
SHTS021270300338
ENGINE (J05E)/TROUBLESHOOTING 2–419
2 Types of HINO-DX data to be measured
SHTS021270300339
2–420 ENGINE (J05E)/TROUBLESHOOTING
3 If the following symptoms occur, FAIL. If not, OK.
a. Pressure is reduced by 5 MPa or more continually for 5 seconds or
more. Replace the supply pump.
Engine speed pattern
Common rail pressure
Actual common rail pressure
a: Pressure is reduced by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300340
b. Pressure is increased by 5 MPa or more continually for 5 seconds or
more. Replace the SCV.
Engine speed pattern
Common rail pressure
Actual common rail pressure
Pressure is increased by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300341
c. The maximum common rail pressure exceeds 222 MPa for even a
moment during pressure increase. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300342
ENGINE (J05E)/TROUBLESHOOTING 2–421
d. After the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300343
e. Before the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure rapidly. Replace the common rail.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300344
f. The maximum common rail pressure exceeds 222 MPa during pres-
sure drop. Check the return pipe.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300345
g. The pressure is disturbed at a given speed and the pressure
decreases at higher speed. Replace the supply pump.
Engine speed pattern
Common rail pressure
The pressure is disturbed
at a given speed and the Actual common rail pressure
10 MPa or more pressure decreases at
higher speed. Target common rail pressure
Remains for 5 seconds or longer.
Time
SHTS021270300346
2–422 ENGINE (J05E)/TROUBLESHOOTING
h. Hunting remains within 10 MPa or more for more than 5 seconds.
Replace the SCV.
Engine speed pattern
Common rail pressure
Range remains within 10 Actual common rail pressure
10 MPa or more MPa or more for more
Target common rail pressure
than 5 seconds.
Remains for 5 seconds or longer.
Time
SHTS021270300347
i. The engine stops during pressure relief. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300348
ENGINE (J05E)/TROUBLESHOOTING 2–423
j. Target common rail pressure during idling deviates from the standard
value. Replace the SCV.
.
<FINAL VALUE OF PUMP CURRENT TARGET test>
1. After engine has reached operating temperature. (More than 82 C
{179.6 F})
2. After air compressor has completed building pressure.
3. A/C, Head lights are off.
4. All other devices turned off. (PTO, Refrigeration compressor. etc)
5. Engine speed: 750 r/min
Criteria
Average current
FINAL VALUE OF 1,740 80 mA
value
PUMP CURRENT
TARGET Fluctuation in cur-
< 80 mA
rent value
Current value [mA]
Target current value
Average current value (30sec)
Fluctuation in current value
Time [sec]
SHTS021270300349
2–424 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0191
Fuel rail pressure sensor
DTC: P0191 Inspection procedure
(main and sub) - out of range
Check
Step Action Description Judgement Yes No
(Yes/No)
The engine
can be started:
Inspect the Go to YES.
1 start of the Inspect the start of the engine. Go to step 4. Go to step 2.
engine Cannot be
started: Go to
NO.
Failure found:
Go to YES. Replace the
Inspect the Check if fuel is leaking or seeping supply pump,
2 Go to step 3.
supply pump out of the supply pump. No failure and go to step
found: Go to 4.
NO.
Select [Actual common rail pres-
sure] from [Data Monitor] in
Failure found:
[Engine] of HINO-DX menu and,
Function Go to YES. Replace the Contact the
start the engine while checking
check of sup- supply pump, Hino national
3 the common rail pressure.
ply pump No failure and go to step service man-
<Standard values>
[HINO-DX] found: Go to 4. ager.
The actual common rail pressure
NO.
rises and stabilizes at a constant
value.
1. Select [Freeze Frame] of the
DTC P0191 in [Fault Informa-
tion] in HINO-DX menu, and
confirm the freeze-frame data.
2. Conduct an SCV test and con- It is the latest
firm the existing data. product num-
ber: Go to
SCV free • For a detailed procedure, Reprogram the
YES.
acceleration refer to the separate "SCV engine ECU
4 Go to step 5.
test [HINO- free acceleration test". and then go to
It is not the lat-
DX] HINT step 5.
est product
The data obtained in this proce- number: Go to
dure will serve as comparison NO.
data in subsequent proce-
dures.
3. Check the engine ECU product
number.
ENGINE (J05E)/TROUBLESHOOTING 2–425
Fuel rail pressure sensor
DTC: P0191 Inspection procedure
(main and sub) - out of range
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Inspect the fuel filter.
• Has the replacement period
expired?
• Is it dirty, damaged, or
clogged?
• Is it a genuine Hino part? Failure found:
2. Check if the fuel inside the fuel Go to YES. Replace the
Inspect the filter is within the standard fuel filter ele-
5 value. Go to step 11.
fuel filter No failure ment, and go
<Measurement conditions> found: Go to to step 6.
While engine is running NO.
<Standard values>
• At least 25.4 mm {1 in.} above
collar and below the element
upper level.
• Fuel level does not continue to
drop during high-speed idle.
1. Check if the fuel pipe and hose Failure found:
between the fuel tank and fuel Go to YES. Repair or
Inspect the filter are clogged, punctured, or replace the
6 Go to step 7.
fuel pipe bent. No failure faulty part, and
2. Make sure the fuel pipe joint found: Go to go to step 7.
bolts are not loose. NO.
Failure found:
1. Check if the breather hose is Go to YES. Repair or
Inspect the
clogged, punctured, or bent. replace the
7 fuel tank Go to step 8.
2. Make sure the check valve is No failure faulty part, and
breather
functioning normally. found: Go to go to step 8.
NO.
Failure found:
Go to YES. Repair or
Inspect the
Make sure the fuel tank feed pipe replace the
8 fuel tank feed Go to step 9.
is not clogged. No failure faulty part, and
pipe
found: Go to go to step 9.
NO.
Failure found:
Remove the
Go to YES.
Drain fuel out of the fuel tank and foreign objects
Inspect the
9 check if there are foreign objects and clean the Go to step 10.
fuel tank No failure
inside the tank. fuel tank. Then
found: Go to
go to step 10.
NO.
Failure found:
Go to YES. Clean the
Inspect the
Make sure the gauze filter (built gauze filter,
10 fuel pump Go to step 11.
into the fuel pump) is not clogged. No failure and go to step
gauze filter
found: Go to 11.
NO.
2–426 ENGINE (J05E)/TROUBLESHOOTING
Fuel rail pressure sensor
DTC: P0191 Inspection procedure
(main and sub) - out of range
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES. Repair or
Inspect the
Make sure the fuel high-pressure replace the
11 fuel high-pres- Go to step 12.
pipe is not leaking fuel. No failure faulty part, and
sure pipe.
found: Go to go to step 12.
NO.
If failure was
Failure found: found in steps
Go to YES. Repair or 6 – 11: Go to
Inspect the
Make sure the bubble separator is replace the step 13.
12 bubble separa-
not clogged. No failure faulty part, and If failure was
tor
found: Go to go to step 13. not found in
NO. steps 6 – 11:
Go to step 14.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
13 inspection Go to step 14.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the results with those not improve: INFORMA-
obtained in step 4 and check if Go to NO. TION section.
they improved.
Failure found:
Go to YES. Repair or
Inspect the Check the connection of the SCV
replace the
14 SCV connec- connector (looseness and poor Go to step 15.
No failure faulty part, and
tor contact).
found: Go to go to step 15.
NO.
Failure found:
Inspect the Go to YES. Repair or
Check the connection of the com-
common rail replace the
15 mon rail pressure sensor connec- Go to step 16.
pressure sen- No failure faulty part, and
tor (looseness and poor contact).
sor connector found: Go to go to step 16.
NO.
1. Disconnect the common rail The measure-
pressure sensor connector and ments meet
measure the voltage between the standard
Inspect the the terminals of the common value: Go to
rail pressure sensor vehicle Repair the
common rail YES.
side connector sensor and
16 pressure sen- Go to step 17.
<Tester connections> then go to step
sor power sup- The measure-
common rail pressure sensor 17.
ply ments do not
vehicle side connector meet the stan-
VC2 – E2 dard value: Go
<Standard values> to NO.
4.5 – 5.5 V
ENGINE (J05E)/TROUBLESHOOTING 2–427
Fuel rail pressure sensor
DTC: P0191 Inspection procedure
(main and sub) - out of range
Check
Step Action Description Judgement Yes No
(Yes/No)
Check any
Select [NE sensor active flag], [G
Inspect the Failure found: faulty sensor
sensor active flag] in [Data Moni-
engine speed Go to YES. and repair or
tor].
main sensor replace it as
17 Start the engine and confirm that Go to step 18.
(crankshaft No failure needed.
the engine main speed sensor
position sen- found: Go to After inspec-
(NE) and sub speed sensor (G)
sor) NO. tion, go to step
operate (stay ON) continuously.
18.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
18 inspection Go to step 19.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
1. Check that the malfunction pat-
tern from the malfunction repro-
duction test carried out in step
18, and replace the pertinent
part.
<Reproduction test results>
The results Procedure
- a, g: Replace the fuel pump. improved: Go completed.
SCV free - b, c, d, h, i, j: Replace the to YES. Perform "After-
acceleration SCV.
19 inspection Go to step 20.
test [HINO-
- e: Replace the common rail. The results did work" of
DX]
- f: Check the fuel return pipe/ not improve: INFORMA-
hose. Go to NO. TION section.
2. After replacing the part, per-
form the SCV test and malfunc-
tion reproduction test again.
3. Compare the test results with
those obtained in step 4 and
check if they improved.
Failure found:
Go to YES. Repair or
Inspect the
Check if the fuel return pipe and replace the
20 fuel return Go to step 21.
hose are clogged. No failure faulty part, and
pipe and hose
found: Go to go to step 21.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
21 inspection Go to step 22.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
2–428 ENGINE (J05E)/TROUBLESHOOTING
Fuel rail pressure sensor
DTC: P0191 Inspection procedure
(main and sub) - out of range
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Go to YES. Repair or
Check again Check the fuel pipe again (steps 6 replace the
22 Go to step 23.
the fuel pipe – 12). No failure faulty part, and
found: Go to go to step 23.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, to YES. Perform "After-
acceleration refer to the separate "SCV
23 inspection Go to step 24.
test [HINO- free acceleration test". The results did work" of
DX] 2. Compare the test results with not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
Failure found:
Go to YES. Repair or
Check again
Check the sensor system again replace the
24 the sensor Go to step 25.
(steps 14 – 17). No failure faulty part, and
system
found: Go to go to step 25.
NO.
1. Perform an SCV test and a
malfunction reproduction test. The results Procedure
improved: Go completed.
SCV free • For a detailed procedure, Contact the
to YES. Perform "After-
acceleration refer to the separate "SCV Hino national
25 inspection
test [HINO- free acceleration test". service man-
The results did work" of
DX] 2. Compare the test results with ager.
not improve: INFORMA-
those obtained in step 4 and Go to NO. TION section.
check if they improved.
ENGINE (J05E)/TROUBLESHOOTING 2–429
DTC: P0192 and P0193
EN01H02127030602016053
P0192: Fuel rail pressure sensor (main) - out of range (Out of range low)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300350
1. Technical description
• The common rail pressure sensor consistently measures common rail pressure.
<Description of malfunction>
• Common rail pressure cannot be correctly sensed.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the common rail pressure sensor (main) remains at 0.7 V (-10.7 MPa) or lower for 0.2 seconds or
longer.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–430 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Sensor internal short.
ENGINE (J05E)/TROUBLESHOOTING 2–431
P0193: Fuel rail pressure sensor (main) - out of range (Out of range high)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300351
1. Technical description
• The common rail pressure sensor consistently measures common rail pressure.
<Description of malfunction>
• Common rail pressure cannot be correctly sensed.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the common rail pressure sensor (main) remains at 4.49 V (260 MPa) or higher for 0.2 seconds or
longer.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–432 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Abnormality in resistance of sensor
• Disconnection or short-circuit in sensor harness
• Engine ECU sensor power supply failure or internal circuit failure
• Irregular contact
ENGINE (J05E)/TROUBLESHOOTING 2–433
INSPECTION PROCEDURE: P0192 and P0193
1 Inspect the common rail pressure sensor connector
1. Check the connection of the common rail pressure sensor connec-
tor (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the common rail pressure sensor
1. Check the installation of the common rail pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the common rail pres-
sure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–434 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the common rail pressure sensor unit
1. Set the starter key to the "LOCK" position.
VC2
PCR2 2. Disconnect the connector of the common rail pressure sensor con-
E2 PCR2 VC2 nector.
(main) (main) (main)
VC1 PCR1 E1
(sub) (sub) (sub) 3. Use the electrical tester to measure the resistance between the
terminals of the common rail pressure sensor connector.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor
PCR2 (1) VC2 (main) – (1) 1.05 – 3.55 k
E2 Starter key: LOCK
E2 PCR2 VC2 PCR2 (main) (2) 6.7 – 18.7 k
(main) (main) (main) (2) PCR2 (main) –
VC1 PCR1 E1 E2 (main)
(sub) (sub) (sub)
SHTS021270300352
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the common rail pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–435
4 Inspect the common rail pressure sensor power supply
1. Set the starter key to the "ON" position.
VC2 E2
2. Use the electrical tester to measure the voltage between the termi-
nals of the common rail pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC2 – E2
SHTS021270300353
Do the measurements meet the standard value?
YES NO
Go to step 5. Go to step 6.
5 Inspect the common rail pressure sensor signal circuit
1. Set the starter key to the "LOCK" position.
VC2 PCR2
2. Use the electrical tester to measure the resistance between the
terminals of the common rail pressure sensor vehicle side connec-
tor.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: LOCK 200 – 250 k
cle side connector
SHTS021270300354 VC2 – PCR2
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
2–436 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect for short-circuits in wire harness of the common rail pressure sensor
1. Set the starter key to the "LOCK" position.
VC2 2. Disconnect the connector of the engine ECU.
GROUND
3. Use the electrical tester to measure the resistance between the
common rail pressure sensor vehicle side connector terminals and
ground.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
PCR2 Starter key: LOCK cle side connector
GROUND VC2 – Ground
PCR2 – Ground
SHTS021270300355
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–437
7 Inspect disconnection of the common rail pressure sensor harness
1. Connect the connector of the common rail pressure sensor.
C D E76
2. Connect the signal check harness to the engine ECU vehicle side
E33 harness. (Do not connect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
E65 D ness)
E64 E76
VC2 (E33) –
Starter key: LOCK E2 (E76) 2 or more
PCR2 (E64) –
E2 (E76)
PC2S (E65) –
E2 (E76)
SHTS021270300356
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–438 ENGINE (J05E)/TROUBLESHOOTING
8 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0192 or P0193) has been
detected in [Fault Information].
SHTS021270300357
Has DTC (P0192 or P0193) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–439
CHECKLIST: P0192 and P0193
Fuel rail pressure sensor (main)
DTC: P0192
- out of range (Out of range low)
Inspection procedure
Fuel rail pressure sensor (main)
DTC: P0193
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the com- needed.
common rail
1 mon rail pressure sensor connec- Perform "After- Go to step 2.
pressure sen- No failure
tor (looseness and poor contact). inspection
sor connector found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
Failure found: properly.
1. Check the installation of the
Inspect the Go to YES. If damaged,
common rail pressure sensor.
common rail replace the
2 2. Make sure there is no dirt, Go to step 3.
pressure sen- No failure sensor.
sor damage or clogging in the found: Go to Perform "After-
sensing unit of the sensor. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the resistance between ments meet
the terminals of the common rail the standard Replace the
pressure sensor connector. value: Go to sensor.
Inspect the
<Tester connections> YES. Perform "After-
common rail
3 (1) VC2 (main) – PCR2 (main) Go to step 4. inspection
pressure sen-
(2) PCR2 (main) – E2 (main) The measure- work" of
sor unit
<Standard values> ments do not INFORMA-
(1) 1.05 – 3.55 k meet the stan- TION section.
(2) 6.7 – 18.7 k dard value: Go
to NO.
The measure-
ments meet
Measure the voltage between the
the standard
terminals of the common rail
Inspect the value: Go to
pressure sensor vehicle side con-
common rail YES.
nector.
4 pressure sen- Go to step 5. Go to step 6.
<Tester connections>
sor power sup- The measure-
VC2 – E2
ply ments do not
<Standard values>
meet the stan-
4.5 – 5.5 V
dard value: Go
to NO.
2–440 ENGINE (J05E)/TROUBLESHOOTING
Fuel rail pressure sensor (main)
DTC: P0192
- out of range (Out of range low)
Inspection procedure
Fuel rail pressure sensor (main)
DTC: P0193
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
ments meet
Measure the voltage between the
the standard
terminals of the common rail
Inspect the value: Go to
pressure sensor vehicle side con-
common rail YES.
nector.
5 pressure sen- Go to step 8. Go to step 6.
<Tester connections>
sor signal cir- The measure-
VC2 – PCR2
cuit ments do not
<Standard values>
meet the stan-
200 – 250 k
dard value: Go
to NO.
The measure-
Disconnect the connector of the
ments meet
engine ECU, and measure the Repair or
Inspect for the standard
resistance between the common replace the
short-circuits value: Go to
rail pressure sensor vehicle side harness.
in wire har- YES.
connector terminals and ground. Perform "After-
6 ness of the Go to step 7.
<Tester connections> inspection
common rail The measure-
VC2 – Ground work" of
pressure sen- ments do not
PCR2 – Ground INFORMA-
sor meet the stan-
<Standard values> TION section.
dard value: Go
to NO.
1. Connect the connector of the
common rail pressure sensor. The measure-
2. Connect the signal check har- ments meet
Repair or
ness, and measure the resis- the standard
Inspect dis- replace the
tance between the terminals of value: Go to
connection of harness.
the engine ECU (signal check YES.
the common Perform "After-
7 harness). Go to step 8.
rail pressure inspection
<Tester connections> The measure-
sensor har- work" of
VC2 (E33) – E2 (E76) ments do not
ness INFORMA-
PCR2 (E64) – E2 (E76) meet the stan-
TION section.
PC2S (E65) – E2 (E76) dard value: Go
<Standard values> to NO.
2 or more
DTC (P0192
Replace the Procedure
or P0193) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0192 or Perform "After- Perform "After-
Go to YES.
8 DTC detected P0193) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–441
DTC: P01A5
EN01H02127030602016054
P01A5: Fuel rail pressure sensor (sub) - out of range (Out of range low)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300358
1. Technical description
• The common rail pressure (sub) sensor constantly measures the common rail pressure.
<Technical Description>
• Common rail pressure is not correctly recognized.
• Possible failure of common rail pressure (sub) sensor or harness GND short-circuit
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• Engine stall condition or engine speed above 500 r/min continues for 5 seconds.
(2) Judgement criteria
• Common rail pressure (sub) sensor voltage is below 1.2 V (-10.7 MPa) for 0.2 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
2–442 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Abnormal sensor resistance
• Harness disconnection or short-circuit
• looseness or poor contact of connector
• Engine ECU sensor power supply or internal circuit failure
ENGINE (J05E)/TROUBLESHOOTING 2–443
INSPECTION PROCEDURE: P01A5
1 Inspect the common rail pressure sensor connector
1. Check the connection of the common rail pressure sensor connec-
tor (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the common rail pressure sensor
1. Check the installation of the common rail pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of common rail pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the common rail pres-
sure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–444 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the common rail pressure sensor unit
1. Set the starter key to the "LOCK" position.
PCR1 2. Disconnect the common rail pressure sensor connector.
VC1 E2 PCR2 VC2
(main) (main) (main)
3. Measure the resistance between the terminals of the sensor using
VC1 PCR1 E1
(sub) (sub) (sub) the electrical tester.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor
(1) VC1 (sub) – (1) 1.05 – 3.55 k
Starter key: LOCK
PCR1 (sub) (2) 6.7 – 18.7 k
E1
PCR1 E2 PCR2 VC2 (2) PCR1 (sub) –
(main) (main) (main) E1 (sub)
VC1 PCR1 E1
(sub) (sub) (sub)
SHTS021270300359
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the common rail pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–445
4 Inspect the common rail pressure sensor power supply
1. Set the starter key to the "ON" position.
E1 VC1
2. Measure the voltage between the terminals of the common rail
pressure sensor vehicle side connector using the electrical tester.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC1 – E1
SHTS021270300360
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect the common rail pressure sensor signal circuit
1. Set the starter key to the "LOCK" position.
PCR1 VC1
2. Use the electrical tester to measure the resistance between the
terminals in the common rail pressure sensor vehicle side connec-
tor.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: LOCK 200 – 250 k
cle side connector
SHTS021270300361 VC1 – PCR1
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
2–446 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect for short-circuits in wire harness of the common rail pressure sensor
1. Set the starter key to the "LOCK" position.
VC1
2. Disconnect the engine ECU connector.
GROUND
3. Use the electrical tester to measure the resistance between the
common rail pressure sensor vehicle side connector terminals and
ground.
Measurement Tester
Standard values
conditions connections
Common rail pres-
PCR1 sure sensor vehi-
GROUND Starter key: LOCK cle side connector
VC1 – Ground
PCR1 – Ground
SHTS021270300362
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–447
7 Inspect disconnection of the common rail pressure sensor harness
1. Connect the common rail pressure sensor connector.
E13
C D E56
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals in the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
E49
E56 D E68
nal check har-
ness)
VC1(E13) –
Starter key: LOCK E1(E56) 2 or more
PCR1(E49) –
E1(E56)
PC1S(E68) –
E1(E56)
SHTS021270300363
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
8 Check the DTC detected (Engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80C
{176F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P01A5 has been detected in [Fault
Information].
SHTS021270300364
Has DTC P01A5 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–448 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P01A5
Fuel rail pressure sensor (sub) - out of range
DTC: P01A5 Inspection procedure
(Out of range low)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the com- needed.
common rail
1 mon rail pressure sensor connec- Perform "After- Go to step 2.
pressure sen- No failure
tor (looseness and poor contact). inspection
sor connector found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the Failure found: properly.
Inspect the common rail pressure sensor. Go to YES. If damaged,
common rail 2. Make sure there is no dirt, replace the
2 Go to step 3.
pressure sen- damage or clogging in the No failure sensor.
sor sensing unit of common rail found: Go to Perform "After-
pressure sensor. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet Replace the
the terminals of the common rail
the standard common rail
pressure.
value: Go to pressure sen-
Inspect the <Tester connections>
YES. sor.
common rail Common rail pressure sensor
3 Go to step 4. Perform "After-
pressure sen- (1) VC1 (sub) – PCR1 (sub)
The measure- inspection
sor unit (2) PCR1 (sub) – E1 (sub)
ments do not work" of
<Standard values>
meet the stan- INFORMA-
(1) 1.05 – 3.55 k
dard value: Go TION section.
(2) 6.7 – 18.7 k
to NO.
Measure the voltage between the
The measure-
terminals of the common rail
ments meet
pressure sensor vehicle side con- Repair or
the standard
nector. replace the
Inspect the value: Go to
<Tester connections> harness.
common rail YES.
Common rail pressure sensor Perform "After-
4 pressure sen- Go to step 5.
vehicle side connector inspection
sor power sup- The measure-
VC1 – E1 work" of
ply ments do not
<Standard values> INFORMA-
meet the stan-
4.5 – 5.5 V TION section.
dard value: Go
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–449
Fuel rail pressure sensor (sub) - out of range
DTC: P01A5 Inspection procedure
(Out of range low)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals in the common rail
the standard
pressure sensor vehicle side con-
Inspect the value: Go to
nector.
common rail YES.
<Tester connections>
5 pressure sen- Go to step 8. Go to step 6.
Common rail pressure sensor
sor signal cir- The measure-
vehicle side connector
cuit ments do not
VC1 – PCR1
meet the stan-
<Standard values>
dard value: Go
200 – 250 k
to NO.
Disconnect the engine ECU con-
The measure-
nector and measure the resis-
ments meet
tance between the common rail Repair or
Inspect for the standard
pressure sensor vehicle side con- replace the
short-circuits value: Go to
nector terminals and ground. harness.
in wire har- YES.
<Tester connections> Perform "After-
6 ness of the Go to step 7.
Common rail pressure sensor inspection
common rail The measure-
vehicle side connector work" of
pressure sen- ments do not
VC1 – Ground INFORMA-
sor meet the stan-
PCR1 – Ground TION section.
dard value: Go
<Standard values>
to NO.
Connect the signal check harness
to the engine ECU vehicle side
The measure-
harness and measure the resis-
ments meet
tance between the terminals in Repair or
the standard
Inspect dis- the engine ECU (signal check replace the
value: Go to
connection of harness). harness.
YES.
the common <Tester connections> Perform "After-
7 Go to step 8.
rail pressure Engine ECU inspection
The measure-
sensor har- (signal check harness) work" of
ments do not
ness VC1 (E13) – E1 (E56) INFORMA-
meet the stan-
PCR1 (E49) – E1 (E56) TION section.
dard value: Go
PC1S (E68) – E1 (E56)
to NO.
<Standard values>
2 or more
DTC P01A5
Replace the Procedure
has been
Perform an engine warm up engine ECU. completed.
detected: Go
Check the (Engine coolant temperature: 80 Perform "After- Perform "After-
to YES.
8 DTC detected C {176 F} or more) and check if inspection inspection
(Engine ECU) P01A5 has been detected in work" of work" of
No DTC has
[Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–450 ENGINE (J05E)/TROUBLESHOOTING
DTC: P01A6
EN01H02127030602016055
P01A6: Fuel rail pressure sensor (sub) - out of range (Out of range high)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
SHTS021270300365
1. Technical description
• The common rail pressure (sub) sensor constantly measures the common rail pressure.
<Technical Description>
• Common rail pressure is not correctly identified.
• Possible failure of common rail pressure (sub) sensor or harness disconnection or +B short.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• Engine stall condition or engine speed above 500 r/min continues for 5 seconds.
(2) Judgement criteria
• Common rail pressure (sub) sensor voltage is above 4.79 V (245.7 MPa) for 0.2 seconds.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
ENGINE (J05E)/TROUBLESHOOTING 2–451
8. Estimated failure factors
• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Irregular contact (disconnection or poor fit of connector)
• Engine ECU sensor power supply or internal circuit failure
2–452 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P01A6
1 Inspect the common rail pressure sensor connector
1. Check the connection of the common rail pressure sensor connec-
tor (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the common rail pressure sensor
1. Check the installation of the common rail pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of common rail pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the common rail pres-
sure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–453
3 Inspect the common rail pressure sensor unit
1. Set the starter key to the "LOCK" position.
PCR1 2. Disconnect the common rail pressure sensor connector.
VC1 E2 PCR2 VC2
(main) (main) (main)
3. Measure the resistance between the terminals of the sensor using
VC1 PCR1 E1
(sub) (sub) (sub) the electrical tester.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor
(1) VC1 (sub) – (1) 1.05 – 3.55 k
Starter key: LOCK
E1
PCR1 (sub) (2) 6.7 – 18.7 k
PCR1 E2 PCR2 VC2 (2) PCR1 (sub) –
(main) (main) (main) E1 (sub)
VC1 PCR1 E1
(sub) (sub) (sub)
SHTS021270300366
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the common rail pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–454 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect the common rail pressure sensor power supply
1. Set the starter key to the "ON" position.
E1 VC1
2. Measure the voltage between the terminals of the common rail
pressure sensor vehicle side connector using the electrical tester.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC1 – E1
SHTS021270300367
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect the common rail pressure sensor signal circuit
1. Set the starter key to the "LOCK" position.
PCR1 VC1
2. Use the electrical tester to measure the resistance between the
terminals of the common rail pressure sensor vehicle side connec-
tor.
Measurement Tester
Standard values
conditions connections
Common rail pres-
sure sensor vehi-
Starter key: LOCK 200 – 250 k
cle side connector
SHTS021270300368 VC1 – PCR1
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
ENGINE (J05E)/TROUBLESHOOTING 2–455
6 Inspect for short-circuits in wire harness of the common rail pressure sensor
1. Set the starter key to the "LOCK" position.
VC1
2. Disconnect the engine ECU connector.
GROUND
3. Use the electrical tester to measure the resistance between the
common rail pressure sensor vehicle side connector terminals and
ground.
Measurement Tester
Standard values
conditions connections
Common rail pres-
PCR1 sure sensor vehi-
GROUND Starter key: LOCK cle side connector
VC1 – Ground
PCR1 – Ground
SHTS021270300369
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–456 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect disconnection of the common rail pressure sensor harness
1. Connect the common rail pressure sensor connector.
E13
C D E56
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals in the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
E49
E56 D E68
nal check har-
ness)
VC1 (E13) –
Starter key: LOCK E1 (E56) 2 or more
PCR1 (E49) –
E1 (E56)
PC1S (E68) –
E1 (E56)
SHTS021270300370
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
8 Check the DTC detected (Engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P01A6 has been detected in [Fault
Information].
SHTS021270300371
Has DTC P01A6 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–457
CHECKLIST: P01A6
Fuel rail pressure sensor (sub) -
DTC: P01A6 Inspection procedure
out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the com- needed.
common rail
1 mon rail pressure sensor connec- Perform "After- Go to step 2.
pressure sen- No failure
tor (looseness and poor contact). inspection
sor connector found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the Failure found: properly.
Inspect the common rail pressure sensor. Go to YES. If damaged,
common rail 2. Make sure there is no dirt, replace the
2 Go to step 3.
pressure sen- damage or clogging in the No failure sensor.
sor sensing unit of common rail found: Go to Perform "After-
pressure sensor. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet Replace the
the terminals of the common rail
the standard common rail
pressure sensor.
value: Go to pressure sen-
Inspect the <Tester connections>
YES. sor.
common rail Common rail pressure sensor
3 Go to step 4. Perform "After-
pressure sen- (1) VC1 (sub) – PCR1 (sub)
The measure- inspection
sor unit (2) PCR1 (sub) – E1 (sub)
ments do not work" of
<Standard values>
meet the stan- INFORMA-
(1) 1.05 – 3.55 k
dard value: Go TION section.
(2) 6.7 – 18.7 k
to NO.
Measure the voltage between the The measure-
terminals of the common rail ments meet Repair or
pressure sensor vehicle side con- the standard replace the
Inspect the
nector. value: Go to harness.
common rail
<Tester connections> YES. Perform "After-
4 pressure sen- Go to step 5.
Common rail pressure sensor The measure- inspection
sor power sup-
vehicle side connector ments do not work" of
ply
VC1 – E1 meet the stan- INFORMA-
<Standard values> dard value: Go TION section.
4.5 – 5.5 V to NO.
2–458 ENGINE (J05E)/TROUBLESHOOTING
Fuel rail pressure sensor (sub) -
DTC: P01A6 Inspection procedure
out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals of the common rail
the standard
pressure sensor vehicle side con-
Inspect the value: Go to
nector.
common rail YES.
<Tester connections>
5 pressure sen- Go to step 8. Go to step 6.
Common rail pressure sensor
sor signal cir- The measure-
vehicle side connector.
cuit ments do not
VC1 – PCR1
meet the stan-
<Standard values>
dard value: Go
200 – 250 k
to NO.
Disconnect the engine ECU con-
The measure-
nector and measure the resis-
ments meet
tance between the common rail Repair or
Inspect for the standard
pressure sensor vehicle side con- replace the
short-circuits value: Go to
nector terminals and ground. harness.
in wire har- YES.
<Tester connections> Perform "After-
6 ness of the Go to step 7.
Common rail pressure sensor inspection
common rail The measure-
vehicle side connector work" of
pressure sen- ments do not
VC1 – Ground INFORMA-
sor meet the stan-
PCR1 – Ground TION section.
dard value: Go
<Standard values>
to NO.
Connect the signal check harness
to the engine ECU vehicle side
The measure-
harness and measure the resis-
ments meet
tance between the terminals in Repair or
the standard
Inspect dis- the engine ECU (signal check replace the
value: Go to
connection of harness). harness.
YES.
the common <Tester connections> Perform "After-
7 Go to step 8.
rail pressure Engine ECU inspection
The measure-
sensor har- (signal check harness) work" of
ments do not
ness VC1(E13) – E1(E56) INFORMA-
meet the stan-
PCR1(E49) – E1(E56) TION section.
dard value: Go
PC1S(E68) – E1(E56)
to NO.
<Standard values>
2 or more
DTC P01A6
Replace the Procedure
has been
engine ECU. completed.
Warm up the engine (engine cool- detected: Go
Check the Perform "After- Perform "After-
ant temperature: 80 C {176 F} to YES.
8 DTC detected inspection inspection
or more) and check if P01A6 has
(Engine ECU) work" of work" of
been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–459
DTC: P0200
EN01H02127030602016056
P0200: Fuel injector driver charge circuit (circuit high)
INFORMATION
1. Technical description
• –
<Description of malfunction>
• Excessively high voltage has been detected in the injector charge circuit.
2. DTC set condition
(1) DTC detection condition
- Starter key "ON".
- Battery voltage is in the range of 10 V to 16 V.
- Fuel injector; deactivated.
(2) Judgement criteria
- Fuel injector driver charge circuit voltage > 105 V
- Failure timer ≥ 0.384 seconds
3. Reset condition
• After normal operation is restored and engine is restarted after engine stall.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag light: OFF
• Engine output is restricted.
• Cruise control function is not available.
• Idling stop system is not available.
• Vehicle start control is not available.
• PTO is not available
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• Cruise control does not work.
• Idling stop system does not work.
• Vehicle start control does not work.
• PTO cannot be used.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• ECU failure.
• Temporary operating error due to radio wave interference or noise.
2–460 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0200
1 Check the engine ECU internal circuit [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
Engine 3. Select [Engine] and check the communication between HINO-DX
and the engine ECU.
4. Erase the malfunction history.
5. Set the starter key to the "LOCK" position.
When
communicat-ion
with the engine
6. In HINO-DX, make sure the engine ECU main relay is OFF. (This
ECU is interrupted cuts off the communication between HINO-DX and the engine
while the engine ECU.)
ECU is connected
to the HINO-DX, 7. Set the starter key to the "ON" position.
the connection
symbol at the left
bottom of the 8. Select [Engine] and check if P0200 has been detected in [Fault
HINO-DX screen Information].
(figure on the left)
becom-es
disconnected.
SHTS021270300372
Has DTC P0200 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–461
CHECKLIST: P0200
DTC: P0200 Fuel injector driver charge circuit (circuit high) Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Engine] in HINO-DX
menu, and check the communi- Procedure
cation between HINO-DX and completed.
the engine ECU. DTC P0200 (Temporary
Replace the
2. Erase the malfunction history, has been operating error
engine ECU.
Check the set the starter key to the detected: Go due to radio
Perform "After-
engine ECU "LOCK" position and make sure to YES. wave interfer-
1 inspection
internal circuit that the engine ECU main relay ence or noise.)
work" of
[HINO-DX] is OFF (Communication No DTC has Perform "After-
INFORMA-
between HINO-DX and the been detected: inspection
TION section.
engine ECU is turned off) Go to NO. work" of
3. Check if P0200 has been INFORMA-
detected in [Engine]. TION section.
2–462 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0201, P0202, P0203 and P0204
EN01H02127030602016057
P0201: Fuel injector - disconnection (#1cyl)
P0202: Fuel injector - disconnection (#2cyl)
P0203: Fuel injector - disconnection (#3cyl)
P0204: Fuel injector - disconnection (#4cyl)
INFORMATION
Engine ECU
46 Injector sub
(#10)
66 11 3 2
(#1)
67 8 8 1 Injector1
(IJ1+)
41
(#40)
61 10 2 2
(#4)
63 6 6 1 Injector2
(IJ2+)
42
(#20) et ra ev
62 2 10 2
(#2)
43 5 5 1 Injector3
(I2+S)
45
(#30)
65 3 11 2
(#3)
47 7 7 1 Injector4
(I1+S)
SHTS021270300373
1. Technical description
• An injection rate is controlled to a valve opening duration of the injector.
• The valve opening duration of the injector is adjusted by the solenoid valve.
<Description of malfunction>
• #1 injector failure or possible harness disconnection (P0201)
• #2 injector failure or possible harness disconnection (P0202)
• #3 injector failure or possible harness disconnection (P0203)
• #4 injector failure or possible harness disconnection (P0204)
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
• Engine speed is higher than 0.
• The fuel injector driver charge circuit is active.
(2) Judgement criteria
• The fuel injector driver circuit remains at 0A until it reaches a threshold.
(Approximately 4 seconds at 750 r/min. This may vary depending on engine speed.)
3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Cruise control function is not available.
• Idling stop system is not available.
• Vehicle start control is not available.
ENGINE (J05E)/TROUBLESHOOTING 2–463
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
• Idling stop system does not work.
• Vehicle start control does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Looseness or poor contact of connector
• vehicle side harness disconnection (engine ECU – injector central connector)
• Injector harness disconnection or short-circuit
• Disconnected coil in the injector
• Malfunction of ECU
2–464 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0201, P0202, P0203 and P0204
1 Inspect the engine ECU connector, injector connector
1. Inspect the connection of the engine ECU connector and the tar-
get's injector connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect disconnection of the engine ECU harness
1. Set the starter key to the "LOCK" position.
E15 E16 E18 E20
E14 E19 2. Connect the signal check harness to the engine ECU. (Do not con-
C nect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
E34 E36 E38 E40
conditions connections
E35 E39 Engine ECU (sig-
SHTS021270300374 nal check har-
Starter key: LOCK ness) 2
Refer to the injec-
tor’s table
<Injector's table>
#1 injector #2 injector #3 injector #4 injector
#1 (E15) – IJ1+(E14) #4 (E20) – IJ2+ (E18) #2 (E19) – IJ2+ (E18) #3 (E16) – IJ1+ (E14)
#1 (E15) – I1+S(E34) #4 (E20) – I2+S (E38) #2 (E19) – I2+S (E38) #3 (E16) – I1+S (E34)
#10 (E35) – IJ1+(E14) #40 (E40) – IJ2+ (E18) #20 (E39) – IJ2+ (E18) #30 (E36) – IJ1+ (E14)
#10 (E35) – I1+S(E34) #40 (E40) – I2+S (E38) #20 (E39) – I2+S (E38) #30 (E36) – I1+S (E34)
Do the measurements meet the standard value?
YES NO
Go to step 3. Go to step 4.
ENGINE (J05E)/TROUBLESHOOTING 2–465
3 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0201, P0202, P0203 and
P0204) has been detected in [Fault Information].
SHTS021270300375
Has DTC (P0201, P0202, P0203 and P0204) has been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
4 Check for disconnection in wire harness of injector central connector
1. Disconnect the injector central connector.
2. Use the electrical tester to measure the resistance between the
terminals in the injector central connector (engine side).
Measurement Tester
Standard values
conditions connections
Injector central
connector (engine
side)
Starter key: LOCK #1 injector: 5 – 10 2
SHTS021270300376 #2 injector: 8 – 11
#3 injector: 3 – 7
#4 injector: 2 – 6
Do the measurements meet the standard value?
YES NO
Repair or replace the wire harness between Go to step 5.
the injector central connector and engine
ECU.
Perform "After-inspection work" of INFOR-
MATION section.
2–466 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect disconnection of the injector harness
1. Disconnect the target's injector harness connector.
2. Use the electrical tester to measure the resistance between the
terminals in the target's injector harness connector (injector side).
Measurement Tester
Standard values
conditions connections
Injector harness
20 C {68 F}:
Starter key: LOCK connector (injec-
0.37 – 0.57
tor side) terminals
SHTS021270300377
Do the measurements meet the standard value?
YES NO
Repair or replace the wire harness between Go to step 6.
the injector central connector and injector
harness connector.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect the injector unit
1. Measure the resistance between the target's injector terminal and
the injector body.
Measurement Tester
Standard values
conditions connections
Injector terminal –
Starter key: LOCK More than 10 M
injector body
SHTS021270300378
Do the measurements meet the standard value?
YES NO
Repair or replace the target's injector har- Replace the injector.
ness. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–467
CHECKLIST: P0201, P0202, P0203 and P0204
DTC: P0201 Fuel injector - disconnection (#1cyl)
DTC: P0202 Fuel injector - disconnection (#2cyl)
Inspection procedure
DTC: P0203 Fuel injector - disconnection (#3cyl)
DTC: P0204 Fuel injector - disconnection (#4cyl)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Inspect the connection of the Go to YES.
engine ECU needed.
engine ECU connector and the
1 connector, Perform "After- Go to step 2.
target’s injector connector (loose- No failure
injector con- inspection
ness and poor contact). found: Go to
nector work" of
NO.
INFORMA-
TION section.
Connect the signal check har- The measure-
ness, and measure the resistance ments meet
between the terminals of the the standard
engine ECU value: Go to
Inspect dis-
(signal check harness). YES.
connection of
<Tester connections> Go to step 3. Go to step 4.
the engine
Engine ECU The measure-
ECU harness
(signal check harness) ments do not
Refer to the injector’s table meet the stan-
<Standard values> dard value: Go
2 to NO.
<Injector's table>
2 #1 injector #2 injector
#1 (E15) – IJ1+ (E14) IJ2+ (E18) – #4 (E20)
#1 (E15) – I1+S (E34) IJ2+ (E18) – #40 (E40)
#10 (E35) – IJ1+ (E14) I2+S (E38) – #4 (E20)
#10 (E35) – I1+S (E34) I2+S (E38) – #40 (E40)
#3 injector #4 injector
IJ2+ (E18) – #2 (E19) IJ1+ (E14) – #3 (E16)
IJ2+ (E18) – #20 (E39) IJ1+ (E14) – #30 (E36)
I2+S (E38) – #2 (E19) I1+S (E34) – #3 (E16)
I2+S (E38) – #20 (E39) I1+S (E34) – #30 (E36)
DTC (P0201,
P0202, P0203,
P0204, P0205 Replace the Procedure
Perform engine warm up. (engine
and P0206) engine ECU. completed.
coolant temperature: 80 C {176
Check the has been Perform "After- Perform "After-
F} or more), and check if the
3 DTC detected detected: Go inspection inspection
DTC (P0201, P0202, P0203 and
(Engine ECU) to YES. work" of work" of
P0204) has been detected in
INFORMA- INFORMA-
[Engine].
No DTC has TION section. TION section.
been detected:
Go to NO.
2–468 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0201 Fuel injector - disconnection (#1cyl)
DTC: P0202 Fuel injector - disconnection (#2cyl)
Inspection procedure
DTC: P0203 Fuel injector - disconnection (#3cyl)
DTC: P0204 Fuel injector - disconnection (#4cyl)
Check
Step Action Description Judgement Yes No
(Yes/No)
Repair or
Measure the resistance between
The measure- replace the
the terminals in the injector cen-
ments meet wire harness
tral connector (engine side).
the standard between the
<Tester connections>
Check for dis- value: Go to injector cen-
Injector central connector
connection in YES. tral connector
(engine side)
4 wire harness and engine Go to step 5.
#1 injector: 5 – 10
of injector cen- The measure- ECU.
#2 injector: 8 – 11
tral connector ments do not Perform "After-
#3 injector: 3 – 7
meet the stan- inspection
#4 injector: 2 – 6
dard value: Go work" of
<Standard values>
to NO. INFORMA-
2
TION section.
Repair or
replace the
The measure-
wire harness
Measure the resistance between ments meet
between the
the terminals in the target’s injec- the standard
injector cen-
tor harness connector (injector value: Go to
Inspect dis- tral connector
side). YES.
connection of and injector
5 <Tester connections> Go to step 6.
the injector harness con-
Injector harness connector The measure-
harness nector.
(injector side) terminals ments do not
Perform "After-
<Standard values> meet the stan-
inspection
20 C {68 F}: 0.37 – 0.57 dard value: Go
work" of
to NO.
INFORMA-
TION section.
The measure-
ments meet Repair or
Measure the resistance between the standard replace the Replace the
the target’s injector terminal and value: Go to injector har- injector.
the injector body. YES. ness. Perform "After-
Inspect the
6 <Tester connections> Perform "After- inspection
injector unit
Injector terminal– injector body The measure- inspection work" of
<Standard values> ments do not work" of INFORMA-
10 M or more meet the stan- INFORMA- TION section.
dard value: Go TION section.
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–469
DTC: P0217
EN01H02127030602016058
P0217: Engine coolant over temperature condition
INFORMATION
Coolant temperature
sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth Z5G (E) 10mA ZJQ (E5)
SHTS021270300379
1. Technical description
• Measure the engine coolant temperature with the coolant temperature sensor.
<Description of malfunction>
• Engine overheating is detected.
2. DTC set condition
(1) DTC detection condition
• The engine must not be stopped.
(2) Judgement criteria
• The coolant temperature value of the engine coolant temperature sensor is above 115 C {239 F} for 30 sec-
onds.
3. Reset condition
• After normal operation is restored
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
• After fixed time, the engine stopped.
• Cruise control function is not available.
• Idling stop system is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
• Idling stop system does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–470 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
(1) Check for the relevant symptom by referring to the Workshop Manual, Engine Introduction, and Troubleshooting
Overheating.
• Faulty coolant-related component
• Faulty cooling system
• Faulty injection system
• Faulty lubricating system
(2) Malfunction of cooling fan, malfunction of fan clutch
(3) Malfunction of coolant temperature sensor
ENGINE (J05E)/TROUBLESHOOTING 2–471
INSPECTION PROCEDURE: P0217
1 Inspect the engine
1. Refer to "Engine Overheating" in the "Engine Introduction/Trouble-
shooting" Workshop Manual and check the related problem areas.
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the cooling fan
1. Check the installation and damage condition of the cooling fan.
Was any failure found?
YES NO
Properly install the cooling fan. Go to step 3.
Replace the cooling fan if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
3 Inspect the fan clutch
1. Check the installation condition of the cooling fan clutch and check
for silicone oil leakage from the clutch.
Was any failure found?
YES NO
Properly install the cooling fan clutch. Go to step 4.
Replace the cooling fan clutch if it is leaking.
Perform "After-inspection work" of INFOR-
MATION section.
2–472 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect the coolant temperature sensor connector
1. Check the connection of the engine coolant temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 5.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect the engine coolant temperature sensor
1. Check the installation of the engine coolant temperature sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine coolant temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 6.
If damaged, replace the engine coolant tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–473
6 Inspect the engine coolant temperature sensor unit
1. Set the starter key to the "LOCK" position.
E THW
2. Disconnect the engine coolant temperature sensor connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine coolant temperature sensor.
Measurement Tester
Standard values
conditions connections
Engine coolant 20 C {68 F}:
temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300380 sor 80 C {176 F}:
THW – E 0.326 – 0.310 k
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the engine coolant temperature sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0217 has been detected in [Fault
Information].
SHTS021270300381
Has DTC P0217 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–474 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0217
DTC: P0217 Engine coolant over temperature condition Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Repair or
Failure found: replace the
Refer to "Engine Overheating" in Go to YES. faulty part.
Inspect the the "Engine Introduction/Trouble- Perform "After-
1 Go to step 2.
engine shooting" Workshop Manual and No failure inspection
check the related problem areas. found: Go to work" of
NO. INFORMA-
TION section.
Properly install
the cooling
fan.
Failure found:
Replace the
Go to YES.
cooling fan if it
Inspect the Check the installation and dam-
2 is damaged. Go to step 3.
cooling fan age condition of the cooling fan. No failure
Perform "After-
found: Go to
inspection
NO.
work" of
INFORMA-
TION section.
Properly install
the cooling fan
clutch.
Failure found: Replace the
Check the installation condition of Go to YES. cooling fan
Inspect the fan the cooling fan clutch and check clutch if it is
3 Go to step 4.
clutch for silicone oil leakage from the No failure leaking.
clutch. found: Go to Perform "After-
NO. inspection
work" of
INFORMA-
TION section.
Connect
securely,
Failure found:
repair if
Inspect the Check the connection of the Go to YES.
needed.
coolant tem- engine coolant temperature sen-
4 Perform "After- Go to step 5.
perature sen- sor connector (looseness and No failure
inspection
sor connector poor contact). found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
engine coolant temperature
Inspect the Go to YES. If damaged,
sensor.
engine cool- replace the
5 2. Make sure there is no dirt, Go to step 6.
ant tempera- No failure sensor.
ture sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the engine cool- NO. inspection
ant temperature sensor. work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–475
DTC: P0217 Engine coolant over temperature condition Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals of the engine cool-
the standard Replace the
ant temperature sensor.
Inspect the value: Go to sensor.
<Tester connections>
engine cool- YES. Perform "After-
Engine coolant temperature sen-
6 ant tempera- Go to step 7. inspection
sor
ture sensor The measure- work" of
THW – WTM-
unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 2.59 – 2.32 k
dard value: Go
80 C {176 F}: 0.326 – 0.310 k
to NO.
DTC P0217
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
7 DTC detected inspection inspection
F} or more), and check if P0217
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–476 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0219
EN01H02127030602016059
P0219: Engine overspeed condition
INFORMATION
Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J 1mA X3F (NE-)
(NE+) J0H 1mA XK4 (NE+)
SHTS021270300382
1. Technical description
• The engine ECU detects the engine speed using the engine speed main sensor (crankshaft position sensor)
mounted on the flywheel housing.
<Description of malfunction>
• Engine speed above rated value is detected.
2. DTC set condition
(1) DTC detection condition
While the engine is in operation
(2) Judgement criteria
An engine speed of more than 3,000 r/min
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: OFF
• Cruise control function is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
Miss-shift (MT vehicle)
Operated with excessive engine oil running around to the air intake system
Irregular contact of connector and harness
Malfunction of engine speed main sensor (crankshaft position sensor)
ENGINE (J05E)/TROUBLESHOOTING 2–477
INSPECTION PROCEDURE: P0219
1 Inspect the engine oil level.
1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the standard value.
Rivet Oil level gauge
FULL ADD
Preferred level
Gauge end
SHTS021270300383
Is the engine oil quantity within the standard value?
YES NO
Go to step 2. Adjust the engine oil quantity according to
the standard value.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the main engine speed sensor connector
1. Check the connection of the main engine speed sensor connector
(looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–478 ENGINE (J05E)/TROUBLESHOOTING
3 Check the main engine speed sensor
1. Check the installation of the main engine speed sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the main engine speed sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If damaged, replace the main engine speed
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the main engine speed sensor power supply
1. Set the starter key to the "LOCK" position.
NE+ NE- 2. Disconnect the main engine speed sensor connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the main engine speed sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300384 Main engine speed
sensor vehicle
Starter key: ON 4.5 – 5.5 V
side connector
NE+ – NE-
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
ENGINE (J05E)/TROUBLESHOOTING 2–479
5 Check for disconnection in wire harness of main engine speed sensor
1. Set the starter key to the "LOCK" position.
NE+ 2. Connect the signal check harness to the engine ECU vehicle side
NE- harness. (Do not connect the harness to the ECU.)
D 3. Use the electrical tester to measure the resistance between the
E72
engine ECU (signal check harness) and each terminal in the main
E52
engine speed sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300385 Engine ECU (sig-
nal check har-
ness) – main
engine speed sen-
Starter key: LOCK Less than 2
sor vehicle side
connector
NE+ (E52) – NE+
NE- (E72) – NE-
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–480 ENGINE (J05E)/TROUBLESHOOTING
6 Check for short-circuit in wire harness of main engine speed sensor
1. Use the electrical tester to measure the resistance between each
D terminal in the engine ECU (signal check harness) and ground.
E52
E72
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
Starter key: LOCK NE+ (E52) –
Ground
NE- (E72) –
SHTS021270300386 Ground
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–481
7 Check the main engine speed sensor signal
1. Connect the signal check harness to the engine ECU.
E52 D E72 2. Connect the main engine speed sensor connector.
3. Start the engine.
4. Use the oscilloscope to measure the voltage between the termi-
nals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
SHTS021270300387 Engine ECU (sig-
nal check har-
Engine idling ness) 56 pulse
NE+ (E52) –
NE- (E72)
1 rotation
56 peaks (pulse)
0V
No pulse (No gear tooth)
SHTS021270300388
Do the measurements meet the standard value?
YES NO
Go to step 8. Replace the main engine speed sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–482 ENGINE (J05E)/TROUBLESHOOTING
8 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0219 has been detected in [Fault
Information].
SHTS021270300389
Has DTC P0219 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–483
CHECKLIST: P0219
DTC: P0219 Engine overspeed condition Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Adjust the
Engine oil level
engine oil
is within the
quantity
stipulated
according to
value: Go to
Check the oil level gauge and the stipulated
Inspect the YES.
1 make sure the engine oil quantity Go to step 2. value.
engine oil level
is within the stipulated value. Perform "After-
Outside the
inspection
stipulated
work" of
value: Go to
INFORMA-
NO.
TION section.
Connect
securely,
Failure found: repair if
Inspect the
Check the connection of the main Go to YES. needed.
main engine
2 engine speed sensor connector No failure Perform "After- Go to step 3.
speed sensor
(looseness and poor contact). found: Go to inspection
connector
NO. work" of
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the Failure found: properly.
main engine speed sensor. Go to YES. If damaged,
Check the
2. Make sure there is no dirt, replace the
3 main engine Go to step 4.
damage or clogging in the No failure sensor.
speed sensor
sensing unit of the main engine found: Go to Perform "After-
speed sensor. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Disconnect the main engine ments meet
speed sensor connector and the standard
measure the voltage between the value: Go to
Inspect the
terminals of the main engine YES.
main engine
4 speed sensor vehicle side con- Go to step 7. Go to step 5.
speed sensor
nector. (NE+ terminal –NE- termi- The measure-
power supply
nal) ments do not
<Standard values> meet the stan-
4.5 – 5.5 V dard value: Go
to NO.
2–484 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0219 Engine overspeed condition Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check harness
to the engine ECU. (Do not con- The measure-
nect harness to the ECU.) Mea- ments meet
Repair or
sure the resistance between the the standard
replace the
Check for dis- engine ECU (signal check har- value: Go to
harness.
connection in ness) and each terminal in the YES.
Perform "After-
5 wire harness main engine speed sensor vehicle Go to step 6.
inspection
of main engine side connector. The measure-
work" of
speed sensor <Tester connections> ments do not
INFORMA-
NE+ (E52) – NE+ meet the stan-
TION section.
NE- (E72) – NE- dard value: Go
<Standard values> to NO.
Less than 2
The measure-
Measure the resistance between ments meet
Repair or
each terminal in the engine ECU the standard
replace the
Check for (signal check harness) and value: Go to
harness.
short-circuit in ground. YES.
Perform "After-
6 wire harness <Tester connections> Go to step 7.
inspection
of main engine NE+ (E52) – Ground The measure-
work" of
speed sensor NE- (E72) – Ground ments do not
INFORMA-
<Standard values> meet the stan-
TION section.
dard value: Go
to NO.
1. Connect the signal check har-
The measure-
ness to the engine ECU and
ments meet
connect the main engine speed
the standard Replace the
sensor connector.
value: Go to sensor.
Check the 2. Use the oscilloscope to mea- YES. Perform "After-
main engine sure the voltage between the
7 Go to step 8. inspection
speed sensor terminals of the engine ECU The measure- work" of
signal (signal check harness). ments do not INFORMA-
<Tester connections> meet the stan- TION section.
NE+ (E52) – NE- (E72) dard value: Go
<Standard values> to NO.
56 pulse
DTC P0219
Replace the Procedure
has been
1. Warm up the engine. (engine engine ECU. completed.
detected: Go
Check the coolant temperature: 80 C Perform "After- Perform "After-
to YES.
8 DTC detected {176 F} or more) inspection inspection
(Engine ECU) 2. Check if P0219 has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–485
DTC: P0222 and P0223
EN01H02127030602016060
P0222: Intake throttle valve position sensor 2 - out of range (Out of range low)
INFORMATION
Engine ECU
(E2R) XFD TYP 0.2A XQT (M-)
(VCR) XFC TYP 1A XQS (M+)
(E2) Z6P TYP 1A ZD6 (E3)
Diesel throttle XSR TYP 0.2A X3V
(VTA2) (VTA2)
(VC) X0N TYP 0.2A XG2 (VC2)
(VTA) X3U TYP 0.2A XK3 (VTA1)
SHTS021270300390
1. Technical description
• The diesel throttle (intake throttle) controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle, a sensor designed to detect a travel of the valve consistently monitors an actual opening to
compare with command value.
<Description of malfunction>
• Low voltage failure of diesel throttle (intake throttle valve) position sensor is detected.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.2 V (5 degrees) or less for 3 seconds or longer.
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–486 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Failure in engine ECU sensor power supply or internal circuit
• Looseness or poor contact of connector
ENGINE (J05E)/TROUBLESHOOTING 2–487
P0223: Intake throttle valve position sensor 2 - out of range (Out of range high)
INFORMATION
Engine ECU
(E2R) XFD TYP 0.2A XQT (M-)
(VCR) XFC TYP 1A XQS (M+)
(E2) Z6P TYP 1A ZD6 (E3)
Diesel throttle XSR TYP 0.2A X3V
(VTA2) (VTA2)
(VC) X0N TYP 0.2A XG2 (VC2)
(VTA) X3U TYP 0.2A XK3 (VTA1)
SHTS021270300391
1. Technical description
• The diesel throttle (intake throttle) controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle (intake throttle), a sensor designed to detect a travel of the valve consistently monitors an
actual opening to compare with command value.
<Description of malfunction>
• Abnormally high voltage of diesel throttle (intake throttle valve) position sensor is detected.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 4.8 V (120 degrees) or less for 3 seconds or longer.
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–488 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Sensor internal short-circuit
• Engine ECU internal circuit failure
ENGINE (J05E)/TROUBLESHOOTING 2–489
INSPECTION PROCEDURE: P0222 and P0223
1 Inspect the intake throttle valve position sensor 2 connector
1. Check the connection of the intake throttle valve position sensor 2
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the intake throttle valve position sensor 2
1. Check the installation of the intake throttle valve position sensor 2.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake throttle valve position sensor 2.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the intake throttle valve
position sensor 2.
Perform "After-inspection work" of INFOR-
MATION section.
2–490 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the intake throttle valve position sensor 2 unit
1. Set the starter key to the "LOCK" position.
VC VTA2 2. Disconnect the intake throttle valve position sensor 2 connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake throttle valve position sensor 2.
Measurement Tester
Standard values
conditions connections
Intake throttle
valve position
(1) 180
sensor 2
VC E2 Starter key: LOCK (2) 3 k
(1) VC – VTA2
(3) 3 k
(2) VC – E2
(3) VTA2 – E2
VTA2 E2
SHTS021270300392
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the intake throttle valve position
sensor 2.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–491
4 Inspect the intake throttle valve position sensor 2 power supply
1. Set the starter key to the "ON" position.
2. Use the electrical tester to measure the voltage between the termi-
E2 VC nals of the intake throttle valve position sensor 2 vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
Intake throttle
valve position
Starter key: ON sensor 2 vehicle 4.5 – 5.5 V
SHTS021270300393 side connector
VC – E2
Do the measurements meet the standard value?
YES NO
Go to step 5. Go to step 6.
5 Inspect the intake throttle valve position sensor 2 signal circuit
1. Set the starter key to the "LOCK" position.
E2 VTA2
2. Use the electrical tester to measure the resistance between the
terminals of the intake throttle valve position sensor 2 vehicle side
connector.
Measurement Tester
Standard values
conditions connections
Intake throttle
valve position
Starter key: LOCK sensor 2 vehicle 25 – 35 k
SHTS021270300394 side connector
VTA2 – E2
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
2–492 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect for short-circuits in wire harness of intake throttle valve position sensor 2
1. Connect the signal check harness to the engine ECU vehicle side
C harness. (Do not connect the harness to the ECU.)
E33
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
E46 E57 VC2 (E33) –
D Starter key: LOCK
Ground
VTA2 (E46) –
Ground
E3 (E57) – Ground
SHTS021270300395
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–493
7 Inspect for disconnections in wire harness of intake throttle valve
1. Connect the intake throttle valve position sensor 2 connector.
E46
C D 2. Use the electrical tester to measure the resistance between the
E33
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
(1) VC2 (E33) – (1) 2 or more
C D E57 Starter key: LOCK VTA2 (E46) (2) 3 k
E33 (2) VC2 (E33) – (3) 3 k
E3 (E57)
(3) VTA2 (E46) –
E3 (E57)
E46 E57
D
SHTS021270300396
Do the measurements meet the standard value?
YES NO
Go to step 8. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–494 ENGINE (J05E)/TROUBLESHOOTING
8 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0222 or P0223) has been
detected in [Fault Information].
SHTS021270300397
Has DTC (P0222 or P0223) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–495
CHECKLIST: P0222 and P0223
Intake throttle valve position sensor 2
DTC: P0222
- out of range (Out of range low)
Inspection procedure
Intake throttle valve position sensor 2
DTC: P0223
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the Go to YES.
intake throttle needed.
intake throttle valve position sen-
1 valve position Perform "After- Go to step 2.
sor 2 connector (looseness and No failure
sensor 2 con- inspection
poor contact). found: Go to
nector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
intake throttle valve position
Inspect the Go to YES. If damaged,
sensor 2.
intake throttle replace the
2 2. Make sure there is no dirt, Go to step 3.
valve position No failure sensor.
sensor 2 damage or clogging in the found: Go to Perform "After-
sensing unit of the intake throt- NO. inspection
tle valve position sensor 2. work" of
INFORMA-
TION section.
Measure the resistance between
the terminals of the intake throttle The measure-
valve position sensor 2. ments meet
<Tester connections> the standard Replace the
Intake throttle valve position sen- value: Go to sensor.
Inspect the
sor 2 YES. Perform "After-
intake throttle
3 (1) VC – VTA2 Go to step 4. inspection
valve position
(2) VC – E2 The measure- work" of
sensor 2 unit
(3) VTA2 – E2 ments do not INFORMA-
<Standard values> meet the stan- TION section.
(1) 180 dard value: Go
(2) 3 k to NO.
(3) 3 k
The measure-
Measure the voltage between the
ments meet
terminals of the intake throttle
the standard
valve position sensor 2 vehicle
Inspect the value: Go to
side connector.
intake throttle YES.
<Tester connections>
4 valve position Go to step 5. Go to step 6.
Intake throttle valve position sen-
sensor 2 The measure-
sor 2 vehicle side connector
power supply ments do not
VC – E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
2–496 ENGINE (J05E)/TROUBLESHOOTING
Intake throttle valve position sensor 2
DTC: P0222
- out of range (Out of range low)
Inspection procedure
Intake throttle valve position sensor 2
DTC: P0223
- out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals of the intake throttle
the standard
valve position sensor 2 vehicle
Inspect the value: Go to
side connector.
intake throttle YES.
<Tester connections>
5 valve position Go to step 8. Go to step 6.
Intake throttle valve position sen-
sensor 2 sig- The measure-
sor 2 vehicle side connector
nal circuit ments do not
VTA2 – E2
meet the stan-
<Standard values>
dard value: Go
25 – 35 k
to NO.
Connect the signal check har-
ness, and measure the resistance The measure-
between the terminals of the ments meet
Repair or
Inspect for engine ECU (signal check har- the standard
replace the
short-circuits ness) and ground. value: Go to
harness.
in wire har- <Tester connections> YES.
Perform "After-
6 ness of intake Engine ECU (signal check har- Go to step 7.
inspection
throttle valve ness) The measure-
work" of
position sen- VC2 (E33) – Ground ments do not
INFORMA-
sor 2 VTA2 (E46) – Ground meet the stan-
TION section.
E3 (E57) – Ground dard value: Go
<Standard values> to NO.
1. Connect the intake throttle
valve position sensor 2 connec-
tor. The measure-
2. Measure the resistance ments meet
Repair or
between the terminals of the the standard
replace the
Inspect for dis- engine ECU (signal check har- value: Go to harness.
connections in ness). YES.
Perform "After-
7 wire harness <Tester connections> Go to step 8.
inspection
of intake throt- (1) VC2 (E33) – VTA2 (E46) The measure-
work" of
tle valve (2) VC2 (E33) – E3 (E57) ments do not
INFORMA-
(3) VTA2 (E46) – E3 (E57) meet the stan-
TION section.
<Standard values> dard value: Go
(1) 2 or more to NO.
(2) 3 k
(3) 3 k
DTC (P0222 Replace the Procedure
or P0223) has engine ECU. completed.
Check the Check if the DTC (P0222 or been detected. Perform "After- Perform "After-
8 DTC detected P0223) has been detected in Go to YES.No inspection inspection
(Engine ECU) [Engine]. DTC has been work" of work" of
detected. Go INFORMA- INFORMA-
to NO. TION section. TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–497
DTC: P0234
EN01H02127030602016061
P0234: Overboost
INFORMATION
Engine ECU
Resistor
YM5 (CAN+)
(PCR1)
(PCR2)
(PC1S)
(PC2S)
YM6 (CAN-)
(THW)
XMH (EVG)
X82 (THA)
(VC2)
X2U (VAF)
X0G (PIM)
X4K (VG)
(VC)
(E5)
(E1)
(E2)
ZJP (E4)
X28
ZJQ
$XV
Z70
XZG
X85
Z72
XZH
XG2
$XW
10mA
10mA
15mA
5mA
5mA
200mA
200mA
15mA
15mA
15mA
15mA
10mA
10mA
10mA
2mA
2mA
X66 (THW)
Actuator power
(VC) J0M
(E) Z6R
(PIM) J0L
(CANH)
(CANH)
relay
(CANL)
(CANL)
Z5G (E)
Coolant temperature
XCV
XCT
EBM
NFA
NFA
#XG
EBH
EBN
EBK
#XV
X71
Z65
EBL
X72
EBJ
sensor
(L)
X36
(FC)
(E2G)
(+B)
(E2)
(THA)
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)
VNT EGR
controller actuator
Boost pressure
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
sensor
Y2E Y4J Z90
Common rail Intake air
Body earth pressure sensor temperature sensor NAT X36 $4
(air flow sensor built in)
SHTS021270300398
1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure. It observes a deviation between the target boost pressure and actual boost pressure to check
if the actual pressure is higher than the target pressure.
<Description of malfunction>
• Boost pressure is higher than the stipulated value.
2. DTC set condition
(1) DTC detection condition
• Water temperature at engine start-up is 0 C {32 F} or more.
• The condition that the intake air temperature at engine start-up is less than 0 C {32 F} remains for 500 sec-
onds or more.
• The condition that the intake air temperature at the engine start-up is higher than 0 C {32 F} remains in the
range of 30 to 200 seconds.
The conditions described below remain for 4 seconds or more.
• The target boost pressure is 40 kPa or more.
• If the engine speed is 750 r/min, fuel injection quantity is 100 mm3/st. cyl or more.
• If the engine speed is in range of 1250 to 1750 r/min, fuel injection quantity is 60 mm3/st.cyl or more.
• If the engine speed is 2500 r/min, fuel injection quantity is 120mm3/st.cyl or more.
• Atmospheric pressure is higher than 75 kPa.
• DPR auto-regeneration is inactive.
2–498 ENGINE (J05E)/TROUBLESHOOTING
(2) Judgement criteria
• Deviation between the target boost pressure and the actual boost pressure: the condition that the deviation
exceeds the range of 15 to 45 kPa remains 30 seconds or more.
• If the deviation of the boost pressure is 15 kPa, the boost pressure value of 220 kPa or less is detected.
• If the deviation of the boost pressure is 45 kPa, the boost pressure value of 250 kPa or more is detected.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Turbocharger noise or damage
• Insufficient output or engine stall because of DPR filter clogging due to abnormal soot generation
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that DTC is not detected after test run (10 minutes after engine startup).
8. Estimated failure factors
• VNT actuator failure (VNT nozzle closed-side failure)
• EGR valve failure (EGR valve closed-side failure)
• Clogged boost pressure sensor hose
• Boost pressure sensor failure (abnormal voltage, power supply or ground fault)
ENGINE (J05E)/TROUBLESHOOTING 2–499
INSPECTION PROCEDURE: P0234
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than P0234 (for exam-
ple, P0045, P0401) has been detected in [Fault Information].
SHTS021270300399
Has a DTC other than P0234 been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
2 Inspect the boost pressure sensor hose.
1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.
2. Make sure the pipe on the intake manifold side is not clogged.
Was any failure found?
YES NO
1. Replace the boost pressure sensor hose. Go to step 3.
2. Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
2–500 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the boost pressure sensor power supply system
1. Set the starter key to the "LOCK" position.
E
2. Disconnect the boost pressure sensor connector.
VC
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300400 Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 4. Inspect the harness and engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–501
4 Inspect the response delay of the VNT controller
1. Select [Check functions] from the menu, then inspect the response
delay at the Target VNT position and Actual VNT position.
(1)
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(2) ages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [VNT check].
(3) Click [Check start].
(4) Select [VNT opening UP]:
(3) • Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT opening DOWN]:
• Inspect the response delay at each step of the Target VNT position
(4) (5) and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.
Standard values
SHTS021270300401
From the Target VNT position to the Actual VNT position,
the response delay should be within 3 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the turbocharger.
Perform "After-inspection work" of INFOR-
MATION section.
2–502 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect the response delay of the EGR valve
1. Select [Check functions] and then [EGR check] from the menu,
then inspect the response delay at the Target EGR position and
(1)
Actual EGR position.
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Click [Check start].
(3) (4) Click [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Click [EGR opening DOWN]:
(4) (5) • Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.
SHTS021270300402 Standard values
From the Target EGR position to the Actual EGR position,
the response delay should be within 5 seconds.
Do the measurements meet the standard value?
YES NO
Check that P0234 is not detected again to Replace the EGR valve.
complete the check. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–503
CHECKLIST: P0234
DTC: P0234 Overboost Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC P0045,
P0401 has
Check if any DTC other than been detected: Go to the diag-
Check the
P0234 (for example, P0045, Go to YES. nostic proce-
1 DTC detected Go to step 2.
P0401) has been detected in dure of a
(Engine ECU)
[Engine]. No DTC has related DTC.
been detected:
Go to NO.
1. Replace the
boost pres-
sure sensor
1. Make sure the boost pressure Failure found: hose.
sensor hose is not clogged, Go to YES. 2. Clean the
Inspect the
ruptured, or cracked. intake mani- Go to step 3.
2 boost pressure
2. Make sure the pipe on the No failure fold pipe.
sensor hose
intake manifold side is not found: Go to Perform "After-
clogged. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the voltage between the ments meet
Inspect the
terminals of the boost pressure the standard
harness and
sensor vehicle side connector. value: Go to
Inspect the engine ECU.
<Tester connections> YES.
boost pressure Perform "After-
3 Boost pressure sensor vehicle Go to step 4.
sensor power inspection
side connector The measure-
supply system work" of
VC – E ments do not
INFORMA-
<Standard values> meet the stan-
TION section.
4.75 – 5.25 V dard value: Go
to NO.
2–504 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0234 Overboost Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Select [Check functions] from the
menu, then inspect the response
delay at the Target VNT position
and Actual VNT position.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [VNT check]. The measure-
(3) Click [Check start] ments meet
(4) Select [VNT opening UP]: the standard Replace the
• Inspect the response delay at value: Go to turbocharger.
Inspect the
each step of the Target VNT YES. Perform "After-
response
4 position and Actual VNT posi- Go to step 5. inspection
delay of the
tion from 0 to 90%. The measure- work" of
VNT controller
(5) Select [VNT opening DOWN]: ments do not INFORMA-
• Inspect the response delay at meet the stan- TION section.
each step of the Target VNT dard value: Go
position and Actual VNT posi- to NO.
tion from 90 to 0%.
<Standard values>
From the Target VNT position to
the Actual VNT position, the
response delay should be within 3
seconds.
Select [Check functions] and then
[EGR check] from the menu, then
inspect the response delay at the
Target EGR position and Actual
EGR position.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check]. The measure- Check that
(3) Click [Check start]. ments meet that P0234 is
(4) Click [EGR opening UP]: the standard not detected Replace the
value: Go to again to com- EGR valve.
Inspect the • Inspect the response delay at
YES. plete the Perform "After-
response each step of the Target EGR
5 check. inspection
delay of the position and Actual EGR posi-
The measure- Perform "After- work" of
EGR valve tion from 0 to 90%.
ments do not inspection INFORMA-
(5) Click [EGR opening DOWN]:
meet the stan- work" of TION section.
• Inspect the response delay at dard value: Go INFORMA-
each step of the Target EGR to NO. TION section.
position and Actual EGR posi-
tion from 90 to 0%.
<Standard values>
From the Target EGR position to
the Actual EGR position, the
response delay should be within 5
seconds.
ENGINE (J05E)/TROUBLESHOOTING 2–505
DTC: P0237
EN01H02127030602016062
P0237: Boost pressure sensor - out of range (Out of range low)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
SHTS021270300403
1. Technical description
• The boost pressure sensor install in the outlet of the diesel throttle consistently detects boost pressure.
<Description of malfunction>
• Boost pressure cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.3 V (32.4 kPa) or less for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–506 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Failure in engine ECU sensor power supply or internal circuit
• Looseness or poor contact of connector
ENGINE (J05E)/TROUBLESHOOTING 2–507
INSPECTION PROCEDURE: P0237
1 Inspect the boost pressure sensor connector
1. Check the connection of the boost pressure sensor connector
(looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the boost pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–508 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect for short-circuit of the boost pressure sensor harness
1. Set the starter key to the “LOCK” position.
C 2. Disconnect the boost pressure sensor connect.
E33
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
D E67 Engine ECU (sig-
E77 nal check har-
ness)
VC2 (E33) –
Starter key: LOCK
Ground
PIM (E67) –
Ground
E4 (E77) – Ground
SHTS021270300404
Do the measurements meet the standard value?
YES NO
Go to step 4. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–509
4 Inspect disconnection of the boost pressure sensor harness
1. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and the boost
C pressure sensor vehicle side connector.
PIM
E33 E VC Measurement Tester
Standard values
conditions connections
D Engine ECU (sig-
nal check har-
ness) – Boost
pressure sensor
E67 E77 Starter key: LOCK vehicle side con- 1
nector
(1) VC2 (E33) – VC
(2) PIM (E67) – PIM
(3) E4 (E77) – E
SHTS021270300405
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–510 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect the boost pressure sensor power supply
1. Connect the engine ECU vehicle side harness to the engine ECU.
2. Set the starter key to the "ON" position.
E VC
3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300406 side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 6. Replace the engine ECU.
6 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0237 has been detected in [Fault
Information].
SHTS021270300407
Has DTC P0237 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–511
CHECKLIST: P0237
Boost pressure sensor - out of range
DTC: P0237 Inspection procedure
(Out of range low)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Go to YES.
Check the connection of the boost needed.
boost pressure
1 pressure sensor connector Perform "After- Go to step 2.
sensor con- No failure
(looseness and poor contact). inspection
nector found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the Failure found: properly.
boost pressure sensor. Go to YES. If damaged,
Inspect the
replace the
2 boost pressure 2. Make sure there is no dirt, Go to step 3.
damage or clogging in the No failure sensor.
sensor
sensing unit of the boost pres- found: Go to Perform "After-
sure sensor. NO. inspection
work" of
INFORMA-
TION section.
Measure the resistance between
The measure-
the terminals of the engine ECU
ments meet
(signal check harness) and Repair or
the standard
ground. replace the
Inspect for value: Go to
<Tester connections> harness.
short-circuit of YES.
Engine ECU (signal check har- Perform "After-
3 the boost pres- Go to step 4.
ness) inspection
sure sensor The measure-
VC2 (E33) – Ground work" of
harness ments do not
PIM (E67) – Ground INFORMA-
meet the stan-
E4 (E77) – Ground TION section.
dard value: Go
<Standard values>
to NO.
1. Measure the resistance
between the terminals of the The measure-
engine ECU (signal check har- ments meet
ness) and the boost pressure Repair or
the standard
sensor vehicle side connector. replace the
Inspect dis- value: Go to
<Tester connections> harness.
connection of YES.
Engine ECU (signal check har- Perform "After-
4 the boost pres- Go to step 5.
sure sensor ness) – Boost pressure sensor The measure-
inspection
vehicle side connector work" of
harness ments do not
(1) VC2 (E33) – VC meet the stan-
INFORMA-
(2) PIM (E67) – PIM dard value: Go
TION section.
(3) E4 (E77) – E to NO.
<Standard values>
1
2–512 ENGINE (J05E)/TROUBLESHOOTING
Boost pressure sensor - out of range
DTC: P0237 Inspection procedure
(Out of range low)
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the voltage between the ments meet
terminals of the boost pressure the standard
sensor vehicle side connector. value: Go to
Inspect the
<Tester connections> YES.
boost pressure Replace the
5 Boost pressure sensor vehicle Go to step 6.
sensor power engine ECU.
side connector The measure-
supply
VC – E ments do not
<Standard values> meet the stan-
4.75 – 5.25 V dard value: Go
to NO.
DTC P0237
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
6 DTC detected inspection inspection
F} or more) and check if P0237
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–513
DTC: P0263, P0266, P0269 and P0272
EN01H02127030602016063
P0263: #1 Injection quantity and timing
P0266: #2 Injection quantity and timing
P0269: #3 Injection quantity and timing
P0272: #4 Injection quantity and timing
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
Engine ECU
X49 (#4) $XY (II+5)
Injector 4 X6Y (#40) X2X (#3)
X1Z (#30)
X47 (#3) $XX (12+5)
Injector 3 X6X (#30) X2W (#2)
X20 (#20)
X45 (#2) %X2 (IJ2+)
Injector 2 X0B (#20) X01 (#4)
X3L (#40)
X42 (#1) %X1 (IJ1+)
Injector 1 X43 (#10) X2V (#1)
X19 (#10)
SHTS021270300408
2–514 ENGINE (J05E)/TROUBLESHOOTING
1. Technical description
• The engine speed main sensor (crankshaft position sensor) monitors the speed of each cylinder.
• For control, it increases or reduces the compensation of the injection quantity of each cylinder to make constant the
speed of each cylinder.
<Description of malfunction>
• If the speed of the #1 cylinder is found abnormal, the DTC P0263 will be detected.
• If the speed of the #2 cylinder is found abnormal, the DTC P0266 will be detected.
• If the speed of the #3 cylinder is found abnormal, the DTC P0269 will be detected.
• If the speed of the #4 cylinder is found abnormal, the DTC P0272 will be detected.
2. DTC set condition
(1) DTC detection condition
1. All the following conditions continue for more than 30 seconds.
• The engine speed is in the range of 250 to 900 r/min.
• The fuel injection quantity is within 0 to 50 mm3/st. cyl.
• The exhaust brake and PTO are inactive.
2. All the following conditions continue for more than 10 seconds.
• The engine speed is within the below table.
• Gear position unchanged
• The fuel injection quantity is less than 45 mm3/st. cyl.
• The coolant temperature is above 71 C {159.8 F}.
• The accelerator opening is 0%.
• The vehicle speed is 0 mile/h.
• Barometric pressure ≥ 75 kPa (10.8 psi)
• The exhaust brake and PTO are inactive.
Engine speed (r/min)
Manual Transmission Automatic Transmission
D range N/A 725-775
N range 725-775 N/A
P range N/A N/A
(2) Judgement criteria
• If the #1 cylinder speed measured by the engine speed main sensor is low, the fuel injection quantity retains a
value lower by 30 to 45 mm3/st.cyl or more for 20 seconds or more.
• If the #1 cylinder speed measured by the engine speed main sensor is high, the fuel injection quantity retains
a value higher by 10 to 20 mm3/st.cyl or less for 20 seconds or more.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
ENGINE (J05E)/TROUBLESHOOTING 2–515
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Excessive vibration while engine is idling.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Common rail: flow damper operational error
• Injector: clogged or stays open
2–516 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0263, P0266, P0269 and P0272
1 Check the DTC detected 1 (Engine ECU)
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if any following DTCs (cylinder #1:
P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected
in [Fault Information] as an "Active".
SHTS021270300409
Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected as an
"Active"?
YES NO
Go to step 2 (Detected as an "Active".) Go to step 9. (Recorded as an "Inactive".)
2 Check the DTC detected 2 (engine ECU)
1. Check if the following DTC are not detected at the same time in the
results of step 1.
• P0263, P0266, P0269, P0272
Select
Engine
SHTS021270300410
Has other "Active" DTC been detected?
YES NO
Go to diagnosis procedure of the related Go to step 3.
DTC.
ENGINE (J05E)/TROUBLESHOOTING 2–517
3 Inspect the fuel line
1. Check that the fuel line has no leaks or clogging.
<Main inspection locations>
- Entry of foreign matter into the fuel tank
- Fuel hose breakage, collapsing, looseness
- High-pressure pipe breakage, collapsing, looseness
A return line from the fuel filter
Fuel filter
Common rail
Injector
Pre fuel
filter
Supply pump
Suction line
Positive pressure line
Fuel tank
High pressure line
Return line
SHTS021270300411
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 4.
Go to step 4 after repair or replacement.
4 Inspect the fuel filter
1. Check that the fuel filter is not dirty or clogged.
Was any failure found?
YES NO
Replace the fuel filter. Go to step 5.
Go to step 5 after replacement.
2–518 ENGINE (J05E)/TROUBLESHOOTING
5 Check the DTC detected 3 (engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if any followings DTCs (cylinder #1:
P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected
in [Fault Information].
SHTS021270300412
Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?
YES NO
Go to step 6. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
6 Perform the cylinder cut-off test (HINO-DX)
1. Use the cruise function to run the engine at 1,500 r/min.
2. Check the engine sound during normal operation. (before Cut-off
test)
Select
Engine 3. Use HINO-DX's [Activation Test] to perform a cut-off test.
(For details, refer to the cut-off test procedure on the following
pages.)
<Cylinder cut-off test>
- This method is generally used to check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
SHTS021270300413
engine and verifying the engine sound or performance.
Did you find the engine sound different?
YES NO
<One of the A to D is always large or same as <There is no clear difference>
α> Go to step 8
Replace the abnormal injector.
After replace, go to step 7.
ENGINE (J05E)/TROUBLESHOOTING 2–519
7 Check the DTC detected 4 (engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if any followings DTCs (cylinder #1:
P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected
in [Fault Information].
SHTS021270300414
Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?
YES NO
Go to step 8. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
8 Replace the common rail assembly
1. Set the starter key to the "LOCK" position.
2. Replace common rail assembly.
Select 3. Perform the engine warm up. (engine coolant temperature: 80 C
Engine {176 F} or more)
4. Stop the engine.
5. Set the starter key to the "ON" position.
6. Select [Engine] and check if any followings DTCs (cylinder #1:
SHTS021270300415
P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected
in [Fault Information].
Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?
YES NO
Go to step 9. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–520 ENGINE (J05E)/TROUBLESHOOTING
9 Inspect the injector
Check the injection quantity and the rotational fluctuation.
1. Start the engine
Select 2. Select [Injection quantity] from the [Data Monitor] menu, and mea-
Engine sure the amount of fuel injection.
SHTS021270300416
3. Select [Engine speed] from the [Data Monitor] menu, and measure
the rotational fluctuation.
NE Rotational fluctuation
@1,500 r/min (measurement by HINO-DX)
Measurement conditions
Engine speed: 1,500 r/min No-load,
Ne (r/min)
T/M shift lever: Neutral position,
A/C off and Air compressor un-operating.
Engine coolant temperature: more than 80 C {176 F}
Engine
Standard values
SHTS021270300417
Type of Q (mm3/st)
AT 5.0q
Do the measurements meet the standard value?
(Both the injection quantity and the rotational fluctuation are within the standard values)
YES NO
Go to step 10 if any following DTCs have Replace the faulty injector.
been detected as an "Active". Perform "After-inspection work" of INFOR-
Procedure completed if following DTCs have MATION section.
been detected as an "Inactive".
(cylinder #1: P0263, #2: P0266, #3: P0269 and
#4: P0272)
ENGINE (J05E)/TROUBLESHOOTING 2–521
10 Check the injector clamp
1. Check that the injector clamp is not loose.
2. Check that there is no "insufficient engagement" of the injector
BOLT clamp claw.
INJECTOR
INJECTION PIPE
INJECTOR
CLAMP
INJECTION
PIPE OIL SEAL
O-RING
SHTS021270300419
Was any failure found?
YES NO
Repair or replace the faulty parts. Go to step 11.
Perform "After-inspection work" of INFOR-
MATION section.
2–522 ENGINE (J05E)/TROUBLESHOOTING
11 Check the valve clearance
1. Check that the valve clearance of each cylinder is within the stan-
dard values. (Check all the valves.)
Rocker arm
Feeler gauge
Measurement conditions Standard values
Cold engine Intake valve:
0.3 mm (0.0118 in.)
Cross head Exhaust valve:
0.45 mm (0.0177 in.)
SHTS021270300420
Cylinder number 1 2 3 4
Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No.1 cylinder at the compres-
sion stroke top dead center
No.4 cylinder at the compres-
Δ Δ Δ Δ
sion stroke top dead center
Do the measurements meet the standard value?
YES NO
Go to step 12. Adjust the valve clearance.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–523
12 Check the engine compression pressure
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
3. Remove the air cleaner.
SST 4. Remove the all injectors.
To
engine 5. Set the special service tool (SST) and measure the compression
on each cylinder one at a time on all 6 cylinders.
SHTS021270300421
Measurement
Standard values
conditions
Engine revolution: Standard values:
150 r/min 3.2-3.4 MPa {33-35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}
Do the measurements meet the standard value?
YES NO
Go to step 13. Repair base engine to correct low compres-
sion.
Perform "After-inspection work" of INFOR-
MATION section.
2–524 ENGINE (J05E)/TROUBLESHOOTING
13 Inspect the engine speed main sensor (Crankshaft position sensor)
1. Inspect the condition of engine speed main sensor (crankshaft
Engine speed main sensor (Crankshaft position sensor) position sensor) connector (looseness or poor contact).
2. Check the installation of the engine speed main sensor. (Crank-
shaft position sensor)
Connector
Flywheel housing
SHTS021270300422
Was any failure found?
YES NO
Repair or replace the faulty parts. Go to step 14.
Perform "After-inspection work" of INFOR-
MATION section.
14 Check the DTC detected 5 (engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if any followings DTCs (cylinder #1:
P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected
in [Fault Information].
SHTS021270300423
Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?
YES NO
Inspect the crankshaft, connecting rods, fly- Procedure completed.
wheel, and other parts of the drive system. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–525
CHECKLIST: P0263, P0266, P0269 and P0272
DTC: P0263 #1 Injection quantity and timing
DTC: P0266 #2 Injection quantity and timing
Inspection procedure
DTC: P0269 #3 Injection quantity and timing
DTC: P0272 #4 Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
Perform the engine warm up.
(engine coolant temperature: 80
C {176 F} or more). Check if Other cylin-
other cylinder’s DTCs (cylinder der’s DTC
#1: P0263, #2: P0266, #3: P0269, have been
Check the
#4: P0272, #5: P0275 and #6: detected: Go Go to stop 2. Go to step 9.
DTC detected
1 P0278) have been detected in to YES. (Detected as (Recorded as
1 (Engine
[Engine]. an "Active") an " Inactive")
ECU)
<List of cylinder’s DTC> No DTC has
#1 cylinder: P0263 been detected:
#2 cylinder: P0266 Go to NO.
#3 cylinder: P0269
#4 cylinder: P0272
The DTC has
Check if the following DTC are not been detected:
Check the Go to diagno-
detected at the same time in the Go to YES.
DTC detected sis procedure
2 results of step 1. Go to step 3.
2 (Engine of the related
No DTC has
ECU) • P0263, P0266, P0269, P0272 DTC.
been detected:
Go to NO.
Check that the fuel line has no
leaks or clogging.
<Main inspection locations> Failure found: Repair or
- Entry of foreign matter into the Go to YES. replace the
Inspect the fuel tank faulty part.
3 Go to step 4.
fuel line No failure Go to step 4
- Fuel hose breakage, collaps- found: Go to after replace-
ing, looseness NO. ment.
- High-pressure pipe breakage,
collapsing, looseness
Failure found.
Replace the
Go to YES.
fuel filter.
Inspect the Check that the fuel filter is not
4 Go to step 5 Go to step 5.
fuel filter dirty or clogged. No failure
after replace-
found: Go to
ment.
NO
The DTCs
Perform engine warm up. (engine Procedure
have been
coolant temperature: 80 C {176 completed.
Check the detected: Go
F} or more), and select [Engine] Perform "After-
DTC detected to YES.
5 and check if any DTCs (cylinder Go to step 6. inspection
3 (Engine
#1: P0263, #2: P0266 #3: P0269 work" of
ECU) No DTC has
and #4: P0272) have been INFORMA-
been detected:
detected in [Engine]. TION section.
Go to NO.
2–526 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0263 #1 Injection quantity and timing
DTC: P0266 #2 Injection quantity and timing
Inspection procedure
DTC: P0269 #3 Injection quantity and timing
DTC: P0272 #4 Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Start the engine and use the
cruise function to run the
engine at 1,500 r/min.
2. Check the engine sound during
normal operation.
There is a
3. Use HINO-DX [Activation Test] clear differ-
to perform a cut-off test. (For ence in sound:
Perform the details, refer to the cut-off test Go to step
cylinder cut-off procedure on the following YES.
6 pages.) Go to step 8. Go to step 7.
test (HINO-
DX) There is no dif-
<Cylinder cut-off test> ference in
- This method is generally used sound: Go to
to check combustion abnormal- NO.
ities by stopping the fuel injec-
tion for one of the cylinder of a
four-cylinder engine and verify-
ing the engine sound or perfor-
mance.
The DTCs
Perform engine warm up. (engine Procedure
have been
coolant temperature: 80 C {176 completed.
Check the detected: Go
F} or more), and select [Engine] Perform "After-
DTC detected to YES.
7 and check if DTC (cylinder Go to step 8. inspection
4 (Engine
#1: P0263, #2: P0266, #3: P0269 work" of
ECU) No DTC has
and #4: P0272) has been INFORMA-
been detected:
detected in [Engine]. TION section.
Go to NO.
1. Replace common rail assembly
and perform the engine warm The DTC has Procedure
up. (engine coolant tempera- been detected: completed.
Replace the ture: 80 C {176 F} or more) Go to YES. Perform "After-
8 common rail 2. Select [Engine] and check if the Go to step 9. inspection
assembly DTC (cylinder No DTC has work" of
#1: P0263, #2: P0266, been detected: INFORMA-
#3: P0269 and #4: P0272) has Go to NO. TION section.
been detected in [Engine].
ENGINE (J05E)/TROUBLESHOOTING 2–527
DTC: P0263 #1 Injection quantity and timing
DTC: P0266 #2 Injection quantity and timing
Inspection procedure
DTC: P0269 #3 Injection quantity and timing
DTC: P0272 #4 Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
Check the injection quantity and
the rotational fluctuation. Go to step 10.
1. Start the engine and select if any follow-
Both the injec-
[Injection quantity] from the ing DTCs have
tion quantity
[Data Monitor] menu, and mea- been detected
and the rota-
sure the amount of fuel injec- as an
tional fluctua-
tion. "Active".Pro- Replace the
tion are within
2. Select [Engine speed] from the the standard cedure com- faulty injector.
[Data Monitor] menu, and mea- values: Go to pleted if Perform "After-
Inspect the
9 sure the rotational fluctuation. following inspection
injector YES.
<Measurement conditions> DTCs have work" of
Engine speed: 1,500 r/min been detected INFORMA-
The measure-
No-load, Neutral, A/C off and Air as an "Inac- TION section.
ments do not
compressor un-operating tive".(cylinder
meet the stan-
Engine coolant temperature: #1: P0263,
dard value: Go
more than 80 C {176 F} #2: P0266,
to NO.
<Standard values> #3: P0269,
Injection quantity (mm3/st): 5.0q #4: P0272)
or more for AT vehicles.
Repair or
Failure found: replace the
1. Check that the injector clamp is
Go to YES faulty parts.
not loose.
Check the Perform "After-
10 2. Check that there is no "insuffi- Go to step 11.
injector clamp No failure inspection
cient engagement" of the injec- found: Go to work" of
tor clamp claw. NO INFORMA-
TION section.
The measure-
Check that the valve clearance of
ments meet
each cylinder is within the stan- Adjust the
the standard
dard values. (Check all the valve clear-
value: Go to
valves.) ance.
Check the YES.
<Measurement conditions> Perform "After-
11 valve clear- Go to step 12.
Cold engine inspection
ance The measure-
<Standard values> work" of
ments do not
Intake valve: 0.3 mm {0.0118 in.} INFORMA-
meet the stan-
Exhaust valve: 0.45 mm {0.0177 TION section.
dard value: Go
in.}
to NO.
2–528 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0263 #1 Injection quantity and timing
DTC: P0266 #2 Injection quantity and timing
Inspection procedure
DTC: P0269 #3 Injection quantity and timing
DTC: P0272 #4 Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Perform the engine warm up.
(engine coolant temperature: The measure-
80 C {176 F} or more) and ments meet Repair base
remove the all injectors. the standard engine to cor-
2. Set the special service tool value: Go to rect low com-
Check the
(SST) and measure the com- YES. pression.
engine com-
12 pression on each cylinder one Go to step 13. Perform "After-
pression pres-
at a time on all 6 cylinders. The measure- inspection
sure
<Measurement conditions> ments do not work" of
Engine revolution: 150 r/min meet the stan- INFORMA-
<Standard values> dard value: Go TION section.
3.2 – 3.4 MPa {33 – 35 kgf/cm2} to NO.
Limit: 2.3 MPa {24 kgf/cm2}
Repair or
Inspect the 1. Check that the installation con- Failure found: replace the
engine speed dition of the engine speed main Go to YES. faulty parts.
main sensor sensor connector. Perform "After-
13 Go to step 14.
(Crankshaft 2. Check that the installation con- No failure inspection
position sen- dition of the engine speed main found: Go to work" of
sor) sensor. NO. INFORMA-
TION section.
Inspect the
crankshaft,
The DTCs connecting
Perform engine warm up. (engine Procedure
have been rods, flywheel,
coolant temperature: 86 C {176 completed.
Check the detected: Go and other
F} or more), and select [Engine] Perform "After-
DTC detected to YES. parts of the
14 and check if DTCs (cylinder inspection
5 (Engine drive system.
#1: P0263, #2: P0266, #3: P0269 work" of
ECU) No DTC has Perform "After-
and #4: P0272) have been INFORMA-
been detected: inspection
detected in [Engine]. TION section.
Go to NO. work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–529
DTC: P026C and P026D
EN01H02127030602016064
P026C: All injector (#1 - #4) Injection quantity and timing
P026D: All injector (#1 - #4) Injection quantity and timing
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
Engine ECU
X49 (#4) $XY (II+5)
Injector 4 X6Y (#40) X2X (#3)
X1Z (#30)
X47 (#3) $XX (12+5)
Injector 3 X6X (#30) X2W (#2)
X20 (#20)
X45 (#2) %X2 (IJ2+)
Injector 2 X0B (#20) X01 (#4)
X3L (#40)
X42 (#1) %X1 (IJ1+)
Injector 1 X43 (#10) X2V (#1)
X19 (#10)
SHTS021270300424
1. Technical description
• The main engine speed sensor (crankshaft position sensor) monitors the engine speed of #1 – #4 cylinders.
• The average injection quantity into #1 – #4 cylinders is increased and decreased so that the engine speed of each
cylinder is kept constant.
<Description of malfunction>
• Abnormal average injection quantity into #1 – #4 cylinders is detected.
2–530 ENGINE (J05E)/TROUBLESHOOTING
2. DTC set condition
(1) DTC detection condition
1. The #1 – #4 injection quantity and timing diagnosis is detecting normally.
2. All the following conditions continue for at least 10 seconds.
Manual Transmission Automatic Transmission
D range N/A 725-775
N range 725-775 N/A
P range N/A N/A
• Engine speed is in the range shown in the table at right. (Engine speed: r/min)
• Gear position is not changed.
• Fuel injection rate < 45 mm3/st. cyl.
• Engine coolant temperature ≥ 71 C {159.8 F}.
• Throttle opening is 0%.
• Vehicle speed is 0 mph.
• Barometric pressure ≥ 75 kPa.
• Exhaust brake and PTO are not in operation.
(2) Judgement criteria
• If the speed of all of cylinders from #1 – #4 measured by the engine speed main sensor is low, the status
where the fuel injection quantity decreases by 30 to 45 mm3/st. cyl or more continues for 20 seconds or more.
• If the speed of all of cylinders from #1 – #4 measured by the engine speed main sensor is low, the status
where the fuel injection quantity decreases by 10 to 20 mm3/st. cyl or more remains for 20 seconds or more.
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Large vibration during idling.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Injector: clogging, constantly injecting
• Use of low-grade fuel
• Crankshaft position sensor phase shifting.
ENGINE (J05E)/TROUBLESHOOTING 2–531
INSPECTION PROCEDURE: P026C and P026D
1 Check the DTC detected 1 (Engine ECU)
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select 3. Connect the vehicle to HINO-DX.
Engine
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P026C or P026D) has been
detected in [Fault Information] as an "Active".
SHTS021270300425
Has DTC (P026C or P026D) been detected as an "Active"?
YES NO
Go to step 2 (Detected as an "Active") Go to step 9. (Recorded as an "Inactive")
2 Check the DTC detected 2 (engine ECU)
1. Check if the following DTC are not detected at the same time in the
results of step 1.
• P0263, P0266, P0269, P0272
Select
Engine
SHTS021270300426
Has other "Active" DTC been detected?
YES NO
Go to diagnosis procedure of the related Go to step 3.
DTC.
2–532 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the fuel line
1. Check that the fuel line has no leaks or clogging.
<Main inspection locations>
- Entry of foreign matter into the fuel tank
- Fuel hose breakage, collapsing, looseness
- High-pressure pipe breakage, collapsing, looseness
A return line from the fuel filter
Fuel filter
Common rail
Injector
Pre fuel
filter
Supply pump
Suction line
Positive pressure line
Fuel tank
High pressure line
Return line
SHTS021270300427
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 4.
Go to step 4 after repair or replacement.
ENGINE (J05E)/TROUBLESHOOTING 2–533
4 Inspect the fuel filter
1. Check that the fuel filter is not dirty or clogged or damaged.
Was any failure found?
YES NO
Replace the fuel filter. Go to step 5.
Go to step 5 after replacement.
5 Check the DTC detected (Engine ECU)
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if the DTC (P026C or P026D) has been
detected in [Fault Information].
SHTS021270300428
Has DTC (P026C or P026D) been detected?
YES NO
Go to step 6. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–534 ENGINE (J05E)/TROUBLESHOOTING
6 Perform the cylinder cut-off test (HINO-DX)
1. Use the cruise function to run the engine at 1,500 r/min.
2. Check the engine sound during normal operation. (before Cut-off
test)
Select 3. Use HINO-DX [Activation Test] to perform a cut-off test.(For
Engine
details, refer to the cut-off test procedure on the following pages.)
<Cylinder cut-off test>
- This method is generally used to check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
engine and verifying the engine sound or performance.
SHTS021270300429
Did you find the engine sound different?
YES NO
<There is a clear difference in sound or per- <There is no difference in sound or perfor-
formance when the injection is cut-off> mance when the injection is cut-off>
Go to step 8. Replace the injector.
Replace the injector (Replace the failed injec-
tor detected by the cut-off test, not the injec-
tor noted in the DTC.)
Go to step 7 after replacement.
7 Check the DTC detected (Engine ECU)
1. Perform the engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if the DTC (P026C or P026D) has been
detected in [Fault Information].
SHTS021270300430
Has DTC (P026C or P026D) been detected?
YES NO
Go to step 8. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–535
8 Replace the common rail assembly
1. Set the starter key to the "LOCK" position.
2. Replace common rail assembly.
3. Perform the engine warm up. (engine coolant temperature: 80 C
Select {176 F} or more)
Engine
4. Stop the engine.
5. Set the starter key to the "ON" position.
6. Select [Engine] and check if the DTC (P026C or P026D) has been
SHTS021270300431
detected in [Fault Information].
Has DTC (P026C or P026D) been detected?
YES NO
Go to step 9. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
2–536 ENGINE (J05E)/TROUBLESHOOTING
9 Inspect the injector
Check the injection quantity.
1. Start the engine
Select 2. Select [Injection quantity] from the [Data Monitor] menu, and mea-
Engine sure the amount of fuel injection.
SHTS021270300432
3. Select [Engine speed] from the [Data Monitor] menu, and measure
the engine speed.
NE Engine speed
@1,500 r/min (measurement by HINO-DX) Measurement conditions
Engine speed: 1,500 r/min No-load,
Ne (r/min)
T/M shift lever: Neutral position,
A/C off and Air compressor un-operating.
Engine coolant temperature: more than 80 C {176 F}
Engine
Standard values
SHTS021270300433
Type of Q (mm3/st)
AT 5.0q
Do the measurements meet the standard value?
(Both the injection quantity and the engine speed are within the standard values)
YES NO
Go to step 10 if P026C or P026D have been Replace the injector.
detected as an "Active". Perform "After-inspection work" of INFOR-
Procedure completed if P026C and/or P026D MATION section.
have been detected as an "Inactive".
ENGINE (J05E)/TROUBLESHOOTING 2–537
10 Check the injector clamp
1. Check that the injector clamp is not loose.
2. Check that there is no "insufficient engagement" of the injector
BOLT clamp claw.
INJECTOR
INJECTION PIPE
INJECTOR
CLAMP
INJECTION
PIPE OIL SEAL
O-RING
SHTS021270300435
Was any failure found?
YES NO
Repair or replace the faulty parts. Go to step 11.
Perform "After-inspection work" of INFOR-
MATION section.
2–538 ENGINE (J05E)/TROUBLESHOOTING
11 Check the valve clearance
1. Check that the valve clearance of each cylinder is within the stan-
dard values. (Check all the valves.)
Rocker arm
Feeler gauge
Measurement conditions Standard values
Cold engine Intake valve:
0.30 mm (0.0118 in.)
Cross head Exhaust valve:
0.45 mm (0.0177 in.)
SHTS021270300436
Cylinder number 1 2 3 4
Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No.1 cylinder at the compres-
sion stroke top dead center
No.4 cylinder at the compres-
Δ Δ Δ Δ
sion stroke top dead center
Do the measurements meet the standard value?
YES NO
Go to step 12. Adjust the valve clearance.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–539
12 Check the engine compression pressure
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine.
3. Remove the all injectors.
SST 4. Set the special service tool (SST) and measure the compression.
To
engine Measurement
Standard values
conditions
SHTS021270300437 Engine revolution: Standard values:
150 r/min 3.2-3.4 MPa {33-35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}
Do the measurements meet the standard value?
YES NO
Go to step 13. Engine overhaul.
Perform "After-inspection work" of INFOR-
MATION section.
2–540 ENGINE (J05E)/TROUBLESHOOTING
13 Inspect the engine speed main sensor (Crankshaft position sensor)
1. Inspect the condition of engine speed main sensor (crankshaft
Engine speed main sensor (Crankshaft position sensor) position sensor) connector (looseness or poor contact).
2. Check the installation of the engine speed main sensor. (Crank-
shaft position sensor)
Connector
Flywheel housing
SHTS021270300438
Was any failure found?
YES NO
Repair or replace the faulty parts. Go to step 14.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–541
14 Check the DTC detected (Engine ECU)
1. Perform an engine warm up. (engine coolant temperature: 80 C
{176 F} or more)
2. Stop the engine
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if the DTC (P026C or P026D) has been
detected in [Fault Information].
SHTS021270300439
Has DTC (P026C or P026D) been detected?
YES NO
Inspect the crankshaft, connecting rods, fly- Procedure completed.
wheel, and other parts of the drive system. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
2–542 ENGINE (J05E)/TROUBLESHOOTING
Flow-Cut off test
<Cylinder cut-off test>
By stopping fuel injection for one of the cylinders of an engine normally running with four, this test detects combustion
abnormalities of each cylinder.
<Purpose>
Evaluation of combustion abnormalities in the cylinders by using sound differences.
<Know-how & examples>
Detect combustion abnormalities of any cylinder from differences in the sound and perform the required corrections.
1 Cylinder cut-off test
1. Start the engine and use the cruise control function to run the
engine at 1,500 r/min.
2. Check that the engine sound at the time of before cut-off test nor-
mal operation. (The sound at this time shall be α.)
3. Select [Activation Test] in the [Check functions] menu on HINO-
DX.
SHTS021270300440
ENGINE (J05E)/TROUBLESHOOTING 2–543
4. Stop injection for cylinder No. 1 and check the engine sound. (The
sound at this time shall be A.) Stop the test after checking.
(2) Execution
HINT
During the test, the engine tries to maintain the original four-cylin-
der speed, but using only three cylinders, so that the sound A
(1) Select the cylinder to deactivate. becomes larger in comparison with the sound α. (No abnormality.)
5. Sequentially stop the injection for cylinders No. 2, No. 3 and No. 4
in the same way as for a cylinder.
No. 1. (The measure sounds shall be B, C and D respectively.)
HINT
• When the difference in the sound is difficult to detect, repeat
steps 4 and 5.
• If the sound of A – D is the same of α, always check for a com-
(3) Injection is stopped when OK is selected.
munication problem.
SHTS021270300441
Did you find the engine sound different?
YES NO
(One out of A to D is abnormally loud or the Comparison of the sounds A to D shows no
same as α) clear difference
Replace the injector Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–544 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P026C and P026D
All injector (#1 – #4)
DTC: P026C
Injection quantity and timing
Inspection procedure
All injector (#1 – #4)
DTC: P026D
Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC (P026C
Perform the engine warm up
or P026D) is
(engine coolant temperature: 80
Check the detected: Go
C {176 F} or more) and select Go to step 2 Go to step 9
DTC detected to YES.
1 [Engine] and check if the DTC (Detected as (Recorded as
1 (Engine
(P026C or P026D) has been an "Active") an "Inactive")
ECU) Is not
detected in [Engine] as an
detected: Go
"Active".
to NO.
Other "Active"
DTC has been
Check the Check if the following DTC are not detected: Go Go to diagno-
DTC detected detected at the same time in the to YES. sis procedure
2 results of step 1. Go to step 3.
2 (Engine of the related
ECU) • P026C, P026D, P0269, P0272 No DTC has DTC.
been detected:
Go to NO.
Check that the fuel line has no
leaks or clogging.
Failure found: Repair of
<Main inspection locations> Go to YES. replace the
Inspect the - Entry of foreign matter into the faulty part.
3 fuel tank Go to step 4
fuel line No failure Go to step 4
- Fuel hose breakage, collaps- found: Go to after repair or
ing, looseness NO. replacement
- High-pressure pipe breakage,
collapsing, looseness
Failure found:
Replace the
Go to YES.
fuel filter.
Inspect the Check that the fuel filter is not
4 Go to step 5 Go to step 5
fuel filter dirty or clogged or damaged. No failure
after replace-
found: Go to
ment
NO.
DTC P026C,
Procedure
Perform the engine warm up P026D have
completed.
(engine coolant temperature: 80 been detected:
Check the Perform "After-
C {176 F} or more) Go to YES.
5 DTC detected Go to step 6. inspection
Check if the DTC (P026C or
(Engine ECU) work" of
P026D) has been detected in No DTC has
INFORMA-
[Engine]. been detected:
TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–545
All injector (#1 – #4)
DTC: P026C
Injection quantity and timing
Inspection procedure
All injector (#1 – #4)
DTC: P026D
Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Use the cruise function to run
the engine at 1,500 r/min.
2. Check the engine sound during
normal operation.
3. Use HINO-DX's [Activation The engine
Test] to perform a cut-off sound was dif-
test.(For details, refer to the Replace the
Perform the ferent: Go to
cut-off test procedure on the failed injector.
cylinder cut-off YES.
6 following pages.) Go to step 8 Go to step 7
test [HINO-
after replace-
DX] There was no
<Cylinder cut-off test> ment.
clear differ-
- This method is generally used ence: NO
to check combustion abnormal-
ities by stopping the fuel injec-
tion for one of the cylinder of a
four-cylinder engine and verify-
ing the engine sound.
DTC (P026C
Procedure
Perform the engine warm up or P026D) has
completed.
(engine coolant temperature: 80 been detected:
Check the Perform "After-
C {176 F} or more) Go to YES.
7 DTC detected Go to step 8. inspection
Check if the DTC (P026C or
(Engine ECU) work" of
P026D) has been detected in No DTC has
INFORMA-
[Engine]. been detected:
TION section.
Go to NO.
DTC (P026C
1. Replace common rail assembly Procedure
or P026D) has
and perform the engine warm completed.
been detected:
Replace the up (engine coolant tempera- Perform "After-
Go to YES.
8 common rail ture: 80 C {176 F} or more) Go to step 9. inspection
assembly 2. Check if the DTC (P026C or work" of
No DTC has
P026D) has been detected in INFORMA-
been detected:
[Engine]. TION section.
Go to NO.
2–546 ENGINE (J05E)/TROUBLESHOOTING
All injector (#1 – #4)
DTC: P026C
Injection quantity and timing
Inspection procedure
All injector (#1 – #4)
DTC: P026D
Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
Check the injection quantity.
1. Start the engine.
Both the injec-
2. Select [Injection quantity] from Go to step 10.
the [Data Monitor] menu, and tion quantity
If the DTC
measure the amount of fuel and the engine
(P026C or
injection. speed are
P026D) has Replace the
3. Select [Engine speed] from the within the been detected injector.
[Data Monitor] menu, and mea- standard val- as an "Active". Perform "After-
Inspect the sure the engine speed. ues: Go to
9 Procedure inspection
injector <Measurement conditions> YES.
completed if work" of
Engine speed: 1,500 r/min P026C and/or INFORMA-
No-load, Neutral, A/C off and Air The measure-
P026D have TION section.
compressor un-operating ment do not
been detected
Engine coolant temperature: meet the stan-
as an "Inac-
more than 80 C {176 F} dard value: Go
tive".
<Standard values> to NO.
3/st): 5.0q
Injection quantity (mm
or more for AT vehicles.
Repair or
Failure found: replace the
1. Check that the injector clamp is
Go to YES. faulty parts.
not loose.
Check the Perform "After-
10 2. Check that there is no "insuffi- Go to step 11
injector clamp No failure inspection
cient engagement" of the injec- found: Go to work" of
tor clamp claw. NO. INFORMA-
TION section.
The measure-
Check that the valve clearance of
ments meet
each cylinder is within the stan- Adjust the
the standard
dard values. (Check all the valve clear-
value: Go to
valves.) ance.
Check the YES.
when engine is cold Perform "After-
11 valve clear- Go to step 12
<Standard values> inspection
ance The measure-
Intake valve: work" of
ments do not
0.3mm (0.0118 in) INFORMA-
meet the stan-
Exhaust valve: TION section.
dard value: Go
0.45mm (0.0177 in)
to NO.
1. Perform an engine warm up.
(engine coolant temperature: The measure-
80 C {176 F} or more) ments meet
the standard Engine over-
2. Stop the engine.
value: Go to haul.
Check the 3. Remove the all injectors YES. Perform "After-
engine com-
12 4. Set the special service tool Go to step 13 inspection
pression pres-
(SST) and measure the com- The measure- work" of
sure
pression. ments do not INFORMA-
Engine revolution: 150 r/min meet the stan- TION section.
<Standard values> dard value: Go
3.2 – 3.4 MPa {33 - 35 kgf/cm2} to NO.
Limit: 2.3 MPa {24 kgf/cm2}
ENGINE (J05E)/TROUBLESHOOTING 2–547
All injector (#1 – #4)
DTC: P026C
Injection quantity and timing
Inspection procedure
All injector (#1 – #4)
DTC: P026D
Injection quantity and timing
Check
Step Action Description Judgement Yes No
(Yes/No)
Repair or
1. Inspect the condition of engine
Inspect the Failure found: replace the
speed main sensor (crankshaft
engine speed Go to YES. faulty parts.
position sensor) connector
main sensor Perform "After-
13 (looseness or poor contact). Go to step 14
(Crankshaft No failure inspection
position sen- 2. Check the installation of the found: Go to work" of
sor) engine speed main sensor. NO. INFORMA-
(Crankshaft position sensor) TION section.
Inspect the
crankshaft,
DTC (P026C connecting
Procedure
Perform an engine warm up. or P026D) has rods, flywheel,
completed.
(engine coolant temperature: been detected: and other
Check the Perform "After-
80 C {176 F} or more) Go to YES. parts of the
14 DTC detected inspection
Check if the DTC (P026C or drive system.
(Engine ECU) work" of
P026D) has been detected in No DTC has Perform "After-
INFORMA-
[Engine]. been detected: inspection
TION section.
Go to NO. work" of
INFORMA-
TION section.
2–548 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0299
EN01H02127030602016065
P0299: Underboost
INFORMATION
Coolant temperature
sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth Z5G (E) 10mA ZJQ (E5)
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72 (E2)
pressure sensor (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
(FC) X71 10mA X4K (VG)
(E2G) XCV 200mA XMH (EVG)
Intake air
temperature sensor (+B) XCT 200mA X2U (VAF)
(air flow sensor built in) (E2) Z65 10mA
(THA) X72 10mA X82 (THA)
SHTS021270300442
1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure. It compares the target boost pressure and actual boost pressure to check if the actual pressure is
lower than the target pressure.
<Description of malfunction>
• The boost pressure is lower than the stipulated value.
2. DTC set condition
(1) DTC detection condition
• Water temperature at the engine start-up is 0 C {32 F} or above.
The conditions described below remain for 4 seconds or more.
• The target boost pressure is 40 kPa or more.
• If the engine speed is 750 r/min, fuel injection quantity is 100 mm3/st. cyl or more.
• If the engine speed is in range of 1250 to 1750 r/min, fuel injection quantity is 60 mm3/st.cyl or more.
• If the engine speed is 2500 r/min, fuel injection quantity is 120 mm3/st.cyl or more.
• Atmospheric pressure is higher than 75 kPa.
• DPR auto-regeneration is not actuated.
(2) Judgement criteria
• Deviation between the target boost pressure and the actual boost pressure: the condition that the deviation
exceeds the range of -15 to -45 kPa remains 30 seconds or more.
• If the deviation of the boost pressure is -15 kPa, the boost pressure value of 140 kPa or less is detected.
• If the deviation of the boost pressure is -40 kPa, the boost pressure value of 250 kPa or more is detected.
ENGINE (J05E)/TROUBLESHOOTING 2–549
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormality in air intake system (disconnected boost hose)
• Turbocharger failure (stuck turbine)
• Malfunction of boost pressure sensor
• Malfunction of air flow sensor
• Malfunction of VNT
• Malfunction of EGR valve
2–550 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0299
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than P0299 (for exam-
ple, P0045, P0401) has been detected in [Fault Information].
SHTS021270300443
Has a DTC other than P0299 been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
2 Inspect the boost pressure sensor hose.
1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.
2. Make sure the pipe on the intake manifold side is not clogged.
Was any failure found?
YES NO
1. Replace the boost pressure sensor hose. Go to step 3.
2. Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–551
3 Inspect the boost pressure sensor power supply system
1. Set the starter key to the "LOCK" position.
E
2. Disconnect the boost pressure sensor connector.
VC
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300444 Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 4. Inspect the harness and engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
2–552 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect the response delay of the VNT controller
1. Select [Check functions] from the menu, then inspect the response
(1) delay at the Target VNT position and Actual VNT position.
! CAUTION
(2) Perform the inspection while the engine is stopped to avoid dam-
ages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [VNT check].
(3) Click [Check start].
(4) Select [VNT opening UP]:
(3)
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT opening DOWN]:
(4) (5) • Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.
SHTS021270300445
Standard values
From the Target VNT position to the Actual VNT position,
the response delay should be within 3 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the turbocharger.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–553
5 Inspect the response delay of the EGR valve
1. Select [Check functions] and then [EGR check] from the menu,
(1) then inspect the response delay at the Target EGR position and
Actual EGR position.
(2)
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Click [Check start].
(3)
(4) Click [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Click [EGR opening DOWN]:
(4) (5)
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.
SHTS021270300446
Standard values
From the Target EGR position to the Actual EGR position,
the response delay should be within 5 seconds.
Do the measurements meet the standard value?
YES NO
Check that P0299 is not detected again to Replace the EGR valve.
complete the check. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
2–554 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0299
DTC: P0299 Underboost Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC P0045,
P0401 has
Check if any DTC other than been detected: Go to the diag-
Check the
P0299 (for example, P0045, Go to YES. nostic proce-
1 DTC detected Go to step 2.
P0401) has been detected in dure of a
(Engine ECU)
[Engine]. No DTC has related DTC.
been detected:
Go to NO.
1. Replace the
boost pres-
sure sensor
1. Make sure the boost pressure Failure found: hose.
sensor hose is not clogged, Go to YES. 2. Clean the
Inspect the
ruptured, or cracked. intake mani- Go to step 3.
2 boost pressure
2. Make sure the pipe on the No failure fold pipe.
sensor hose
intake manifold side is not found: Go to Perform "After-
clogged. NO. inspection
work" of
INFORMA-
TION section.
The measure-
Measure the voltage between the ments meet
Inspect the
terminals of the boost pressure the standard
harness and
sensor vehicle side connector. value: Go to
Inspect the engine ECU.
<Tester connections> YES.
boost pressure Perform "After-
3 Boost pressure sensor vehicle Go to step 4.
sensor power inspection
side connector The measure-
supply system work" of
VC – E ments do not
INFORMA-
<Standard values> meet the stan-
TION section.
4.75 – 5.25 V dard value: Go
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–555
DTC: P0299 Underboost Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Select [Check functions] from the
menu, then inspect the response
delay at the Target VNT position
and Actual VNT position.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [VNT check]. The measure-
(3) Click [Check start] ments meet
(4) Select [VNT opening UP]: the standard Replace the
• Inspect the response delay at value: Go to turbocharger.
Inspect the
each step of the Target VNT YES. Perform "After-
response
4 position and Actual VNT posi- Go to step 5. inspection
delay of the
tion from 0 to 90%. The measure- work" of
VNT controller
(5) Select [VNT opening DOWN]: ments do not INFORMA-
• Inspect the response delay at meet the stan- TION section.
each step of the Target VNT dard value: Go
position and Actual VNT posi- to NO.
tion from 90 to 0%.
<Standard values>
From the Target VNT position to
the Actual VNT position, the
response delay should be within 3
seconds.
Select [Check functions] and then
[EGR check] from the menu, then
inspect the response delay at the
Target EGR position and Actual
EGR position.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check]. The measure- Check that
(3) Click [Check start]. ments meet that P0299 is
(4) Click [EGR opening UP]: the standard not detected Replace the
value: Go to again to com- EGR valve.
Inspect the • Inspect the response delay at
YES. plete the Perform "After-
response each step of the Target EGR
5 check. inspection
delay of the position and Actual EGR posi-
The measure- Perform "After- work" of
EGR valve tion from 0 to 90%.
ments do not inspection INFORMA-
(5) Click [EGR opening DOWN]:
meet the stan- work" of TION section.
• Inspect the response delay at dard value: Go INFORMA-
each step of the Target EGR to NO. TION section.
position and Actual EGR posi-
tion from 90 to 0%.
<Standard values>
From the Target EGR position to
the Actual EGR position, the
response delay should be within 5
seconds.
2–556 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0300
EN01H02127030602016066
P0300: All injector (#1 - #4) Misfire
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
SHTS021270300447
1. Technical description
• The main engine speed sensor (crankshaft position sensor) monitors the engine speed of #1 – #4 cylinders.
• The average injection quantity into #1 – #4 cylinders is increased and decreased so that the engine speed of each
cylinder is kept constant.
<Description of malfunction>
• Two or more of the following DTCs are detected: P0301, P0302, P0303, P0304.
ENGINE (J05E)/TROUBLESHOOTING 2–557
2. DTC set condition
(1) DTC detection condition
1. All the following conditions continue for at least 30 seconds:
• Engine speed is between 250 – 900 r/min.
• Fuel injection rate is within 0 – 50 mm3/st. cyl.
• Exhaust brake and PTO are not in operation.
2. All the following conditions continue for at least 10 seconds:
• Engine speed is in the range shown in table at below.
• Gear position is not changed.
• Fuel injection rate < 45 mm3/st. cyl.
• Engine coolant temperature ≥ 71 C {159.8 F}.
• Throttle opening is 0%.
• Vehicle speed is 0 mile / h.
• Atmospheric pressure is 75 kPa or more.
• Exhaust brake and PTO are not in operation.
Engine speed (r/min)
MT AT
D range N/A 725 - 775
N range 725 - 775 N/A
P range N/A N/A
(2) Judgement criteria
• Failure is determined when two or more of P0301, P0302, P0303, and P0304 are detected for 3 seconds.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Excessive vibration while engine is idling.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Injector: clogging, constantly injecting
2–558 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0300
1 Inspect the fuel pipes
1. Check the fuel pipe (high-pressure pipe between the common rail
and injector) and verify that there are no bends, ruptures, or loose
connections in it.
A return line from the fuel filter
Fuel filter
Common rail
Injector
Pre fuel
filter
Supply pump
Suction line
Positive pressure line
Fuel tank
High pressure line
Return line
SHTS021270300448
Was any failure found?
YES NO
Repair or replace the faulty part, Go to step 3.
go to step 2.
ENGINE (J05E)/TROUBLESHOOTING 2–559
2 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if P0300 has been detected in [Fault
Information].
SHTS021270300449
Has DTC P0300 been detected?
YES NO
Go to step 3. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
3 Perform the cylinder cut-off test
1. Use the cruise function to run the engine at 1,500 r/min.
2. Check the engine sound during normal operation.
Select
3. Select [Engine], and [Activation Test] to perform a cut-off test.
Engine
For details, refer to "Flow-Cut off test" procedure.
<Cylinder cut-off test>
- This method is generally used to check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
engine and verifying the injectors' sound.
SHTS021270300450
Did you notice a difference in engine sound?
YES NO
<There is a clear difference in sound or per- <There is no difference in sound or perfor-
formance when the injection is cut-off> mance when the injection is cut-off>
Go to step 4. Replace the injector (Replace the failed injec-
tor detected by the cut-off test, not the injec-
tor noted in the DTC.)
Go to step 5 after replacement.
2–560 ENGINE (J05E)/TROUBLESHOOTING
4 Check the DTC detected (Engine ECU) 2
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if P0300 has been detected in [Fault
Information].
SHTS021270300451
Has DTC P0300 been detected?
YES NO
Go to step 5. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
5 Replace the common rail assembly [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Replace the common rail assembly with a new one.
Select
3. Warm up the engine. (engine coolant temperature: 80 C {176 F}
Engine
or more)
4. Stop the engine and set the starter key to the "ON" position.
5. Select [Engine] and check if P0300 has been detected in [Fault
Information].
SHTS021270300452
Has DTC P0300 been detected?
YES NO
Go to step 6. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–561
6 Check the compression ratio
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine.
3. Remove injectors from all cylinders.
SST 4. Install the special tool (SST) and measure the compression ratio of
TO each cylinder.
ENGINE
Measurement conditions Standard values
SHTS021270300453 Standard values:
3.2 – 3.4 MPa {33 – 35 kgf/
Engine revolution: 150 r/min
cm2}
Limit: 2.3 MPa {24 kgf/cm2}
Do the measurements meet the standard value?
YES NO
Go to step 7. Overhaul the engine.
Perform "After-inspection work" of INFOR-
MATION section.
7 Check the DTC detected (Engine ECU) 3
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if P0300 has been detected in [Fault
Information].
SHTS021270300454
Has DTC P0300 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–562 ENGINE (J05E)/TROUBLESHOOTING
Flow-Cut off test
<Cylinder cut-off test>
By stopping fuel injection for one of the cylinders of an engine normally running with six, this test detects combustion
abnormalities of each cylinder.
<Purpose>
Evaluation of combustion abnormalities of each cylinder by sound difference.
<Know-how & examples>
Detect combustion abnormalities of any cylinder from differences in the sound and perform the required corrections.
1 Cylinder cut-off test
1. Start the engine and use the cruise control function to run the
engine at 1,500 r/min.
2. Check that the engine sound at the time of normal operation. (The
sound at this time shall be α.)
3. Select [Activation Test] in the [Check functions] menu on HINO-
DX.
SHTS021270300455
ENGINE (J05E)/TROUBLESHOOTING 2–563
4. Stop injection for cylinder No. 1 and check the engine sound. (The
sound at this time shall be A.) Stop the test after checking.
2 Execution
HINT
During the test, the engine tries to maintain the original four-cylin-
der speed, but using only three cylinders, so that the sound A
1 Select the cylinder to deactivate. becomes larger in comparison with the sound. (This is not abnor-
mal.)
As the engine is running with combustion of one cylinder less
than normal, it is normal that the vibrations increase.
For an engine with no injection or reduced injection quantity,
injection stop causes no vibration change.
For engines increasing the injection quantity for some cylinders,
the vibrations become larger when all cylinders are operating, and
the vibrations decrease when injection is stopped for the defec-
tive cylinder.
3 Injection is stopped when OK is selected.
5. Sequentially stop the injection for cylinders No. 2, No. 3 and No. 4
in the same way as for a cylinder No. 1. (The measure sounds
SHTS021270300456 shall be B, C and D respectively.)
HINT
• When the difference in the sound is difficult to detect, repeat
steps 4 and 5.
• if one of the sounds A to D is the same as α, always check for a
communication problem of the injector.
Did you notice a difference in engine sound?
YES NO
<One out of A to D is abnormally loud or the Comparison of the sounds A to D shows no
same as α> clear difference
Replace the abnormal injector. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–564 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0300
DTC: P0300 All injector (#1 – #4) Misfire Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found: Repair or
Check the fuel pipe (high-pres-
Go to YES. replace the
sure pipe between the common
Inspect the faulty part.
1 rail and injector) and verify that Go to step 3.
fuel pipes No failure Go to step 2
there are no bends, ruptures, or
found: Go to after repair or
loose connections in it.
NO. replacement.
DTC P0300
Procedure
has been
completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After-
coolant temperature: 80 C {176 to YES.
2 DTC detected Go to step 3. inspection
F} or more), and check if P0300
(Engine ECU) work" of
has been detected in [Engine]. No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
1. Start the engine, and use the
cruise function to maintain the
engine speed at 1,500 r/min.
2. Check the sound of the engine
(during normal operation)
before the test.
The engine
3. Select [Engine] from HINO-DX sound was dif-
menu, and perform the [Cut off ferent: Go to Replace the
Perform the test] from [Activation Test]. YES. failed injector.
3 cylinder cut-off For detailed instructions, refer to Go to step 4 Go to step 5.
test "Flow-Cut off test". The engine after replace-
sound was not ment
<Cylinder cut-off test> different Go to
- <Using a standard 4-cylinders NO.
operating engine, this method
stops one of the cylinders' fuel
injection to check for combus-
tion abnormalities through dif-
ferences in the combustion
sound.
DTC P0300
Procedure
has been
completed.
Check the Perform engine warm up. (engine detected: Go
Perform "After-
DTC detected coolant temperature: 80 C {176 to YES.
4 Go to step 5. inspection
(Engine ECU) F} or more), and check if P0300
work" of
2 has been detected in [Engine]. No DTC has
INFORMA-
been detected:
TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–565
DTC: P0300 All injector (#1 – #4) Misfire Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Set the starter key to the
"LOCK" position.
2. Replace the common rail DTC P0300
Procedure
assembly with a new one. has been
completed.
detected: Go
Replace the 3. Warm up the engine. (engine Perform "After-
to YES.
5 common rail coolant temperature: 80 C Go to step 6. inspection
[HINO-DX] {176 F} or more) No DTC has
work" of
4. Stop the engine and set the INFORMA-
been detected:
starter key to the "ON" position. Go to NO. TION section.
5. Check if P0300 has been
detected in [Engine].
1. Warm up the engine. (engine
coolant temperature: 80 C
{176 F} or more) The measure-
ments meet
2. Stop the engine.
the standard Overhaul the
3. Remove injectors from all cylin- value: Go to engine.
Check the ders. YES. Perform "After-
6 compression 4. Install the special tool (SST) Go to step 7. inspection
ratio and measure the compression The measure- work" of
ratio of each cylinder. ments do not INFORMA-
<Measurement conditions> meet the stan- TION section.
Engine revolution: 150 r/min dard value: Go
<Standard values> to NO.
3.2 – 3.4 MPa {33 – 35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}
DTC P0300
Replace the Procedure
has been
engine ECU. completed.
Check the Perform engine warm up. (engine detected: Go
Perform "After- Perform "After-
DTC detected coolant temperature: 80 C {176 to YES.
7 inspection inspection
(Engine ECU) F} or more), and check if P0300
work" of work" of
3 has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–566 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0301, P0302, P0303 and P0304
EN01H02127030602016067
P0301: #1 Misfire
P0302: #2 Misfire
P0303: #3 Misfire
P0304: #4 Misfire
INFORMATION
Flow damper Injection
pipe Injector
Common rail
Pressure feeding pipe
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Fuel pump
Overflow
valve
Pre fuel filter Fuel tank
Fuel filter
SHTS021270300457
1. Technical description
• The main speed sensor monitors the speed of each cylinder.
• For control, it increases or reduces the compensation of the injection quantity of each cylinder to make constant the
speed of each cylinder.
<Description of malfunction>
• If the speed of the #1 cylinder is found abnormal, the DTC P0301 will be detected.
• If the speed of the #2 cylinder is found abnormal, the DTC P0302 will be detected.
• If the speed of the #3 cylinder is found abnormal, the DTC P0303 will be detected.
• If the speed of the #4 cylinder is found abnormal, the DTC P0304 will be detected.
ENGINE (J05E)/TROUBLESHOOTING 2–567
2. DTC set condition
(1) DTC detection condition
1. All the following conditions continue for more than 30 seconds.
• The engine speed is in the range of 250 to 900 r/min.
• The fuel injection quantity is within 0 to 50 mm3/st. cyl.
• The exhaust brake and PTO are inactive.
2. All the following conditions continue for more than 10 seconds.
• The engine speed is within the below table.
• Gear position unchanged
• The fuel injection quantity is less than 45 mm3/st. cyl.
• The coolant temperature is above 71 C {159.8 F}.
• The accelerator opening is 0%.
• The vehicle speed is 0 mile/h.
• Barometric pressure ≥ 75 kPa.
• The exhaust brake and PTO are inactive.
Engine speed (r/min)
Manual Transmission Automatic Transmission
D range N/A 725-775
N range 725-775 N/A
P range N/A N/A
(2) Judgement criteria
If all the following conditions continue for more than 10 seconds, diagnostic judgment will take place.
• The fuel injection quantity is more than 40 mm3/st. cyl.
• The speed of each cylinder measured by engine speed main sensor (crankshaft position sensor) becomes
abnormal.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Excessive vibration while engine is idling.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–568 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Common rail: flow damper operational error
• Injector: clogged or stays open
ENGINE (J05E)/TROUBLESHOOTING 2–569
INSPECTION PROCEDURE: P0301, P0302, P0303 and P0304
1 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if any DTC other than (P0301, P0302,
P0303 or P0304) has been detected in [Fault Information].
SHTS021270300458
Has any DTC other than (P0301, P0302, P0303 or P0304) been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2–570 ENGINE (J05E)/TROUBLESHOOTING
2 Inspect the fuel injection pipe between common rail and injector
1. Check the fuel pipe (high-pressure pipe between the common rail
and injector) and verify that there are no bends, ruptures, or loose
connections in it.
A return line from the fuel filter
Fuel filter
Common rail
Injector
Pre fuel
filter
Supply pump
Suction line
Positive pressure line
Fuel tank
High pressure line
Return line
SHTS021270300459
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 4.
Go to step 3 after repair or replacement.
ENGINE (J05E)/TROUBLESHOOTING 2–571
3 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if the DTC (P0301, P0302, P0303 or
P0304) has been detected in [Fault Information].
SHTS021270300460
Has DTC (P0301, P0302, P0303 or P0304) been detected?
YES NO
Go to step 4. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
4 Perform the cylinder cut-off test
1. Start the engine and use the cruise function to run the engine at
1,500 r/min.
2. Check the engine sound during normal operation.
Select
Engine
3. Select [Engine], and [Activation Test] to perform a cut-off test.
For details, refer to the cut-off test procedure.
<Cylinder cut-off test>
- This method is generally used to Check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
engine and verifying the injectors' sound.
SHTS021270300461
Did you find the engine sound different?
YES NO
<There is a clear difference in sound or per- <There is no difference in sound or perfor-
formance when the injection is cut-off> mance when the injection is cut off>
Go to step 5. Replace the injector (Replace the failed injec-
tor detected by the cut-off test, not the injec-
tor noted in the DTC.).
Go to step 5 after replacement.
2–572 ENGINE (J05E)/TROUBLESHOOTING
5 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if the DTC (P0301, P0302, P0303 or
P0304) has been detected in [Fault Information].
SHTS021270300462
Has DTC been detected?
YES NO
Go to step 6. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
6 Replace the common rail assembly
1. Set the starter key to the "LOCK" position.
2. Replace the common rail assembly.
Select
3. Warm up the engine. (engine coolant temperature: 80 C {176 F}
Engine
or more)
4. Stop the engine and the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0301, P0302, P0303 or
P0304) has been detected in [Fault Information].
SHTS021270300463
Has DTC (P0301, P0302, P0303 or P0304) been detected?
YES NO
Go to step 7. Procedure completed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–573
7 Check the engine compression pressure
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine.
3. Remove the all injectors
SST 4. Set the special service tool (SST) and measure the compression.
TO
ENGINE Measurement conditions Standard values
3.2 – 3.4 MPa
SHTS021270300464 Engine revolution: 150 r/min {33 – 35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}
Do the measurements meet the standard value?
YES NO
Go to step 8. Overhaul the engine.
Perform "After-inspection work" of INFOR-
MATION section.
8 Check the DTC detected (Engine ECU)
1. Warm up the engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if the DTC (P0301, P0302, P0303 or
P0304) has been detected in [Fault Information].
SHTS021270300465
Has DTC (P0301, P0302, P0303 or P0304) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–574 ENGINE (J05E)/TROUBLESHOOTING
Flow-Cut off test
<Cylinder cut-off test>
By stopping fuel injection for one of the cylinders of an engine normally running with four, this test detects combustion
abnormalities of any cylinder.
<Purpose>
Evaluation of combustion abnormalities of each cylinder by sound difference.
<Know-how & examples>
Detect combustion abnormalities of any cylinder from differences in the sound and perform the required corrections.
1 Cylinder cut-off test
1. Start the engine and use the cruise control function to run the
engine at 1,500 r/min.
2. Check that the engine sound at the time of normal operation. (The
sound at this time shall be α.)
3. Select [Activation Test] in the [Check functions] menu on HINO-
DX.
SHTS021270300466
ENGINE (J05E)/TROUBLESHOOTING 2–575
4. Stop injection for cylinder No. 1 and check the engine sound. (The
sound at this time shall be A.) Stop the test after checking.
2 Execution
HINT
During the test, the engine tries to maintain the original four-cylin-
der speed, but using only three cylinders, so that the sound A
1 Select the cylinder to deactivate. becomes larger in comparison with the sound. (This is not abnor-
mal.)
As the engine is running with combustion of one cylinder less
than normal, it is normal that the vibrations increase.
For an engine with no injection or reduced injection quantity,
injection stop causes no vibration change.
For engines increasing the injection quantity for some cylinders,
the vibrations become larger when all cylinders are operating, and
the vibrations decrease when injection is stopped for the defec-
tive cylinder.
3 Injection is stopped when OK is selected.
5. Sequentially stop the injection for cylinders No. 2, No. 3 and No. 4
in the same way as for a cylinder No. 1. (The measure sounds
SHTS021270300467 shall be B, C and D respectively.)
HINT
• When the difference in the sound is difficult to detect, repeat
steps 4 and 5.
• if one of the sounds A to D is the same as α, always check for a
communication problem of the injector.
Did you notice a difference in engine sound?
YES NO
<One out of A to D is abnormally loud or the Comparison of the sounds A to D shows no
same as α> clear difference
Replace the injector. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–576 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0301, P0302, P0303 and P0304
DTC: P0301 #1 Misfire
DTC: P0302 #2 Misfire
Inspection procedure
DTC: P0303 #3 Misfire
DTC: P0304 #4 Misfire
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Warm up the engine. (engine DTC has been
coolant temperature: 80 C detected: Go
Go to diagno-
Check the {176 F} or more) to YES.
sis procedure
1 DTC detected 2. Check if any DTC other than Go to step 2.
of a related
(Engine ECU) (P0301, P0302, P0303 or No DTC has
DTC.
P0304) has been detected in been detected:
[Engine]. Go to NO.
Failure found: Repair or
Inspect the Make sure that the fuel pipe (the
Go to YES. replace the
fuel injection high pressure pipe between the
faulty part.
2 pipe between common rail and the injector) is Go to step 4.
No failure Go to step 3
common rail not crashed, bent, loose and that
found: Go to after repair or
and injector it has no leaks.
NO. replacement.
DTC has been Procedure
1. Warm up the engine. (engine
detected: Go completed.
coolant temperature: 80 C
Check the to YES. Perform "After-
{176 F} or more)
3 DTC detected Go to step 4. inspection
(Engine ECU) 2. Check if the DTC (P0301, No DTC has work" of
P0302, P0303 or P0304) has been detected: INFORMA-
been detected in [Engine]. Go to NO. TION section.
1. Start the engine and use the
cruise function to run the
engine at 1500 r/min.
2. Check the engine sound during
normal operation.
There was a
3. Use HINO-DX [Activation Test] difference in
to perform a cut-off test. the engine
(For details, refer to the cut-off There is no
Perform the sound: Go to
test procedure on the following clear differ-
4 cylinder cut-off YES. Go to step 5
pages.) ence: Go to
test
step 6.
There was no
<Cylinder cut-off test> difference: Go
- This method is generally used to NO.
to Check combustion abnor-
malities by stopping the fuel
injection for one of the cylinder
of a four-cylinder engine and
verifying the injectors' sound.
DTC has been Procedure
1. Warm up the engine. (engine
detected: Go completed.
coolant temperature: 80 C
Check the to YES. Perform "After-
{176 F} or more)
5 DTC detected Go to step 6. inspection
(Engine ECU) 2. Check if the DTC (P0301, No DTC has work" of
P0302, P0303 or P0304) has been detected: INFORMA-
been detected in [Engine]. Go to NO. TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–577
DTC: P0301 #1 Misfire
DTC: P0302 #2 Misfire
Inspection procedure
DTC: P0303 #3 Misfire
DTC: P0304 #4 Misfire
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Replace the common rail
DTC has been Procedure
assembly and warm up the
detected: Go completed.
Engine. (engine coolant tem-
Replace the to YES. Perform "After-
perature: 80C {176 F} or
6 common rail Go to step 7 inspection
more)
assembly No DTC has work" of
2. Check if the DTC (P0301, been detected: INFORMA-
P0302, P0303 or P0304) has Go to NO. TION section.
been detected in [Engine].
1. Warm up the engine. (engine
coolant temperature: 80 C The measure-
{176 F} or more) and remove ments meet
the all injectors. the standard Overhaul the
2. Set the special service tool value: Go to engine.
Check the
(SST) and measure the com- YES. Perform "After-
engine com-
7 pression. Go to step 8 inspection
pression pres-
<Measurement conditions> The measure- work" of
sure
Engine revolution:150 r/min ments do not INFORMA-
<Standard values> meet the stan- TION section.
Standard value: dard value: Go
3.2 – 3.4 MPa {33 – 35 kgf/cm2} to NO.
Limit: 2.3 MPa {24 kgf/cm2}
DTC has been Replace the Procedure
detected: Go engine ECU. completed.
Check the Check if the DTC (P0301, P0302, to YES. Perform "After- Perform "After-
8 DTC detected P0303 or P0304) has been inspection inspection
(Engine ECU) detected in [Engine]. No DTC has work" of work" of
been detected: INFORMA- INFORMA-
Go to NO. TION section. TION section.
2–578 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0335
EN01H02127030602016068
P0335: Engine speed main sensor (Crankshaft position sensor) - disconnection
INFORMATION
Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J 1mA X3F (NE-)
(NE+) J0H 1mA XK4 (NE+)
SHTS021270300468
1. Technical description
• The engine speed main sensor (crankshaft position sensor) consistently measures pulses from the engine speed
main sensor (crankshaft position sensor).
<Description of malfunction>
• Pulses from the engine speed main sensor (crankshaft position sensor) cannot be sensed.
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
• Engine speed of 0 r/min or more
(2) Judgement criteria
• With the engine running, engine speed main sensor does not detect pulses for continuous 0.8 seconds or lon-
ger. (at 750 r/min)
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
• Engine output is restricted.
• Cruise control function is not available.
• Idling stop system is not available.
• Regeneration failure of DPR.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• Cruise control does not work.
• Idling stop system does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
ENGINE (J05E)/TROUBLESHOOTING 2–579
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to adhesion of dirt, damage,
etc.)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
2–580 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0335
1 Inspect the engine speed main sensor (crankshaft position sensor) connector
1. Check the connection of the engine speed main sensor (crank-
shaft position sensor) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine speed main sensor (crankshaft position sensor)
1. Check the installation of the engine speed main sensor (crankshaft
position sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine speed main sensor (crankshaft position sensor).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine speed main
sensor (crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–581
3 Inspect the engine speed main sensor (crankshaft position sensor) unit
1. Set the starter key to the "LOCK" position.
2. Disconnect the engine speed main sensor (crankshaft position
NE- NE+ sensor) connector.
3. Use the electrical tester to measure the resistance between the
terminals of the engine speed main sensor (crankshaft position
sensor).
Measurement Tester
Standard values
conditions connections
SHTS021270300469 Engine speed
main sensor
20 C {68 F}:
Starter key: LOCK (crankshaft posi-
108.5 – 142.5
tion sensor)
NE+ – NE-
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the engine speed main sensor
(crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
2–582 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect the engine speed main sensor (crankshaft position sensor) power supply
1. Set the starter key to the "ON" position.
NE+ NE- 2. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed main sensor (crankshaft position sensor)
vehicle side connector.
Measurement Tester
Standard values
conditions connections
Engine speed
main sensor
(crankshaft posi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300470 tion sensor) vehi-
cle side connector
NE+ – NE-
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
ENGINE (J05E)/TROUBLESHOOTING 2–583
5 Inspect for short-circuit of the engine speed main sensor (crankshaft position sensor) har-
ness
1. Set the starter key to the "LOCK" position.
E52 D
2. Connect the signal check harness to the engine ECU. (Do not con-
E72
nect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300471 nal check har-
ness)
Starter key: LOCK NE+ (E52) –
Ground
NE- (E72) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–584 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect disconnection of the engine speed main sensor (crankshaft position sensor) harness
1. Connect the engine speed main sensor (crankshaft position sen-
sor) connector.
E52 D E72
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
20 C {68 F}:
Starter key: LOCK ness)
108.5 – 142.5
SHTS021270300472 NE+ (E52) – NE-
(E72)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0335 has been detected in [Fault
Information].
SHTS021270300473
Has DTC P0335 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–585
CHECKLIST: P0335
Engine speed main sensor
DTC: P0335 Inspection procedure
(Crankshaft position sensor) - disconnection
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Inspect the Failure found:
Check the connection of the repair if
engine speed Go to YES.
engine speed main sensor needed.
main sensor
1 (crankshaft position sensor) con- Perform "After- Go to step 2.
(crankshaft No failure
nector (looseness and poor con- inspection
position sen- found: Go to
tact). work" of
sor) connector NO.
INFORMA-
TION section.
Clean the
sensing unit
1. Check the installation of the and install it
Inspect the engine speed main sensor Failure found: properly.
engine speed (crankshaft position sensor). Go to YES. If damaged,
main sensor 2. Make sure there is no dirt, replace the
2 Go to step 3.
(crankshaft damage or clogging in the No failure sensor.
position sen- sensing unit of the engine found: Go to Perform "After-
sor) speed main sensor (crankshaft NO. inspection
position sensor). work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet
the terminals of the engine speed
the standard Replace the
Inspect the main sensor (crankshaft position
value: Go to sensor.
engine speed sensor).
YES. Perform "After-
main sensor <Tester connections>
3 Go to step 4. inspection
(crankshaft Engine speed main sensor
The measure- work" of
position sen- (crankshaft position sensor)
ments do not INFORMA-
sor) unit NE+ – NE-
meet the stan- TION section.
<Standard values>
dard value: Go
20 C {68 F}: 108.5 – 142.5
to NO.
Measure the voltage between the The measure-
terminals of the engine speed ments meet
Inspect the main sensor (crankshaft position the standard
engine speed sensor) vehicle side connector. value: Go to
main sensor <Tester connections> YES.
4 (crankshaft Engine speed main sensor Go to step 7. Go to step 5.
position sen- (crankshaft position sensor) vehi- The measure-
sor) power cle side connector ments do not
supply NE+ – NE- meet the stan-
<Standard values> dard value: Go
4.5 – 5.5 V to NO.
2–586 ENGINE (J05E)/TROUBLESHOOTING
Engine speed main sensor
DTC: P0335 Inspection procedure
(Crankshaft position sensor) - disconnection
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check har-
The measure-
ness, and measure the resistance
ments meet
Inspect for between the terminals of the Repair or
the standard
short-circuit of engine ECU (signal check har- replace the
value: Go to
the engine ness) and ground. harness.
YES.
speed main <Tester connections> Perform "After-
5 Go to step 6.
sensor (crank- Engine ECU (signal check har- inspection
The measure-
shaft position ness) work" of
ments do not
sensor) har- NE+ (E52) – Ground INFORMA-
meet the stan-
ness NE- (E72) – Ground TION section.
dard value: Go
<Standard values>
to NO.
1. Connect the engine speed
main sensor (crankshaft posi- The measure-
tion sensor) connector. ments meet
Inspect dis- Repair or
2. Measure the resistance the standard
connection of replace the
between the terminals of the value: Go to
the engine harness.
engine ECU (signal check har- YES.
speed main Perform "After-
6 ness). Go to step 7.
sensor (crank- inspection
<Tester connections> The measure-
shaft position work" of
Engine ECU (signal check har- ments do not
sensor) har- INFORMA-
ness) meet the stan-
ness TION section.
NE+ (E52) – NE- (E72) dard value: Go
<Standard values> to NO.
20 C {68 F}: 108.5 – 142.5
DTC P0335
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up. (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
7 DTC detected inspection inspection
F} or more), and check if P0335
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–587
DTC: P0336
EN01H02127030602016069
P0336: Engine speed main sensor (Crankshaft position sensor) - rationality
INFORMATION
Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J 1mA X3F (NE-)
(NE+) J0H 1mA XK4 (NE+)
SHTS021270300474
1. Technical description
• The engine speed main sensor (crankshaft position sensor) consistently measures pulses from the engine speed
main sensor (crankshaft position sensor).
<Description of malfunction>
• Pulses from the engine speed main sensor (crankshaft position sensor) cannot be correctly sensed.
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
• Engine speed of 500 r/min or more
(2) Judgement criteria
• Make a judgment when the abnormal number of engine speed main sensor pulses (not 56 pulses) per engine
revolution is continuously detected. For example, 50 seconds at 750 r/min
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–588 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Abnormal resistance of sensor
• Improper pulses
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to adhesion of dirt, damage,
etc.)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
ENGINE (J05E)/TROUBLESHOOTING 2–589
INSPECTION PROCEDURE: P0336
1 Inspect the engine speed main sensor (crankshaft position sensor) connector
1. Check the connection of the engine speed main sensor (crank-
shaft position sensor) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine speed main sensor (crankshaft position sensor)
1. Check the installation of the engine speed main sensor (crankshaft
position sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine speed main sensor (crankshaft position sensor).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine speed main
sensor (crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
2–590 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the engine speed main sensor (crankshaft position sensor) power supply
1. Set the starter key to the "LOCK" position.
NE+ NE- 2. Disconnect the engine speed main sensor (crankshaft position
sensor) connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed main sensor (crankshaft position sensor)
vehicle side connector.
Measurement Tester
SHTS021270300475 Standard values
conditions connections
Engine speed
main sensor
(crankshaft posi-
Starter key: ON 4.5 – 5.5 V
tion sensor) vehi-
cle side connector
NE+ – NE-
Do the measurements meet the standard value?
YES NO
Go to step 6. Go to step 4.
ENGINE (J05E)/TROUBLESHOOTING 2–591
4 Inspect disconnection of the engine speed main sensor (crankshaft position sensor) harness
1. Set the starter key to the "LOCK" position.
NE+ 2. Connect the signal check harness to the engine ECU engine
NE- speed main sensor (crankshaft position sensor to the ECU)
D 3. Use the electrical tester to measure the resistance between the
E72
terminals of the engine ECU and engine speed main sensor
E52
(crankshaft position sensor) vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300476 Engine ECU (sig-
nal check har-
ness) – engine
speed main sen-
sor (crankshaft
Starter key: LOCK Less than 2
position sensor)
vehicle side con-
nector
NE+ (E52) – NE+
NE- (E72) – NE-
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–592 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect for short-circuit of the engine speed main sensor (crankshaft position sensor) har-
ness
1. Use the electrical tester to measure the resistance between the
D terminals of the engine ECU and ground.
E52
E72
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
Starter key: LOCK NE+ (E52) –
Ground
NE- (E72) –
SHTS021270300477 Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–593
6 Check the engine speed main sensor (crankshaft position sensor) signal
1. Connect the signal check harness to the engine ECU.
E52 D E72 2. Connect the engine speed main sensor (crankshaft position sen-
sor) connector.
3. Start the engine.
4. Use the oscilloscope to measure the signal voltage between the
terminals in the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
SHTS021270300478
Engine ECU (sig-
nal check har-
With engine idling ness) Pulse 56
NE+ (E52) –
NE- (E72)
1 rotation
56 peaks (pulse)
0V
No pulse (No gear tooth)
SHTS021270300479
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the engine speed main sensor
(crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
2–594 ENGINE (J05E)/TROUBLESHOOTING
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0336 has been detected in [Fault
Information].
SHTS021270300480
Has DTC P0336 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–595
CHECKLIST: P0336
Engine speed main sensor
DTC: P0336 Inspection procedure
(Crankshaft position sensor) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Inspect the Failure found:
Check the connection of the repair if
engine speed Go to YES.
engine speed main sensor needed.
main sensor
1 (crankshaft position sensor) con- Perform "After- Go to step 2.
(crankshaft No failure
nector (looseness and poor con- inspection
position sen- found: Go to
tact). work" of
sor) connector NO.
INFORMA-
TION section.
Clean the
sensing unit
1. Check the installation of the and install it
Inspect the engine speed main sensor Failure found: properly.
engine speed (crankshaft position sensor). Go to YES. If damaged,
main sensor 2. Make sure there is no dirt, replace the
2 Go to step 3.
(crankshaft damage or clogging in the No failure sensor.
position sen- sensing unit of the engine found: Go to Perform "After-
sor) speed main sensor (crankshaft NO. inspection
position sensor). work" of
INFORMA-
TION section.
Disconnect the engine speed
The measure-
main sensor (crankshaft position
ments meet
sensor) connector and measure
Inspect the the standard
the voltage between the terminals
engine speed value: Go to
of the sensor vehicle side connec-
main sensor YES.
tor.
3 (crankshaft Go to step 6. Go to step 4.
<Tester connections>
position sen- The measure-
Main engine speed sensor vehicle
sor) power ments do not
side connector
supply meet the stan-
NE+ – NE-
dard value: Go
<Standard values>
to NO.
4.5 – 5.5 V
Connect the signal check harness
to measure the resistance
The measure-
between the terminals of the
ments meet
Inspect dis- engine ECU and engine speed Repair or
the standard
connection of main sensor (crankshaft position replace the
value: Go to
the engine sensor) vehicle side connector. harness.
YES.
speed main <Tester connections> Perform "After-
4 Go to step 5.
sensor (crank- Engine ECU (signal check har- inspection
The measure-
shaft position ness) – engine speed main sen- work" of
ments do not
sensor) har- sor vehicle side connector INFORMA-
meet the stan-
ness NE+ (E52) – NE+ TION section.
dard value: Go
NE- (E72) – NE-
to NO.
<Standard values>
Less than 2
2–596 ENGINE (J05E)/TROUBLESHOOTING
Engine speed main sensor
DTC: P0336 Inspection procedure
(Crankshaft position sensor) - rationality
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
Inspect for the terminals of the engine ECU Repair or
the standard
short-circuit of and ground. replace the
value: Go to
the engine <Tester connections> harness.
YES.
speed main Engine ECU (signal check har- Perform "After-
5 Go to step 6.
sensor (crank- ness) inspection
The measure-
shaft position NE+ (E52) – Ground work" of
ments do not
sensor) har- NE- (E72) – Ground INFORMA-
meet the stan-
ness <Standard values> TION section.
dard value: Go
to NO.
1. Connect the signal check har-
ness to the engine ECU.
2. Connect the engine speed
The measure-
main sensor (crankshaft posi-
ments meet
tion sensor) connector. Replace the
the standard
3. Start the engine. engine speed
value: Go to
Check the main sensor.
4. Use an oscilloscope to mea- YES.
engine speed Perform "After-
6 sure the signal voltage between Go to step 7.
main sensor inspection
the terminals in the engine The measure-
signal work" of
ECU (signal check harness). ments do not
INFORMA-
<Tester connections> meet the stan-
TION section.
Engine ECU (signal check har- dard value: Go
ness) to NO.
NE+ (E52) – NE- (E72)
<Standard values>
Pulse 56
DTC P0336
Replace the Procedure
has been
1. Perform engine warm up. engine ECU. completed.
detected: Go
Check the (engine coolant temperature: Perform "After- Perform "After-
to YES.
7 DTC detected 80 C {176 F} or more) inspection inspection
(Engine ECU) 2. Check if P0336 has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–597
DTC: P0340
EN01H02127030602016070
P0340: Engine speed sub sensor (Camshaft position sensor) - disconnection
INFORMATION
Engine ECU
(G-) N44 15mA X4Z (G-)
Engine speed sub sensor (G1) N43 5mA XZA (G+)
(VG) N45 15mA EB5 (VCG)
SHTS021270300481
1. Technical description
• The engine speed sub sensor (camshaft position sensor) consistently measures pulses from the engine speed sub
sensor (camshaft position sensor).
<Description of malfunction>
• Pulses from the engine speed sub sensor (camshaft position sensor) cannot be sensed.
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
• Engine speed of 0 r/min or more
(2) Judgement criteria
• With the engine running, the engine speed sub sensor (camshaft position sensor) does not detect pulses for
continuous 0.8 seconds or longer. (at 750 r/min)
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Idling stop system is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Idling stop system does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
2–598 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0340
1 Inspect the engine speed sub sensor (camshaft position sensor) connector
1. Check the connection of the engine speed sub sensor (camshaft
position sensor) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine speed sub sensor (camshaft position sensor)
1. Check the installation of the engine speed sub sensor (camshaft
position sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine speed sub sensor (camshaft position sensor).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine speed sub
sensor (camshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–599
3 Inspect the sensor power supply 1
1. Disconnect the engine speed sub sensor (camshaft position sen-
sor) connector.
G- VG 2. Set the starter key to the "ON" position.
3. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed sub sensor (camshaft position sensor)
vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300482 Engine speed sub
sensor (camshaft
position sensor)
Starter key: ON 4.5 – 5.5 V
vehicle side con-
nector
G- – VG
Do the measurements meet the standard value?
YES NO
Go to step 5. Go to step 4.
2–600 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect the sensor power supply 2
1. Set the starter key to the "LOCK" position.
2. Connect the signal check harness to the engine ECU.
E53 D
3. Connect the engine speed sub sensor (camshaft position sensor)
connector.
E54 4. Set the starter key to the "ON" position.
5. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).
SHTS021270300483
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
Starter key: ON ness) 4.5 – 5.5 V
G- (E54) –
VCG (E53)
Do the measurements meet the standard value?
YES NO
Repair or replace the harness. Replace the engine ECU.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
5 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if P0340 has been detected in [Fault
Information].
SHTS021270300484
Has DTC P0340 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–601
CHECKLIST: P0340
DTC: P0340 Camshaft position sensor - disconnection Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely.
Inspect the Failure found:
Repair if
engine speed Check the connection of the Go to YES.
needed.
sub sensor engine speed sub sensor (cam-
1 Perform "After- Go to step 2.
(camshaft shaft position sensor) connector No failure
inspection
position sen- (looseness and poor contact). found: Go to
work" of
sor) connector NO.
INFORMA-
TION section.
Clean the
sensing unit
1. Check the installation of the and install it
Inspect the engine speed sub sensor (cam- Failure found: properly.
engine speed shaft position sensor). Go to YES. If damaged,
sub sensor 2. Make sure there is no dirt, replace the
2 Go to step 3.
(camshaft damage or clogging in the No failure sensor.
position sen- sensing unit of the engine found: Go to Perform "After-
sor) speed sub sensor (camshaft NO. inspection
position sensor). work" of
INFORMA-
TION section.
1. Disconnect the engine speed
sub sensor (camshaft position
sensor) connector. The measure-
2. Measure the voltage between ments meet
the terminals of the engine the standard
speed sub sensor (camshaft value: Go to
Inspect the position sensor) vehicle side YES.
3 sensor power connector. Go to step 5. Go to step 4.
supply 1 <Tester connections> The measure-
engine speed sub sensor (cam- ments do not
shaft position sensor) vehicle side meet the stan-
connector dard value: Go
G- – VG to NO.
<Standard values>
4.5 – 5.5 V
1. Connect the signal check har-
ness to the engine ECU.
2. Connect the engine speed sub The measure-
sensor (camshaft position sen- ments meet
Repair or
sor) connector. the standard Replace the
replace the
3. Measure the voltage between value: Go to engine ECU.
harness.
Inspect the the terminals of the engine YES. Perform "After-
Perform "After-
4 sensor power ECU inspection
inspection
supply 2 (signal check harness). The measure- work" of
work" of
<Tester connections> ments do not INFORMA-
INFORMA-
Engine ECU (signal check har- meet the stan- TION section.
TION section.
ness) dard value: Go
G- (E54) – VCG (E53) to NO.
<Standard values>
4.5 – 5.5 V
2–602 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0340 Camshaft position sensor - disconnection Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC P0340
Replace the Procedure
has been
engine ECU. completed.
detected: Go
Check the Perform "After- Perform "After-
Check if P0340 has been to YES.
5 DTC detected inspection inspection
detected in [Engine].
(Engine ECU) work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–603
DTC: P0341
EN01H02127030602016071
P0341: Engine speed sub sensor (Camshaft position sensor) - rationality
INFORMATION
Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J 1mA X3F (NE-)
(NE+) J0H 1mA XK4 (NE+)
SHTS021270300485
1. Technical description
• The engine speed sub sensor (camshaft position sensor) consistently measures pulses from the engine speed sub
sensor (camshaft position sensor).
<Description of malfunction>
• Pulses from the sub engine speed sub sensor cannot be correctly sensed.
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
• Engine speed of 500 r/min or more
(2) Judgement criteria
• The number of the engine speed sub sensor pulses per 2 engine revolutions is continuously abnormal (other
than 5 pulses). (For example, 100 seconds for 750 r/min).
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–604 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Abnormal resistance of sensor
• Improper pulses
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to adhesion of dirt, damage,
etc.)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
ENGINE (J05E)/TROUBLESHOOTING 2–605
INSPECTION PROCEDURE: P0341
1 Inspect the engine speed sub sensor (camshaft position sensor) connector
1. Check the connection of the engine speed sub sensor (camshaft
position sensor) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the engine speed sub sensor (camshaft position sensor)
1. Check the installation of the engine speed sub sensor (camshaft
position sensor).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the engine speed sub sensor (camshaft position sensor).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the engine speed sub
sensor (camshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
2–606 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect for short-circuit of the engine speed sub sensor (camshaft position sensor) harness
1. Set the starter key to the "LOCK" position.
E54
D E73 2. Connect the signal check harness to the engine ECU vehicle side
E53
harness. (Do not connect the harness to the ECU.)
3. Disconnect the engine speed sub sensor (camshaft position sen-
sor) connector.
4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and ground.
Measurement Tester
SHTS021270300486 Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness)
Starter key: LOCK VCG (E53) –
Ground
G- (E54) – Ground
G+ (E73) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 4. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–607
4 Inspect disconnection of the engine speed sub sensor (camshaft position sensor) harness
1. Use the electrical tester to measure the resistance between the
E54 terminals of the engine ECU (signal check harness) and engine
D E73 G- speed sub sensor (camshaft position sensor) vehicle side connec-
E53
G1 tor.
VG Measurement Tester
Standard values
conditions connections
Engine speed sub
sensor (camshaft
position sensor)
vehicle side con-
nector – Engine
SHTS021270300487
Starter key: LOCK Less than 2
ECU (signal check
harness)
VC – VCG (E53)
G- – G- (E54)
G1 – G+ (E73)
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–608 ENGINE (J05E)/TROUBLESHOOTING
5 Inspect the engine speed main sensor (crankshaft position sensor) power supply
1. Set the starter key to the "LOCK" position.
2. Connect the signal check harness to the engine ECU.
G- VG
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed sub sensor (camshaft position sensor)
vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300488
Engine speed sub
sensor (camshaft
position sensor)
Starter key: LOCK 4.5 – 5.5 V
vehicle side con-
nector
G- – VG
Do the measurements meet the standard value?
YES NO
Go to step 6. Replace the engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–609
6 Inspect the engine speed sub sensor (camshaft position sensor) signal
1. Connect the engine speed sub sensor (camshaft position sensor)
connector.
E73
A B
2. Start the engine.
V80
3. Use the oscilloscope to measure the signal voltage between the
terminals in the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300489 nal check har-
With engine idling ness) Pulse 5
G+ (E73) – E04
(V80)
2 rotation
5V
0V
SHTS021270300490
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the engine speed sub sensor (cam-
shaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
2–610 ENGINE (J05E)/TROUBLESHOOTING
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0341 has been detected in [Fault
Information].
SHTS021270300491
Has DTC P0341 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–611
CHECKLIST: P0341
DTC: P0341 Camshaft position sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Inspect the Failure found:
repair if
engine speed Check the connection of the Go to YES.
needed.
sub sensor engine speed sub sensor (cam-
1 Perform "After- Go to step 2.
(camshaft shaft position sensor) connector No failure
inspection
position sen- (looseness and poor contact). found: Go to
work" of
sor) connector NO.
INFORMA-
TION section.
Clean the
sensing unit
1. Check the installation of the and install it
Inspect the engine speed sub sensor (cam- Failure found: properly.
engine speed shaft position sensor). Go to YES. If damaged,
sub sensor 2. Make sure there is no dirt, replace the
2 Go to step 3.
(camshaft damage or clogging in the No failure sensor.
position sen- sensing unit of the engine found: Go to Perform "After-
sor) speed sub sensor (camshaft NO. inspection
position sensor). work" of
INFORMA-
TION section.
1. Connect the signal check har-
ness to the engine ECU. (Do
not connect harness to the
ECU.)
The measure-
2. Disconnect the engine speed ments meet
Inspect for sub sensor (camshaft position Repair or
the standard
short-circuit of sensor) connector. replace the
value: Go to
the engine 3. Measure the resistance harness.
YES.
speed sub between the engine ECU termi- Perform "After-
3 Go to step 4.
sensor (cam- nals and ground. inspection
The measure-
shaft position <Tester connections> work" of
ments do not
sensor) har- Engine ECU (signal check har- INFORMA-
meet the stan-
ness ness) TION section.
dard value: Go
VCG (E53) – Ground to NO.
G- (E54) – Ground
G+ (E73) – Ground
<Standard values>
2–612 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0341 Camshaft position sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Measure the resistance between
the terminals of the engine ECU
(signal check harness) and
The measure-
engine speed sub sensor (cam-
ments meet
Inspect dis- shaft position sensor) vehicle side Repair or
the standard
connection of connector. replace the
value: Go to
the engine <Tester connections> harness.
YES.
speed sub engine speed sub sensor (cam- Perform "After-
4 Go to step 5.
sensor (cam- shaft position sensor) vehicle side inspection
The measure-
shaft position connector – Engine ECU (signal work" of
ments do not
sensor) har- check harness) INFORMA-
meet the stan-
ness VC – VCG (E53) TION section.
dard value: Go
G- – G- (E54)
to NO.
G1- – G+ (E73)
<Standard values>
Less than 2
1. Connect the signal check har-
ness to the engine ECU.
The measure-
2. Measure the voltage between ments meet
Inspect the the terminals of the engine the standard Replace the
engine speed speed sub sensor (camshaft value: Go to engine ECU.
main sensor position sensor) vehicle side YES. Perform "After-
5 (crankshaft connector. Go to step 6. inspection
position sen- <Tester connections> The measure- work" of
sor) power Engine speed sub sensor (cam- ments do not INFORMA-
supply shaft position sensor) vehicle side meet the stan- TION section.
connector dard value: Go
G- – VG to NO.
<Standard values>
4.5 – 5.5 V
1. Connect the engine speed sub
sensor (camshaft position sen-
sor) connector. The measure-
2. Start the engine. ments meet
3. Using the oscilloscope, mea- the standard Replace the
Inspect the
sure the voltage waveform value: Go to sensor.
camshaft posi-
between the terminals of the YES. Perform "After-
tion sensor
6 engine ECU (signal check har- Go to step 7. inspection
(engine speed
ness). The measure- work" of
sub sensor
<Tester connections> ments do not INFORMA-
signal)
Engine ECU (signal check har- meet the stan- TION section.
ness) dard value: Go
G+ (E73) – E04 (V80) to NO.
<Standard values>
5 pulse
DTC P0341
Replace the Procedure
has been
1. Perform engine warm up. engine ECU. completed.
detected: Go
Check the (engine coolant temperature: Perform "After- Perform "After-
to YES.
7 DTC detected 80 C {176 F} or more) inspection inspection
(Engine ECU) 2. Check if P0341 has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–613
DTC: P0381
EN01H02127030602016072
P0381: Glow lamp (wait-to-start lamp) - circuit
INFORMATION
Engine ECU
Combination meter
20mA J04 (GLW-)
(GIND) J33
Glow indicator light
SHTS021270300492
1. Technical description
• The light will light up when the glow lamp is in drive status or light out when it is in non-drive status.
<Description of malfunction>
• Disconnection, +B short-circuit or GND short-circuit is likely to have occurred in the glow light circuit.
2. DTC set condition
(1) DTC detection condition
<Glow light in non-drive status>
• Glow light in non-drive status
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
<Glow light in drive status>
• Glow light in drive status
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
<Glow light in non-drive status>
• Voltage of the glow light circuit remains at 7 V or lower for 10 seconds or longer.
<Glow light in drive status>
• Voltage of the glow light circuit remains at 8.4 V or higher for 3 seconds or longer.
3. Reset condition
• After normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Glow light fails to operate.
2–614 ENGINE (J05E)/TROUBLESHOOTING
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Failure of glow light (in combination meter)
• Disconnection or short-circuit in sensor harness
• Irregular contact (disconnection or poor fit of connector)
• GND short-circuit in engine ECU internal power supply
ENGINE (J05E)/TROUBLESHOOTING 2–615
INSPECTION PROCEDURE: P0381
1 Inspect the combination meter connector
1. Check the connection of the combination meter connector (loose-
ness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Check the combination meter operation
1. Set the starter key to the "ON" position.
2. Check the operation of the combination meter (various instruments
and displays).
Was any failure found?
YES NO
Inspect the combination meter. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–616 ENGINE (J05E)/TROUBLESHOOTING
3 Check the glow light circuit
1. Set the starter key to the "LOCK" position.
V7
A B 2. Connect the signal check harness to the engine ECU.
V80
3. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
Starter key ON:
nal check har-
SHTS021270300493 Starter key: 10 V or more
ness)
ON/LOCK Starter key LOCK:
GIND (V7) – GLW-
Less than 7 V
(V80)
Do the measurements meet the standard value?
YES NO
Go to step 6. Go to step 4.
ENGINE (J05E)/TROUBLESHOOTING 2–617
4 Check for short-circuit in wire harness of glow light
1. Set the starter key to the "LOCK" position.
A V7 2. Disconnect the signal check harness from the engine ECU. (Leave
the vehicle side engine ECU connector connected.)
3. Disconnect the combination meter 40P connector.
4. Use the electrical tester to measure the resistance between the
GIND (V7) terminal in the engine ECU (signal check harness) and
ground.
Measurement Tester
SHTS021270300494 Standard values
conditions connections
Engine ECU (sig-
nal check har-
Starter key: LOCK ness)
GIND (V7) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–618 ENGINE (J05E)/TROUBLESHOOTING
5 Check for disconnection in glow light wire harness
1. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) and the combination meter
40P vehicle side connector terminals.
A V7
Measurement Tester
Standard values
conditions connections
GLW- Engine ECU (sig-
nal check har-
ness) –
Starter key: LOCK combination Less than 1
meter 40P vehicle
SHTS021270300495 side connector
GIND (V7) – GLW-
Do the measurements meet the standard value?
YES NO
Replace the combination meter. Repair or replace the harness.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
6 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P0381 has been detected in [Fault
Information].
SHTS021270300496
Has DTC P0381 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–619
CHECKLIST: P0381
DTC: P0381 Glow lamp (wait-to-start lamp) - circuit Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely.
Failure found:
Repair if
Inspect the Go to YES.
Check the connection of the com- needed.
combination
1 bination meter connector (loose- Perform "After- Go to step 2.
meter connec- No failure
ness and poor contact). inspection
tor found: Go to
work" of
NO.
INFORMA-
TION section.
Inspect the
Failure found: combination
1. Set the starter key to the "ON"
Check the Go to YES. meter.
position.
combination Perform "After-
2 2. Check the operation of the Go to step 3.
meter opera- No failure inspection
tion combination meter (various found: Go to work" of
instruments and displays). NO. INFORMA-
TION section.
Connect the signal check har-
The measure-
ness, and measure the voltage
ments meet
between the terminals of the
the standard
engine ECU (signal check har-
value: Go to
ness).
Check the YES.
<Tester connections>
3 glow light cir- Go to step 6. Go to step 4.
Engine ECU (signal check har-
cuit The measure-
ness)
ments do not
GIND (V7) – GLW- (V80)
meet the stan-
<Standard values>
dard value: Go
Starter key ON: 10 V or more
to NO.
Starter key LOCK: less than 7 V
1. Disconnect the signal check
harness from the engine ECU.
(Leave the vehicle side engine
ECU connector connected.) The measure-
ments meet
2. Disconnect the combination Repair or
the standard
meter 40P connector. replace the
value: Go to
Check for 3. Measure the resistance harness.
YES.
short-circuit in between the GIND (V7) termi- Perform "After-
4 Go to step 5.
wire harness nal in the engine ECU (signal inspection
The measure-
of glow light check harness) and ground. work" of
ments do not
<Tester connections> INFORMA-
meet the stan-
Engine ECU (signal check har- TION section.
dard value: Go
ness) to NO.
GIND (V7) – Ground
<Standard values>
2–620 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0381 Glow lamp (wait-to-start lamp) - circuit Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Measure the resistance between
The measure-
the engine ECU (signal check
ments meet
harness) and the combination Replace the Repair or
the standard
meter 40P vehicle side connector combination replace the
value: Go to
Check for dis- terminals. meter. harness.
YES.
connection in <Tester connections> Perform "After- Perform "After-
5
glow light wire Engine ECU (signal check har- inspection inspection
The measure-
harness ness) – Combination meter 40Pin work" of work" of
ments do not
vehicle side connector INFORMA- INFORMA-
meet the stan-
GIND (V7) – GLW- TION section. TION section.
dard value: Go
<Standard values>
to NO.
Less than 1
DTC P0381
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
6 DTC detected inspection inspection
F} or more), and check if P0381
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–621
DTC: P0401
EN01H02127030602016073
P0401: EGR low flow
INFORMATION
Reference Coolant temperature sensor Engine ECU
X66 (THW) 10mA X28 (THW)
A Body earth 10mA
B Z5G (E) ZJQ (E5)
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
B Common rail
(E2) EBN 15mA Z72 (E2)
A pressure sensor
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
Gas passage $XW (PC2S)
(E2) Z7Q 10mA
Intake manifold
temperature sensor (THA) X0Q 10mA XZJ (THIA)
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
(FC) X71 10mA X4K (VG)
A-A B-B XCV 200mA XMH (EVG)
Intake air (E2G)
temperature sensor (+B) XCT 200mA X2U (VAF)
(air flow sensor built in) (E2) Z65 10mA
(THA) X72 10mA X82 (THA)
SHTS021270300497
1. Technical description
• The measured EGR rate, which is calculated from the air flow sensor, boost pressure sensor, and intake manifold
temperature sensor, is compared with the predicted EGR rate, and malfunction is detected.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Either the fuel injection rate is 30 - 90 mm3/st. cyl. with an engine speed of 2,000 – 2,250 r/min, or the rate is
30 - 80 mm3/st. cyl. with an engine speed of 2,250 – 2,500 r/min.
• Engine speed fluctuation ≤ 117.2 r/min/sec.
• Fuel injection rate fluctuation ≤ 54.7 mm3/st. cyl. sec.
• Predicted EGR flow rate ≥ 40 g/sec.
• Atmospheric pressure ≥ 75 kPa.
• Exhaust brake is not actuated.
(2) Judgement criteria
• The value of parameters calculated from the measured EGR rate, predicted EGR rate, and EGR valve feed-
back quantity is at least 0.2 conditions continue for at least 30 seconds.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
2–622 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Turbocharger noise or damage
• Abnormal consumption of DEF solution
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Obstruction due to buildup of soot or foreign substances in inlet/outlet of EGR cooler gas passageway
• Obstruction due to buildup of soot or foreign substances in EGR valve.
• Malfunction of intake system
• Air flow sensor failure
• Boost pressure sensor failure
• Intake manifold temperature sensor failure
• SCV failure
• Injector failure
ENGINE (J05E)/TROUBLESHOOTING 2–623
INSPECTION PROCEDURE: P0401
1 Inspect the air cleaner element
1. Check the air cleaner element for dirt, clogging, or damage.
2. Make sure the element is a Hino genuine part.
Was any failure found?
YES NO
Clean or replace the air cleaner element. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the air flow sensor
1. Check the installation of the air flow sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the air flow sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the air flow sensor.
Perform "After-inspection work" of INFOR-
MATION section.
3 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the boost pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–624 ENGINE (J05E)/TROUBLESHOOTING
4 Check the boost pressure sensor output signal
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Start the engine.
Engine
4. Select [Engine] from the menu.
5. Select [Actual boost pressure] from the [Data Monitor] menu.
6. Race the engine from idle to NMR and verify that the boost pres-
sure output signal varies.
SHTS021270300498
Standard values
There is no abnormal change in the sensor output signal.
(The pressure sensor signal response changes according
to the engine speed)
Was there no abnormal change in the sensor output signal?
YES NO
Go to step 5. Replace the boost pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect the intake air temperature sensor (intake manifold)
1. Check the installation of the intake air temperature sensor (intake
manifold).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intake manifold).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 6.
If damaged, replace the intake air tempera-
ture sensor (intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–625
6 Inspect the intake air temperature sensor (intake manifold) unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake air temperature sensor (intake manifold)
connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intake manifold).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
SHTS021270300499 ture sensor (intake 7.336 – 5.794 k
Starter key: LOCK
manifold) 50 C {122 F}:
THA – E2 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 7. Replace the intake air temperature sensor
(intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
2–626 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect the response delay of the EGR valve
1. Select [Check functions] and then [EGR check] from the menu,
then inspect the response delay at the Target EGR position and
(1) Actual EGR position.
! CAUTION
(2)
Perform the inspection while the engine is stopped to avoid dam-
ages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Select [Start].
(4) Select [EGR opening UP]:
(3)
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
(4) (5) • Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.
Standard values
SHTS021270300500
From the Target EGR position to the Actual EGR position,
the response delay should be within 5 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 8. Replace the EGR valve.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–627
8 Inspect the EGR cooler
1. Check if soot is obstructing the inlet/outlet of the EGR cooler gas
passageway.
2. Check if there are foreign substances stuck to the EGR cooler
coolant passageway.
3. Check the EGR cooler coolant passageway for obstruction due to
deformation or other damage.
4. Check if coolant is leaking from the EGR cooler.
Was any failure found?
YES NO
Remove the soot in the inlet/outlet of the gas Go to step 9.
passageway, or repair or replace the faulty
part.
Perform "After-inspection work" of INFOR-
MATION section.
9 Inspect the EGR valve
1. Check the EGR valve for damage due to incursion of foreign sub-
stances.
2. Check if the inlet/outlet of the exhaust gas passageway is
obstructed by soot.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 10.
passageway.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–628 ENGINE (J05E)/TROUBLESHOOTING
10 Inspect the SCV
1. Perform an SCV test and a malfunction reproduction test.
• For a detailed procedure, refer to the separate "SCV free accelera-
tion test".
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 11.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–629
11 Inspect the injector
Check the injection quantity and the rotational fluctuation.
1. Start the engine.
Select 2. Select [Injection quantity] from [Data Monitor] on HINO-DX menu
Engine and measure the fuel injection quantity.
SHTS021270300501
NE Rotational fluctuation 3. Select [Engine speed] from [Data Monitor] on HINO-DX menu and
@1,500 r/min (measurement by HINO-DX) measure the engine speed fluctuation.
Measurement conditions
Ne (r/min)
Engine speed: 1,500 r/min
No-load, Neutral, A/C off and Air compressor un-operating
Engine coolant temperature: more than 80 C {176 F}
Engine
Standard values
SHTS021270300502
Type of Q (mm3/st)
AT 5.0q
Do the measurements meet the standard values? (Are both injection quantity and engine speed
fluctuation within the standard values?)
YES NO
Go to step 12. Replace the injector.
Perform "After-inspection work" of INFOR-
MATION section.
2–630 ENGINE (J05E)/TROUBLESHOOTING
12 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0401 has been detected in [Fault
Information].
SHTS021270300504
Has DTC P0401 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–631
SCV FREE ACCELERATION TEST
1 Test method
<Engine speed pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Control the engine revolution by means of operating Cruise Control
system.
Engine speed pattern
2500 r/min - Measure each engine
Engine speed
speed for 20 seconds.
2000 r/min
1500 r/min
1000 r/min
750r/min
Time
SHTS021270300505
<Acceleration pattern>
1. After engine has reached operating temperature (more than 82 C
{179.6 F}).
2. After air compressor completed building pressure.
3. A/C, Head lights off.
4. All devices off. (PTO, Refrigeration compressor. etc)
5. Check that actual common rail pressure following target.
Acceleration pattern
At least three times, repeating the Wide-Open Throttle
100%
opening
Throttle
20sec 20sec
0%
Time
SHTS021270300506
2–632 ENGINE (J05E)/TROUBLESHOOTING
2 Types of HINO-DX data to be measured
SHTS021270300507
ENGINE (J05E)/TROUBLESHOOTING 2–633
3 If the following symptoms occur, FAIL. If not, OK.
a. Pressure is reduced by 5 MPa or more continually for 5 seconds or
more. Replace the supply pump.
Engine speed pattern
Common rail pressure
Actual common rail pressure
a: Pressure is reduced by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300508
b. Pressure is increased by 5 MPa or more continually for 5 seconds or
more. Replace the SCV.
Engine speed pattern
Common rail pressure
Actual common rail pressure
Pressure is increased by 5
MPa or more continually for Target common rail pressure
5 seconds or more.
Time
SHTS021270300509
c. The maximum common rail pressure exceeds 222 MPa for even a
moment during pressure increase. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300510
2–634 ENGINE (J05E)/TROUBLESHOOTING
d. After the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300511
e. Before the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure rapidly. Replace the common rail.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300512
f. The maximum common rail pressure exceeds 222 MPa during pres-
sure drop. Check the return pipe.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300513
ENGINE (J05E)/TROUBLESHOOTING 2–635
g. The pressure is disturbed at a given speed and the pressure
decreases at higher speed. Replace the supply pump.
Engine speed pattern
Common rail pressure
The pressure is disturbed
at a given speed and the Actual common rail pressure
10 MPa or more pressure decreases at
higher speed. Target common rail pressure
Remains for 5 seconds or longer.
Time
SHTS021270300514
h. Hunting remains within 10 MPa or more for more than 5 seconds.
Replace the SCV.
Engine speed pattern
Common rail pressure
㪩㪸㫅㪾㪼㩷㫉㪼㫄㪸㫀㫅㫊㩷㫎㫀㫋㪿㫀㫅㩷㪈㪇 Actual common rail pressure
10 MPa or more 㪤㪧㪸㩷㫆㫉㩷㫄㫆㫉㪼㩷㪽㫆㫉㩷㫄㫆㫉㪼
Target common rail pressure
㫋㪿㪸㫅㩷㪌㩷㫊㪼㪺㫆㫅㪻㫊㪅
Remains for 5 seconds or longer.
Time
SHTS021270300515
i. The engine stops during pressure relief. Replace the SCV.
Accelerator pattern
Common rail pressure
222 MPa
Actual common rail pressure
Target common rail pressure
Time
SHTS021270300516
2–636 ENGINE (J05E)/TROUBLESHOOTING
j. Target common rail pressure during idling deviates from the standard
value. Replace the SCV.
.
<FINAL VALUE OF PUMP CURRENT TARGET test>
1. After engine has reached operating temperature. (more than 82 C
{179.6 F})
2. After air compressor has completed building pressure.
3. A/C, Head lights are off.
4. All other devices turned off. (PTO, Refrigeration compressor. etc)
5. Engine speed: 750 r/min
Criteria
Average current
FINAL VALUE OF 1740 80 mA
value
PUMP CURRENT
TARGET Fluctuation in cur-
< 80 mA
rent value
Current value [mA]
Target current value
Average current value (30sec)
Fluctuation in current value
Time [sec]
SHTS021270300517
ENGINE (J05E)/TROUBLESHOOTING 2–637
CHECKLIST: P0401
DTC: P0401 EGR low flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Clean or
replace the air
Failure found:
cleaner ele-
1. Check the air cleaner element Go to YES.
Inspect the air ment.
for dirt, clogging, or damage.
1 cleaner ele- Perform "After- Go to step 2.
2. Make sure the element is a No failure
ment inspection
Hino genuine part. found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the air Failure found: properly.
flow sensor. Go to YES. If damaged,
Inspect the air 2. Make sure there is no dirt, replace the
2 Go to step 3.
flow sensor damage or clogging in the No failure sensor.
sensing unit of the air flow sen- found: Go to Perform "After-
sor. NO. inspection
work" of
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the Failure found: properly.
boost pressure sensor. Go to YES. If damaged,
Inspect the
replace the
3 boost pressure 2. Make sure there is no dirt, Go to step 4.
damage or clogging in the No failure sensor.
sensor
sensing unit of the boost pres- found: Go to Perform "After-
sure sensor. NO. inspection
work" of
INFORMA-
TION section.
1. Select [boost pressure sensor]
No abnormal
from the [Data Monitor] of
change in the
[Engine].
sensor output Replace the
2. Race the engine from idle to signal: Go to sensor.
Check the NMR and check that the boost YES. Perform "After-
boost pressure pressure output signal varies.
4 Go to step 5. inspection
sensor output <Standard values>
Abnormal work" of
signal There is no abnormal change in change in the INFORMA-
the sensor output signal. (The sensor output TION section.
pressure sensor signal response signal: Go to
changes according to the engine NO.
speed)
2–638 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0401 EGR low flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Clean the
sensing unit
1. Check the installation of the and install it
intake air temperature sensor Failure found: properly.
Inspect the
(intake manifold). Go to YES. If damaged,
intake air tem-
2. Make sure there is no dirt, replace the
5 perature sen- Go to step 6.
damage or clogging in the No failure sensor.
sor (intake
sensing unit of the intake air found: Go to Perform "After-
manifold)
temperature sensor (intake NO. inspection
manifold). work" of
INFORMA-
TION section.
Disconnect the intake air temper-
ature sensor (intake manifold) The measure-
connector and measure the resis- ments meet
tance between the terminals of the standard Replace the
Inspect the the intake air temperature sensor value: Go to sensor.
intake air tem- (intake manifold). YES. Perform "After-
6 perature sen- <Tester connections> Go to step 7. inspection
sor (intake Intake air temperature sensor The measure- work" of
manifold) unit (intake manifold) ments do not INFORMA-
THA – E2 meet the stan- TION section.
<Standard values> dard value: Go
20 C {68 F}: 7.336 – 5.794 k to NO.
50 C {122 F}: 2.435 – 2.41 k
ENGINE (J05E)/TROUBLESHOOTING 2–639
DTC: P0401 EGR low flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Check functions] and
then [EGR check] from the
menu, then inspect the
response delay at the Target
EGR position and Actual EGR
position.
! CAUTION
Perform the inspection while
the engine is stopped to avoid
damages. The measure-
<Inspection procedure> ments meet
(1) Select [Check functions]. the standard Replace the
(2) Select [EGR check]. value: Go to EGR valve.
Inspect the
(3) Click [Check start]. YES. Perform "After-
response
7 (4) Click [EGR opening UP]: Go to step 8. inspection
delay of the
The measure- work" of
EGR valve • Inspect the response delay at ments do not INFORMA-
each step of the Target EGR meet the stan- TION section.
position and Actual EGR posi- dard value: Go
tion from 0 to 90%. to NO.
(5) Click [EGR opening DOWN]:
• Inspect the response delay at
each step of the Target EGR
position and Actual EGR posi-
tion from 90 to 0%.
<Standard values>
From the Target EGR position to
the Actual EGR position, the
response delay should be within 5
seconds.
1. Check if soot is obstructing the Remove the
inlet/outlet of the EGR cooler soot in the
gas passageway. inlet/outlet of
the gas pas-
2. Check if there are foreign sub- Failure found:
sageway, or
stances stuck to the EGR Go to YES.
repair or
Inspect the cooler coolant passageway.
8 replace the Go to step 9.
EGR cooler 3. Check the EGR cooler coolant No failure
faulty part.
passageway for obstruction found: Go to
Perform "After-
due to deformation or other NO.
inspection
damage. work" of
4. Check if coolant is leaking from INFORMA-
the EGR cooler TION section.
2–640 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0401 EGR low flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Remove for-
eign sub-
stances and
clean the pas-
1. Check the EGR valve for dam- Failure found:
sageway.
age due to incursion of foreign Go to YES.
Replace the
Inspect the substances.
9 EGR valve if it Go to step 10.
EGR valve 2. Check if the inlet/outlet of the No failure
is damaged.
exhaust gas passageway is found: Go to
Perform "After-
obstructed by soot. NO.
inspection
work" of
INFORMA-
TION section.
Repair or
Failure found: replace the
1. Perform an SCV test and a
Go to YES. faulty part.
malfunction reproduction test.
Inspect the Perform "After-
10 • For a detailed procedure, refer Go to step 11.
SCV No failure inspection
to the separate "SCV free found: Go to work" of
acceleration test". NO. INFORMA-
TION section.
Check the injection quantity and
the rotational fluctuation.
1. Start the engine.
2. Select [Injection quantity] from
[Data Monitor] on HINO-DX The measure-
menu and measure the fuel ments meet
injection quantity. the standard Replace the
3. Select [Engine speed] from value: Go to injector.
[Data Monitor] on HINO-DX YES. Perform "After-
Inspect the menu and measure the engine
11 Go to step 12. inspection
injector speed fluctuation. The measure- work" of
<Tester connections> ments do not INFORMA-
Engine speed: 1,500 r/min meet the stan- TION section.
No-load, Neutral, A/C off and Air dard value: Go
compressor un-operating to NO.
Engine coolant temperature:
more than 80 C {176 F}
<Standard values>
Injection quantity (mm3/st): 5.0q
or more for with AT vehicles.
DTC P0401
Replace the Procedure
has been
1. Perform engine warm up. engine ECU. completed.
detected: Go
Check the (engine coolant temperature: Perform "After- Perform "After-
to YES.
12 DTC detected 80 C {176 F} or more) inspection inspection
(Engine ECU) 2. Check if P0401 has been work" of work" of
No DTC has
detected in [Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–641
DTC: P0402
EN01H02127030602016074
P0402: EGR high flow
INFORMATION
Engine ECU
Resistor
YM5 (CAN+)
(PCR1)
(PCR2)
(PC1S)
(PC2S)
YM6 (CAN-)
(THW)
XZJ (THIA)
XMH (EVG)
X82 (THA)
(VC2)
X2U (VAF)
X0G (PIM)
X4K (VG)
(VC)
(E5)
(E1)
(E2)
ZJP (E4)
X28
ZJQ
$XV
Z70
XZG
X85
Z72
XZH
XG2
$XW
10mA
10mA
15mA
15mA
5mA
200mA
200mA
10mA
10mA
15mA
15mA
15mA
15mA
10mA
10mA
10mA
2mA
2mA
X66 (THW)
Actuator power
(VC) J0M
(E) Z6R
(PIM) J0L
(CANH)
(CANH)
relay
(CANL)
(CANL)
Z5G (E)
Coolant temperature
XCV
XCT
EBM
#XG
EBH
EBN
NFA
NFA
EBK
(E2) E7Q
#XV
X71
Z65
EBL
(THG) E7P
X72
EBJ
sensor
(L)
X36
(FC)
(E2G)
(+B)
(E2)
(THA)
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)
VNT EGR
controller actuator
Boost pressure
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
sensor
Y2E Y4J Z90
Common rail Intake manifold Intake air
Body earth pressure sensor temperature temperature sensor NAT X36 $4
sensor (air flow sensor built in)
SHTS021270300518
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when coolant temperature is low (≤ 40 C {104 F}).
• Engine ECU calculates the actual EGR rate based on information from the boost pressure sensor, engine speed
sensor, intake manifold temperature sensor, and air flow sensor.
• Engine ECU compares the actual EGR rate and the theoretical EGR rate stored in the ECU memory.
<Description of malfunction>
• EGR rate may be over-applied.
2–642 ENGINE (J05E)/TROUBLESHOOTING
2. DTC set condition
(1) DTC detection condition
The following conditions continue for at least 30 seconds.
• Starter key "ON".
• DPR auto-regeneration is inactive.
• Engine coolant temperature is 30 C {86 F} or less.
• Engine speed of 1000 r/min or less.
• Exhaust brake is not actuated.
Otherwise, the following conditions continue for at least 30 seconds.
• Starter key "ON".
• Engine coolant temperature is 30 C {86 F} or more.
• Engine speed of 750 r/min or less.
• Fuel injection rate 80 mm3/st. cyl.
• Exhaust brake is not actuated.
(2) Judgement criteria
• When EGR feedback (value of theoretical EGR rate - actual EGR rate) stays above the threshold value for at
least 30 seconds.
• Above criterion is determined from the boost pressure, intake manifold temperature, air intake quantity, fuel
injection rate, and engine speed.
3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• EGR valve is fully closed.
<Symptoms on the vehicle due to malfunction>
• Faulty engine revving (engine hesitation)
• Insufficient output or engine stall because of DPF clogging due to faulty catalyst regeneration
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Intake manifold temperature sensor failure
• Air flow sensor failure
• Boost pressure sensor failure
• Injector failure
• EGR valve failure
• Clogged intake system
• VNT controller failure
ENGINE (J05E)/TROUBLESHOOTING 2–643
INSPECTION PROCEDURE: P0402
1 Check the response delay of the EGR valve
1. Set the starter key to the "LOCK" position.
(1) 2. Connect the vehicle to HINO-DX.
3. Set the starter key to the "ON" position.
(2)
4. Select [Check functions] and then [EGR check] from the menu,
then inspect the response delay at the Target EGR position and
Actual EGR position.
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.
(3)
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(4) (5) (3) Select [Start].
(4) Select [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
SHTS021270300519
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.
Standard values
From the Target EGR position to the Actual EGR position,
the response delay should be within 5 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 2. Replace the EGR valve.
Perform "After-inspection work" of INFOR-
MATION section.
2–644 ENGINE (J05E)/TROUBLESHOOTING
2 Check the response delay of the VNT controller
1. Select [Check functions] from the menu, then inspect the response
delay at the Target VNT position and Actual VNT position.
(1)
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(2)
ages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [VNT check].
(3) Select [Start].
(4) Select [VNT opening UP]:
(3) • Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT opening DOWN]:
• Inspect the response delay at each step of the Target VNT position
(4) (5) and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.
Standard values
SHTS021270300520 From the Target VNT position to the Actual VNT position,
the response delay should be within 3 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 3. Replace the turbocharger.
Perform "After-inspection work" of INFOR-
MATION section.
3 Inspect the air cleaner element
1. Check the air cleaner element for dirt, clogging, or damage.
2. Make sure the element is a Hino genuine part.
Was any failure found?
YES NO
Clean or replace the air cleaner element. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–645
4 Inspect the air flow sensor
1. Check the installation of the air flow sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the air flow sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 5.
If damaged, replace the air flow sensor.
Perform "After-inspection work" of INFOR-
MATION section.
5 Inspect the air flow sensor connector
1. Check the connection of the air flow sensor connector (looseness
and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 6.
Perform "After-inspection work" of INFOR-
MATION section.
6 Check the air intake system
1. Check the air intake system (between air flow sensor and diesel
throttle) for dirt, clogging, or damage.
Was any failure found?
YES NO
Clean or replace parts as needed. Go to step 7.
Perform "After-inspection work" of INFOR-
MATION section.
2–646 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the boost pressure sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 8.
If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
8 Inspect the intake air temperature sensor (intake manifold) connector
1. Check the connection of the intake air temperature sensor (intake
manifold) connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 9.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–647
9 Inspect the intake air temperature sensor (intake manifold)
1. Check the installation of the intake air temperature sensor (intake
manifold).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intake manifold).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 10.
If damaged, replace the intake air tempera-
ture sensor (intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the intake air temperature sensor (intake manifold) unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake air temperature sensor (intake manifold)
connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intake manifold).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
SHTS021270300521 ture sensor (intake 7.336 – 5.794 k
Starter key: LOCK
manifold) 50 C {122 F}:
THA – E2 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 11. Replace the intake air temperature sensor
(intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
2–648 ENGINE (J05E)/TROUBLESHOOTING
11 Inspect the EGR valve
1. Check the EGR valve for damage due to foreign substances.
2. Check if there is soot obstructing the exhaust gas passageway
inlet or outlet.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 12.
valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–649
12 Inspect the injector
Check the injection quantity and the rotational fluctuation.
1. Start the engine
Select
Engine
SHTS021270300522
2. Select [Injection quantity] from the [Data Monitor] menu, and mea-
sure the amount of fuel injection.
NE Rotational fluctuation
@1,500 r/min (measurement by HINO-DX)
3. Select [Engine speed] from the [Data Monitor] menu, and measure
the rotational fluctuation.
Ne (r/min)
Measurement conditions
Engine speed: 1,500 r/min No-load,
T/M shift lever: Neutral position,
A/C off and Air compressor un-operating.
Engine
Engine coolant temperature: more than 80 C {176 F}
Standard values
SHTS021270300523
Type of Q (mm3/st)
AT 5.0q
Do the measurements meet the standard value?
(Both the injection quantity and the rotational fluctuation are within the standard values)
YES NO
Go to step 13. Replace the injector.
Perform "After-inspection work" of INFOR-
MATION section.
2–650 ENGINE (J05E)/TROUBLESHOOTING
13 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine.
Select
Engine 3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P0402 has been detected in [Fault
Information].
SHTS021270300525
Has DTC P0402 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–651
CHECKLIST: P0402
DTC: P0402 EGR high flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Select [Check functions] and then
[EGR check] from the menu, then
inspect the response delay at the
Target EGR position and Actual
EGR position.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check]. The measure-
(3) Select [Start]. ments meet
(4) Select [EGR opening UP]: the standard Replace the
value: Go to EGR valve.
Check the • Inspect the response delay at
YES. Perform "After-
response each step of the Target EGR
1 Go to step 2. inspection
delay of the position and Actual EGR posi-
The measure- work" of
EGR valve tion from 0 to 90%.
ments do not INFORMA-
(5) Select [EGR opening DOWN]:
meet the stan- TION section.
• Inspect the response delay at dard value: Go
each step of the Target EGR to NO.
position and Actual EGR posi-
tion from 90 to 0%.
<Standard values>
From the Target EGR position to
the Actual EGR position, the
response delay should be within 5
seconds.
Select [Check functions] from
HINO-DX menu, and inspect the
time lag (follow-up) of the speci-
fied VNT opening and the actual
VNT opening.
<Inspection procedure>
(1) Select [Check functions].
(2) Select the [VNT inspection]. The measure-
(3) Select [Start]. ments meet
(4) Select [VNT opening UP]: the standard Replace the
value: Go to turbocharger.
Check the • Inspect each step (0 – 90%) of
YES. Perform "After-
response the time lag (follow-up) of the
2 Go to step 3. inspection
delay of the VNT Specified Opening and
The measure- work" of
VNT controller actual opening
ments do not INFORMA-
(5) Select [VNT opening DOWN]:
meet the stan- TION section.
• Inspect each step (90 – 0%) of dard value: Go
the time lag (follow-up) of the to NO.
VNT Specified Opening and
actual opening
<Standard values>
From the Target VNT position to
the Actual VNT position, the
response delay should be within 3
seconds.
2–652 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0402 EGR high flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Clean or
replace the air
Failure found:
cleaner ele-
1. Check the air cleaner element Go to YES.
Inspect the air ment.
for dirt, clogging, or damage.
3 cleaner ele- Perform "After- Go to step 4.
2. Make sure the element is a No failure
ment inspection
Hino genuine part. found: Go to
work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the air Failure found: properly.
flow sensor. Go to YES. If damaged,
Inspect the air 2. Make sure there is no dirt, replace the
4 Go to step 5.
flow sensor damage or clogging in the No failure sensor.
sensing unit of the air flow sen- found: Go to Perform "After-
sor. NO. inspection
work" of
INFORMA-
TION section.
Connect
securely,
Failure found:
repair if
Go to YES.
Inspect the air Check the connection of the air needed.
5 flow sensor flow sensor connector (loose- Perform "After- Go to step 6.
No failure
connector ness and poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Clean or
Failure found: replace as
Check the air intake system Go to YES. needed.
Check the air (between air flow sensor and die- Perform "After-
6 Go to step 7.
intake system sel throttle) for dirt, clogging, or No failure inspection
damage. found: Go to work" of
NO. INFORMA-
TION section.
Clean the
1. Check the installation of the Failure found:
sensing unit
boost pressure sensor. Go to YES.
Inspect the and install it
7 boost pressure 2. Make sure there is no dirt, properly. Go to step 8.
damage or clogging in the No failure
sensor If damaged,
sensing unit of the boost pres- found: Go to
replace the
sure sensor. NO.
sensor.
Connect
Inspect the Failure found: securely.repair
intake air tem- Check the connection of the Go to YES. if needed.
perature sen- intake air temperature sensor Perform "After-
8 Go to step 9.
sor (intake (intake manifold) connector No failure inspection
manifold) con- (looseness and poor contact). found: Go to work" of
nector NO. INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–653
DTC: P0402 EGR high flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Clean the
sensing unit
1. Check the installation of the and install it
intake manifold temperature Failure found: properly.
Inspect the
sensor. Go to YES. If damaged,
intake air tem-
2. Make sure there is no dirt, replace the
9 perature sen- Go to step 10.
damage or clogging in the No failure sensor.
sor (intake
sensing unit of the intake air found: Go to Perform "After-
manifold)
temperature sensor (intake NO. inspection
manifold). work" of
INFORMA-
TION section.
The measure-
Measure the resistance between
ments meet
the terminals of the intake air tem-
the standard Replace the
perature sensor (intake manifold).
Inspect the value: Go to sensor.
<Tester connections>
intake air tem- YES. Perform "After-
Intake air temperature sensor
10 perature sen- Go to step 11. inspection
(intake manifold)
sor (intake The measure- work" of
THA – E2
manifold) unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k
dard value: Go
50 C {122 F}: 2.435 – 2.41 k
to NO.
Remove for-
eign sub-
stances and
clean the
Failure found:
1. Check the EGR valve for dam- valve.
Go to YES.
age due to foreign substances. Replace the
Inspect the
11 2. Check if there is soot obstruct- EGR valve if it Go to step 12.
EGR valve No failure
ing the exhaust gas passage- is damaged.
found: Go to
way inlet or outlet. Perform "After-
NO.
inspection
work" of
INFORMA-
TION section.
2–654 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0402 EGR high flow Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Check the injection quantity and
the rotational fluctuation.
1. Start the engine.
2. Select [Injection quantity] from
[Data Monitor] menu, and mea- The measure-
sure the amount of fuel injec- ments meet
tion. the standard Replace the
3. Select [Engine speed] from value: Go to injector.
Inspect the [Data Monitor] menu, and mea- YES. Perform "After-
12 injector [HINO- sure the rotational fluctuation. Go to step 13. inspection
DX] <Measurement conditions> The measure- work" of
Engine speed: 1,500 r/min ments do not INFORMA-
No-load, Neutral, A/C off and Air meet the stan- TION section.
compressor un-operating dard value: Go
Engine coolant temperature: to NO.
more than 80 C {176 F}
<Standard values>
Injection quantity (mm3/st): 5.0q
or more for with AT vehicles.
DTC P0402
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
13 DTC detected inspection inspection
F} or more), and check if P0402
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–655
DTC: P0404
EN01H02127030602016075
P0404: Valve position control failure - DC motor out of range, functional
(EGR valve stick failure)
INFORMATION
Engine ECU Resistor
(CAN+)
(CAN-)
YM5
YM6
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
NFB
#XG
NFA
#XV
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Y2E Y4J Z90
NAT X36 $4
SHTS021270300526
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• Wiping operation from "fully open fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.
<Description of malfunction>
• Failure message is received from EGR controller.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• A target EGR valve opening is 10 C {50 F} or more.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The intercooler temperature sensor is -15 C {5 F} or more.
(2) Judgement criteria
• The condition that Duty is 40% or more during motor control mode remains for 3 seconds or more.
The above content is judged if any of the following conditions is met:
• When 600 seconds elapses if the intercooler temperature sensor is -15 C {5 F}.
• When 360 seconds elapses if the intercooler temperature sensor is 0 C {32 F}.
• Instant if the intercooler temperature sensor is higher than 0 C {32 F}.
2–656 ENGINE (J05E)/TROUBLESHOOTING
3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Fuel injection limit
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Insufficient engine output
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• EGR valve ring parts are damaged due to incursion of foreign substances
• Soot adhesion to EGR valve sealing face and gas passageway, and motor abnormal heat rise due to damage
caused by hard foreign substances. (Hardened carbon may peel off from EGR cooler upstream of EGR valve.)
*1. If there is no problem with the above, foreign substance damage occurred when the MIL was ON, but at present
the foreign substances are thought to have dropped off and normal operation restored.
*2. This DTC may be detected because there is freezing inside the EGR valve when the outside temperature is low.
When the interior thaws, however, normal operation will be restored.
ENGINE (J05E)/TROUBLESHOOTING 2–657
INSPECTION PROCEDURE: P0404
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if P0404 has been detected in [Fault
Information].
SHTS021270300527
Has a DTC other than P0404 been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2 Inspect the EGR valve
1. Check if the link joining the actuator and valve unit is disconnected
or damaged due to incursion of foreign substances.
2. Check if there is soot obstructing the exhaust gas passageway
inlet or outlet.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 3.
valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–658 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the EGR valve connector
1. Check the connection of the EGR valve connector (looseness and
poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the EGR valve power supply
1. Set the starter key to the "LOCK" position.
+B E 2. Disconnect the EGR valve connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300528 EGR valve vehicle
Starter key: ON side connector 10 – 16 V
+B – E
Do the measurements meet the standard value?
YES NO
Go to step 5. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace if needed.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–659
5 Check the response delay of the EGR valve
1. Select [Check functions] and check the time lag (following charac-
teristics) of the target EGR valve opening and actual EGR valve
(1)
opening.
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Select [Start].
(3) (4) Select [EGR opening UP]:
• Check each step from 0% – 90% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
(4) (5) (5) (5) Select [EGR opening DOWN]:
• Check each step from 90% – 0% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
HINT
In EGR openings from 0% – 90%, 1 step corresponds to a 10%
change.
SHTS021270300529
Standard values
The response delay should be less than 5 seconds.
Do the measurements meet the standard value?
YES NO
Replace the engine ECU. Replace the EGR valve.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–660 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0404
Valve position control failure - DC motor out of
DTC: P0404 Inspection procedure
range, functional (EGR valve stick failure)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0404
have been
Go to diagno-
Check the Check if any DTC other than detected: Go
sis procedure
1 DTC detected P0404 have been detected in to YES. Go to step 2.
of a related
(Engine ECU) [Engine].
DTC.
No DTC has
been detected.
Go to NO.
Remove for-
eign sub-
stances and
1. Check if the link joining the clean the
Failure found:
actuator and valve unit is dis- valve.
Go to YES.
connected or damaged due to Replace the
Inspect the
2 incursion of foreign substances. EGR valve if it Go to step 3.
EGR valve No failure
2. Check if there is soot obstruct- found: Go to is damaged.
ing the exhaust gas passage- Perform "After-
NO.
way inlet or outlet. inspection
work" of
INFORMA-
TION section.
Connect
securely,
Failure found:
repair if
Go to YES.
Inspect the Check the connection of the EGR needed.
3 EGR valve valve connector (looseness and Perform "After- Go to step 4.
No failure
connector poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Check the wire
harness (actu-
The measure- ator power
ments meet supply and
Disconnect the EGR valve con- the standard ground) and
nector and measure the voltage value: Go to battery volt-
Inspect the between the terminals of the EGR YES. age.
4 EGR valve valve vehicle side connector. Go to step 5. Repair or
power supply (+B – E) The measure- replace if
<Standard values> ments do not needed.
10 – 16 V meet the stan- Perform "After-
dard value: Go inspection
to NO. work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–661
Valve position control failure - DC motor out of
DTC: P0404 Inspection procedure
range, functional (EGR valve stick failure)
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Check functions] and
check the time lag (following
characteristics) of the target
EGR valve opening and actual
EGR valve opening.
! CAUTION
Perform the inspection while
the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Check functions].
The measure-
(2) Select [EGR check].
ments meet
(3) Select [Start].
the standard Replace the Replace the
(4) Select [EGR opening UP]:
value: Go to engine ECU. valve.
Check the • Check each step from 0% – YES. Perform "After- Perform "After-
response 90% of the time lag (following
5 inspection inspection
delay of the characteristics) of the target The measure- work" of work" of
EGR valve EGR valve opening and actual ments do not INFORMA- INFORMA-
EGR valve opening. meet the stan- TION section. TION section.
(5) Select [EGR opening DOWN]: dard value: Go
• Check each step from 90% – to NO.
0% of the time lag (following
characteristics) of the target
EGR valve opening and actual
EGR valve opening.
HINT
In EGR openings from 0% –
90%, 1 step corresponds to a
10% change.
<Standard values>
The response delay should be
within 5 seconds.
2–662 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0405 and P0406
EN01H02127030602016076
P0405: EGR valve controller position sensor signal too low
(EGR actuator position sensor signal too low)
INFORMATION
Engine ECU Resistor
(CAN+)
(CAN-)
YM5
YM6
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
NFB
#XG
NFA
#XV
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Y2E Y4J Z90
NAT X36 $4
SHTS021270300530
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.
<Description of malfunction>
• EGR actuator system is malfunctioning.
2. DTC set condition
(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the angle difference between the position sensor input and the hole IC is ±5 or more
remains for 1 second or more.
3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Fuel injection limit
ENGINE (J05E)/TROUBLESHOOTING 2–663
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Damaged element inside EGR valve actuator
2–664 ENGINE (J05E)/TROUBLESHOOTING
P0406: Valve position sensor magnet lost (EGR actuator position sensor signal too high)
INFORMATION
Engine ECU Resistor
(CAN+)
(CAN-)
YM5
YM6
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
NFB
#XG
NFA
#XV
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Y2E Y4J Z90
NAT X36 $4
SHTS021270300531
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.
<Description of malfunction>
• EGR actuator system is malfunctioning.
2. DTC set condition
(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the magnetic flux of the position sensor is less than 35kA/m remains for 1 second or more.
3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Fuel injection limit
ENGINE (J05E)/TROUBLESHOOTING 2–665
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Damaged element inside EGR valve actuator
• Damaged output shaft magneto inside EGR valve actuator
2–666 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0405 and P0406
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than (P0405 or P0406)
has been detected in [Fault Information].
SHTS021270300532
Has any DTC other than (P0405 or P0406) been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2 Inspect the EGR valve connector
1. Check the connection of the EGR valve connector (looseness and
poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–667
3 Inspect the EGR valve power supply
1. Set the starter key to the "LOCK" position.
+B E 2. Disconnect the EGR valve connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300533 EGR valve vehicle
Starter key: ON side connector 10 – 16 V
+B – E
Do the measurements meet the standard value?
YES NO
Replace the EGR valve, and go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
4 Check the DTC detected (Engine ECU)
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if the DTC (P0405 or P0406) has been
detected in [Fault Information].
Select
Engine
SHTS021270300534
Has DTC (P0405 or P0406) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–668 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0405 and P0406
EGR valve controller position
DTC: P0405 sensor signal too low
(EGR actuator position sensor signal too low) Inspection procedure
Valve position sensor magnet lost
DTC: P0406
(EGR actuator position sensor signal too high)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than (P0405 or
P0406) has
Go to diagno-
Check the Check if any DTC other than been detected:
sis procedure
1 DTC detected (P0405 or P0406) has been Go to YES. Go to step 2.
of a related
(Engine ECU) detected in [Engine].
DTC.
No DTC has
been detected.
Go to NO.
Connect
securely,
Failure found:
repair if
Go to YES.
Inspect the Check the connection of the EGR needed.
2 EGR valve valve connector (looseness and Perform "After- Go to step 3.
No failure
connector poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Check the wire
harness (actu-
The measure- ator power
ments meet supply and
Disconnect the EGR valve con- the standard ground) and
nector and measure the voltage value: Go to battery volt-
Replace the
Inspect the between the terminals of the EGR YES. age.
EGR valve,
3 EGR valve valve vehicle side connector. Repair or
and go to step
power supply (+B – E) The measure- replace parts
4.
<Standard values> ments do not as needed.
10 – 16 V meet the stan- Perform "After-
dard value: Go inspection
to NO. work" of
INFORMA-
TION section.
DTC (P0405
Replace the Procedure
or P0406) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0405 or Perform "After- Perform "After-
Go to YES.
4 DTC detected P0406) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–669
DTC: P041B
EN01H02127030602016077
P041B: EGR gas temperature sensor - rationality
INFORMATION [at engine start]
Engine ECU
Resistor
XSW (THAO)
YM5 (CAN+)
(PCR1)
(PCR2)
(PC1S)
(PC2S)
YM6 (CAN-)
X4A (THG)
X82 (THA)
(VC2)
X0G (PIM)
(VC)
(E1)
(E2)
ZJP (E4)
$XV
Z70
XZG
X85
Z72
XZH
XG2
$XW
15mA
15mA
10mA
10mA
15mA
15mA
15mA
15mA
10mA
10mA
10mA
10mA
5mA
2mA
2mA
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
EBM
EBH
EBN
(E2) E7Q
EBK
EBL
(THG) X7U
(THG) E7P
EBJ
(E2) Z2N
#XG
NFA
NFA
#XV
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)
(VC) J0M
(E) Z6R
(E2) Z65
(THA) X72
(PIM) J0L
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Common rail EGR cooler outlet Intercooler outlet Y2E Y4J Z90
pressure sensor temperature sensor temperature sensor
NAT X36 $4
Intake manifold Boost pressure
temperature sensor sensor
SHTS021270300535
1. Technical description
• The EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler.
<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 20 seconds or more.
• The engine speed is 1000 r/min or less.
• Fuel injection quantity is 35 mm3/st.cyl or less.
• Engine coolant temperature is in the range of -30 to 30 C {-22 to 86 F}.
• The battery voltage is in the range of 10 to 16 V.
• Exhaust brake not actuated
• EGR valve opening is fully open.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the average EGR gas temperature is 70 C {158 F} or less.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag Lamp: OFF
2–670 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or damage)
• Abnormal resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply or internal circuit failure
ENGINE (J05E)/TROUBLESHOOTING 2–671
P041B: EGR gas temperature sensor - rationality
INFORMATION [at engine running 1]
Engine ECU
Resistor
XSW (THAO)
YM5 (CAN+)
(PCR1)
(PCR2)
(PC1S)
(PC2S)
YM6 (CAN-)
X4A (THG)
X82 (THA)
(VC2)
X0G (PIM)
(VC)
(E1)
(E2)
ZJP (E4)
$XV
Z70
XZG
X85
Z72
XZH
XG2
$XW
15mA
15mA
10mA
10mA
15mA
15mA
15mA
15mA
10mA
10mA
10mA
10mA
5mA
2mA
2mA
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
EBM
EBH
EBN
(E2) E7Q
EBK
EBL
(THG) X7U
(THG) E7P
EBJ
(E2) Z2N
#XG
NFA
NFA
#XV
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)
(VC) J0M
(E) Z6R
(E2) Z65
(THA) X72
(PIM) J0L
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Common rail EGR cooler outlet Intercooler outlet Y2E Y4J Z90
pressure sensor temperature sensor temperature sensor
NAT X36 $4
Intake manifold Boost pressure
temperature sensor sensor
SHTS021270300536
1. Technical description
• The EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler.
<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 11 seconds or more.
• The battery voltage is in the range of 10 to 16 V.
• The condition that the engine speed remains at 500 r/min or more for 5 seconds or more.
The conditions described below remain for 40 seconds or more.
• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st. cyl or more.
• The EGR gas flow rate is 36 kg/h or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl.sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mph or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow sensor) is -10 C {14 F} or more.
• Exhaust brake and DPR are not actuated.
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency based on engine speed, fuel injection quantity and EGR
gas outlet temperature are as follows: If the EGR gas flow rate is 144 kg/h: The efficiency is higher than 105%.
If the EGR gas flow rate is 100 kg/h: the efficiency is higher than 115%.
2–672 ENGINE (J05E)/TROUBLESHOOTING
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag Lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Malfunction of intake air temperature sensor (intercooler outlet)
• Malfunction of intake air temperature sensor (intake manifold)
• Malfunction of boost pressure sensor
- Loose/disconnected sensor or failure in sensing area (contamination, clogging or damage)
- Abnormal resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply
ENGINE (J05E)/TROUBLESHOOTING 2–673
P041B: EGR gas temperature sensor - rationality
INFORMATION [at engine running 2]
Engine ECU
Resistor
XSW (THAO)
YM5 (CAN+)
(PCR1)
(PCR2)
(PC1S)
(PC2S)
YM6 (CAN-)
X4A (THG)
X82 (THA)
(VC2)
X0G (PIM)
(VC)
(E1)
(E2)
ZJP (E4)
$XV
Z70
XZG
X85
Z72
XZH
XG2
$XW
15mA
15mA
10mA
10mA
15mA
15mA
15mA
15mA
10mA
10mA
10mA
10mA
5mA
2mA
2mA
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
EBM
EBH
EBN
(E2) E7Q
EBK
EBL
(THG) X7U
(THG) E7P
EBJ
(E2) Z2N
#XG
NFA
NFA
#XV
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)
(VC) J0M
(E) Z6R
(E2) Z65
(THA) X72
(PIM) J0L
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Common rail EGR cooler outlet Intercooler outlet Y2E Y4J Z90
pressure sensor temperature sensor temperature sensor
NAT X36 $4
Intake manifold Boost pressure
temperature sensor sensor
SHTS021270300537
1. Technical description
• The EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler.
<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
The conditions described below remain for 11 seconds or more.
• The battery voltage is in the range of 10 to 16 V.
• The condition that the engine speed remains at 500 r/min or more for 5 seconds or more.
The conditions described below remain for 40 seconds or more.
• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st. cyl or more.
• The EGR gas flow rate is 36 kg/h or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl.sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mile/h or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow sensor) is -10 C {14 F} or more.
• Exhaust brake and DPR are not actuated.
2–674 ENGINE (J05E)/TROUBLESHOOTING
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency is less than 80%;
• If the values of difference between the calculated intake manifold air intake temperature and the actual intake
manifold air intake temperature) are as follows: If the EGR rate is 0%: the difference is 10 C {50 F} or more.
If the EGR rate is 20%: the difference is 17 C {62.6 F} or more. If the EGR rate is 60%: the difference is 60
C {140 F} or more. In addition;
• The calculated intercooler efficiencies are as follows. If the vehicle speed is 13 mile/h: the efficiency is higher
than 30%. If the vehicle speed is 25 mile/h: the efficiency is higher than 50%.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag Lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Malfunction of intake air temperature sensor (intercooler outlet)
• Malfunction of intake air temperature sensor (intake manifold)
• Malfunction of boost pressure sensor
- Loose/disconnected sensor or failure in sensing area (contamination, clogging or damage)
- Abnormal resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply
ENGINE (J05E)/TROUBLESHOOTING 2–675
INSPECTION PROCEDURE: P041B
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if P041B (for example, P0401, P0402,
P0404, P0234, P0299, P22D3, turbocharger, EGR system DTC)
has been detected in [Fault Information].
HINT
Intercooler outlet temperature sensor characteristic abnormality
judgement is performed based on the boost pressure and EGR
SHTS021270300538
rate data.
If EGR system or Turbo DTC are detected, perform another failure
diagnosis starting from the first DTC associated with the malfunc-
tion.
Has a DTC other than P041B been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
2 Inspect the EGR cooler outlet temperature sensor connector
1. Check the connection of the EGR cooler outlet temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–676 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the EGR cooler outlet temperature sensor
1. Check the installation of the EGR cooler outlet temperature sen-
sor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the EGR cooler outlet temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 4.
If damaged, replace the EGR cooler outlet
temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the EGR cooler outlet temperature sensor unit
1. Set the starter key to the "LOCK" position.
THG E2 2. Disconnect the EGR cooler outlet temperature sensor connector.
3. Use the electrical tester to measure the resistance between the
terminals of the EGR cooler outlet temperature sensor.
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
EGR cooler outlet 13.7 – 29.8 k
SHTS021270300539 temperature sen- 50 C {122 F}:
Starter key: LOCK
sor 7.13 – 13.7 k
THG – E2 80 C {176 F}:
4.1 – 7.13 k
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the EGR cooler outlet temperature
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–677
5 Inspect the EGR cooler outlet temperature sensor power supply
1. Set the starter key to the "ON" position.
E2 THG 2. Use the electrical tester to measure the voltage between the termi-
nals of the EGR cooler outlet temperature sensor vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
EGR cooler outlet
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300540 connector
THG – E2
Do the measurements meet the standard value?
YES NO
Go to step 8. Go to step 6.
6 Inspect for short-circuit of the EGR cooler outlet temperature sensor harness
1. Set the starter key to the "LOCK" position.
E45 D 2. Connect the signal check harness to the engine ECU. (Do not con-
E77
nect harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
terminals of the EGR cooler outlet temperature sensor and
ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300541 Engine ECU (sig-
nal check har-
ness)
Starter key: LOCK
THG2 (E45) –
Ground
E4 (E77) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–678 ENGINE (J05E)/TROUBLESHOOTING
7 Inspect disconnection of the EGR cooler outlet temperature sensor harness
1. Connect the EGR cooler outlet temperature sensor connector.
E45 D 2. Use the electrical tester to measure the resistance between the
E77
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
Engine ECU (sig-
13.7 – 29.8 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.13 – 13.7 k
THG (E45) –
SHTS021270300542 80 C {176 F}:
E4 (E77)
4.1 – 7.13 k
Do the measurements meet the standard value?
YES NO
Replace the engine ECU. Repair or replace the harness.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
8 Inspect the intake air temperature sensor (intake manifold)
1. Check the installation of the intake air temperature sensor (intake
manifold).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intake manifold).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 9.
If damaged, replace the intake air tempera-
ture sensor (intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–679
9 Inspect the intake air temperature sensor (intake manifold) unit
1. Set the starter key to the "LOCK" position.
E2 THA 2. Disconnect the intake air temperature sensor (intake manifold)
connector.
3. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intake manifold).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
SHTS021270300543 ture sensor (intake 7.336 – 5.794 k
Starter key: LOCK
manifold) 50 C {122 F}:
THA – E2 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 10. Replace the intake air temperature sensor
(intake manifold).
Perform "After-inspection work" of INFOR-
MATION section.
10 Inspect the intake air temperature sensor (intercooler outlet)
1. Check the installation of the intake air temperature sensor (inter-
cooler outlet).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the intake air temperature sensor (intercooler outlet).
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 11.
If damaged, replace the intake air tempera-
ture sensor (intercooler outlet).
Perform "After-inspection work" of INFOR-
MATION section.
2–680 ENGINE (J05E)/TROUBLESHOOTING
11 Inspect the intake air temperature sensor (intercooler outlet) unit
1. Disconnect the intake air temperature sensor (intercooler outlet)
connector.
THG E2
2. Use the electrical tester to measure the resistance between the
terminals of the intake air temperature sensor (intercooler outlet).
Measurement Tester
Standard values
conditions connections
Intake air tempera- 20 C {68 F}:
ture sensor (inter- 7.336 – 5.794 k
Starter key: LOCK
cooler outlet) 50 C {122 F}:
SHTS021270300544 THG – E2 2.435 – 2.41 k
Do the measurements meet the standard value?
YES NO
Go to step 12. Replace the intake air temperature sensor
(intercooler outlet).
Perform "After-inspection work" of INFOR-
MATION section.
12 Inspect the boost pressure sensor hose
1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.
2. Make sure the pipe on the intake manifold side is not clogged.
Was any failure found?
YES NO
Replace the boost pressure sensor hose. Go to step 13.
Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–681
13 Inspect the boost pressure sensor power supply system
1. Disconnect the boost pressure sensor connector.
E
2. Set the starter key to the "ON" position.
VC
3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.
Measurement Tester
Standard values
conditions connections
Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300545 side connector
VC – E
Do the measurements meet the standard value?
YES NO
Go to step 14. Inspect the sensor power supply outlet volt-
age of the wire harness and engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
14 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if P041B has been detected in [Fault
Information].
SHTS021270300546
Has DTC P041B been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–682 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P041B
DTC: P041B EGR gas temperature sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Check if any DTC other than
P041B (for example, P0401,
P0402, P0404, P0234, P0299, DTC other
than P041B
P22D3, turbocharger, EGR sys-
tem DTC) has been detected in (like P0401,
[Engine]. P0402, P0404,
P0234, P0299,
HINT
P22D3) or the Go to the diag-
Check the Intercooler outlet temperature
EGR turbo nostic proce-
1 DTC detected sensor characteristic abnor- Go to step 2.
system have dure of a
(Engine ECU) mality judgement is performed
been detected: related DTC.
based on the boost pressure
Go to YES
and EGR rate data.
If EGR system or Turbo DTC
Have not been
are detected, perform another
detected: Go
failure diagnosis starting from
to NO.
the first DTC associated with
the malfunction.
Connect
securely,
Failure found:
Inspect the repair if
Check the installation of the EGR Go to YES.
EGR cooler needed.
cooler outlet temperature sensor
2 outlet temper- Perform "After- Go to step 3.
connector (looseness and poor No failure
ature sensor inspection
contact). found: Go to
connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
EGR cooler outlet temperature
Inspect the Go to YES. If damaged,
sensor connector.
EGR cooler replace the
3 2. Make sure there is no dirt, Go to step 4.
outlet temper- No failure sensor.
ature sensor damage or clogging in the found: Go to Perform "After-
sensing unit of the EGR cooler NO. inspection
outlet temperature sensor. work" of
INFORMA-
TION section.
Measure the resistance between The measure-
the terminals of the EGR cooler ments meet
outlet temperature sensor. the standard Replace the
Inspect the <Tester connections> value: Go to sensor.
EGR cooler EGR cooler outlet temperature YES. Perform "After-
4 outlet temper- sensor Go to step 5. inspection
ature sensor THG – E2 The measure- work" of
unit <Standard values> ments do not INFORMA-
20 C {68 F}: 13.7 – 29.8 k meet the stan- TION section.
50 C {122 F}: 7.13 – 13.7 k dard value: Go
80 C {176 F}: 4.1 – 7.13 k to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–683
DTC: P041B EGR gas temperature sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the voltage between the
ments meet
terminals of the EGR cooler outlet
the standard
temperature sensor vehicle side
Inspect the value: Go to
connector.
EGR cooler YES.
<Tester connections>
5 outlet temper- Go to step 8. Go to step 6.
EGR cooler outlet temperature
ature sensor The measure-
sensor vehicle side connector
power supply ments do not
THG – E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
Connect the signal check har-
The measure-
ness, and measure the resistance
ments meet
between the terminals of the EGR Repair or
Inspect for the standard
cooler outlet temperature sensor replace the
short-circuits value: Go to
and ground. harness.
of the EGR YES.
<Tester connections> Perform "After-
6 cooler outlet Go to step 7.
Engine ECU (signal check har- inspection
temperature The measure-
ness) work" of
sensor har- ments do not
THG (E45) – Ground INFORMA-
ness meet the stan-
E4 (E77) – Ground TION section.
dard value: Go
<Standard values>
to NO.
1. Connect the EGR cooler outlet
temperature sensor connector.
The measure-
2. Measure the resistance ments meet
between the terminals of the Repair or
Inspect for dis- the standard Replace the
engine ECU (signal check har- replace the
connection of value: Go to engine ECU.
ness). harness.
the EGR YES. Perform "After-
<Tester connections> Perform "After-
7 cooler outlet inspection
Engine ECU (signal check har- inspection
temperature The measure- work" of
ness) work" of
sensor har- ments do not INFORMA-
THG (E45) – E4 (E77) INFORMA-
ness meet the stan- TION section.
<Standard values> TION section.
dard value: Go
20 C {68 F}: 13.7 – 29.8 k to NO.
50 C {122 F}: 7.13 – 13.7 k
80 C {176 F}: 4.1 – 7.13 k
Clean the
sensing unit
1. Check the installation of the and install it
intake air temperature sensor Failure found: properly.
Inspect the
(intake manifold) connector. Go to YES. If damaged,
intake air tem-
2. Make sure there is no dirt, replace the
8 perature sen- Go to step 9.
damage or clogging in the No failure sensor.
sor (intake
sensing unit of the intake air found: Go to Perform "After-
manifold)
temperature sensor (intake NO. inspection
manifold). work" of
INFORMA-
TION section.
2–684 ENGINE (J05E)/TROUBLESHOOTING
DTC: P041B EGR gas temperature sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure-
Measure the resistance between
ments meet
the terminals of the intake air tem-
the standard Replace the
perature sensor (intake manifold).
Inspect the value: Go to sensor.
<Tester connections>
intake air tem- YES. Perform "After-
Intake air temperature sensor
9 perature sen- Go to step 10. inspection
(intake manifold)
sor (intake The measure- work" of
THA – E2
manifold) unit ments do not INFORMA-
<Standard values>
meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k
dard value: Go
50 C {122 F}: 2.435 – 2.41 k
to NO.
Clean the
sensing unit
1. Check the installation of the and install it
Inspect the intake air temperature sensor Failure found: properly.
intake air tem- (intercooler outlet) connector. Go to YES. If damaged,
perature sen- 2. Make sure there is no dirt, replace the
10 Go to step 11.
sor damage or clogging in the No failure sensor.
(intercooler sensing unit of the intake air found: Go to Perform "After-
outlet) temperature sensor (intercooler NO. inspection
outlet). work" of
INFORMA-
TION section.
Measure the resistance between The measure-
the terminals of the intake air tem- ments meet
perature sensor (intercooler out- the standard Replace the
Inspect the
let). value: Go to sensor.
intake air tem-
<Tester connections> YES. Perform "After-
perature sen-
11 Intake air temperature sensor Go to step 12. inspection
sor
(intercooler outlet) The measure- work" of
(intercooler
THG – E2 ments do not INFORMA-
outlet) unit
<Standard values> meet the stan- TION section.
20 C {68 F}: 7.336 – 5.794 k dard value: Go
50 C {122 F}: 2.435 – 2.41 k to NO.
Replace the
boost pressure
sensor hose.
Failure found:
1. Make sure that the boost pres- Clean the
Go to YES.
Inspect the sure hose sensor has no clog- intake mani-
12 boost pressure ging, punctures, or cracks. fold pipe. Go to step 13.
No failure
sensor hose 2. Make sure there is no clogging Perform "After-
found: Go to
in the intake manifold side pipe. NO. inspection
work" of
INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–685
DTC: P041B EGR gas temperature sensor - rationality Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
The measure- Inspect the
Measure the voltage between the ments meet sensor power
terminals of the boost pressure the standard supply outlet
sensor vehicle side connector. value: Go to voltage of the
Inspect the
<Tester connections> YES. harness and
boost pressure
13 Boost pressure sensor vehicle Go to step 14. engine ECU.
sensor power
side connector The measure- Perform "After-
supply system
VC – E ments do not inspection
<Standard values> meet the stan- work" of
4.75 – 5.25 V dard value: Go INFORMA-
to NO. TION section.
DTC P041B Replace the Procedure
has been engine ECU. completed.
Perform engine warm up. (engine
Check the detected: Go Perform "After- Perform "After-
coolant temperature: 80 C {176
14 DTC detected to YES. inspection inspection
F} or more), and check if P041B
(Engine ECU) No DTC has work" of work" of
has been detected in [Engine].
been detected: INFORMA- INFORMA-
Go to NO. TION section. TION section.
2–686 ENGINE (J05E)/TROUBLESHOOTING
DTC: P041C and P041D
EN01H02127030602016078
P041C: EGR gas temperature sensor - out of range (Out of range low)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
EGR cooler outlet (THG) X7U 10mA X4A (THG)
temperature sensor (E2) Z2N 10mA
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
SHTS021270300547
1. Technical description
• The installed EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR
cooler.
<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key is "ON".
• The condition that fuel injection quantity is 40 mm3/sc.cyl or less remains for 10 seconds or more.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.27 V or less (740 C {1364 F} or higher) for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
ENGINE (J05E)/TROUBLESHOOTING 2–687
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Short-circuit in the sensor.
• Disconnection or short-circuit of the harness.
• Malfunction of sensor power supply in the engine ECU.
2–688 ENGINE (J05E)/TROUBLESHOOTING
P041D: EGR gas temperature sensor - out of range (Out of range high)
INFORMATION
Engine ECU
$XV (PC1S)
EBK 15mA Z70 (E1)
(E1)
(PCR1) EBJ 2mA XZG (PCR1)
(VC1) EBH 15mA X85 (VC)
Common rail EBN 15mA Z72
pressure sensor (E2) (E2)
(PCR2) EBM 2mA XZH (PCR2)
(VC2) EBL 15mA XG2 (VC2)
$XW (PC2S)
EGR cooler outlet (THG) X7U 10mA X4A (THG)
temperature sensor (E2) Z2N 10mA
(VC) J0M 15mA
Boost pressure sensor (PIM) J0L 5mA X0G (PIM)
(E) Z6R 15mA ZJP (E4)
SHTS021270300548
1. Technical description
• The installed EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR
cooler.
<Description of malfunction>
• The EGR cooler outlet temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• Intake air temperature is -20 C {-4 F} or more.
(2) Judgement criteria
• Output of the sensor remains at 4.97 V or higher (-40 C {-40 F} or lower) for 3 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag Lamp: OFF
ENGINE (J05E)/TROUBLESHOOTING 2–689
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor.
• Short-circuit in the sensor.
• Malfunction of the sensor power supply in the engine ECU.
• Disconnect and short-circuit of the harness.
• Irregular contact of the connector.
2–690 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P041C and P041D
1 Inspect the EGR cooler outlet temperature sensor connector
1. Check the connection of the EGR cooler outlet temperature sensor
connector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the EGR cooler outlet temperature sensor
1. Check the installation of the EGR cooler outlet temperature sen-
sor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the EGR cooler outlet temperature sensor.
Was any failure found?
YES NO
Clean the sensing unit and install it properly. Go to step 3.
If damaged, replace the EGR cooler outlet
temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–691
3 Inspect the EGR cooler outlet temperature sensor
1. Set the starter key to the "LOCK" position.
THG E2 2. Disconnect the EGR cooler outlet temperature sensor connector.
3. Use the electrical tester to measure the resistance between the
terminals of the EGR cooler outlet temperature sensor.
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
EGR cooler outlet 13.7 – 29.8 k
SHTS021270300549 temperature sen- 50 C {122 F}:
Starter key: LOCK
sor 7.13 – 13.7 k
THG – E2 80 C {176 F}:
4.1 – 7.13 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the EGR cooler outlet temperature
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the EGR cooler outlet temperature sensor power supply
1. Set the starter key to the "ON" position.
E2 THG 2. Use the electrical tester to measure the voltage between the termi-
nals of the EGR cooler outlet temperature sensor vehicle side con-
nector.
Measurement Tester
Standard values
conditions connections
EGR cooler outlet
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300550 connector
THG – E2
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
2–692 ENGINE (J05E)/TROUBLESHOOTING
5 Check for short-circuit in wire harness of EGR cooler outlet temperature sensor
1. Set the starter key to the "LOCK" position.
E45 D 2. Connect the signal check harness to the engine ECU vehicle side
E77
harness. (Do not connect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
EGR cooler outlet temperature sensor terminals and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300551 nal check har-
ness)
Starter key: LOCK
THG (E45) –
Ground
E4 (E77) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Check for disconnection in wire harness of EGR cooler outlet temperature sensor
1. Connect the EGR cooler outlet temperature sensor connector.
E45 D 2. Use the electrical tester to measure the resistance between the
E77
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
Engine ECU (sig-
13.7 – 29.8 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.13 – 13.7 k
THG (E45) –
SHTS021270300552 80 C {176 F}:
E4 (E77)
4.1 – 7.13 k
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–693
7 Check the DTC detected (Engine ECU)
1. Warm up the Engine. (engine coolant temperature: 80 C {176 F}
or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine
3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P041C or P041D) has been
detected in [Fault Information].
SHTS021270300553
Has DTC (P041C or P041D) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–694 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P041C and P041D
EGR gas temperature sensor -
DTC: P041C
out of range (Out of range low)
Inspection procedure
EGR gas temperature sensor -
DTC: P041D
out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
Inspect the repair if
Check the connection of the EGR Go to YES.
EGR cooler needed.
cooler outlet gas temperature
1 outlet gas tem- Perform "After- Go to step 2.
sensor connector (looseness and No failure
perature sen- inspection
poor contact). found: Go to
sor connector work" of
NO.
INFORMA-
TION section.
Clean the
sensing unit
and install it
1. Check the installation of the
Failure found: properly.
Inspect the EGR cooler outlet gas tempera-
Go to YES. If damaged,
EGR cooler ture sensor.
replace the
2 outlet gas tem- 2. Make sure there is no dirt, Go to step 3
No failure sensor.
perature sen- damage or clogging in the found: Go to Perform "After-
sor sensing unit of the EGR cooler NO. inspection
outlet gas temperature sensor. work" of
INFORMA-
TION section.
Disconnect the EGR cooler outlet
gas temperature sensor connec-
The measure-
tor and measure the resistance
ments meet
between the terminals of the EGR
the standard Replace the
cooler outlet gas temperature
Inspect the value: Go to sensor.
sensor.
EGR cooler YES. Perform "After-
<Tester connections>
3 outlet gas tem- Go to step 4. inspection
Engine ECU (signal check har-
perature sen- The measure- work" of
ness)
sor unit ments do not INFORMA-
THG – E2
meet the stan- TION section.
<Standard values>
dard value: Go
20 C {68 F}: 13.7 – 29.8 k
to NO.
50 C {122 F}: 7.13 – 13.7 k
80 C {176 F}: 4.1 – 7.13 k
The measure-
Measure the voltage between the
ments meet
terminals of the EGR cooler outlet
the standard
Inspect the gas temperature sensor vehicle
value: Go to
EGR cooler side connector.
YES.
outlet gas tem- <Tester connections>
4 Go to step 7. Go to step 5.
perature sen- EGR cooler outlet temperature
The measure-
sor power sensor vehicle side connector
ments do not
supply THG – E2
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–695
EGR gas temperature sensor -
DTC: P041C
out of range (Out of range low)
Inspection procedure
EGR gas temperature sensor -
DTC: P041D
out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Set the starter key to the
"LOCK" position.
2. Connect the signal check har- The measure-
ness to the engine ECU vehicle ments meet
side harness. (Do not connect Repair or
the standard
Check for harness to the ECU.) replace the
value: Go to
short-circuit in 3. Use the electrical tester to harness.
YES.
wire harness measure the resistance Perform "After-
5 Go to step 6.
of EGR cooler between the EGR cooler outlet inspection
The measure-
outlet temper- gas temperature sensor termi- work" of
ments do not
ature sensor nals and ground. INFORMA-
meet the stan-
<Tester connections> TION section.
dard value: Go
THG (E45) – Ground to NO.
E4 (E77) – Ground
<Standard values>
Connect the EGR cooler outlet
The measure-
gas temperature sensor connec-
ments meet
tor measure the resistance Repair or
the standard
Check for dis- between the terminals of the replace the
value: Go to
connection in engine ECU (signal check har- harness.
YES.
wire harness ness). Perform "After-
6 Go to step 7.
of EGR cooler <Tester connections> inspection
The measure-
outlet temper- THG (E45) – E4 (E77) work" of
ments do not
ature sensor <Standard values> INFORMA-
meet the stan-
20 C {68 F}: 13.7 – 29.8 k TION section.
dard value: Go
50 C {122 F}: 7.13 – 13.7 k
to NO.
80 C {176 F}: 4.1 – 7.13 k
DTC (P041C
Replace the Procedure
or P041D) has
Warm up the engine (engine cool- engine ECU. completed.
been detected:
Check the ant temperature: 80 C {176 F}). Perform "After- Perform "After-
Go to YES.
7 DTC detected Check if the DTC (P041C or inspection inspection
(Engine ECU) P041D) has been detected in work" of work" of
No DTC has
[Engine]. INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–696 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0420
EN01H02127030602016079
P0420: Tentative determination of ATC deterioration
INFORMATION
1. Technical description
<Description of malfunction>
• If the ATC (oxidation catalyst) is not generating heat, the engine ECU tentatively determines abnormality as ATC
deterioration (P0420).
• When this DTC is detected, perform troubleshooting for P0148 (abnormality in post injection) and P0421 (determi-
nation of ATC deterioration).
2. DTC set condition
(1) DTC detection condition
• –
(2) Judgement criteria
• –
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• P0420
ENGINE (J05E)/TROUBLESHOOTING 2–697
INSPECTION PROCEDURE: P0420
1 Check the DTC detected [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the diagnostic system (HINO-DX) to the vehicle.
Select
3. Set the starter key to the "ON" position.
Engine
4. On the screen of the diagnostic system, select [Engine] and check
[Fault Information] for DTC P0420.
SHTS021270300554
Has DTC P0420 been detected?
YES NO
Perform DTC-specific troubleshooting for. Procedure completed.
• P0148
• P0421
2–698 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0420
DTC: P0420 Tentative determination of ATC deterioration Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Set the starter key to the
"LOCK" position. DTC P0420
2. Connect the diagnostic system has been Perform DTC-
(HINO-DX) to the vehicle. detected: Go specific trou-
Check the bleshooting
3. Set the starter key to the "ON" to YES. Procedure
1 DTC detected for.
position. completed.
[HINO-DX]
No DTC has • P0148
4. On the screen of the diagnostic
been detected: • P0421
system, select [Engine] and
Go to NO.
check [Fault Information] for
DTC P0420.
ENGINE (J05E)/TROUBLESHOOTING 2–699
DTC: P0421
EN01H02127030602016080
P0421: Determination of ATC deterioration
INFORMATION
1. Technical description
<Description of malfunction>
• If post injection is performed normally but the ATC (oxidation catalyst) is not generating heat, the engine ECU
detects abnormality as ATC functional deterioration.
2. DTC set condition
(1) DTC detection condition
• The vehicle speed is 0 km/h.
• A change in the engine revolution is 312 r/min/sec or less.
• A change in the fuel injection quantity is 312 mm3/st/sec or less.
• A change in the fuel pressure is 93.7 MPa/sec or less.
• The target operating current of the fuel pump is not less than 1500 mA but not more than 1800 mA.
(2) Judgement criteria
• A change in the operating current of the fuel pump upon post injection exceeds the specified value.
• Malfunction determination time: 10 seconds
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• ATC deterioration caused by use of low-grade fuel
• Contamination in the sensing area of the exhaust gas temperature sensor (DPF inlet), improper installation of sen-
sors
2–700 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0421
1 Inspect fuel
1. Open the fuel cap and check fuel for abnormality (in color and
smell).
Was any failure found?
YES NO
Replace the fuel with good quality fuel and Go to step 3.
then go to Step 2.
2 Check the DTC detected [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the diagnostic system (HINO-DX) to the vehicle.
Select
3. Set the starter key to the "ON" position.
Engine
4. Perform DPR manual regeneration.
5. After completion of regeneration, on the screen of the diagnostic
system, select [Engine] and check [Fault Information] for DTC
P0421.
SHTS021270300555
Has DTC P0421 been detected?
YES NO
Go to step 3. Procedure completed.
3 Inspect the exhaust gas temperature sensor (DPF inlet) connector
1. Inspect the exhaust gas temperature sensor (DPF inlet) connector
for improper connection (improper fitting and defective contact).
Was any failure found?
YES NO
Connect securely, repair if necessary. Go to step 4.
ENGINE (J05E)/TROUBLESHOOTING 2–701
4 Inspect the exhaust gas temperature sensor (DPF inlet)
1. Inspect the exhaust gas temperature sensor (DPF inlet) for
improper installation.
2. Check the sensing area of the exhaust gas temperature sensor
(DPF inlet) for dirt, clogging, and damage.
Was any failure found?
YES NO
Clean the sensing area and install the sensor Replace the ATC.
properly.
If damage is found, replace the sensor.
2–702 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0421
DTC: P0421 Determination of AT deterioration Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Replace the
Go to YES.
Open the fuel cap and check fuel fuel with good
1 Inspect fuel for abnormality (in color and quality fuel Go to step 3.
No failure
smell). and then go to
found: Go to
Step 2.
NO.
1. Set the starter key to the
"LOCK" position.
2. Connect the diagnostic system
(HINO-DX) to the vehicle. DTC P0421
has been
3. Set the starter key to the "ON" detected: Go
Check the position. to YES. Procedure
2 DTC detected 4. Perform DPR manual regener- Go to step 3.
completed.
[HINO-DX] ation. No DTC has
5. After completion of regenera- been detected:
tion, on the screen of the diag- Go to NO.
nostic system, select [Engine]
and check [Fault Information]
for DTC P0421.
Inspect the Failure found:
exhaust gas Inspect the exhaust gas tempera- Go to YES. Connect
temperature ture sensor (DPF inlet) connector securely,
3 Go to step 4.
sensor (DPF for improper connection (improper No failure repair if neces-
inlet) connec- fitting and defective contact). found: Go to sary.
tor NO.
Clean the
1. Inspect the exhaust gas tem-
Failure found: sensing area
Inspect the perature sensor (DPF inlet) for
Go to YES. and install the
exhaust gas improper installation.
sensor prop- Replace the
4 temperature 2. Check the sensing area of the No failure erly. ATC.
sensor (DPF exhaust gas temperature sen- found: Go to If damage is
inlet) sor (DPF inlet) for dirt, clog- NO. found, replace
ging, and damage. the sensor.
ENGINE (J05E)/TROUBLESHOOTING 2–703
DTC: P0422
EN01H02127030602016081
P0422: DOC deterioration
INFORMATION
1. Technical description
<Description of malfunction>
• If the DOC is not generating heat or if the DOC is generating heat but temperature does not increase at the DOC
outlet, the engine ECU detects DOC deterioration.
2. DTC set condition
(1) DTC detection condition
• Determined during completion of DPR regeneration with the engine running.
• The exhaust gas flow rate is 150 kg/h or more.H9
• The engine revolution is 1000 r/min or more.
• The fuel injection quantity is 30 mm3/st or more.
And, the conditions described below remain for 3 seconds.
• A change in the engine revolution is 625 r/min/sec or less.
• A change in the fuel injection quantity is 625 mm3/sec/st or less.
• The vehicle speed is 18.8 mile/h or more.
And, the conditions described below remain for 10 seconds.
• The predicted detection temperature of the exhaust gas temperature sensor (DPF inlet) calculated by the
engine ECU is 450 C {842 F} or more.
(2) Judgement criteria
• The temperature detected at the exhaust gas temperature sensor (DPF inlet) remains 385 C {725 F} or less
for 30 seconds.
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• DOC deterioration caused by use of low-grade fuel
• Contamination in the sensing area of the exhaust gas temperature sensor (DPF inlet), improper installation of sen-
sors
2–704 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0422
1 Inspect fuel
1. Open the fuel cap and check fuel for abnormality (in color and
smell).
Was any failure found?
YES NO
Replace the fuel with good quality fuel and Go to step 3.
then go to Step 2.
2 Check the DTC detected [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the diagnostic system (HINO-DX) to the vehicle.
Select
3. Set the starter key to the "ON" position.
Engine
4. Perform DPR manual regeneration.
5. After completion of regeneration, on the screen of the diagnostic
system, select [Engine] and check [Fault Information] for DTC
P0422.
SHTS021270300556
Has DTC P0422 been detected?
YES NO
Go to step 3. Procedure completed.
3 Inspect the exhaust gas temperature sensor (DPF inlet) connector
1. Inspect the exhaust gas temperature sensor (DPF inlet) connector
for improper connection (improper fitting and defective contact).
Was any failure found?
YES NO
Connect securely, repair if necessary. Go to step 4.
ENGINE (J05E)/TROUBLESHOOTING 2–705
4 Inspect the exhaust gas temperature sensor (DPF inlet)
1. Inspect the exhaust gas temperature sensor (DPF inlet) for
improper installation.
2. Check the sensing area of the exhaust gas temperature sensor
(DPF inlet) for dirt, clogging, and damage.
Was any failure found?
YES NO
Clean the sensing area and install the sensor Replace the DPR.
properly.
If damage is found, replace the sensor.
2–706 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0422
DTC: P0422 DOC deterioration Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Failure found:
Replace the
Go to YES.
Open the fuel cap and check fuel fuel with good
1 Inspect fuel for abnormality (in color and quality fuel Go to step 3.
No failure
smell). and then go to
found: Go to
Step 2.
NO.
1. Set the starter key to the
"LOCK" position.
2. Connect the diagnostic system
(HINO-DX) to the vehicle. DTC P0422
has been
3. Set the starter key to the "ON" detected: Go
Check the position. to YES. Procedure
2 DTC detected 4. Perform DPR manual regener- Go to step 3.
completed
[HINO-DX] ation. No DTC has
5. After completion of regenera- been detected:
tion, on the screen of the diag- Go to NO.
nostic system, select [Engine]
and check [Fault Information]
for DTC P0422.
Inspect the Failure found:
exhaust gas Inspect the exhaust gas tempera- Go to YES. Connect
temperature ture sensor (DPF inlet) connector securely,
3 Go to step 4.
sensor (DPF for improper connection (improper No failure repair if neces-
inlet) connec- fitting and defective contact). found: Go to sary.
tor NO.
Clean the
1. Inspect the exhaust gas tem-
Failure found: sensing area
Inspect the perature sensor (DPF inlet) for
Go to YES. and install the
exhaust gas improper installation.
sensor prop- Replace the
4 temperature 2. Check the sensing area of the No failure erly. DPR.
sensor (DPF exhaust gas temperature sen- fund: Go to If damage is
inlet) sor (DPF inlet) for dirt, clog- NO. found, replace
ging, and damage. the sensor.
ENGINE (J05E)/TROUBLESHOOTING 2–707
DTC: P0489 and P0490
EN01H02127030602016082
P0489: EGR valve controller motor (open circuit) (EGR actuator motor open circuit)
INFORMATION
Engine ECU Resistor
(CAN+)
(CAN-)
YM5
YM6
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
NFB
#XG
NFA
#XV
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Y2E Y4J Z90
NAT X36 $4
SHTS021270300557
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.
<Description of malfunction>
• EGR actuator system is malfunctioning.
2. DTC set condition
(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria.
• The condition that the actual current applied to the motor built-in the EGR actuator is 0.6 A or less remains for
2 seconds or more.
3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".
2–708 ENGINE (J05E)/TROUBLESHOOTING
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Fuel injection limit
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Damaged EGR actuator motor
ENGINE (J05E)/TROUBLESHOOTING 2–709
P0490: EGR valve controller motor (short circuit) (EGR actuator motor short circuit)
INFORMATION
Engine ECU Resistor
(CAN+)
(CAN-)
YM5
YM6
Actuator power
(CANH)
(CANH)
relay
(CANL)
(CANL)
NFB
#XG
NFA
#XV
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Y2E Y4J Z90
NAT X36 $4
SHTS021270300558
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.
<Description of malfunction>
• EGR actuator system is malfunctioning.
2. DTC set condition
(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 V to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the actual current applied to the motor built-in the EGR actuator is 70 A or more remains for
2 seconds or more.
3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Fuel injection limit
2–710 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Damaged EGR actuator motor
• Abnormal battery voltage
ENGINE (J05E)/TROUBLESHOOTING 2–711
INSPECTION PROCEDURE: P0489 and P0490
1 Check the DTC detected 1 (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than DTC of this
inspection has been detected in [Fault Information].
SHTS021270300559
Has a DTC other than DTC of this inspection been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2 Inspect the EGR valve connector
1. Check the connection of the EGR valve connector (looseness and
poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–712 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the EGR valve power supply
1. Set the starter key to the "LOCK" position.
+B E 2. Disconnect the EGR valve connector.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300560 EGR valve vehicle
Starter key: ON side connector 10 – 16 V
+B – E
Do the measurements meet the standard value?
YES NO
Replace the EGR valve, and go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
4 Check the DTC detected 2 (Engine ECU)
1. Set the starter key to the "ON" position.
2. Select [Engine] and check if the DTC (P0489 or P0490) has been
detected in [Fault Information].
Select
Engine
SHTS021270300561
Has DTC (P0489 or P0490) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–713
CHECKLIST: P0489 and P0490
EGR valve controller motor (open circuit)
DTC: P0489
(EGR actuator motor open circuit)
Inspection procedure
EGR valve controller motor (short-circuit)
DTC: P0490
(EGR actuator motor short-circuit)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than DTC
(P0489 or
Check the P0490) has Go to diagno-
Check if any DTC other than DTC
DTC detected been detected: sis procedure
1 (P0489 or P0490) has been Go to step 2.
1 (Engine Go to YES. of a related
detected in [Engine].
ECU) DTC.
No DTC has
been detected:
Go to NO.
Connect
securely,
Failure found:
repair if
Go to YES.
Inspect the Check the connection of the EGR needed.
2 EGR valve valve connector (looseness and Perform "After- Go to step 3.
No failure
connector poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Check the wire
harness (actu-
The measure- ator power
Disconnect the EGR valve con- ments meet supply and
nector, and measure the voltage the standard ground) and
between the terminals of the EGR value: Go to battery volt-
Replace the
Inspect the valve vehicle side connector. YES. age.
EGR valve,
3 EGR valve <Tester connections> Repair or
and go to step
power supply EGR valve vehicle side connector The measure- replace parts
4.
+B – E ments do not as needed.
<Standard values> meet the stan- Perform "After-
10 – 16 V dard value: Go inspection
to NO. work" of
INFORMA-
TION section.
DTC (P0489
Replace the Procedure
or P0490) has
engine ECU. completed.
Check the been detected:
Check if the DTC (P0489 or Perform "After- Perform "After-
DTC detected Go to YES.
4 P0490) has been detected in inspection inspection
2 (Engine
[Engine]. work" of work" of
ECU) No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–714 ENGINE (J05E)/TROUBLESHOOTING
DTC: P049D
EN01H02127030602016083
P049D: Position failure (EGR actuator wiping fault)
INFORMATION
Engine ECU Resistor
(CAN+)
(CAN-)
YM5
YM6
Actuator power
(CANH)
(CANH) relay
(CANL)
(CANL)
NFB
#XG
NFA
#XV
(L)
X36
VNT EGR
controller actuator
(GND)
(+B)
(E)
(+B)
Y4K
Y4J
Z90
Y2E
Y2E Y4J Z90
NAT X36 $4
SHTS021270300562
1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• Wiping operation from "fully open fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.
<Description of malfunction>
• Failure message is received from EGR controller.
2. DTC set condition
(1) DTC detection condition
• The starter key is "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When wiping (valve opens and closes with key LOCK) results in valve moving 10 beyond the learned value in
the closing direction for more than 1 seconds.
3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.
ENGINE (J05E)/TROUBLESHOOTING 2–715
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Fuel injection quantity is limited.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Disconnected or bent EGR valve link.
• Valve or valve seat has come off.
2–716 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P049D
1 Check the DTC detected [HINO-DX]
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than P049D has been
detected in [Fault Information]
SHTS021270300563
Has a DTC other than P049D been detected?
YES NO
Go to the diagnosis procedure of a related Go to step 2.
DTC.
2 Inspect the EGR valve
1. Check if the link joining the actuator and valve unit is disconnected
or bent.
2. Check if there is soot obstructing the exhaust gas passageway
inlet or outlet.
3. Check if the valve or valve seat has come off.
4. Manually push the actuator-side lever and check if the valve opens
and closes.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 3.
EGR valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–717
3 Inspect the EGR valve connector
1. Check the connection of the EGR valve connector (looseness and
poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the EGR valve power supply
1. Set the starter key to the "LOCK" position.
+B E 2. Disconnect the EGR valve.
3. Set the starter key to the "ON" position.
4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.
Measurement Tester
Standard values
conditions connections
SHTS021270300564 EGR valve vehicle
Starter key: ON side connector 10 – 16 V
+B – E
Do the measurements meet the standard value?
YES NO
Go to step 5. Check the wire harness (actuator power sup-
ply and ground) and battery voltage. If neces-
sary, repair or replace.
Perform "After-inspection work" of INFOR-
MATION section.
2–718 ENGINE (J05E)/TROUBLESHOOTING
5 Check the response delay of the EGR controller
1. Select [Check functions] [EGR check] from the menu, and inspect
the response delay at the Target EGR position and Actual EGR
(1)
position.
! CAUTION
(2)
Perform the inspection while the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Select [Start].
(3) (4) Select [EGR opening UP].
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN].
(4) (5) • Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of 10% per step between 0 –
90%.
SHTS021270300565 Standard values
The response delay should be less than 5 seconds.
Do the measurements meet the standard value?
YES NO
Replace the engine ECU. Replace the valve.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–719
CHECKLIST: P049D
DTC: P049D Position failure (EGR actuator wiping fault) Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P049D
have been
Go to the diag-
Check the Check if any DTC other than detected: Go
nosis proce-
1 DTC detected P049D have been detected in to YES. Go to step 2.
dure of a
(Engine ECU) [Engine]
related DTC.
No DTC has
been detected.
Go to NO.
Remove for-
1. Check if the link joining the eign sub-
actuator and valve unit is dis- stances and
connected or bent. clean the
Failure found:
2. Check if there is soot obstruct- valve.
Go to YES.
ing the exhaust gas passage- Replace the
Inspect the
2 way inlet or outlet. EGR valve if it Go to step 3.
EGR valve No failure
3. Check if the valve or valve seat is damaged.
found: Go to
has come off. Perform "After-
NO.
inspection
4. Manually push the actuator-
work" of
side lever and check if the valve
INFORMA-
opens and closes.
TION section.
Connect
securely and
Failure found:
repair if
Go to YES.
Inspect the Check the installation of the EGR needed.
3 EGR valve valve connector (looseness and Perform "After- Go to step 4.
No failure
connector poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Check the wire
harness (actu-
The measure-
ator power
ments meet
Measure the voltage between the supply and
the standard
terminals of the EGR valve vehi- ground) and
value: Go to
cle side connector. battery volt-
Inspect the YES.
<Tester connections> age. If neces-
4 EGR valve Go to step 5.
EGR valve vehicle side connector sary, repair or
power supply The measure-
+B – E replace.
ments do not
<Standard values> Perform "After-
meet the stan-
10 – 16 V inspection
dard value: Go
work" of
to NO.
INFORMA-
TION section.
2–720 ENGINE (J05E)/TROUBLESHOOTING
DTC: P049D Position failure (EGR actuator wiping fault) Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Check functions] [EGR
check] from the menu, and
inspect the response delay at
the Target EGR position and
Actual EGR position.
<Inspection procedure>
(1) Select [Check functions].
(2) Select [EGR check].
(3) Select [Start]. The measure-
(4) Select [EGR opening UP]: ments meet
• Inspect the response delay at the standard Replace the Replace the
Check the each step of the Target EGR value: Go to engine ECU. valve.
response position and Actual EGR posi- YES. Perform "After- Perform "After-
5 delay of the tion from 0 to 90%. inspection inspection
EGR control- (5) Select [VNT opening DOWN]: The measure- work" of work" of
ler [HINO-DX] ments do not INFORMA- INFORMA-
• Inspect the response delay at
meet the stan- TION section. TION section.
each step of the Target EGR
dard value: Go
position and Actual EGR posi-
to NO.
tion from 90 to 0%.
HINT
The EGR opening position
changes of 10% per step
between 0 – 90%.
<Standard values>
The response delay should be
less than 5 seconds.
ENGINE (J05E)/TROUBLESHOOTING 2–721
DTC: P04D5 and P04D6
EN01H02127030602016084
P04D5: Exhaust brake - circuit (Circuit low)
INFORMATION
Max : 61.1A
F ENG-2 30A Rating : 14.5A U2-ACT
NAT %X7 X36 X35 N1B
(L ) (+ ) (L) (B) (L )
(SOL+)
Z23 N16
Y1T
(-S) (+S)
Exhasut brake Actuator power relay
magnetic valve
(SOL-)
1.2A Y1U
(EX1B) ZTH
(EXB) LDJ
Engine ECU
SHTS021270300566
1. Technical description
• –
<Description of malfunction>
• Exhaust brake magnetic valve is not working properly.
• Possible magnetic valve failure or GND short-circuit
2. DTC set condition
(1) DTC detection condition
• Exhaust brake inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• The condition that the exhaust brake magnetic valve circuit voltage is 2.8 V or less remains for 3 seconds or
more.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• The auxiliary brake control is stopped.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
2–722 ENGINE (J05E)/TROUBLESHOOTING
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• GND short-circuit in exhaust brake drive signal line
• Malfunction of exhaust brake magnetic valve
• Malfunction of engine ECU
ENGINE (J05E)/TROUBLESHOOTING 2–723
P04D6: Exhaust brake - circuit (Circuit high)
INFORMATION
Max : 61.1A
F ENG-2 30A Rating : 14.5A U2-ACT
NAT %X7 X36 X35 N1B
(L ) (+ ) (L) (B) (L )
(SOL+)
Z23 N16
Y1T
(-S) (+S)
Exhasut brake Actuator power relay
magnetic valve
(SOL-)
1.2A Y1U
(EX1B) ZTH
(EXB) LDJ
Engine ECU
SHTS021270300567
1. Technical description
• –
<Description of malfunction>
• Exhaust brake magnetic valve is not working properly.
• Possible magnetic valve failure or +B short-circuit or disconnection
2. DTC set condition
(1) DTC detection condition
• Exhaust brake inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• The condition that the exhaust brake magnetic valve circuit voltage is 3 V or more remains for 3 seconds or
more.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Exhaust brake operates at all times (or does not operate when operation request is received).
6. Pre-inspection work
• Check the battery voltage and make sure it is okay.
2–724 ENGINE (J05E)/TROUBLESHOOTING
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• +B short-circuit or disconnection in exhaust brake drive signal line.
• Malfunction of exhaust brake magnetic valve.
• Malfunction of engine ECU.
ENGINE (J05E)/TROUBLESHOOTING 2–725
INSPECTION PROCEDURE: P04D5 and P04D6
1 Inspect the exhaust brake magnetic valve connector
1. Check the connection of the exhaust brake magnetic valve con-
nector (looseness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the exhaust brake magnetic valve
1. Check the installation of the exhaust brake magnetic valve.
Was any failure found?
YES NO
Install the exhaust brake magnetic valve cor- Go to step 3.
rectly.
Replace the exhaust brake magnetic valve if
it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–726 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the exhaust brake magnetic valve unit
1. Set the starter key to the "LOCK" position.
SOL+ SOL- 2. Disconnect the exhaust brake magnetic valve connector.
3. Use the electrical tester to measure the resistance between the
terminals of the exhaust brake magnetic valve.
Measurement Tester
Standard values
conditions connections
Exhaust brake
Starter key: LOCK magnetic valve 8.3 – 18.3
SHTS021270300568 SOL+ – SOL-
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the exhaust brake magnetic valve.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect for power – circuit of the exhaust brake magnetic valve
1. Set the starter key to the "ON" position.
SOL+ 2. Using the electrical tester, measure the pressure between the
exhaust brake magnetic valve vehicle side connector SOL+ termi-
nal and ground.
Measurement Tester
Standard values
conditions connections
Exhaust brake
magnetic valve
Starter key: LOCK vehicle side con- 10 – 16 V
SHTS021270300569 nector
SOL+ – Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the wire harness between
the fuse (ECU3) and the magnetic valve.
ENGINE (J05E)/TROUBLESHOOTING 2–727
5 Inspect for short-circuit of the exhaust brake magnetic valve harness
1. Disconnect the engine ECU connector.
SOL-
2. Use the electrical tester to measure the resistance between the
terminals of the exhaust brake magnetic valve vehicle side con-
nector and ground.
Measurement Tester
Standard values
conditions connections
Exhaust brake
magnetic valve
Starter key: LOCK vehicle side con-
SHTS021270300570 nector
SOL- – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect disconnection of the exhaust brake magnetic valve harness
1. Connect the signal check harness to the engine ECU.
V4 A 2. Use the electrical tester to measure the resistance between the
SOL-
terminals of the exhaust brake magnetic valve vehicle side con-
nector and the engine ECU.
Measurement Tester
Standard values
conditions connections
Exhaust brake
magnetic valve
vehicle side con-
SHTS021270300571 Starter key: LOCK nector – Engine 1 or less
ECU (signal check
harness)
SOL- – EXB(V4)
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–728 ENGINE (J05E)/TROUBLESHOOTING
7 Check the DTC detected (Engine ECU)
1. Stop the engine and set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if the DTC (P04D5 or P04D6) has been
detected in [Fault Information].
SHTS021270300572
Has DTC (P04D5 or P04D6) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–729
CHECKLIST: P04D5 and P04D6
DTC: P04D5 Exhaust brake - circuit (Circuit low)
Inspection procedure
DTC: P04D6 Exhaust brake - circuit (Circuit high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Inspect the Check the connection of the Go to YES.
needed.
exhaust brake exhaust brake magnetic valve
1 Perform "After- Go to step 2.
magnetic valve connector (looseness and poor No failure
inspection
connector contact). found: Go to
work" of
NO.
INFORMA-
TION section.
Install the
valve correctly.
Replace the
Failure found: exhaust brake
Go to YES. magnetic valve
Inspect the
Check the installation of the if it is dam-
2 exhaust brake Go to step 3.
exhaust brake magnetic valve. No failure aged.
magnetic valve
found: Go to Perform "After-
NO. inspection
work" of
INFORMA-
TION section.
The measure-
Disconnect the exhaust brake
ments meet
magnetic valve connector and
the standard Replace the
measure the resistance between
value: Go to valve.
Inspect the the terminals of the exhaust brake
YES. Perform "After-
exhaust brake magnetic valve.
3 Go to step 4. inspection
magnetic valve <Tester connections>
The measure- work" of
unit Exhaust brake magnetic valve
ments do not INFORMA-
SOL+ – SOL-
meet the stan- TION section.
<Standard values>
dard value: Go
8.3 – 18.3
to NO.
The measure-
ments meet
the standard Repair or
Inspect for Using the electrical tester, mea- value: Go to replace the
power – circuit sure the pressure between the YES. wire harness
4 of the exhaust exhaust brake magnetic valve Go to step 5. between the
brake mag- vehicle side connector SOL+ ter- The measure- fuse (ECU3)
netic valve minal and ground. ments do not and the mag-
meet the stan- netic valve.
dard value: Go
to NO.
2–730 ENGINE (J05E)/TROUBLESHOOTING
DTC: P04D5 Exhaust brake - circuit (Circuit low)
Inspection procedure
DTC: P04D6 Exhaust brake - circuit (Circuit high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Disconnect the engine ECU con- The measure-
nector and measure the resis- ments meet
Repair or
tance between the exhaust brake the standard
Inspect for replace the
magnetic valve vehicle side con- value: Go to
short-circuit of harness.
nector terminals and ground. YES.
the exhaust Perform "After-
5 <Tester connections> Go to step 6.
brake mag- inspection
Exhaust brake magnetic valve The measure-
netic valve work" of
vehicle side connector ments do not
harness INFORMA-
1.SOL- – Ground meet the stan-
TION section.
<Standard values> dard value: Go
to NO.
Connect the signal check harness
to the engine ECU and measure The measure-
the resistance between the termi- ments meet
Repair or
nals of the exhaust brake mag- the standard
Inspect dis- replace the
netic valve vehicle side connector value: Go to
connection of harness.
and the engine ECU. YES.
the exhaust Perform "After-
6 <Tester connections> Go to step 7.
brake mag- inspection
Exhaust brake magnetic valve The measure-
netic valve work" of
vehicle side connector – Engine ments do not
harness INFORMA-
ECU (signal check harness) meet the stan-
TION section.
SOL- – EXB(V4) dard value: Go
<Standard values> to NO.
1 or less
DTC (P04D5
Replace the Procedure
or P04D6) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P04D5 or Perform "After- Perform "After-
Go to YES.
7 DTC detected P04D6) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–731
DTC: P0500 and P0501
EN01H02127030602016085
P0500: Vehicle speed sensor - low
INFORMATION
Engine ECU
Combination meter
0.1A EJE (SP02)
(SP1) U27
Vehicle speed signal
SHTS021270300573
1. Technical description
• The engine ECU consistently measures pulses from the vehicle speed sensor through combination meter.
<Description of malfunction>
• Pulses from the vehicle speed sensor cannot be sensed.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
The conditions described below remain for 5 seconds or longer.
• Engine speed is 1,200 r/min or more.
• Gear position: neutral.
• The fuel injection quantity is 60 mm3/st. cyl or more.
• Engine coolant temperature is 50 C {122 F} or higher.
• Battery voltage is in the range of 10 V to 16 V.
• PTO is not actuated.
(2) Judgement criteria
• Output of the vehicle speed sensor remains at a vehicle speed of 0 km/h for 5 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–732 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
• Vehicle speed sensor failure
• Malfunction of pulse modulator (in combination meter)
• Harness disconnection or short-circuit
• Irregular contact (disconnection or poor fit of connector)
ENGINE (J05E)/TROUBLESHOOTING 2–733
P0501: Vehicle speed sensor - high
INFORMATION
Engine ECU
Combination meter
0.1A EJE (SP02)
(SP1) U27
Vehicle speed signal
SHTS021270300574
1. Technical description
• The Engine ECU consistently measures pulses from the vehicle speed sensor.
<Description of malfunction>
• Pulses from the vehicle speed sensor are improper.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Engine speed is 0 r/min or more.
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• Vehicle speed pulse frequency remains at 256 Hz or higher (112 miles/h) for 5 seconds or longer.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Abnormal resistance of sensor
• Malfunction of pulse modulator
• Harness disconnection or short-circuit
• Irregular contact (disconnection or poor fit of connector)
• Noise
2–734 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0500 and P0501
1 Inspect the combination meter
1. Drive the vehicle and confirm that the combination meter (speed-
ometer) is working properly.
Was any failure found?
YES NO
Check the combination meter (vehicle speed Go to step 2.
signal system).
Perform "After-inspection work" of INFOR-
MATION section.
2 Check the DTC detected (vehicle control ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Set the starter key to the "ON" position.
VCS
4. Select [VCS] and check if the DTC (P0500 or P0501) has been
detected in [Fault Information].
SHTS021270300575
Has DTC (P0500 or P0501) been detected?
YES NO
Go to step 3. Go to step 5.
ENGINE (J05E)/TROUBLESHOOTING 2–735
3 Inspect for short-circuits in wire harness of vehicle speed signal circuit
1. Set the starter key to the "LOCK" position.
V14 A 2. Disconnect the combination meter connector.
GROUND
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
4. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300576
Engine ECU (sig-
nal check har-
Starter key: LOCK ness) – Ground
V14 (SP1) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 4. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–736 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect for disconnection in wire harness of vehicle speed signal circuit
1. Use the electrical tester to measure the resistance between the
combination meter vehicle side connector terminal and engine
V14 A ECU (signal check harness) terminal.
Measurement Tester
Standard values
conditions connections
SPD2
Combination
meter vehicle side
connector –
Starter key: LOCK engine ECU (sig- Less than 1
nal check har-
SHTS021270300577 ness)
SPD2 – V14 (SP1)
Do the measurements meet the standard value?
YES NO
Replace the combination meter. Repair or replace the harness.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–737
5 Inspect for disconnection in wire harness of vehicle speed signal circuit
1. Set the starter key to the "LOCK" position.
V14 A 2. Disconnect the combination meter connector.
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
SPD2
4. Use the electrical tester to measure the resistance between the
combination meter vehicle side connector terminal and engine
ECU (signal check harness) terminal.
Measurement Tester
SHTS021270300578 Standard values
conditions connections
Combination
meter vehicle side
connector –
Starter key: LOCK engine ECU (sig- Less than 1
nal check har-
ness)
SPD2 – V14 (SP1)
Do the measurements meet the standard value?
YES NO
Replace the engine ECU. Repair or replace the harness.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–738 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0500 and P0501
DTC: P0500 Vehicle speed sensor - low
Inspection procedure
DTC: P0501 Vehicle speed sensor - high
Check
Step Action Description Judgement Yes No
(Yes/No)
Check the
combination
Failure found: meter (vehicle
Go to YES. speed signal
Inspect the Drive the vehicle and confirm that
system).
1 combination the combination meter (speedom- Go to step 2.
No failure Perform "After-
meter eter) is working properly.
found: Go to inspection
NO. work" of
INFORMA-
TION section.
DTC (P0500
or P0501) has
Check the
Check if the DTC (P0500 or been detected.
DTC detected
2 P0501) has been detected in Go to YES.No Go to step 3. Go to step 5.
(vehicle con-
[VCS]. DTC has been
trol ECU)
detected. Go
to NO.
1. Disconnect the combination
meter connector. The measure-
2. Connect the signal check har- ments meet
Repair or
ness, and measure the resis- the standard
Inspect for replace the
tance between the engine ECU value: Go to
short-circuits harness.
(signal check harness) and YES.
in wire har- Perform "After-
3 ground. Go to step 4.
ness of vehicle inspection
<Tester connections> The measure-
speed signal work" of
Engine ECU (signal check har- ments do not
circuit INFORMA-
ness) Ground meet the stan-
TION section.
V14 (SP1) – Ground dard value: Go
<Standard values> to NO.
Measure the resistance between
The measure-
the combination meter vehicle
ments meet
side connector terminal and Replace the Repair or
the standard
Inspect for dis- engine ECU (signal check har- combination replace the
value: Go to
connection in ness) terminal. meter. harness.
YES.
wire harness <Tester connections> Perform "After- Perform "After-
4
of vehicle Combination meter vehicle side inspection inspection
The measure-
speed signal connector – engine ECU (signal work" of work" of
ments do not
circuit check harness) INFORMA- INFORMA-
meet the stan-
SPD2 – V14 (SP1) TION section. TION section.
dard value: Go
<Standard values>
to NO.
1 or less
ENGINE (J05E)/TROUBLESHOOTING 2–739
DTC: P0500 Vehicle speed sensor - low
Inspection procedure
DTC: P0501 Vehicle speed sensor - high
Check
Step Action Description Judgement Yes No
(Yes/No)
Measure the resistance between
The measure-
the combination meter vehicle
ments meet
side connector terminal and Repair or
the standard Replace the
Inspect for dis- engine ECU (signal check har- replace the
value: Go to engine ECU.
connection in ness) terminal. harness.
YES. Perform "After-
wire harness <Tester connections> Perform "After-
5 inspection
of vehicle Combination meter vehicle side inspection
The measure- work" of
speed signal connector – engine ECU (signal work" of
ments do not INFORMA-
circuit check harness) INFORMA-
meet the stan- TION section.
SPD2 – V14 (SP1) TION section.
dard value: Go
<Standard values>
to NO.
Less than 1
2–740 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0504
EN01H02127030602016086
P0504: Brake Switch Correlation
INFORMATION
Engine ECU
Brake switch
12.7mA EKE (NC-)
(ST1-) J4K
Stop light switch signal
SHTS021270300579
1. Technical description
• The brake switch detects brake input during deceleration.
<Description of malfunction>
• Malfunction of the brake switch caused by disconnection has been detected.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• Absence of input of the brake switch is detected during deceleration.
(2) Judgement criteria
• Absence of input of the brake switch remains for 3 seconds or longer during deceleration.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: OFF
• Cruise control function is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Brake switch failure (stuck switch)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
• CAN signal: Noise
ENGINE (J05E)/TROUBLESHOOTING 2–741
INSPECTION PROCEDURE: P0504
1 Inspect the brake switch connector
1. Check the connection of the brake switch connector (looseness
and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the brake switch
1. Check the installation of the brake switch.
2. Check if the brake switch is properly adjusted.
Was any failure found?
YES NO
Adjust the brake switch so that it is correctly Go to step 3.
installed.
Perform "After-inspection work" of INFOR-
MATION section.
2–742 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the brake switch unit
1. Set the starter key to the "LOCK" position.
NC- NC+ 2. Disconnect the brake switch connector.
3. Use the electrical tester to measure the resistance between the
terminals of the brake switch.
Measurement Tester
Standard values
conditions connections
• Depress brake
Brake switch pedal:
Starter key: LOCK
SHTS021270300580 NC+ – NC- • Release brake
pedal: 2 max.
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the brake switch.
Perform "After-inspection work" of INFOR-
MATION section.
4 Check the brake switch power supply
1. Set the starter key to the "ON" position.
NC+ 2. Use the electrical circuit to measure the voltage between the NC+
terminal in the brake switch vehicle side connector and ground.
Measurement Tester
Standard values
conditions connections
Brake switch vehi-
Starter key: ON cle side connector More than 10 V
NC+ – Ground
SHTS021270300581
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the brake switch power
supply circuit (fuse, wire harness).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–743
5 Check the brake switch signal
1. Set the starter key to the "LOCK" position.
B 2. Connect the brake switch connector.
V75
V80
3. Connect the signal check harness to the engine ECU.
4. Set the starter key to the "ON" position.
5. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).
Measurement Tester
SHTS021270300582 Standard values
conditions connections
Engine ECU (sig- • Depress brake
nal check har- pedal: 0 V
Starter key: ON ness) • Release brake
ST1 (V75) – pedal: 10 V or
E04 (V80) more
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the wire harness between
the brake switch and the engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
2–744 ENGINE (J05E)/TROUBLESHOOTING
6 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if P0504 have been detected in [Fault
Information].
SHTS021270300583
Has DTC P0504 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–745
CHECKLIST: P0504
DTC: P0504 Brake Switch Correlation Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
securely,
Failure found:
repair if
Go to YES.
Inspect the Check the connection of the brake needed.
1 brake switch switch connector (looseness and Perform "After- Go to step 2.
No failure
connector poor contact). inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Adjust the
brake switch
Failure found: so that it is
1. Check the installation of the Go to YES. correctly
Inspect the brake switch. installed.
2 Go to step 3.
brake switch 2. Check if the brake switch is No failure Perform "After-
properly adjusted. found: Go to inspection
NO. work" of
INFORMA-
TION section.
The measure-
Disconnect the brake switch con- ments meet
nector and measure the resis- the standard Replace the
tance between the terminals of value: Go to brake switch.
Inspect the the brake switch. YES. Perform "After-
3 brake switch <Tester connections> Go to step 4. inspection
unit Brake switch The measure- work" of
<Standard values> ments do not INFORMA-
• Depress brake pedal: meet the stan- TION section.
• Release brake pedal: 2 max. dard value: Go
to NO.
The measure- Repair or
Measure the voltage between the
ments meet replace the
NC+ terminal in the brake switch
the standard brake switch
vehicle side connector and
value: Go to power supply
ground.
Check the YES. circuit (fuse,
<Tester connections>
4 brake switch Go to step 5. wire harness).
Brake switch vehicle side connec-
power supply The measure- Perform "After-
tor
ments do not inspection
NC+ – Ground
meet the stan- work" of
<Standard values>
dard value: Go INFORMA-
10 V or more
to NO. TION section.
2–746 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0504 Brake Switch Correlation Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Connect the brake switch con-
nector and Connect the signal
check harness to the engine Repair or
The measure-
ECU. replace the
ments meet
wire harness
2. Measure the voltage between the standard
between the
the terminals of the engine value: Go to
brake switch
Check the ECU (signal check harness). YES.
and the engine
5 brake switch <Tester connections> Go to step 6.
ECU.
signal Engine ECU (signal check har- The measure-
Perform "After-
ness) ments do not
inspection
BSW2(V75) – PGD4(V80) meet the stan-
work" of
<Standard values> dard value: Go
INFORMA-
• Depress brake pedal: 0 V to NO.
TION section.
• Release brake pedal: 10 V or
more
DTC P0504
Replace the Procedure
has been
engine ECU. completed.
detected: Go
Check the Perform "After- Perform "After-
Check if P0504 has been to YES.
6 DTC detected inspection inspection
detected in [Engine].
(Engine ECU) work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–747
DTC: P0519
EN01H02127030602016087
P0519: Idle speed control system
INFORMATION
1. Technical description
• A difference between a target speed and an actual speed is detected during idling in the engine ECU.
<Description of malfunction>
• A difference between a target speed and an actual speed has been detected during idling.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
The conditions described below remain for 10 seconds or longer.
• Accelerator pedal opening = 0%
• Engine coolant temperature is 60 C {140 F} or higher.
• The target idling speed is within the range of 745 to 755 r/min.
• Vehicle speed is 0 mile/h.
(2) Judgement criteria
• A difference between a target engine speed and an actual engine speed remains at 25 r/min or higher for 15
seconds or longer.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• Extremely large load applied to engine while it is idling
• Excessive fuel injection quantity
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Increase in injector injection rate
• Dragging/interference with transmission
• Failure in air compressor
• Failure in power steering pump
2–748 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0519
1 Check the DTC detected (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select
3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than P0519 has been
detected in [Fault Information].
SHTS021270300584
Has a DTC other than P0519 been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
ENGINE (J05E)/TROUBLESHOOTING 2–749
2 Check the injector fuel injection quantity [HINO-DX]
1. Start the engine.
2. Select [Injection quantity] from [Data Monitor] in HINO-DX menu
and measure the fuel injection quantity.
Select 3. Select [Engine speed] from [Data Monitor] on HINO-DX menu, and
Engine
measure the engine speed.
Measurement conditions Standard values
Engine speed: AT model:
1,500 r/min (no load) 12 mm3/st maximum
Engine coolant temperature: MT model:
NE Engine speed 80 C {176 F} minimum 10 mm3/st maximum
@1,500 r/min (measurement by HINO-DX)
Standard values
Ne (r/min)
Q (mm3/st)
Engine
Type of
AT 5.0q
SHTS021270300585
Do the measurements meet the standard value?
YES NO
Go to step 3. Replace the injector.
Perform "After-inspection work" of INFOR-
MATION section.
2–750 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the air compressor
1. Check the air compressor for failure.
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the power steering pump
1. Check the power steering pump for failure.
Was any failure found?
YES NO
Repair or replace the faulty part. Go to step 5.
Perform "After-inspection work" of INFOR-
MATION section.
5 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "ON" position.
Select
Engine
3. Select [Engine] and check if P0519 has been detected in [Fault
Information].
SHTS021270300587
Has DTC P0519 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–751
CHECKLIST: P0519
DTC: P0519 Idle speed control system Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0519
has been
Go to the diag-
Check the Check if any DTC other than detected: Go
nostic proce-
1 DTC detected P0519 has been detected in to YES. Go to step 2.
dure of a
(Engine ECU) [Engine].
related DTC.
No DTC has
been detected.
Go to NO.
Select [Injection quantity] from
The measure-
[Data Monitor] in HINO-DX menu
ments meet
and measure the fuel injection
the standard Replace the
quantity.
value: Go to injector.
Check the <Measurement conditions>
YES. Perform "After-
injector fuel Engine speed: 1,500 r/min (no
2 Go to step 3. inspection
injection quan- load)
The measure- work" of
tity [HINO-DX] Engine coolant temperature: 80C
ments do not INFORMA-
{176F} minimum
meet the stan- TION section.
<Standard values>
dard value: Go
AT model: 12mm3/st maximum
to NO.
MT model: 10mm3/st maximum
Repair or
Failure found: replace the
Go to YES. faulty part.
Inspect the air Check the air compressor for fail- Perform "After-
3 Go to step 4.
compressor ure. No failure inspection
found: Go to work" of
NO. INFORMA-
TION section.
Repair or
Failure found: replace the
Go to YES. faulty part.
Inspect the
Check the power steering pump Perform "After-
4 power steer- Go to step 5.
for failure. No failure inspection
ing pump
found: Go to work" of
NO. INFORMA-
TION section.
DTC P0519
Replace the Procedure
has been
engine ECU. completed.
Perform engine warm up (engine detected: Go
Check the Perform "After- Perform "After-
coolant temperature: 80 C {176 to YES.
5 DTC detected inspection inspection
F} or more), and check if P0519
(Engine ECU) work" of work" of
has been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–752 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0521
EN01H02127030602016088
P0521: Malfunction of oil pressure switch (High)
INFORMATION
Engine ECU
Oil pressure switch
H26 6.1mA GCP (OSW)
Body earth
(S)
12.3mA XZP (DM)
SHTS021270300588
1. Technical description
• A rise in engine oil pressure is sensed by the oil pressure switch.
<Description of malfunction>
• Abnormality (high-pressure) in engine oil pressure is detected.
2. DTC set condition
(1) DTC detection condition
• The engine stopped.
• Engine coolant temperature of 30 C {86 F} or more.
(2) Judgement criteria
• The oil pressure switch continues to be OFF (high-pressure detection) for more than 3 seconds.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Insufficient oil pan oil quantity.
• Malfunction of oil pressure switch.
• +B short-circuit of disconnection harness.
• Engine oil viscosity is high.
ENGINE (J05E)/TROUBLESHOOTING 2–753
INSPECTION PROCEDURE: P0521
1 Check the engine oil level
1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the stipulated value.
2. Check the engine oil condition (dirt, viscosity).
Rivet Oil level gauge
FULL ADD
Preferred level
Gauge end
SHTS021270300589
Was any failure found?
YES NO
Adjust the engine oil quantity so that it is Go to step 2.
within the stipulated value.
Change the oil if it is dirty.
Perform "After-inspection work" of INFOR-
MATION section.
2 Check for engine oil leaks
1. Make sure there is no oil leaking from the engine unit or from
around the oil pressure switch.
Was any failure found?
YES NO
Repair the faulty part. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–754 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the oil pressure switch connector
1. Check the connection of the oil pressure switch connector (loose-
ness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the oil pressure switch unit
1. Set the starter key to the "LOCK" position.
2. Disconnect the oil pressure switch connector.
3. Use the electrical tester to measure the resistance between the
terminals of the oil pressure switch and ground.
Measurement conditions Standard values
• Stop the engine (OFF) With engine stopped:
Less than 1
• Start the engine (ON) With engine running:
SHTS021270300590
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the oil pressure switch.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–755
5 Inspect for short-circuit of the oil pressure switch harness
1. Set the starter key to the "LOCK" position.
E41 D 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
3. Disconnect the oil pressure switch connector.
4. Use the electrical tester to measure the resistance between the
OSW (E41) terminal in the engine ECU (signal check harness)
and ground.
Measurement Tester
SHTS021270300591 Standard values
conditions connections
Engine ECU (sig-
nal check har-
Starter key: LOCK ness)
OSW (E41) –
Ground
Do the measurements meet the standard value?
YES NO
Replace the engine ECU. Replace or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–756 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0521
DTC: P0521 Malfunction of oil pressure switch (High) Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Adjust the
engine oil
quantity so
that it is within
1. Check the oil level gauge and Failure found:
the stipulated
make sure the engine oil quan- Go to YES.
value. Change
Check the tity is within the stipulated
1 the oil if it is Go to step 2.
engine oil level value. No failure
dirty.
2. Check the engine oil condition found: Go to
Perform "After-
(dirt, viscosity). NO.
inspection
work" of
INFORMA-
TION section.
Repair the
Failure found:
faulty part.
Go to YES.
Check for Make sure there is no oil leaking Perform "After-
2 engine oil from the engine unit or from inspection Go to step 3.
No failure
leaks around the oil pressure switch. work" of
found: Go to
INFORMA-
NO.
TION section.
Connect
securely,
Failure found:
repair if
Inspect the oil Go to YES.
Check the connection of the oil needed.
pressure
3 pressure switch connector (loose- Perform "After- Go to step 4.
switch connec- No failure
ness and poor contact). inspection
tor found: Go to
work" of
NO.
INFORMA-
TION section.
Disconnect the oil pressure switch
connector and measure the resis-
tance between the terminals of The measure-
the oil pressure switch and ments meet
ground. Replace the oil
the standard
<Tester connections> pressure
value: Go to
switch.
Inspect the oil • Stop the engine (OFF) YES.
Perform "After-
4 pressure • Start the engine (ON) Go to step 5.
inspection
switch unit <Standard values> The measure-
work" of
With engine stopped: ments do not
INFORMA-
Less than 1 meet the stan-
TION section.
With engine running: dard value: Go
to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–757
DTC: P0521 Malfunction of oil pressure switch (High) Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Connect the signal check har-
ness to the engine ECU. (Do
not connect harness to the The measure-
ECU.) disconnect the oil pres- ments meet
Repair or
sure switch connector. the standard
replace the
Inspect for 2. Measure the resistance value: Go to
harness.
short-circuit of between the OSW (E41) termi- YES.
Replace the Perform "After-
5 the oil pres- nal in the engine ECU (signal engine ECU. inspection
sure switch check harness) and ground. The measure-
work" of
harness <Tester connections> ments do not
INFORMA-
Engine ECU (signal check har- meet the stan-
TION section.
ness) dard value: Go
OSW (E41) – Ground to NO.
<Standard values>
2–758 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0524
EN01H02127030602016089
P0524: Engine oil pressure Too Low
INFORMATION
Engine ECU
Oil pressure switch
H26 6.1mA GCP (OSW)
Body earth
(S)
12.3mA XZP (DM)
SHTS021270300592
1. Technical description
• A drop in engine oil pressure is sensed by the oil pressure switch.
<Description of malfunction>
• Drop in engine oil pressure is detected.
2. DTC set condition
(1) DTC detection condition
• While the engine is in operation - Always
(2) Judgement criteria
• The oil pressure switch continues to be ON for more than 30 seconds.
3. Reset condition
• Immediately after normal operation is restored.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
• Cruise control is not available.
• After fixed time, engine stopped.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
• After fixed time, engine stopped.
<Symptoms on the vehicle due to malfunction>
• Drop in engine oil pressure
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Drop in oil pan oil quantity: Drop in pressure due to air suction
• Malfunction of oil pressure circuit: Drop in pressure due to oil leakage
• Malfunction of oil pressure switch: Correct oil pressure cannot be sensed.
• GND short-circuit of harness: The sensing result of the oil pressure switch becomes invalid.
ENGINE (J05E)/TROUBLESHOOTING 2–759
INSPECTION PROCEDURE: P0524
1 Check the engine oil level
1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the stipulated value.
2. Check the engine oil condition (dirt, viscosity).
Rivet Oil level gauge
FULL ADD
Preferred level
Gauge end
SHTS021270300593
Was any failure found?
YES NO
Adjust the engine oil quantity so that it is Go to step 2.
within the stipulated value.
Change the oil if it is dirty.
Perform "After-inspection work" of INFOR-
MATION section.
2 Check for engine oil leaks
1. Make sure there is no oil leaking from the engine unit or from
around the oil pressure switch.
Was any failure found?
YES NO
Repair the faulty part. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
2–760 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the oil pressure switch connector
1. Check the connection of the oil pressure switch connector (loose-
ness and poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 4.
Perform "After-inspection work" of INFOR-
MATION section.
4 Inspect the oil pressure switch unit
1. Set the starter key to the "LOCK" position.
2. Disconnect the oil pressure switch connector.
3. Use the electrical tester to measure the resistance between the
terminals of the oil pressure switch and ground.
Measurement conditions Standard values
• Stop the engine (OFF) With engine stopped:
Less than 1
• Start the engine (ON) With engine running:
SHTS021270300594
Do the measurements meet the standard value?
YES NO
Go to step 5. Replace the oil pressure switch.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–761
5 Inspect for short-circuit of the oil pressure switch harness
1. Set the starter key to the "LOCK" position.
E41 D 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
3. Disconnect the oil pressure switch connector.
4. Use the electrical tester to measure the resistance between the
OSW (E41) terminal in the engine ECU (signal check harness)
and ground.
Measurement Tester
SHTS021270300595 Standard values
conditions connections
Engine ECU (sig-
nal check har-
Starter key: LOCK ness)
OSW (E41) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Replace or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–762 ENGINE (J05E)/TROUBLESHOOTING
6 Inspect disconnection of the oil pressure switch harness
1. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and oil pressure switch vehicle side
E41 D connector.
OIL
E2R Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
nal check har-
ness) – Oil
Starter key: LOCK pressure switch Less than 1
vehicle side con-
SHTS021270300596 nector
OSW (E41) – S
Do the measurements meet the standard value?
YES NO
Replace the engine ECU. Repair or replace the harness.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–763
CHECKLIST: P0524
DTC: P0524 Engine oil pressure Too Low Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
Adjust the
engine oil
quantity so
that it is within
1. Check the oil level gauge and Failure found:
the stipulated
make sure the engine oil quan- Go to YES.
value. Change
Check the tity is within the stipulated
1 the oil if it is Go to step 2.
engine oil level value. No failure
dirty.
2. Check the engine oil condition found: Go to
Perform "After-
(dirt, viscosity). NO.
inspection
work" of
INFORMA-
TION section.
Repair the
Failure found:
faulty part.
Go to YES.
Check for Make sure there is no oil leaking Perform "After-
2 engine oil from the engine unit or from inspection Go to step 3.
No failure
leaks around the oil pressure switch. work" of
found: Go to
INFORMA-
NO.
TION section.
Connect
securely,
Failure found:
repair if
Inspect the oil Go to YES.
Check the connection of the oil needed.
pressure
3 pressure switch connector (loose- Perform "After- Go to step 4.
switch connec- No failure
ness and poor contact). inspection
tor found: Go to
work" of
NO.
INFORMA-
TION section.
Disconnect the oil pressure switch
connector and measure the resis- The measure-
tance between the terminals of ments meet
Replace the oil
the oil pressure switch and the standard
pressure
ground. value: Go to
switch.
Inspect the oil <Tester connections> YES.
Perform "After-
4 pressure Go to step 5.
• Stop the engine (OFF) inspection
switch unit The measure-
• Start the engine (ON) work" of
ments do not
<Standard values> INFORMA-
meet the stan-
With engine stopped: TION section.
dard value: Go
Less than 1 to NO.
With engine running:
2–764 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0524 Engine oil pressure Too Low Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Connect the signal check har-
ness to the engine ECU. (Do
not connect harness to the The measure-
ECU.) disconnect the oil pres- ments meet
Repair or
sure switch connector. the standard
replace the
Inspect for 2. Measure the resistance value: Go to
harness.
short-circuit of between the OSW (E41) termi- YES.
Perform "After-
5 the oil pres- nal in the engine ECU (signal Go to step 6.
inspection
sure switch check harness) and ground. The measure-
work" of
harness <Tester connections> ments do not
INFORMA-
Engine ECU (signal check har- meet the stan-
TION section.
ness) dard value: Go
OSW (E41) – Ground to NO.
<Standard values>
Measure the resistance between The measure-
the terminals of the engine ECU ments meet
Repair or
and oil pressure switch vehicle the standard Replace the
replace the
Inspect dis- side connector. value: Go to engine ECU.
harness.
connection of <Tester connections> YES. Perform "After-
Perform "After-
6 the oil pres- Engine ECU (signal check har- inspection
inspection
sure switch ness) – Oil pressure switch vehi- The measure- work" of
work" of
harness cle side connector ments do not INFORMA-
INFORMA-
OSW (E41) – S meet the stan- TION section.
TION section.
<Standard values> dard value: Go
Less than 1 to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–765
DTC: P0545 and P0546
EN01H02127030602016090
P0545: Exhaust gas temperature sensor (DOC1 inlet) - out of range (Out of range low)
INFORMATION
Engine ECU
Exhaust gas (TOIL) VKF TYP 0.001A XYD (THO1)
temperature sensor (GND) ZKT TYP 0.004A XJQ (E5)
(DOC1 inlet)
SHTS021270300597
1. Technical description
• The exhaust gas temperature sensor (DOC1 inlet) consistently detects exhaust gas temperature.
• A reading taken by the exhaust gas temperature sensor (DOC1 inlet) is used to control DPR regeneration.
<Description of malfunction>
• Exhaust gas temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Battery voltage is in the range of 10 V to 16 V.
(2) Judgement criteria
• Voltage of the exhaust gas temperature sensor (DOC1 inlet) remains less than 0.063 V (1,165 C {2,219 F})
for 3 seconds.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–766 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
Exhaust gas temperature sensor (DOC1 inlet):
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Abnormal resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact (disconnection or poor fit of connector)
ENGINE (J05E)/TROUBLESHOOTING 2–767
P0546: Exhaust gas temperature sensor (DOC1 inlet) - out of range (Out of range high)
INFORMATION
Engine ECU
Exhaust gas (TOIL) VKF TYP 0.001A XYD (THO1)
temperature sensor (GND) ZKT TYP 0.004A XJQ (E5)
(DOC1 inlet)
SHTS021270300598
1. Technical description
• The exhaust gas temperature sensor (DOC1 inlet) consistently detects exhaust gas temperature.
• A reading taken by the exhaust gas temperature sensor (DOC1 inlet) is used to control DPR regeneration.
<Description of malfunction>
• Exhaust gas temperature cannot be correctly recognized.
2. DTC set condition
(1) DTC detection condition
• Intake air temperature is -20 C {-4 F} or higher.
• Battery voltage is in the range of 10 V to 16 V.
• The engine speed remains at 690 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Voltage of the exhaust gas temperature sensor (DOC1 inlet) remains at 4.958 V or higher (-46 C {-50.8 F} or
lower) for 3 seconds.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–768 ENGINE (J05E)/TROUBLESHOOTING
8. Estimated failure factors
Exhaust gas temperature sensor (DOC1 inlet):
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Abnormal resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact (disconnection or poor fit of connector)
ENGINE (J05E)/TROUBLESHOOTING 2–769
INSPECTION PROCEDURE: P0545 and P0546
1 Inspect the exhaust gas temperature sensor (DOC1 inlet) connector
1. Check the connection of the exhaust gas temperature sensor
(DOC1 inlet) connector (looseness or poor contact).
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the exhaust gas temperature sensor (DOC1 inlet)
1. Check the installation of the exhaust gas temperature sensor
(DOC1 inlet).
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the exhaust gas temperature sensor (DOC1 inlet).
Was any failure found?
YES NO
Clean the sensing unit and connect the sen- Go to step 3.
sor securely.
If damaged, replace the exhaust gas temper-
ature sensor (DOC1 inlet).
Perform "After-inspection work" of INFOR-
MATION section.
2–770 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the exhaust gas temperature sensor (DOC1 inlet) unit
1. Set the starter key to the "LOCK" position.
TOIL GND
2. Disconnect the exhaust gas temperature sensor (DOC1 inlet) con-
nector.
3. Use the electrical tester to measure the resistance between the
terminals of the exhaust gas temperature sensor (DOC1 inlet).
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
SHTS021270300599 Exhaust gas tem- 13.7 – 29.8 k
perature sensor 50 C {122 F}:
Starter key: LOCK
(DOC1 inlet) 7.13 – 13.7 k
TOIL – GND 80 C {176 F}:
4.1 – 7.13 k
Do the measurements meet the standard value?
YES NO
Go to step 4. Replace the exhaust gas temperature sensor
(DOC1 inlet).
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–771
4 Inspect the sensor power supply
1. Set the starter key to the "ON" position.
GND TOIL
2. Use the electrical tester to measure the voltage between the termi-
nals of the exhaust gas temperature sensor (DOC1 inlet).
Measurement Tester
Standard values
conditions connections
Exhaust gas tem-
perature sensor
Starter key: ON (DOC1 inlet) vehi- 4.5 – 5.5 V
cle side connector
SHTS021270300600 TOIL – GND
Do the measurements meet the standard value?
YES NO
Go to step 7. Go to step 5.
5 Check short-circuit in wire harness of exhaust gas temperature sensor (DOC1 inlet)
1. Set the starter key to the "LOCK" position.
E43
D E58 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
3. Use the electrical tester to measure the resistance between the
engine ECU (signal check harness) terminals and ground.
Measurement Tester
Standard values
conditions connections
Engine ECU (sig-
SHTS021270300601 nal check har-
ness)
Starter key: LOCK
THO1 (E43) –
Ground
E5 (E58) – Ground
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
2–772 ENGINE (J05E)/TROUBLESHOOTING
6 Check disconnection in wire harness of exhaust gas temperature sensor (DOC1 inlet)
1. Connect the exhaust gas temperature sensor (DOC1 inlet) con-
nector.
E43 D E58
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
20 C {68 F}:
Engine ECU (sig-
13.7 – 29.8 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.13 – 13.7 k
SHTS021270300602
THO1 (E43) –
80 C {176 F}:
E3 (E58)
4.1 – 7.13 k
Do the measurements meet the standard value?
YES NO
Go to step 7. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
7 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine and set the starter key to the "LOCK" position.
Select
Engine 3. Connect the vehicle to HINO-DX.
4. Set the starter key to the "ON" position.
5. Select [Engine] and check if the DTC (P0545 or P0546) has been
detected in [Fault Information].
SHTS021270300603
Has DTC (P2470 or P2471) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–773
CHECKLIST: P0545 and P0546
Exhaust gas temperature sensor (DOC1 inlet) -
DTC: P0545
out of range (Out of range low)
Inspection procedure
Exhaust gas temperature sensor (DOC1 inlet) -
DTC: P0546
out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect
Failure found: securely,
Inspect the
Go to YES. repair if
exhaust gas Check the connection of the
needed.
temperature exhaust gas temperature sensor
1 No failure Perform "After- Go to step 2.
sensor (DOC1 (DOC1 inlet) connector (loose-
found: Go to inspection
inlet) connec- ness or poor contact).
NO. work" of
tor
INFORMA-
TION section.
Clean the
sensing unit
1. Check the installation of the and install it
exhaust gas temperature sen- Failure found: properly.
Inspect the
sor (DOC1 inlet). Go to YES. If damaged,
exhaust gas
2. Make sure there is no dirt, replace the
2 temperature Go to step 3.
damage or clogging in the No failure sensor.
sensor (DOC1
sensing unit of the exhaust gas found: Go to Perform "After-
inlet)
temperature sensor (DOC1 NO. inspection
inlet). work" of
INFORMA-
TION section.
Measure the resistance between The measure-
Replace the
the terminals of the exhaust gas ments meet
exhaust gas
temperature sensor (DOC1 inlet). the standard
temperature
Inspect the <Tester connections> value: Go to
sensor (DOC1
exhaust gas Exhaust gas temperature sensor YES.
inlet).
3 temperature (DOC1 inlet) Go to step 4.
Perform "After-
sensor (DOC1 TOIL – GND The measure-
inspection
inlet) unit <Standard values> ments do not
work" of
20 C {68 F}: 13.7 – 29.8 k meet the stan-
INFORMA-
50 C {122 F}: 7.13 – 13.7 k dard value: Go
TION section.
80 C {176 F}: 4.1 – 7.13 k to NO.
The measure-
Measure the voltage between the
ments meet
terminals of the exhaust gas tem-
the standard
perature sensor (DOC1 inlet).
value: Go to
<Tester connections>
Inspect the YES.
Exhaust gas temperature sensor
4 sensor power Go to step 7. Go to step 5.
(DOC1 inlet) vehicle side connec-
supply The measure-
tor
ments do not
TOIL – GND
meet the stan-
<Standard values>
dard value: Go
4.5 – 5.5 V
to NO.
2–774 ENGINE (J05E)/TROUBLESHOOTING
Exhaust gas temperature sensor (DOC1 inlet) -
DTC: P0545
out of range (Out of range low)
Inspection procedure
Exhaust gas temperature sensor (DOC1 inlet) -
DTC: P0546
out of range (Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the signal check har-
The measure-
ness, and measure the resistance
ments meet
between the terminals of the Repair or
Check short- the standard
engine ECU (signal check har- replace the
circuit in wire value: Go to
ness) and ground. harness.
harness of YES.
<Tester connections> Perform "After-
5 exhaust gas Go to step 6.
Engine ECU (signal check har- inspection
temperature The measure-
ness) work" of
sensor (DOC1 ments do not
THO1 (E43) – Ground INFORMA-
inlet) meet the stan-
E5 (E58) – Ground TION section.
dard value: Go
<Standard values>
to NO.
1. Connect the exhaust gas tem-
perature sensor (DOC1 inlet)
connector. The measure-
2. Measure the resistance ments meet
Repair or
Check for dis- between the terminals of the the standard
replace the
connection in engine ECU (signal check har- value: Go to
harness.
wire harness ness). YES.
Perform "After-
6 of exhaust gas <Tester connections> Go to step 7.
inspection
temperature Engine ECU (signal check har- The measure-
work" of
sensor (DOC1 ness) ments do not
INFORMA-
inlet) THO1 (E43) – E3 (E58) meet the stan-
TION section.
<Standard values> dard value: Go
20 C {68 F}: 13.7 – 29.8 k to NO.
50 C {122 F}: 7.13 – 13.7 k
80 C {176 F}: 4.1 – 7.13 k
DTC (P0545
Replace the Procedure
or P0546) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0545 or Perform "After- Perform "After-
Go to YES.
7 DTC detected P0546) has been detected in inspection inspection
(Engine ECU) [Fault Information]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–775
DTC: P0562 and P0563
EN01H02127030602016091
P0562: Battery voltage - out of range (Out of range low)
INFORMATION
Engine ECU
(+BM) JFZ 3.2 (Inrush : 6.87A)
(+B2) XAU 3.2 (Inrush : 6.87A)
(+B1) X0D 3.2 (Inrush : 6.87A)
(+B) X21 3.2 (Inrush : 6.87A)
To EDU relay
SHTS021270300604
1. Technical description
• –
<Description of malfunction>
• Excessive low voltage has been detected in the ECU power supply.
2. DTC set condition
(1) DTC detection condition
• Engine speed of 0 r/min or more.
(2) Judgement criteria
• Engine ECU power supply voltage is 9 V or less for 2 seconds or less.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Fusible Link, FUSE: Fusing, irregular contact, partial engagement
• Connectors, harnesses and terminals: Disconnection, irregular contact, looseness
• Battery: Over discharge, service life
• Alternator: Power generation failure
• ECU: Malfunction
2–776 ENGINE (J05E)/TROUBLESHOOTING
P0563: Battery voltage - out of range (Out of range high)
INFORMATION
Engine ECU
(+BM) JFZ 3.2 (Inrush : 6.87A)
(+B2) XAU 3.2 (Inrush : 6.87A)
(+B1) X0D 3.2 (Inrush : 6.87A)
(+B) X21 3.2 (Inrush : 6.87A)
To EDU relay
SHTS021270300605
1. Technical description
• –
<Description of malfunction>
• Excessively high voltage has been detected in the ECU power supply.
2. DTC set condition
(1) DTC detection condition
• Engine speed of 0 r/min or more.
(2) Judgement criteria
• Engine ECU power supply voltage is 17 V or more for 2 seconds or more.
3. Reset condition
• After restoration to normal condition
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Fusible Link, FUSE: Fusing, irregular contact, partial engagement
• Alternator failure (abnormal voltage or requires adjustment)
• ECU: Malfunction
ENGINE (J05E)/TROUBLESHOOTING 2–777
INSPECTION PROCEDURE: P0562 and P0563
1 Inspect the fuse or fusible link
1. Check for fusing or improper fit.
Was any failure found?
YES NO
Connect the fusible link properly or replace. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the connection of the battery cable
1. Check if the battery cable is properly installed (tightly fastened).
• Each battery terminal
• Alternator terminal
Was any failure found?
YES NO
Connect properly. If necessary, repair the Go to step 3.
cable.
Perform "After-inspection work" of INFOR-
MATION section.
2–778 ENGINE (J05E)/TROUBLESHOOTING
3 Inspect the alternator
1. Start the engine.
2. Use the electrical tester to measure the voltage between the alter-
nator B terminal and ground.
Measurement Tester
Standard values
conditions connections
Alternator B –
Engine idling 13.5 V or more
Ground
Do the measurements meet the standard value?
YES NO
Go to step 4. Repair or replace the alternator.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–779
4 Inspect the engine ECU power supply
1. Set the starter key to the "LOCK" position.
A V18 B V58 2. Connect the signal check harness to the engine ECU.
V59
3. Start the engine.
V39 V80
V38 V79 4. Use the electrical tester to measure the voltage between the termi-
V78
nals of the engine ECU (signal check harness).
Measurement Tester
Standard values
conditions connections
SHTS021270300606 Engine ECU (sig-
nal check har-
ness)
(+) – (-)
+B (V18) – E01
(V39)
Engine idling 10 – 16 V
+B1 (V38) – E02
(V59)
+B2 (V58) – E03
(V79)
+BM (V78) – E04
(V80)
Do the measurements meet the standard value?
YES NO
Go to step 5. Check the engine ECU wire harness (power
supply circuit).
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
2–780 ENGINE (J05E)/TROUBLESHOOTING
5 Check the DTC detected (Engine ECU)
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select 3. Select [Engine] and check if the DTC (P0562 or P0563) has been
Engine detected in [Fault Information].
SHTS021270300607
Has DTC (P0562 or P0563) been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–781
CHECKLIST: P0562 and P0563
Battery voltage - out of range
DTC: P0562
(Out of range low)
Inspection procedure
Battery voltage - out of range
DTC: P0563
(Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
Connect the
fusible link
Failure found:
properly or
Go to YES.
Inspect the replace.
1 fuse or fusible Check for fusing or improper fit. Perform "After- Go to step 2.
No failure
link inspection
found: Go to
work" of
NO.
INFORMA-
TION section.
Connect prop-
erly. If neces-
Failure found:
Check if the battery cable is prop- Go to YES. sary, repair the
Inspect the
erly installed (tightly fastened). cable.
connection of
2 Perform "After- Go to step 3.
the battery • Each battery terminal No failure
inspection
cable • Alternator terminal found: Go to
work" of
NO.
INFORMA-
TION section.
The measure-
ments meet
While the engine is idle, measure Repair or
the standard
the voltage between the alterna- replace the
value: Go to
tor B terminal and ground. alternator.
YES.
Inspect the <Tester connections> Perform "After-
3 Go to step 4.
alternator Alternator inspection
The measure-
B terminal – Ground work" of
ments do not
<Standard values> INFORMA-
meet the stan-
13.5 V or more TION section.
dard value: Go
to NO.
While the engine is idle, measure
Check the
the voltage between the terminals
The measure- engine ECU
of the engine ECU (signal check
ments meet wire harness
harness).
the standard (power supply
<Tester connections>
value: Go to circuit).
Engine ECU (signal check har-
Inspect the YES. Repair or
ness)
4 engine ECU Go to step 5. replace parts
(+) – (–)
power supply The measure- as needed.
+B (V18) – E01 (V39)
ments do not Perform "After-
+B1 (V38) – E02 (V59)
meet the stan- inspection
+B2 (V58) – E03 (V79)
dard value: Go work" of
+BM (V78) – E04 (V80)
to NO. INFORMA-
<Standard values>
TION section.
10 – 16 V
2–782 ENGINE (J05E)/TROUBLESHOOTING
Battery voltage - out of range
DTC: P0562
(Out of range low)
Inspection procedure
Battery voltage - out of range
DTC: P0563
(Out of range high)
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC (P0562
Replace the Procedure
or P0563) has
engine ECU. completed.
been detected:
Check the Check if the DTC (P0562 or Perform "After- Perform "After-
Go to YES.
5 DTC detected P0563) has been detected in inspection inspection
(Engine ECU) [Engine]. work" of work" of
No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–783
DTC: P05F1
EN01H02127030602016092
P05F1: Crankcase ventilation system - disconnection between the CV valve and the intake
manifold
INFORMATION
Coolant temperature
sensor Engine ECU
X66 (THW) 10mA X28 (THW)
Body earth Z5G (E) 10mA ZJQ (E5)
X71 10mA X4K (VG)
(FC)
XCV 200mA XMH
(E2G) (EVG)
XCT 200mA X2U
(+B) (VAF)
Z65 10mA
(E2) X72 X82
(THA) 10mA (THA)
Intake air temperature sensor
(built in the air flow sensor)
SHTS021270300608
1. Technical description
• The closed breather circuit is malfunctioning and the air flow sensor detects trouble when air enters through the
malfunctioning part.
<Description of malfunction>
• Closed breather malfunction is detected.
2. DTC set condition
(1) DTC detection condition
• The engine speed is in the range of 720 to 960 r/min.
• A change in the engine speed is 234.4 r/min/sec or less.
• The fuel injection quantity is in the range of 0 mm3/st. cyl to 80 mm3/st. cyl.
• A change in fuel injection quantity is 78.1 mm3/st. cyl/sec or less.
• Engine coolant temperature is 55 C {131 F} or less.
• A target EGR valve opening is 0% or less.
• Exhaust brake not actuated
(2) Judgement criteria
• Theoretical air quantity calculated from boost pressure and atmospheric pressure and actual air quantity are
compared for at least 10 seconds, and the ratio of theoretical air quantity to actual air quantity is at least 1.12.
And:
• Difference between DCY value prior to above result and current DCY value is 0.10 or less; and
• When prior DCY the starter key is turned "LOCK" and engine is stopped, (boost pressure - atmospheric pres-
sure) ≥ 18 kPa, and that condition did not continue for 3 seconds or more.
3. Reset condition
• After normal operation is restored
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
2–784 ENGINE (J05E)/TROUBLESHOOTING
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• –
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.).
• EGR valve failure.
• Diesel throttle valve failure.
• Intercooler failure (due to dirt, clogging, etc.).
• Engine ECU sensor power supply (air flow sensor dedicated 12 V power supply) failure or internal circuit failure.
ENGINE (J05E)/TROUBLESHOOTING 2–785
INSPECTION PROCEDURE: P05F1
1 Inspect the air cleaner element
1. Check the air cleaner element for dirt, clogging, or damage.
2. Make sure the element is a Hino genuine part.
Was any failure found?
YES NO
Clean or replace the air cleaner element. Go to step 2.
Perform "After-inspection work" of INFOR-
MATION section.
2 Check the air intake system
1. Check the intake hose and verify that there are no disconnections,
clogging, punctures, or cracks.
2. Check the breather hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.
3. Check the intercooler hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.
Was any failure found?
YES NO
Repair or replace the intake system hoses. Go to step 3.
Perform "After-inspection work" of INFOR-
MATION section.
3 Inspect the air flow sensor
1. Check the installation of the air flow sensor.
2. Make sure there is no dirt, damage or clogging in the sensing unit
of the air flow sensor.
Was any failure found?
YES NO
Replace the air flow sensor if the sensing Go to step 4.
unit is dirty, clogged, or damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–786 ENGINE (J05E)/TROUBLESHOOTING
4 Inspect for short-circuit of the air flow sensor harness
1. Set the starter key to the "LOCK" position.
C D
E12 2. Disconnect the air flow sensor connector.
3. Connect the signal check harness to the engine ECU. (Do not con-
E74 E78 nect harness to the ECU.)
4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU and ground.
Measurement Tester
Standard values
conditions connections
SHTS021270300609
Engine ECU (sig-
nal check har-
ness)
VAF (E12) –
Starter key: LOCK
Ground
VG (E74) – Ground
EVG (E78) –
Ground
Do the measurements meet the standard value?
YES NO
Go to step 5. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–787
5 Inspect disconnection of the air flow sensor harness
1. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and air flow
C sensor vehicle side connector.
E12
Measurement Tester
Standard values
conditions connections
+B E2G Engine ECU (sig-
D
FC nal check har-
ness) – Air flow
sensor vehicle
E74 E78
Starter key: LOCK Less than 1
side connector
VAF (E12) – +B
VG (E74) – FC
EVG (E78) – E2G
SHTS021270300610
Do the measurements meet the standard value?
YES NO
Go to step 6. Repair or replace the harness.
Perform "After-inspection work" of INFOR-
MATION section.
6 Inspect the EGR valve
1. Check the EGR valve for damage due to foreign substances.
2. Check if there is soot obstructing the exhaust gas passageway
inlet or outlet.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 7.
valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–788 ENGINE (J05E)/TROUBLESHOOTING
7 Check the response delay of the EGR valve [HINO-DX]
1. Set the starter key to the "ON" position.
(1) 2. Select [Check functions] and then [EGR check] from the menu,
then inspect the response delay at the Target EGR position and
(2) Actual EGR position.
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.
<Inspection procedure>
(1) Select [Check functions].
(3) (2) Select [EGR check].
(3) Select [Start].
(4) Select [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
(4) (5) and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.
SHTS021270300611
Standard values
From the Target EGR position to the Actual EGR position,
the response delay should be within 5 seconds.
Do the measurements meet the standard value?
YES NO
Go to step 8. Replace the EGR valve.
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–789
8 Inspect the intake throttle valve
1. Stop the engine.
2. Check the operating status of the intake throttle valve (for incorrect
opening or sticky valve).
Was any failure found?
YES NO
Replace the intake throttle valve. Go to step 9.
Perform "After-inspection work" of INFOR-
MATION section.
9 Inspect the intercooler
1. Check if there is an obstruction due to clogging inside the inter-
cooler.
Was any failure found?
YES NO
Remove foreign substances and clean the Go to step 10.
intercooler.
Replace the intercooler if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–790 ENGINE (J05E)/TROUBLESHOOTING
10 Check the DTC detected (Engine ECU)
1. Perform engine warm up. (engine coolant temperature: 80 C {176
F} or more)
2. Stop the engine.
Select
Engine
3. Set the starter key to the "ON" position.
4. Select [Engine] and check if P05F1 has been detected in [Fault
Information].
SHTS021270300612
Has DTC P05F1 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–791
CHECKLIST: P05F1
Crankcase ventilation system - disconnection
DTC: P05F1 Inspection procedure
between the CV valve and the intake manifold
Check
Step Action Description Judgement Yes No
(Yes/No)
Clean or
replace the air
Failure found:
1. Check there is no dirt, damage cleaner ele-
Go to YES.
Inspect the air or clogging in the air cleaner ment.
1 cleaner ele- element. Perform "After- Go to step 2.
No failure
ment 2. Make sure the element is a inspection
found: Go to
Hino genuine part. work" of
NO.
INFORMA-
TION section.
1. Check the intake hose and ver-
ify that there are no disconnec-
tions, clogging, punctures, or Repair or
cracks. replace the
Failure found:
intake system
2. Check the breather hose and Go to YES.
hoses.
Check the air verify that there are no discon-
2 Perform "After- Go to step 3.
intake system nections, clogging, punctures, No failure
inspection
or cracks. found: Go to
work" of
3. Check the intercooler hose and NO.
INFORMA-
verify that there are no discon- TION section.
nections, clogging, punctures,
or cracks.
If the sensing
unit is dirty,
clogging or
1. Check the installation of the air Failure found:
damaged,
flow sensor. Go to YES.
replace the
Inspect the air 2. Make sure there is no dirt,
3 sensor. Go to step 4.
flow sensor damage or clogging in the No failure
Perform "After-
sensing unit of the air flow sen- found: Go to
inspection
sor. NO.
work" of
INFORMA-
TION section.
1. Disconnect the air flow sensor
connector and connect the sig-
nal check harness to the
The measure-
engine ECU. Do not connect to
ments meet
the ECU. Repair or
the standard
2. Measure the resistance replace the
Inspect for value: Go to
between the terminals of the harness.
short-circuit of YES.
engine ECU and ground. Perform "After-
4 the air flow Go to step 5.
<Tester connections> inspection
sensor har- The measure-
Engine ECU (signal check har- work" of
ness ments do not
ness) INFORMA-
meet the stan-
VAF (E12) – Ground TION section.
dard value: Go
VG (E74) – Ground to NO.
EVG (E78) – Ground
<Standard values>
2–792 ENGINE (J05E)/TROUBLESHOOTING
Crankcase ventilation system - disconnection
DTC: P05F1 Inspection procedure
between the CV valve and the intake manifold
Check
Step Action Description Judgement Yes No
(Yes/No)
Measure the resistance between
the engine ECU (signal check The measure-
harness) and the airflow sensor ments meet
Repair or
vehicle side connector terminals. the standard
replace the
Inspect dis- <Measurement parts> value: Go to
harness.
connection of Engine ECU (signal check har- YES.
Perform "After-
5 the air flow ness) and the airflow sensor vehi- Go to step 6.
inspection
sensor har- cle side connector. The measure-
work" of
ness VAF (E12) – +B ments do not
INFORMA-
VG (E74) – FC meet the stan-
TION section.
EVG (E78) – E2G dard value: Go
<Reference value> to NO.
Less than 1
Remove for-
eign sub-
stances and
clean the
Failure found:
1. Check the EGR valve for dam- valve.
Go to YES.
age due to foreign substances. Replace the
Inspect the
6 2. Check if there is soot obstruct- EGR valve if it Go to step 7.
EGR valve No failure
ing the exhaust gas passage- is damaged.
found: Go to
way inlet or outlet. Perform "After-
NO.
inspection
work" of
INFORMA-
TION section.
Select [Check functions] and then
[EGR check] from the menu, then
inspect the response delay at the
Target EGR position and Actual
EGR position. The measure-
<Inspection procedure> ments meet
(1) Select [Check functions]. the standard Replace the
Check the (2) Select [EGR check]. value: Go to EGR valve.
response (3) Select [Start]. YES. Perform "After-
7 delay of the (4) Select [EGR opening UP]: Go to step 8. inspection
EGR valve • Inspect the response delay at The measure- work" of
[HINO-DX] each step of the Target EGR ments do not INFORMA-
position and Actual EGR posi- meet the stan- TION section.
tion from 0 to 90%. dard value: Go
(5) Select [EGR opening DOWN]: to NO.
• Inspect the response delay at
each step of the Target EGR
position and Actual EGR posi-
tion from 90 to 0%.
Replace the
Failure found: intake throttle
Stop the engine and check the Go to YES. valve.
Inspect the
operating status of the intake Perform "After-
8 intake throttle Go to step 9.
throttle valve (for incorrect open- No failure inspection
valve
ing or sticky valve). found: Go to work" of
NO. INFORMA-
TION section.
ENGINE (J05E)/TROUBLESHOOTING 2–793
Crankcase ventilation system - disconnection
DTC: P05F1 Inspection procedure
between the CV valve and the intake manifold
Check
Step Action Description Judgement Yes No
(Yes/No)
Remove for-
eign sub-
stances and
clean the inter-
Failure found:
cooler.
Go to YES.
Check if there is an obstruction Replace the
Inspect the
9 due to clogging inside the inter- intercooler if it Go to step 10.
intercooler No failure
cooler. is damaged.
found: Go to
Perform "After-
NO.
inspection
work" of
INFORMA-
TION section.
DTC P05F1
Replace the Procedure
has been
engine ECU. completed.
Warm up the engine (engine cool- detected: Go
Check the Perform "After- Perform "After-
ant temperature: 80 C {176 F} to YES.
10 DTC detected inspection inspection
or more) and check if P05F1 has
(Engine ECU) work" of work" of
been detected in [Engine]. No DTC has
INFORMA- INFORMA-
been detected:
TION section. TION section.
Go to NO.
2–794 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0605
EN01H02127030602016093
P0605: Flash ROM error
INFORMATION
1. Technical description
• Engine ECU flash ROM failure is detected.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
(2) Judgement criteria
• Flash ROM check sum error
• Failure determination time ≥ 96 msec
3. Reset condition
• After restoration to normal condition and starter key "OFF"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: ON
• Engine output is restricted.
• Cruise control function is not available.
• Idling stop system is not available.
• Vehicle start control is not available.
• PTO is not available
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• Cruise control does not work.
• Idling stop system does not work.
• Vehicle start control does not work.
• PTO cannot be used.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Malfunction of engine ECU circuit.
• Temporary malfunction caused by radio frequency interference or noise.
ENGINE (J05E)/TROUBLESHOOTING 2–795
INSPECTION PROCEDURE: P0605
1 Inspect the engine ECU circuit [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
Engine 3. Select [Engine] and check the communication between HINO-DX
and the engine ECU.
4. Erase the trouble history.
5. Set the starter key to the "LOCK" position.
When
communication with 6. Make sure the engine ECU main relay is OFF in HINO-DX menu.
the engine ECU is (This cuts off the communication between HINO-DX and the
interrupted while the engine ECU.)
engine ECU is
connec-ted to
HINO-DX, the 7. Set the starter key to the "ON" position.
connection symbol
at the left bottom of 8. Select [Engine] and check if P0605 has been detected in [Fault
HINO-DX screen Information].
(figure on the left)
becomes
disconnected.
SHTS021270300613
Has DTC P0605 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
2–796 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0605
DTC: P0605 Flash ROM error Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Engine] in HINO-DX
menu and check the communi- Procedure
cation between HINO-DX and completed.
the engine ECU and erase the DTC P0605 (Temporary
trouble history. Replace the
has been operating error
engine ECU.
Inspect the 2. Set the starter key to the detected: Go due to radio
Perform "After-
engine ECU "LOCK" position and make sure to YES. wave interfer-
1 inspection
circuit [HINO- the engine ECU main relay is ence or noise.)
work" of
DX] OFF in HINO-DX menu. (This No DTC has Perform "After-
INFORMA-
cuts off the communication been detected: inspection
TION section.
between HINO-DX and the Go to NO. work" of
engine ECU.) INFORMA-
3. Check if P0605 has been TION section.
detected in [Engine].
ENGINE (J05E)/TROUBLESHOOTING 2–797
DTC: P0606
EN01H02127030602016094
P0606: Control module processor
INFORMATION
1. Technical description
• Engine ECU internal failure is detected.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Starter key "ON"
(2) Judgement criteria
• IC for monitoring microcomputer failure inside ECU is detected.
• Failure determination time ≥ 96 msec
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
• Engine is stopped.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine is stopped.
<Symptoms on the vehicle due to malfunction>
• Engine is stalled.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors
• Malfunction of engine ECU circuit.
• Temporary malfunction caused by radio frequency interference or noise.
2–798 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0606
1 Inspect the engine ECU circuit [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
Engine 3. Select [Engine] in HINO-DX menu and check the communication
between HINO-DX and the engine ECU.
4. Erase the trouble history.
5. Set the starter key to the "LOCK" position.
When
communication with 6. Make sure the engine ECU main relay is OFF in HINO-DX menu.
the engine ECU is (This cuts off the communication between HINO-DX and the
interrupted while engine ECU.)
the engine ECU is
connec-ted to the
HINO-DX, the 7. Set the starter key to the "ON" position.
connection symbol
at the left bottom of 8. Select [Engine] and check if P0606 has been detected in [Fault
the HINO-DX
Information].
screen (figure on
the left) becomes
disconnected.
SHTS021270300614
Has DTC P0606 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–799
CHECKLIST: P0606
DTC: P0606 Control module processor Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Engine] in HINO-DX
menu and check the communi-
cation between HINO-DX and
Procedure
the engine ECU.
completed.
2. Erase the trouble history. DTC P0606 (Temporary
Replace the
3. Set the starter key to the has been operating error
engine ECU.
Inspect the "LOCK" position. detected: Go due to radio
Perform "After-
engine ECU 4. Make sure the engine ECU to YES. wave interfer-
1 inspection
circuit [HINO- main relay is OFF in HINO-DX ence or noise.)
work" of
DX] menu. (This cuts off the com- No DTC has Perform "After-
INFORMA-
munication between HINO-DX been detected: inspection
TION section.
and the engine ECU.) Go to NO. work" of
INFORMA-
5. Set the starter key to the "ON"
TION section.
position.
6. Check if P0606 has been
detected in [Engine].
2–800 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0607
EN01H02127030602016095
P0607: Control module performance
INFORMATION
1. Technical description
• Engine ECU internal failure is detected.
<Description of malfunction>
• –
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
(2) Judgement criteria
• Failure of IC for monitoring inside engine ECU is detected.
• Failure determination time ≥ 96 msec
3. Reset condition
• After restoration to normal condition.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
• Engine output is restricted.
• Cruise control function is not available.
• Idling stop system is not available.
• Vehicle start control is not available.
• PTO is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• Cruise control does not work.
• Idling stop system does not work.
• Vehicle start control does not work.
• PTO cannot be used.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Malfunction of engine ECU circuit.
• Temporary malfunction caused by radio frequency interference or noise.
ENGINE (J05E)/TROUBLESHOOTING 2–801
INSPECTION PROCEDURE: P0607
1 Inspect the engine ECU circuit [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
Engine 3. Select [Engine] in HINO-DX menu and check the communication
between HINO-DX and the engine ECU.
4. Erase the trouble history.
5. Set the starter key to the "LOCK" position.
When
communication with 6. Make sure the engine ECU main relay is OFF in HINO-DX menu.
the engine ECU is (This cuts off the communication between HINO-DX and the
interrupted while
the engine ECU is
engine ECU.)
connec-ted to the
HINO-DX, the 7. Set the starter key to the "ON" position.
connection symbol
at the left bottom of
8. Select [Engine] and check if P0607 has been detected in [Fault
the HINO-DX
screen (figure on Information].
the left) becomes
disconnected.
SHTS021270300615
Has DTC P0607 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
2–802 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0607
DTC: P0607 Control module performance Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Select [Engine] in HINO-DX
menu and check the communi-
cation between HINO-DX and
Procedure
the engine ECU.
completed.
2. Erase the trouble history. DTC P0607 (Temporary
Replace the
3. Set the starter key to the has been operating error
engine ECU.
Inspect the "LOCK" position. detected: Go due to radio
Perform "After-
engine ECU 4. Make sure the engine ECU to YES. wave interfer-
1 inspection
circuit [HINO- main relay is OFF in HINO-DX ence or noise.)
work" of
DX] menu. (This cuts off the com- No DTC has Perform "After-
INFORMA-
munication between HINO-DX been detected: inspection
TION section.
and the engine ECU.) Go to NO. work" of
INFORMA-
5. Set the starter key to the "ON"
TION section.
position.
6. Check if P0607 has been
detected in [Engine].
ENGINE (J05E)/TROUBLESHOOTING 2–803
DTC: P0610
EN01H02127030602016096
P0610: VIN data error
INFORMATION
<Vehicle control ECU> <Engine ECU>
CAN communication
䌑䌒
SHTS021270300616
1. Technical description
• Receipt of vehicle information (VIN) is detected.
<Description of malfunction>
• Vehicle information is not received or the wrong vehicle information is received.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
The conditions described above remain for 5 seconds or longer.
HINT
This DTC is detected when replacing the engine ECU and the VIN information from the vehicle control ECU has
not been received.
(2) Judgement criteria
• Engine ECU can not receive VIN information from the vehicle control ECU.
3. Reset condition
• After restoration to normal condition and starter key "LOCK"
4. Indication, warning or system control regulation when the DTC is set.
• MIL: OFF
• Diag lamp: ON
• Cruise control function is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Cruise control does not work.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Vehicle control ECU failure
• Engine ECU failure
• Malfunction of vehicle power supply (noise)
• CAN circuit failure (noise)
2–804 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0610
1 Check the DTC detected 1 (Engine ECU)
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO-DX.
Select 3. Set the starter key to the "ON" position.
Engine
4. Select [Engine] and check if any DTC other than P0610 (for exam-
ple, U1001, U110A) has been detected in [Fault Information].
SHTS021270300617
Has a DTC other than P0610 been detected?
YES NO
Go to the diagnostic procedure of a related Go to step 2.
DTC.
2 Inspect the vehicle Information [HINO-DX]
1. Select [VCS] and read the vehicle information (VIN) written in the
Vehicle control ECU at system fix.
2. Compare the data with the vehicle's VIN LABEL, and check if the
Select vehicle information (VIN) that has been written to the Vehicle con-
Vehicle ECU trol ECU is correct.
SHTS021270300618
Is the vehicle Information (VIN) in the vehicle control ECU correct?
YES NO
Go to step 4. Go to step 3.
ENGINE (J05E)/TROUBLESHOOTING 2–805
3 Reprogram the vehicle control ECU [HINO-DX]
1. Use HINO-DX, and perform [ECU reprogram] from vehicle control
ECU.
2. Select [Engine] from the HINO-DX menu, and read the DTC that
Select has been detected in [Fault Information].
Engine
SHTS021270300619
Has DTC P0610 been detected?
YES NO
Replace the vehicle control ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
4 Reprogram the Engine ECU [HINO-DX]
1. Use HINO-DX, and perform [ECU reprogram] from engine ECU.
2. Select [Engine] from the HINO-DX menu, and read the DTC that
has been detected in [Fault Information].
Select
Engine
SHTS021270300620
Has DTC P0610 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–806 ENGINE (J05E)/TROUBLESHOOTING
CHECKLIST: P0610
DTC: P0610 VIN data error Inspection procedure
Check
Step Action Description Judgement Yes No
(Yes/No)
DTC other
than P0610
have been
Check if any DTC other than Go to diagno-
Check the detected: Go
P0610 (for example U1001, sis procedure
1 DTC detected. to YES. Go to step 2.
U110A) have been detected in of a related
(Engine ECU)
[Engine]. DTC.
No DTC has
been detected.
Go to NO.
The vehicle
1. Select [VCS] from HINO-DX
information
menu, and read at system fix
(VIN) is cor-
the vehicle information (VIN)
rect: Go to
Check the that have been written to the
YES.
vehicle infor- vehicle control ECU.
2 Go to step 4. Go to step 3.
mation [HINO- 2. Compare with the vehicle's VIN The vehicle
DX] LABEL, and check if the vehicle information
information (VIN) that has been (VIN) is not
written to the ECU vehicle infor- correct: Go to
mation is correct. NO.
DTC P0610
1. Use HINO-DX, and perform Replace the Procedure
has been
Reprogram the [ECU reprogram] from Vehicle vehicle ECU. completed.
detected: Go
vehicle control control ECU. Perform "After- Perform "After-
to YES.
3 information 2. Select [Engine] from HINO-DX inspection inspection
ECU [HINO- menu, and read the DTC that work" of work" of
No DTC has
DX] have been detected in [Fault INFORMA- INFORMA-
been detected:
Information]. TION section. TION section.
Go to NO.
DTC P0610
1. Use HINO-DX, and perform Replace the Procedure
has been
[ECU reprogram] from engine engine ECU. completed.
detected: Go
Reprogram the ECU. Perform "After- Perform "After-
to YES.
4 engine ECU 2. Select [Engine] from HINO-DX inspection inspection
[HINO-DX] menu, and read the DTC that work" of work" of
No DTC has
have been detected in [Fault INFORMA- INFORMA-
been detected:
Information]. TION section. TION section.
Go to NO.
ENGINE (J05E)/TROUBLESHOOTING 2–807
DTC: P0611
EN01H02127030602016097
P0611: Fuel injector driver charge circuit - circuit (circuit low)
INFORMATION
1. Technical description
• –
<Description of malfunction>
• Low voltage failure of injector actuation charging circuit is detected.
2. DTC set condition
(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 V to 16 V.
• With the injector not operating
(2) Judgement criteria
• Injector driver charge circuit voltage remains at 55 V or less for 0.096 seconds or more.
3. Reset condition
• After normal operation is restored and engine is restarted after engine stall.
4. Indication, warning or system control regulation when the DTC is set.
• MIL: ON
• Diag lamp: OFF
• Engine output is restricted.
• Cruise control function is not available.
• Idling stop system is not available.
• Vehicle start control is not available.
• PTO is not available.
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>
• Engine output is insufficient.
• Cruise control does not work.
• Idling stop system does not work.
• Vehicle start control does not work.
• PTO cannot be used.
<Symptoms on the vehicle due to malfunction>
• –
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
8. Estimated failure factors
• Engine ECU failure
• Temporary operating error due to radio wave interference or noise.
2–808 ENGINE (J05E)/TROUBLESHOOTING
INSPECTION PROCEDURE: P0611
1 Inspect the engine ECU circuit [HINO-DX]
1. Connect the vehicle to HINO-DX.
2. Set the starter key to the "ON" position.
Select
Engine
3. Select [Engine] in HINO-DX menu and check the communication
between HINO-DX and the engine ECU.
4. Erase the trouble history.
5. Set the starter key to the "LOCK" position.
When
communication with 6. Make sure the engine ECU main relay is OFF in HINO-DX menu.
the engine ECU is
interrupted while
(This cuts off the communication between HINO-DX and the
the engine ECU is engine ECU.)
connected to the
HINO-DX, the 7. Set the starter key to the "ON" position.
connection symbol
at the left bottom of
the HINO-DX 8. Select [Engine] and check if P0611 has been detected in [Fault
screen (figure on Information].
the left) becomes
disconnected.
SHTS021270300621
Has DTC P0611 been detected?
YES NO
Replace the engine ECU. Procedure completed.
Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
ENGINE (J05E)/TROUBLESHOOTING 2–809
CHECKLIST: P0611
Fuel injector driver charge circuit
DTC: P0611 Inspection procedure
- circuit (circuit low)
Check
Step Action Description Judgement Yes No
(Yes/No)
1. Connect the vehicle to HINO-
DX.
2. Set the starter key to the "ON"
position.
3. Select [Engine] in HINO-DX Procedure
menu and check the communi- completed.
cation between HINO-DX and DTC P0611 (Temporary
the engine ECU. Replace the
has been operating error
engine ECU.
Inspect the 4. Erase the trouble history. detected: Go due to radio
Perform "After-
engine ECU 5. Set the starter key to the to YES. wave interfer-
1 inspection
circuit [HINO- "LOCK" position. ence or noise.)
work" of
DX] No DTC has Perform "After-
6. Make sure the engine ECU INFORMA-
been detected: inspection
main relay is OFF in HINO-DX TION section.
Go to NO. work" of
menu. (This cuts off the com-
INFORMA-
munication between HINO-DX
TION section.
and the engine ECU.)
7. Set the starter key to the "ON"
position.
8. Check if DTC P0611 has been
detected in [Engine].
Hino Motors Sales U.S.A., Inc.
41180 Bridge Street, Novi, MI 48375
Telephone: (248) 699-9300
PRINTED IN JAPAN
Pub.No. S7-LXJE03A 1/4 '13. 2
'13. 3
S7-LXJE03B 1/7 '13. 6
S7-LXJE03C 1/7 '13. 7
