For Authorized Service Dealers Only
ISUZU N-Series 4HK1 Engine
Common Rail System (CRS) Service
Manual
Issued : November 2011
50000057E
© 2011 by DENSO CORPORATION
All rights reserved. This material may not be reproduced
or copied, in whole or in part, without the written
permission of DENSO Corporation.
Table of Contents
Table of Contents
Operation Section
1. Applicable Vehicles and Parts Information
1.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Applicable Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 List of Primary Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. Common Rail System (CRS)
2.1 CRS Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
3. Supply Pump
3.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3.2
3.3
3.4
4. Rail
4.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
4.2 Rail Pressure S ensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
4.3
5. Injectors
5.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
6. Control System Parts
6.1 Engine ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
6.2
7. Exhaust Gas Treatment System
7.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
7.2
7.3
8. Diagnostic Trouble Codes (DTC)
8.1 DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -21
9. Control System Component Information
9.1 Engine ECU Terminal Layout Diagram s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
9.2 Connector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Tabl e of Contents
Operation Section
1. Applicable Vehicles and Parts Information
1.1 Outline
As a result of a model change to the ISUZU 4HK1 engine beginning from May 2010, the Common Rail System (CRS) has also changed. This manual describes items specif ic to the parts used in the CRS for the
4HK1 engine. For CRS basics, refer to the "COMM ON RA IL SYSTEM SERVICE MANU AL -OPE RATION
(Doc ID: 00400534EA)."
Compliance with Exhau st Gas Regulations
The CRS for the 4HK1 engine has undergone the following improvements to comply with US10 exhaust gas
regulations.
Combustion Improvements
• System pressure: Increased to 200 MPa
1–1
• Supply pump: Operating pressure of 200 MPa, uses positive pressure system
• Rail: Operating pressure of 200 MPa
• Injectors: Uses the G3 type
Improved Post-P ro cessi ng
• Particulate Matter (PM) reduction: Diesel Particulate Filter (DPF)
• NOx Reduction: Urea Selective Catalytic Reduct ion (SCR)
1.2 Applicable Vehicle
Vehicle Manufac-
Vehicle Name Engine Type Exhaust Volume
turer
ISUZU N SERIES 4HK1 5.2 L May 2010
Production Start
Date
1–2
Operation Section
1.3 List of Primary Parts
Part Name
Supply Pump 294000-112# 8-98081771-2 HP4 Supply Pump
Rail 095440-155# 8-98081768-0
Injector 295050-032# 8-98110607-2 G3 Type
Engine ECU 275800-875# 8-98160981-2
Crankshaft Position Sensor 949979-031# 8-97606943-0
Cylinder Recognition Sensor 949979-169# 8-98019024-0
Fuel Pressure Sensor 499000-829# 8-98105928-0
Exhaust Gas Temperature Sen-
sor
Exhaust Gas Temperature Sen-
sor
Differential Pressure Sensor 104990-101# 8-97359985-2
DENSO Part Num-
ber
265600-125# 8-98004329-0 DPF Side
265600-126# 8-98004330-0 SCR Side
Manufacturer Part
Remarks
Number
Operation Section
2. Common Rail System (CRS)
2.1 CRS Outline
The CRS for the ISUZU 4HK 1 engine uses the f ollowing fuel flow path to prevent air from mi xing with the
fuel. The feed pump for the supply pump draws in fuel that is then initially sent to a main filter outside of the
supply pump. Air inside the fuel is released from the air bleed valve on the main filter. Next, the fuel is returned again to the suppl y pump, and then sent to the rail under high pressure.
Fuel Temperature
Vehicle Speed
Accelerator Position
Boost Pressure
Intake Air Temperature
Coolant Temperature
Crankshaft Position
Cylinder Recogni tion Signal
Engin e ECU
Rail Pressure Sensor
Injector
1–3
Intake Air Mass
Suction Control Valve
(SCV)
to Fu el Ad dit ion
Valve (DPF)
Fuel Te mperat ure Sens or
Conventional Supply Pump
to Rail
Supply Pump
Main Filter
(Positive Pressure Type)
Rail
Pressure Limiter
Sub-Filter
(Negative Pressure Type)
Air Bleed Valve
Fuel Ta nk
Sucti on
Discharge
Feed
Return
Suppl y Pump
Fuel Filter
Fuel Ta nk
Q006718E
1–4
Operation Section
3. Supply Pump
3.1 Outline
The supply pump used with the ISUZU 4HK1 engine is an HP3 type adapted to positive pressure filter use.
In comparison to conventional supply pu mps, the 4HK1 engine sup ply pump includes a feed pump out let
port, and main filter pump inlet port. Posi tive pres sure is app lied to the main filter by s endin g fuel from the
feed pump to the main filter. In addition, the supply pump uses a normal ly open SV3 typ e Suction Cont rol
Valve (SCV).
Fuel Inlet (from Main Filter )
Suction Control Valve (SCV)
Fuel Outlet
(Overflow, to Fuel Tank)
Supply Pump Adapted
to Positive Pressure Filter Use
Fuel Outlet
(Overflow,
to Fuel Tank)
Fuel Outlet
(to Main Filter)
Fuel Inlet
(from Sub-Fi lter)
Fuel Temperature Sensor
Conventional Supply Pump
Suction Control Valve
(SCV)
Fuel Inlet
Q006719E
Operation Section
The 4HK1 engine CRS has been adapted to positive pressure filter use to achieve the following effects:
• Stabilize the fuel supply by placing the fuel filter under positive pressure
• Suppress filter clogs and increasing filter life
• Reduce diagnostic abnormalities caused by pressure f luct uations that ar ise wh en air intermi xing is suppressed
Rear Cover
A rear cover has been added to supply pumps adapted to positive pressure filters since the fuel drawn into
the supply pump is sent to an external main filter. Rear cover construction features the following items:
• A relief valve to adjust the fuel returning to the supply pump
• A check valve to increase priming performance t o the ne wly added fuel flow path (i.e., to the main filter)
Feed Pump
The feed pump cover and feed pump plate have changed. Moreove r, the discharge port on the feed pump
plate is blocked off.
1–5
Feed Pump Plate
Rear Cover
Discharge-Side Port Obstruction
Feed Pump Cover
Relief Valve
Rear Cover
Check Valve
Q006720E
1–6
Operation Section
In a conventional supply pu mp, fuel is s ent d irectly through the following f low path: feed pump SCV
plunger chamber rail. However, in the supply pump adapted to positive pressure filter use, t he fu el flow
path is as follows: feed pump
Flow Path for Supp ly P ump Adapte d to Po siti ve Pressur e Filt er Use
Flow Path for a Conventional Su pply Pump
main filter SCV plunger chamber rail.
Q004898E
Operation Section
1–7
The SCV used with the ISUZU 4HK1 engine is a normally open SV3 type. The SV3 typ e has the following
features:
• A more compact design compared to the SV1 type due to a small er solenoid
• Improved valve sliding performance
Plunger
<External View>
Supply Pump
Valve Body
Valve Spring
Solenoid
Needle Valve Armature
<Cross-Sectional Diagram>
Q006721E
Needle Valve
Short Duty ON Duration
Large Valve Opening
Large Suction Quantity
Large Valve
Opening
Cylinder Cylinder
Operation Concept Diagram
Long Duty ON Duration
Small Valve Opening
Small Suction Quantity
Small Valve
Opening
Q006722E
1–8
Operation Section
The fuel temperature se nsor detects the fuel temperat ure, and sends corresponding signals t o the engine
ECU. The ECU then uses the signal in formation to calculate an injection correc tion suited t o the fuel temperature.
<Reference: Temperature/Resistance Characteristics>
Temperature ( )
Fuel Temperature Sensor
Resistance (k )
Q006723E
Operation Section
4. Rail
4.1 Outline
Compared to a conventional rail, the rail used with the ISUZU 4HK1 engine is adapted to high pressure (200
MPa). The rail distributes fuel sent from the supply pump to each injector.
1–9
Fuel Inlet
Pressure Limiter
to Injectors
Rail Pressure Sensor
4.2 Rail Pressure Sensor
The rail pressure sensor detects fuel pressure inside the rail. There are two rail pressure sensors to provide
a backup in case of a malfunction. In addition, the output signal for each sensor system is offset.
Q006724E
Rail Pressure (MPa)
Q006725E
1–10
Operation Section
The pressure limiter used with the ISUZU 4HK1 engine is adapted to a pressure of 200 MPa. The pressure
limiter opens to release fuel from the rail when the internal pressure becomes abnormall y high. Pressure
limiter construction and characteristics are as shown in the figure below.
Housing
to Fuel Tank
Spring
Valve
Open Valve
from Rail
Closed Valve
Valve Body
Q004915E
Operation Section
5. Injectors
5.1 Outline
The 4HK1 engine CRS us es G3 type inject ors. G3 inject ors are des igne d to suppor t a system pressure of
200 MPa, to improve responsiveness, and to increase resistance against foreign material adherence to the
nozzle.
G3 type operation and QR code (I D code) injection quantity corrections are the same as for G2 type with
conventional QR codes. (How ever, the QR code correction points differ.)
QR Code
ID Codes
1–11
High-Pressure Fuel
(from Rail)
Pressure Pin
Solenoid Valve
Control Chamber
Command Piston
Nozzle Spring
Nozzle Needle
Q006726E.
1–12
Operation Section
10 Correction Points
Injection Quantity Q
Actuation Pulse Width TQ
Correction Points Using QR Codes
Q006727E
Operation Section
6. Control System Parts
6.1 Engine ECU
The engine ECU conducts overall engine control. The engine ECU for the ISUZU 4HK1 engine is mounted
in the cabin, and contains a built-in inject or actuation circuit, thereby eliminating the Electronic Dri ve Unit
(EDU).
1–13
Q006728
1–14
Operation Section
(1) Crankshaft Position Sensor (NE Sensor) and Cylinder Recognition Sensor (G Sensor)
• The 4HK1 engine CRS uses a crankshaft position sensor (NE sensor) and cylinder recognition sensor (G
sensor). Both sensors are Magnetic Resistance Ele men t (MRE) types.
Crank Position Sensor
(NE Sensor)
Cylinder Recognition Sensor
(G Sensor)
Q006729E
Crankshaft Position Sensor
The crankshaft position sensor detects the cranksh aft angle. The pulsar has 56 teeth (separated at 6°
intervals, with four missing teeth t o detect Top Dead Center [TDC] for cylinders no. 1 and no. 4).
<Circuit Diagram>
Engine ECU
Sensor
Four Missing Teeth
NE Input Circuit
Pulsar
Q006730E
Cylinder R ecognition Sensor (G)
The cylinder recognition sensor i dentifies the eng ine cylinders. The pul sar has five teeth (r ecogn ition
of TDC for each cylinder + recognition of cylinder no. 1).
Pulsars
Cylinder No. 1
Recognition
<Circuit Diagram>
Engine ECU
Sensor
G Input Circuit
Q006731E
Operation Section
1–15
• The 4HK1 engine CRS is equipped with a fuel pressure sensor to detect fuel pressure between the feed
pump outlet on the supply pump, and the main filter. Sensor output determines correction control for the
fuel addition valve, and whether a main filter clog exists. The fuel pressure sensor is a semiconductor type
device that uses a characteristic of silicone crystals in which electrical resistance changes when the pressure applied to the crystals is varied.
Engine ECU
Output Voltage (V)
Fuel Pressure (MPa)
Q006732E
(3) Engine Oil Pressure Sensor
• The engine oil pressure sensor detects engine oil pressure. If engine oil pressure reaches an abnormally
high value, the sensor stops the engine.
Engine ECU
Output Voltage (V)
Q006733E
1–16
Operation Section
7. Exhaust Gas Treatment System
7.1 Outline
The 4HK1 engine CRS adds a Diesel Particulate Filter (DPF) to eliminate Particulate Matter (PM), and uses
urea Selective Catalytic Reduction (SCR) to reduce NOx. Urea SCR adds urea to the exhaust gas, and the
SCR catalyst reduces the NOx. The exhaust gas temperature sensor and differential pressure sensor used
in the 4HK1 engine exhaust gas treatment system are mad e by DENSO.
Urea SCR
ECU
Urea Tank
Differential Pressure Sensor
Urea F ee d Device
Fuel Addition Valve
Oxidation Catalyst
Exhaust Gas Temperature Sensor
DPF
Exhaust Gas Temperature Sensor
Urea SCR Catalyst
Oxidation Catalyst
Urea Ad dition Valve
Q006734E
Operation Section
Part Function
Conducts HC and CO purification, as well as NOx oxidation (NO Å® NO2).
(Adding NO2 promotes NOx reduction.)
Diesel Particulate Filter (DPF) Traps PM and conducts PM oxidation treatment.
Urea SCR Catalyst Uses urea added to the exhaust gas to reduce the NOx.
1–17
Oxidation Catalyst (Post-Urea
SCR Catalyst)
Exhaust Gas Temperature
Sensor (DPF)
Purifies any urea (ammonia) not used in NO x reduction.
Measures the exhaust gas temperature at the DPF, and then outputs corre-
sponding signals to the engi ne ECU . The engi ne ECU controls DPF regen-
eration based on the aforementioned signals.
Measures the difference in exhaust gas pres sure across the DPF, and then
outputs corresponding signals to t he engine ECU. Th e engine ECU calcuDifferential Pressure Sensor
lates the quantity of PM accum ulated in the DPF based on the aforem en-
tioned signals, and then determines whether or not to conduct PM
regeneration.
NOx Sensor
Exhaust Gas Temperature
Sensor (Urea SCR)
Mounted upstream of the urea SCR catalyst to measure the NOx concentra-
tion in the exhaust gas before passing through the catalyst.
Mounted upstream of the urea SCR catalyst to measure the exhaust gas
temperature before passing through the catalyst.
Urea Addition Valve Adds urea to the exhaust gas based on signals from the urea SCR ECU .
Urea Feed Device
Draws urea from the urea tank that is then pumped to the urea addit ion
valve. The pumping pressure is based on control from the urea SCR ECU.
Calculates the optimal urea addition quantity based on signals from the NOx
sensor, exhaust gas temperature sensor (urea SCR), etc. Controls the urea
Urea SCR ECU
feed device and urea addition valve s o that the optimal amount of urea i s
added to the system. In addition, outputs urea SCR system diagnosis to the
engine ECU.
Exhaust Gas Temperature Sensor
The exhaust gas temperature se nsor detects the exhaust gas temperature in the vicini ty of the catalyst. A
thermistor is used for actual temperature detection.
Temperature - Resistance Characteristics
265600-125#
(DPF Side)
265600-126#
(SCR Side)
Temperature Resistance Value
*The only difference between the two
sensors is the thread pit ch.
(The specifications are the same.)
Q006735E
1–18
Operation Section
The differential pressure sensor detects the difference in exhaust gas pressure across the DPF . The sensor
is a semiconductor type devi ce that uses a characteristic of silicone cry stals in which electrical resistance
changes when the pressure applied to the crystals is varied.
Engine ECU
Fuel Pressure (kPa)
Q006736E.
Operation Section
1–19
The following is an outline of PM regeneration control in the 4HK1 engine CRS. PM regeneration can be
performed both manually and automatically.
PM regeneration is normally conducted automatically when the system determines that a set quantity of PM
has accumulated in the DPF. However, there are cases in which PM regeneration does not take place automatically due to driving conditions. When P M is not being regenerated automatically, the following two
indicator lights flash: 1) the light built into the switc h for the exhau st gas puri fication dev ice, and 2) the exhaust gas purification device light located inside the meter panel. These indicator lights are alerts prompting
the user to press the exhaust gas purification device switch and begin man ual PM regenerat ion. When an
alert occurs, press the exh aust gas purification device switch near the dr iver's seat to manually start P M
regeneration.
Control
The accumulated quantity of PM i s inferred from the differential pressure sensor signa ls (difference in exhaust gas pressure across the DPF). PM regeneration occurs when the accumulated PM quantity is determined to be high (a large differential pressure across the DPF).
In PM regeneration mode, after-injection has been added to the normal injection pattern (pre-injection, main
injection). Injection is also performed from the fuel addition valve.
The actual control sequence adds the after-injection firs t to ra ise the catalyst temperat ure. Next, w hen the
catalyst temperature reaches a set value, injection occurs from the fuel addition valve, and full-scale regeneration begins.
Regeneration judgments and injection control are conducted by inferring the catalyst tem perature base on
signals from the exhaust gas temperature sensors before and after each catalyst.
Top Dead Center (TDC)
Main Injection
Pre-Injection
Q006737E.
1–20
Operation Section
Urea SCR adds an aqueous urea solution to the exhaust gas, and the SCR catalysts reduces the NOx. The
aqueous urea solution is not used as is during NOx reduction. In actuality, the ammonia produced when the
solution undergoes hydrolysis is used to reduce the NOx. A system that contains an aqueous urea solution
is used due to the inherent danger of mounting a source of ammonia directly on the vehicle.
The urea SCR ECU controls t he urea SCR based p rimarily on the exhaust gas tempe rature and the NO x
concentration in the exhaust gas. Ammo nia is generated from th e aqueous urea solut ion by using the exhaust gas heat to conduct hydrolysis. As suc h, the following values are required to add the sol ution from
the urea addition valve into the exhaust gas: 1) the quantity of urea that will undergo hydrolysis, calculated
from the exhaust gas tempe rature; and 2) th e optimal quantity of solution to be added, calculated from the
NOx concentration in the exhaust gas.
(1) NOx Reduction Mechanism
• An oxidation catalyst prior to the urea SCR that initially oxidizes NO into NO2. This catalyst promotes the
NOx reduction reaction when NO2 increases.
• Adds the aqueous urea solution to the exhaust gas after it has passed through the DPF . The added aqueous urea solution is hydrolysized by exhaust gas heat and converted into ammonia and CO2.
• Uses the ammonia generated from the aqueous urea solution to reduce and convert the NOx into N2 (nitrogen) and H2O (water).
• Purifies any ammonia not used in NOx reduction.
Oxidation Catalyst DPF
NNO Oxidized in to NO2 Ammonia Generation NOX Reduction
Urea Ad dition Valve
Urea SCR Catalyst
Aimed at t he N OX
reduction reaction (1)
in the urea SCR catalyst .
Reaction in the Urea SCR Catalyst
An aqueous urea soluti on is hydr olysi zed u
sing the exhaust gas heat t o gen erat e
ammonia.
Reaction
Four reduction reaction s ar e trig gere d in the cata lyst
to reduce t he NOX. H owe ver , the reactio n ( 1)
is the most efficient.
Reduction
Catalyst
Q004928E
8. Diagnostic Trouble Codes (DTC)
8.1 DTC Lis t
DTC Detection Item
P000F Rail pressure too low
P0016 Crankshaft position-intake camshaft position correlation bank 1
Operation Section
1–21
P0027
P003A Variable Geometry Turbo (VGT) module wiping too wide error
P0045
P0046 VGT module control response abnormal
P006E VGT module power supply voltage low error
P0079 Ex haust throttle GND short
P007C Charge Air Cooler (CAC) out temperature sensor circuit low voltage
P007D CAC out temperature sensor circuit high voltage
P0080 Exhaust throttle +B short
P0087 Rail pressure low during power enrichment
P0088
P0089 Rail pressur e exceeds high upper limit
P0091 Rail fuel pressure regulator solenoid 1 control circuit
P0092 Rail fuel pressure regulator solenoid 1 control circuit
Exhaust brake valve stick
Exhaust throttle valve stick
VGT module motor circuit short and GND short/position cont rol abnormal/power supply
voltage high error
Rail pressure too high
Fuel pressure regulator 1 performan ce
P0093 Rail fuel pressure low during idle or deceleration fuel cut-off
P0097 Intake manifold temperature sensor 2 circuit low
P0098 Intake manifold temperature sensor 2 circuit high
P00AF VGT module memory access abnormal
P0101
P0102 MAF meter circuit low
P0103 MAF meter circuit high
P0112 Intake air temperature sensor circuit low
P0113 Intake air temperature sensor circuit hig h
P0116 Engine coolant temperature sens or p erformance
P0117 Engine coolant temperature sensor circuit low
P0118 Engine coolant temperature sensor circuit high
P011C CAC temperature outlet sensor surveillance
P0126 Engine coolant temperature insufficient for stable operation
Mass Air Flow (MAF) meter rationality low
MAF meter rationality high
1–22
Operation Section
DTC Detection Item
P0128 Engine coolant temperature below thermostat regulating temperature
P0171 Injector quantity lean performance
P0172 Injector quantity rich performance
P0181 Fuel temperature sensor intermediate hold
P0182 Fuel temperature sensor A circuit low
P0183 Fuel temperature sensor A circuit high
Rail pressure sub-sensor signal kee ping the middle range
P018B
P018C Rail pressure sub-sensor circuit low voltage
P018D Rail pressure sub-sensor circuit high voltage
P0191
P0192 Rail pressure sensor circuit low voltage
P0193 Rail pressure sensor circuit high voltage
P0201 TWV 1 output open load injector #1 coil open
P0202 TWV 4 output open load injector #2 coil open
P0203 TWV 2 output open load injector #3 coil open
P0204 TWV 3 output open load injector #4 coil open
P020A
P020B
Rail pressure sub-sensor performance 1
Rail pressure sub-sensor performance 2
Rail pressure sensor signal keeping the middle range
Rail pressure sensor performance 1
Rail pressure sensor performance 2
Injector #1 quantity increase failure
Injector #1 quantity decrease failure
Injector #2 quantity increase failure
Injector #2 quantity decrease failure
P020C
P020D
P0219
P0234 Turbo/supercharger engine overboost
P0237 Turbo/supercharger boost sensor A circuit low
P0238 Turbo/supercharger boost sensor A circuit high
P0261 Injector #1 (TWV 1) load short (coil short/terminal short)
P0264 Injector #4 (TWV 4) load short (coil short/terminal short)
P0267 Injector #2 (TWV 2) load short (coil short/terminal short)
P0270 Injector #3 (TWV 3) load short (coil short/terminal short)
P0299 Turbo/supercharger engine underboost
P02E2 ITHR DC motor output open load motor open load
Injector #3 quantity increase failure
Injector #3 quantity decrease failure
Injector #4 quantity increase failure
Injector #4 quantity decrease failure
Engine overrun
Engine overrun 2
Operation Section
DTC Detection Item
P02E3 ITHR DC motor output short to battery/short to GND motor short
Intake throttle stuck closed
1–23
P02E7
P02E8 Intake throttle position too low
P02E9 Intake throttle position too high
P0300 Engine misfire detected
P0301 Cylinder 1 misfire detected
P0302 Cylinder 2 misfire detected
P0303 Cylinder 3 misfire detected
P0304 Cylinder 4 misfire detected
P0335 Crankshaft position sensor A circuit
P0336 Crankshaft position sensor A performance
P0340 Intake camshaft position sensor circuit bank 1
P0341 Intake camshaft position sensor performance bank 1
P0381
P0401 MAF meter performance (Exhaust Gas Recirculation [EGR] negative deviation)
Intake throttle stuck open
Intake throttle open learning error
Intake throttle closed learning error
Wait to start light control module internal circuit (short to BATT)
Wait to start light control module internal circuit (open load/short to GND)
P0402 M AF meter performance (EGR positive deviation)
EGR duty error
P0403
P0404 EGR open position performance
P0405 EGR brushless motor position sensor signal invalid low
P0406 EGR brushless motor position sensor signal invalid high
P040B EGR gas sensor performanc e
P040C EGR gas temperature too low
P040D EGR gas temperature too high
P041B EGR gas sensor 2 performance
P041C EGR gas temperature 2 too low
P041D EGR gas temperature 2 too high
P0420 DP F deterioration 2
P042E EGR closed position performance
P046C EGR closed learning
EGR brushless motor circuit too high
EGR brushless motor circuit too low
EGR brushless motor circuit too open
P0500 Vehicle speed sensor circuit
P0506 Low target idle speed
P0507 High target idle speed
1–24
Operation Section
DTC Detection Item
P0512 Starter switch short to BATT
P0522 Oil pressure sensor signal too low
P0523 Oil pressure sensor signal too high
P0545 Exhaust gas temperature before oxidation catalyst too low
P0546 Exhaust gas temperature before oxidation catalyst too high
P0562 System low voltage status determination
P0563 Sy stem high voltage status determination
P0567 Cruise control resume switch determination
P0568 Cruise control set switch determination
P0571 Cruise control brake switch determination
P0602 QR code error
P0606
P062F Control module long term memory performance
P0642 Battery 5 V reference 1 circuit low
P0643 Battery 5 V reference 1 circuit high
P064C
P0650
P0652 Battery 5 V reference 2 circuit low
P0653 Battery 5 V reference 2 circuit high
P0671 Cylinder 1 glow plug circuit
P0672 Cylinder 2 glow plug circuit
P0673 Cylinder 3 glow plug circuit
P0674 Cylinder 4 glow plug circuit
P0687 Main relay diagnostics; main relay stuck closed
Engine ECU processor (main CPU fault)
Engine ECU processor (watchdog IC fault)
Glow plug module control circuit
Glow plug module INTST
Glow plug module MEEPST
Malfunction Indicator Lamp (MIL) control circuit monitoring (short to BATT)
MIL control circuit monitoring (open load/short to GND)
P0698 Battery 5 V reference 3 circuit low
P0699 Battery 5 V reference 3 circuit high
P0700 Transmission control module requested MIL illu mination monitoring
P1072 Compressor outlet temperature sensor circuit low voltage
P1073 Compressor outlet temperature sens or circuit high voltage
P1076 CAC in temperature sensor circuit low voltage
P1077 CAC in temperature sensor circuit high voltage
P1078 CAC temperature inlet sensor surveilla nce
P1085
P1102 Rail pressure sensor performance (correlation abnormal)
Supply pump protection
Supply pump exchange
DTC Detection Item
P1125 Accelerator Pedal Position (APP) system
P113A O2 signal of NOx sensor rationality
P1236 CAC performance
P1259 Rail fuel pressure low during power enrichment
Operation Section
1–25
P1261
P1463 DeNOx-DS error for SVS lighting request
P1470 DP F exhaust presse r performa nce
P1471 DP F regeneration insufficiency
P160B Q DATA cross check error
P2002 DP F deterioration (II)
P2032 Exhaust gas temperature before DPF too low
P2033 Exhaust gas temperature before DPF too high
P20C9 DeNOx-DS error for MIL lighting request
P20CB Exhaust injector circuit GND short/open load
P20CC
P20CF Exhaust injector pe rformance
P20DE
P20DF Exhaust injector pressure sensor circuit low voltage
Capacitor charge-up circuit malfunction (insufficient charge)
Capacitor charge-up circuit malfunction (excessive charge)
Exhaust injector circuit BATT short
Exhaust injector circuit load short
Exhaust injector pressure sensor performance high
Exhaust injector pressure sensor performance low
P20E0 Exhaust injector pressure sensor circuit high voltage
P20E2 Exhaust gas temperature sensor surveillance
P2122 Accelerator pedal position sensor no. 1 low range
P2123 Accelerator pedal position sensor no. 1 h igh range
P2127 Accelerator pedal position sensor no. 2 low range
P2128 Accelerator pedal position sensor no. 2 h igh range
P2138 Accelerator pedal position sensor no. 1 & 2 correlation check
P2146 COM 1 output open load; Bot h TWV 1 and 3 (and 5) open load
P2147 COM 1 output short to GND; TWV 1 or 3 (or 5) output short to GND
P2148 COM 1 output short to BATT; TWV 1 or 3 (or 5) output short to BATT
P2149 COM 2 output open load; B oth TWV 2 or 4 (or 6) open load
P2150 COM 2 output short to GND; TWV 2 or 4 (or 6) output short to GND
P2151 COM 2 output short to BATT; TWV 2 or 4 (or 6) output short to BATT
P2199 THA-THA 2 sensor surveillance
P2227 Barometric pressure (BARO) sensor performance
P2228 Barometric pressure (BARO) sensor circui t low voltage
P2229 Barometric pressure (BARO) sensor circui t high voltage
P2262 Turbo/supercharger engine underboost
1–26
Operation Section
DTC Detection Item
P2263
P226B Turbo/supercharger engine overboost
P2413
P2428
P244B DPF PM over accumulation
P244C DPF deterioration
P244D
P2453 DPF pressure sensor performance
P2454 Exhaust gas pressure reference too low
P2455 Exhaust gas pressure reference too high
P2457 EGR c oole r inferiority
P2459 DPF regeneration excessive frequency
P2463 DPF trip over accumulation
VGT slow response up side
VGT slow response down side
EGR slow response ON
EGR slow response OF F
Exhaust gas temperature sensor b efore oxidation catalyst too high
Exhaust gas temperature sensor before oxidation catalyst too low
Exhaust gas temperature s ensor before DPF too high
Exhaust gas tempe rature sensor before DPF too low
P254C Au xiliary e ngine RPM sensor circuit low
P254D Au xiliary engine RPM s ensor circuit high
P2564 VGT hole IC sensor circuit low
P2565 VGT hole IC sensor circuit high
P256C Idle Air Cont rol (IAC) valve control circuit low voltage
P256D IAC valve control circuit high voltage
P268A QR code not programmed
U0001 CAN bus 2 reset counter overrun
U0073 CAN bus reset counter overrun
U0101 Lost CAN c ommunication (CAN SOH) with TM control system
U0106 Glow plug module communication failure
U010C VGT module communication failure
U010E DeNOx-DS c ommunication time-out
U0121 CAN ABS SOH diagnostic
U0307 GPCM engine ID diagnostic
9. Control System Component Information
9.1 Engine ECU Terminal Layout Diagram s
ACG
+
Battery
-
B
KEY SW
Accel er ator
Posi ti on
Sensor
Idle Up
Volume
Accel er ator
Posi ti on
Sensor
PTO SW
PTO LAMP
Magne ti c Valve
Magne ti c Cl ut ch
START
ON
ACC
OFF
Main Relay
BATT
Vehicle
Speed Sensor
APS1APS2
PTO
Remote PTO Resume
PTO Set Speed A SW
PTO Set Speed B SW
Cruise Main (ON/OFF)
Cruise Resume/Accel
Cruise Set/Coast
Enabl e Re l ay
B
A
Exhaust Brake
PTO Disable SW
Remote PTO Set
CAB Con tr ol Di sabl e SW
Ignore Brake/Clutch SW
PTO Tap UpPTO Tap Down
PTO Fe ed bac k SW
Brake1 (Normally Open)
Brake2 (Normally Closed)
Clutch SW (MT Vehicles)
DPF Regeneration
Air Conditioner
IG1-SW
M-R EL
M-R EL
+B
+B
+B
BATT
VSS
APS1 - VCC
APS1
APS1-GND
APS2 - VCC
APS2
APS2-GND
IDLUP-VCC
IDLUP
IDLUP-GND
P ACL-VCC
P ACL
P ACL-GND
EXB-SW
PTODIS-SW
RSET-SW
RRES-SW
SSPA-SW
SSPB-SW
CCDIS-SW
IGBC-SW
CRM-SW
CRR-SW
CRS-SW
PTOEN-SW
PTOEN- REL
PTOFB-S W
BK1-SW
BK2-SW
CL-SW
DPFREG-SW
AC-SW
STA-SW
STA-REL
DPFSOL
EXBCUT-SW
MIL
GL-L
CANH
CANL
T ACHO
VSOUT1
DPFD-VCC
DPFD
DPFD-GND
THDOC
THDO C -G ND
THCSF
THCSF-GND
LOCOL-SW
IDESEN-S W
IDM1
IDM2
COMMON1
TWV-A
TWV-C
COMMON2
TWV-B
TWV-D
DPF Exhaust
Throttle
Meter
VGS C/U
Low Coolant Level SW
Idl e Engi ne Sto p Ena ble SW
Operation Section
C
Star ter Rel ay
Exhaust
Sokno id Val ve
Malfu nct ion Indi cat or Lam p
Glow Lamp
Twisted
Pair
SAEJ1 939- 1 1 Com pli ant
Twisted Pair
Twisted
T acho
Vehicle Speed
PWM Output
M+
M-
Injector #1
Injector #4
Injector #3
Injector #2
B
Starter Motor
Cut R elay
ABS
Pair
Contr oll er
MT Vehicles Only
Glow Pl ug
Control Module
Glo w P lug
DPF Differential
Pressure Sensor
Exhaust Gas
T emperature Sensor-1
(Oxidation Catalyst)
Exhaust Gas
T emperature Sensor-2
(SCR)
Diesel Throttle
DC Motor
1–27
P/N SW
A
A
B
AT
A
C
:Option Circuit
T erminals with no external circuit commands writ ten in parenthesis are auxiliary circuits.
Q006845E
1–28
Operation Section
Crankshaft
Position Sensor
Cylinder
Recognition Sensor
Manifold Absolute
Pressure sensor
Rail Pressure
Sensor1
Rail Pressure
Sensor2
Diesel Throttle
Position Sensor
A
Mass Air
Flow Meter
Coolant T emperature
Sensor
Fuel T emperature
Sensor
EGR T emperature
Sensor (IN)
EGR T emperature
Sensor (OUT)
NE-VCC
NE
NE-G ND
G-VCC
G
G-GND
PB-VCC
PBOOST
PB-GND
PFUEL1-VCC
PFUEL1
PFUEL1-GND
PFUEL2-VCC
PFUEL2
THCAI1-GND
PFUEL2-GND
ITH-VCC
ITH
ITH-GND
MAF
MAF-GND
THA
THA-GND
THCA O1 -G ND
THCOT-GND
(THCAO2-GND)
Atmos pheri c
Pressure
Sensor
(BARO)
THW
THW -G ND
THL
THL- G ND
THEGRI
THEGRI-GND
THEGRO
THEGRO-GND
IMT
IMT-GND
EGRPOS-VCC
EGRPOS-W
EGRPOS-GND
SCVHI
SCVHI
SCVLO
SCVLO
EXT PI P+
EXT PI P-
ISOH
ISOL
THCAI1
THCOT
(THCAO2)
EXPS-VCC
EXPS
EXPS-GND
EGRPOS-U
EBM-U
EGRPOS-V
EBM-V
EBM-W
SCV
Twisted Pair
Fuel Addi tion Valve
ISO CAN
SAE.CON
DCU
CAC In
T emperature
CAC Out
T emperature
Compressor Outlet
T emperature
Fuel Addition Valve
Pressure Sensor
EGR Valve Dr ive DC
Brushless Motor
P-GND
P-GND
Oil Pressure
Sensor
POIL-VCC
POIL
POIL -G ND
P-GND
P-GND
GND
GND
CASE-GND
:Option Circuit
T erminals with no external circuit commands writ ten in parenthesis are auxiliary circuits.
Power GND
Power GND
Power GND
Power GND
Signal GND
Signal GND
Case GND
Q006846E
9.2 Connector Diagram
Operation Section
1–29
Q006847
Service Division DENSO CORPORATION
1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan
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