4hk1 6hk1


ENGINE MECHANICAL (4HK1, 6HK1) 1A-1
ENGINE
ENGINE MECHANICAL (4HK1, 6HK1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1, 6HK1) . . . . . . . . 1A-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-81
Precautions on Service Work . . . . . . . . . . . . . . . 1A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-87
Main Data and Specifications. . . . . . . . . . . . . . 1A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-93
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 1A-14 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-100
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Piston, Connecting Rod . . . . . . . . . . . . . . . . . .1A-102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-16 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-102
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-102
Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-103
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-113
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-24 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-113
Turbocharger and Exhaust Manifold . . . . . . . . . . 1A-25 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-25 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-27 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-32 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-118
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-118
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-121
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-51 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-123
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . .1A-125
Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-53 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-125
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-127
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-54 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-132
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-56 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-132
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-57 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . .1A-133
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-58 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-133
Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-133
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-137
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-138
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-63 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-138
Fixing torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-138
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-140
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-140
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-68 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-140
Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-145
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-69 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-149
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-69 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-149
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .1A-151
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-151
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-151
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-152
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Lubrication System . . . . . . . . . . . . . . . . . . . . . .1A-156
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-78 Precautions on Service Work . . . . . . . . . . . . .1A-156
1A-2 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check . . . . . . . . . . . . . . . . . . . . . . . 1A-157
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-158
Oil Port Cover ASM. . . . . . . . . . . . . . . . . . . . . . 1A-159
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-161
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-161
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-177
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-177
ISUZU DIESEL ENGINE (4HK1, 6HK1)

Precautions on Service Work Matters that require attention in specifically dealing
with this engine.
Matters that require attention in terms of
maintenance Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
To prevent damage to the engine and ensure reliability
are made with extreme precision. For this reason, they
of its performance, pay attention to the following in
are highly sensitive to foreign matter and if it gets in, it
maintaining the engine: When taking down the engine
can lead to an accident on the road, for instance; thus,
on the ground, do not make the bearing surface of the
make sure that foreign matter will be prevented from
oil pan touch directly the ground. Use a wood frame, for
getting in.
example, to support the engine with the engine foot and
When servicing the fuel system, every precaution must
the flywheel housing.
be taken to prevent the entry of foreign material into the
Because there is only a small clearance between the
system.
oil pan and the oil pump strainer, it can damage the
oil pan and the oil strainer. Before beginning the service procedure, wash the
fuel line and the surrounding area.
When the air duct or air cleaner is removed, cover
the air intake opening to prevent foreign matter Perform the service procedures with clean hands.
from getting into the cylinder. If it gets into it, it can Do not wear work gloves.
considerably damage the cylinder and others while Immediately after removing the fuel hose and/or
the engine is operating. fuel pipe, carefully tape vinyl bags over the
When maintaining the engine, never fail to remove exposed ends of the hose or pipe.
the battery ground cable. If not, it may damage the If parts are to be replaced (fuel hose, fuel pipe,
wire harness or electrical parts. If you need etc.) do not open the new part packaging until
electricity on for the purpose of inspection, for installation.
instance, watch out for short circuits and others.
Apply engine oil to the sliding contact surfaces of Work procedure
the engine before reassembling it. This ensures The fuel opening must be quickly sealed when
adequate lubrication when the engine is first removing the fuel pipe, injection pipe, fuel injector,
started. fuel supply pump, and common rail.
When valve train parts, pistons, piston rings, The eyebolts and gasket must be stored in a clean
connecting rods, connecting rod bearings or parts box with a lid to prevent adhesion of foreign
crankshaft journal bearings are removed, put them matter.
in order and keep them. Fuel leakage could cause fires. Therefore, after
When installing them, put them back to the same finishing the work, wipe off the fuel that has leaked
location as they were removed. out and make sure there is no fuel leakage after
Gaskets, oil seals, O-rings, etc. must be replaced starting the engine.
with new ones when the engine is reassembled.
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust may be
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
Surfaces covered with liquid gasket must be
assembled within 7 minutes of gasket application.
If more than 7 minutes have elapsed, remove the
existing liquid gasket and apply new liquid gasket.
When assembling or installing parts, fasten them
with the specified tightening torque so that they
may be installed properly.
How to read the model
4HK1
Name
1. Cast The Engine Model 2. Stamp An Engine Number
6HK1

Name
1. Stamp An Engine Number
Explanations on functions and operation Cylinder liner

The cylinder liner is selected to match an internal
Electronic engine control
diameter of a bore of the cylinder block and built, which
With the control unit, the range from injection to air
is imprinted on the left side of the cylinder.
intake/exhaust, including fuel injection quantity,
injection timing, intake air restriction, EGR, and idling Piston
rpm, is controlled. The piston is aluminum-alloy and an autothermatic
piston with a strut cast, while the combustion chamber
Cylinder block
is a round reentrant type.
The cylinder block is cast-iron with the center distance
of each bore being equal and is of the highly rigid, Cylinder head
symmetrical structure with the crankshaft center being The cylinder head is cast-iron and there are 4 valves
the center. The bearing cap is of the ladder frame per cylinder. The angular tightening method of the
structure and tightened up under the plastic range cylinder head bolt further increases reliability and
rotation angle method. durability.
Crankshaft Rotate the crankshaft to make the No.1 cylinder
Tuftriding is given, while on the No. 1 balance weight meet the compression top dead center (TDC).
imprinted is the grade of each journal diameter. 4HK1
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Common rail-type electronic control injection
system
The common rail-type electronic control injection
system is composed of a fuel supply pump that sets the
target pressure of high-pressure fuel and supply it, a
common rail that measures such high-pressure fuel
and a fuel injector that turns it into a fine spray and
injects it. Each is controlled via ECM based upon
various signals, while injection timing or fuel injection 6HK1
quantity is controlled under every possible driving
condition.
Fuel injector
The fuel injector is a 7-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injectors according to ID code data in
memory. At the replacement of fuel injectors, ID code
data should be stored in ECM.
Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system
The preheating system consists the ECM, the glow Insert a 0.4 mm thickness gauge into a clearance
relay, glow plugs and the glow indicator lamp. The between the rocker arm and the bridge to check it
preheating system is operated when the engine coolant and adjust it if needed.
temperature is low, and make the engine easy to start.
Valve clearance mm (in)
Lubrication system
It is an oil filter with full-flow bypass, which uses a Intake valve 0.4 (0.016)
water-cool oil cooler and oil jet to cool the piston. Exhaust valve 0.4 (0.016)
Function check Caution:

Inspection/adjustment of valve clearance Adjust while being cold.
1. Inspection of valve clearance 2. Adjustment of valve clearance
Remove the cylinder head cover.
Caution:
Remove the fuel injector harness ASM. Adjust valve clearance carefully so that the bridge may
Loosen the terminal nuts alternately to remove. become level (hit the end of the 2 valve axes).
Remove the leak off pipe.
a. Completely loosen all of the bridge and rocker With a thickness gauge kept inserted, tighten
arm adjusting nuts and adjusting screws an adjusting screw of the bridge lightly and
(4HK1: 8 nuts and 8 screws, 6HK1: 12 nuts and make sure that the tip of the adjusting screw
12 screws). touches the end of valve axis and the
b. Place a 0.4 mm thickness gauge between the movement of the thickness gauge has become
No. 1 cylinder rocker arm end and the bridge tight.
cap. Then, check if the end of the valve axis on the
c. Tighten the rocker arm adjusting screw until the opposite side is unstable or hits diagonally. If
thickness gauge is snug (not tight) between the so, loosen the bridge adjusting screw a little so
rocker arm end and the bridge cap. that the end of the valves on both sides may
touch properly.
d. Tighten the rocker arm lock nut.
Valve bridge clearance: 0.1 mm (0.0039 in) or
e. Tighten the bridge adjusting screw until the less
bridge contacts the valve head.
After making an adjustment so that the end of
f. Tighten the bridge lock nut. the valves on both sides may touch properly,
g. Check that the thickness gauge is still held tighten up an adjusting screw nut of the bridge
snugly between the rocker arm end and the with a flathead screwdriver so that the bridge
bridge cap. If it is too tight, slightly loosen the adjusting screw may not rotate.
bridge adjusting screw and lock nut to restore Tightening torque: 22 N m (16 lb ft)
snugness.
h. Remove the thickness gauge. Caution:
i. Repeat Steps 2 through 5 for the remaining If the adjusting screw of the bridge is poorly adjusted,
cylinders. the bridge would tilt and be pushed down and seized,
which may damage the bridge guide, for example.
Tightening torque: 22 N m (16 lb ft) Thus, adjust it accurately.
Tightening torque:
Name
1. Rocker Arm Rocker arm adjustment screw 22 N m (16 lb ft)
2. Bridge Cap nut
3. Bridge Bridge adjustment screw nut 22 N m (16 lb ft)
Adjustment table (4HK1)
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
No. 1 cylinder
Compression top dead center position
No. 4 cylinder
Adjustment table (6HK1)

Cylinder No. 1 2 3 4 5 6
Valve arrangement IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 cylinder
No. 6 cylinder
If the No. 1 cylinder is the compression TDC,

adjust a valve clearance with mark given on
the table and if the No. 4 (4HK1) or No. 6
(6HK1) cylinder is the compression TDC, that
with mark.
4HK1
6HK1

4HK1

Attach the harness ASM to the fuel injector.

Tighten the harness bracket with the
designated torque. Name
1. Fuel Injector Harness Connector
Tightening torque: 48 N m (35 lb ft)
6HK1
Install the terminal nuts on the fuel injector.
Note:
Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
Install the cylinder head cover.
Refer to the Cylinder Head Cover.
Compression pressure inspection
Warm-up the engine.

Remove a negative terminal of the battery and
remove all the glow plugs.
Remove the harness connector for the fuel injector
built on the lower head cover (no fuel will be 
injected). Name
1. Fuel Injection Harness Connector
Caution:
When the harness connector is removed, ECM judges
Install the negative terminal of the battery.
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory Turn on the starter to emit foreign matter within the
of ECM. cylinders.
(For how to clear memory of ECM, refer to the Engine Install an adapter and a gauge of a compression
Control System Section) gauge of the special tool.
Compression gauge: 5-8840-2675-0 (J-26999-12)

Compression gauge adapter
4HK1: EN-46722
6HK1: 5-8840-2622-0
Turn on the starter to inspect compression
pressure.
4HK1
Compression pressure MPa (psi) / 200 rpm
Standard 2.84 3.24 (412 469)
Limit 1.96 (284)
Differences among
294 kPa (43)
the cylinders
6HK1
Compression pressure MPa (psi) / 200 rpm
Standard 3.24 (469)
Limit 2.26 (327)
Differences among
294 kPa (43)
the cylinders
Measure each cylinder one by one.
Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
Remove a compression gauge of the special tool.
Remove a negative terminal of the batteries.
Install a harness connector for the fuel injector built
on the lower head cover.
Install all the glow plugs.
Install the negative terminal of the battery.
Main Data and Specifications
Item Engine model 4HK1

Type Diesel/4-cycle/water cooled-type, inline four-cylinder
OHC
Combustion chamber form Direct injection type
Cylinder liner type Dry type
Number of cylinders - cylinder bore mm (in) 4-115 (4.53) 125 (4.92)
strokes
Displacement cc (cu.in) 5193 (317)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3.23 (468)/200
Idle speed rpm 800
Valve clearance Intake 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold)
Ignition type Compressed ignition
Injection order 1-3-4-2
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 13.0 (13.7) 20.5 (21.7)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Thermostat valve-opening temperature C ( F) 85 (185)
Volume of coolant L (qts) 14 (14.8) (incl. radiator)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Multi-hole type
7-hole and 0.16 mm (0.0063 in) inside diameter
Charging system
Generator type AC type
Power output V/A 24 - 50
Regulator type IC

Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5

Type Diesel/4-cycle/water cooled-type, inline four-cylinder
OHC
Combustion chamber form Direct injection type
Cylinder liner type Dry type
Number of cylinders - cylinder bore mm (in) 6-115 (4.53) 125 (4.92)
strokes
Displacement cc (cu.in) 7790 (475)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3.04 (441)/200
Idle speed rpm For Hitachi products: 800, For JCB and Sumitomo
products: 900
Valve clearance Intake 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold)
Ignition type Compressed ignition
Injection order 1-5-3-6-2-4
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 28 (29.6) 38 (40.2)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Thermostat valve-opening temperature C ( F) 82 (180)
Volume of coolant L (qts) 14.5 (15.3)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type

Injection nozzle type Multi-hole type
7-hole and 0.16 mm (0.0063 in) inside diameter
Charging system
Generator type AC type
Power output V/A 24 - 120
Regulator type IC
Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5
Special tool
Illustration Tool Number/Description
5-8840-26750-0
J-26999-12
Compression gauge
EN-46722
Compression gauge
adapter
(4HK1)
5-8840-2622-0
Compression gauge
adapter
(6HK1)
Cylinder Head Cover

Components
4HK1
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
6HK1

Name
2. Gasket 4. Gasket
Removal
1. Remove the head cover.
2. Remove the gasket.
4HK1 4HK1
Name Name
6HK1
6HK1


Name
1. Head Cover Name
1. Head Cover Case
3. Remove the fuel injector harness connector. 2. Fuel Injector Harness Connector
4. Remove the head cover case.
5. Remove the gasket.
Installation
1. Install the gasket on the lower cover.
2. Install the head cover case.
Tightening torque: 4HK1: 18 N m (13 lb ft),
6HK1: 13 N m (9.6 lb ft)
3. Install the fuel injector harness connector.
Caution: 4HK1
Push it in thoroughly until the claws of the lock raise.
4HK1
6HK1
Name
1. Head Cover Case
6HK1


Name
1. Head Cover Case
4. Install the gasket on the head cover.

5. Install the head cover and tighten up according to
the orders given on the figure.
6HK1: 13 N m (9.6 lb ft)
Torque Specifications
4HK1
6HK1




Inlet Cover
Components
4HK1
Name
1. Case ASM 3. Inlet Pipe Gasket
2. Inlet Cover 4. Inlet Pipe
6HK1
Name
1. Case ASM 3. Inlet Pipe Gasket
2. Inlet Cover 4. Inlet Pipe
Removal 4HK1
1. Remove the common rail.
Refer to the Common Rail in the fuel system
section.
2. Remove the inlet pipe.
3. Remove the case ASM.
6HK1 Caution:
Be careful not to forget to fasten the bolt indicated
with an arrow.
Tighten up the stud part together with the common
rail.
4. Remove the inlet cover.

On the place where the case ASM is to be installed
inside the inlet cover (arrowed) is a bolt. Be careful
not to forget to remove it.
* 4HK1 is shown for illustration.
Peel the liquid gasket off carefully.
2. Install the case ASM.
Apply the liquid gasket and mount within 7
minutes.

4HK1
Installation
1. Install the inlet cover.
Apply the liquid gasket (ThreeBond 1207C or
equivalent) by using a bead diameter of 2.5 5.5
mm (0.1 0.2 in) along a groove of the inlet cover.
Install within seven minutes after applying liquid

gasket.

6HK1
3. Install the gasket on the inlet pipe and tighten up

with the specified torque.
4. Install the common rail.
section.
4HK1
6HK1

 

Turbocharger and Exhaust Manifold

Components
4HK1
Name
1. Oil Feed Pipe 5. Turbo Charger ASM
2. Water Return Pipe 6. Exhaust Adapter
3. Exhaust Manifold 7. Oil Return Pipe
4. Water Feed Pipe
6HK1
  

Name
1. Oil Feed Pipe 4. Exhaust Adapter
2. Exhaust Manifold 5. Oil Return Pipe
3. Turbo Charger ASM
Removal
1. Loosen the radiator drain cock to drain coolant.
(4HK1 only)
2. Remove the air intake duct from the turbocharger
and the air cleaner.
3. Remove the charge air pipe from the turbocharger
and the charge air cooler.
4. Disconnect the front exhaust pipe.
5. Remove the EGR pipe.
6. Remove the oil feed pipe.
7. Remove the oil return pipe.
8. Remove the water feed pipe. (4HK1 only)
Remove the water return pipe. (4HK1 only) 6HK1
  

Name Name
1. Water Return Pipe 1. Exhaust Manifold
2. Turbocharger
9. Remove the heat protector on the turbocharger. 3. Exhaust Adapter
10. Remove the exhaust adapter bolts.
11. Remove the four turbocharger clamping nuts.
12. Remove the turbocharger from the exhaust Inspection
manifold. Inspection of exhaust manifold
13. Remove the exhaust manifold. Inspect the plane surface of the plane on which the
4HK1 manifold and the cylinder head are to be installed.
Manifold installation plane surface mm (in)

Standard 0.3 (0.01) or less
Limit 0.5 (0.02)
Caution:
If the plane surface exceeds the limit, replace it.
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter

Check a crack in the exhaust manifold visually.
Carefully inspect he turbocharger for abrasion and/or
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.
Wheel shaft axial play

Use a dial gauge to measure the wheel axle shaft play
when a force of 12 N (2.6 lb) is alternately applied to
both sides of the compressor wheel.
4HK1
Axial play mm (in)
Standard 0.03 0.06 (0.0012 0.0024)
Limit 0.09 (0.0035)
6HK1
Axial play mm (in)
Standard 0.06 0.09 (0.0024 0.0036)
Name
Limit 0.11 (0.0043)
1. Oil Outlet
2. Oil Inlet
Installation
1. Put the gasket in to install the exhaust manifold.
4HK1: Tighten up with the 2 nuts and 6 bolts
according to the order given on the figure.

6HK1: Tighten up with the 12 nuts according to the
order given on the figure.

34 N m (25 lb ft) for (7) only
Caution:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.
Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between
the wheel shaft and the bearing.
4HK1
Clearance mm (in)
Standard 0.056 0.127 (0.0022 0.0050)
Limit 0.14 (0.0055)
6HK1
Clearance mm (in)
Standard 0.10 0.17 (0.0039 0.0067)
Limit 0.205 (0.0081)
4HK1 4HK1
6HK1
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
6HK1
  

2. Install the gasket and turbocharger to the exhaust

manifold. Tighten the nuts to the specified torque.

3. Tighten the adapter bolts (exhaust manifold side) 
to the specified torque.
Name
Tightening torque: 32.4 N m (24 lb ft) 1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
4. Install the water feed pipe to the turbocharger.

(4HK1 only)
Tighten the joint bolts to the specified torque.

Install the pipe bracket and tighten the bolts to the
specified torque.

4HK1 7. Install the turbocharger oil feed pipe to the top of
the turbocharger. Tighten the joint bolts to the
specified torque.
6HK1: 34.5 N m (25 lb ft)
Install the pipe bracket and tighten the bolts to the
specified torque.

8. Tighten the oil return pipe bolts to the specified
torque.
Tightening torque (Turbocharger side):
4HK1: 9 N m (78 lb ft),
6HK1: 17.6 N m (13 lb ft)
Tightening torque (Cylinder block):

4HK1: 22 N m (15 lb ft),
6HK1: 17.6 N m (13 lb ft)
Name
1. Water Feed Pipe
5. Install the water return pipe. Tighten the joint bolts

to the specified torque. (4HK1 only)

6. Install the water return pipe bracket. Tighten the
bolts to the specified torque. (4HK1 only)

Install the rubber hose between the water return
pipe and the thermostat housing.
4HK1
Name
1. Oil Return Pipe
9. Install the air intake duct and tighten the bolts to

the specified torque.
Tightening torque: 10 N m (87 lb in)

10. Install the charge air pipe in the turbo charger and
the charge air cooler.
Tightening torque:
Duct bolt 21 N m (15 lb ft)
Duct clip 6 N m (52 lb in)
11. Install the front exhaust pipe to the turbocharger
and tighten the nuts to the specified torque.
Name
1. Water Return Pipe Tightening torque: 67 N m (49 lb ft)
12. Add cooling water to the radiator. (4HK1 only)

13. Install the EGR pipe.
Put the gasket between both ends of the EGR pipe
and install to the specified torque.

14. Replenish the coolant. (4HK1 only)
4HK1
6HK1

 
  


Timing Gear Train

Components
4HK1
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Crankshaft Position Sensor
5. PTO Idle Gear Cover 11. Oil Pan
6. Flywheel 12. Fuel Supply Pump
6HK1



 



Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Idle Gear A Shaft
5. PTO Idle Gear Cover 11. PTO Idle Gear Shaft
6. Flywheel 12. Oil Pump
Removal
1. Remove the cylinder head cover.
Refer to Cylinder Head Cover.
2. Remove the rocker arm shaft ASM.
Refer to Rocker Arm Shaft ASM.
3. Remove the camshaft ASM.
Refer to Camshaft ASM.
4. Remove the cylinder head ASM.
Refer to the Cylinder Head.
5. Remove the fuel supply pump ASM.
Refer to Fuel Supply Pump in the fuel system 6HK1
section.
7. Remove the flywheel.

* 4HK1 is shown for illustration. Install the crankshaft stopper on the starter part of
6. Remove the crankshaft position sensor. the flywheel housing to stop the crankshaft from
Remove the crankshaft position sensor before rotating.
remove flywheel.
Caution:
4HK1 Check if the stopper meshes with the ring gear without
fail and is installed properly.
Special tool
Crankshaft stopper: 5-8840-2230-0 (EN-47680)
Loosen the fastening bolts of the flywheel little by

little according to the order given on the figure.
After loosening all the bolts, remove the stopper to

remove the flywheel.
8. Remove the rear oil seal.

Refer to the Crankshaft Rear Oil Seal.
9. Use the slinger remover to remove the slinger.
Caution: Never fail to remove the bolt(s) given on the figure.
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
8-9439-6858-0 (For 6HK1)

14. Remove the idle gear A.
15. Remove the idle gear A shaft. (6HK1)
16. Remove the oil pump. (6HK1)
17. Remove the idle gear B.
18. Remove the idle gear B shaft.
10. Remove the oil pan.

11. Remove the PTO idle gear cover.
12. Remove the PTO idle gear.
Inspection
* 4HK1 is shown for illustration. 1. Measurement of idle gear backlash
13. Remove the flywheel housing. Apply a dial gauge on the teeth of the idle gear to
be measured and move the gear to right and left
lightly to read how much the dial gauge shook
(never fail to fix the gear).
If the measurement exceeds the limit, replace the

idle gear.
Backlash of the timing gear mm (in)

Standard 0.10 0.17 (0.004 0.006)
Limit 0.30 (0.01)
Measure backlash of the idle gear before removing

the idle gear A.
3. Outside diameter of idle gear shaft

Use a micrometer to measure an external diameter
of each idle gear shaft.

shaft.
4HK1
2. Measurement of end clearance of the idle gear.
Outside diameter of idle gear shaft mm (in)
Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance. Standard 29.959 29.980 (1.179 1.180)
Limit 29.80 (1.173)
If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
External diameter of the idle gear A shaft mm (in)
Axial play of idle gear mm (in) Standard 39.959 39.975 (1.573 1.574)
Standard 0.080 0.140 (0.003 0.006) Limit 39.80 (1.567)
Limit 0.20 (0.008)
Measure an end clearance of the idle gear before

removing the idle gear B.
6HK1 6HK1
Outside diameter of idle gear shaft mm (in) Clearance between the idle gear and the mm (in)
shaft
Standard 29.959 29.980 (1.179 1.180)
Standard 0.020 0.062 (0.0007 0.0024)
Limit 29.9 (1.177)
Limit 0.200 (0.0079)
External diameter of the idle gear A shaft mm (in)
Clearance between the idle gear A and the mm (in)
Standard 49.950 49.975 (1.967 1.968)
shaft
Limit 49.9 (1.965)
Standard 0.025 0.075 (0.0010 0.0030)
Limit 0.200 (0.0079)
4. Clearance between the idle gear and the idle gear

shaft
Measure an inside diameter of the idle gear
bushing to calculate a clearance between the idle Installation
gear and the idle gear shaft.
1. Install the idle gear B shaft.
If the measurement exceeds the limit, replace Tighten the idle gear B shaft to the specified
either the idle gear or the shaft. torque.
4HK1
Clearance between the idle gear and the mm (in) After installation, apply engine oil to the shaft.
shaft
Standard 0.020 0.062 (0.0007 0.0024)
Limit 0.200 (0.0079)
Clearance between the idle gear A and the mm (in)

shaft
Standard 0.025 0.066 (0.0009 0.0026)
Limit 0.200 (0.0079)

Name
2. Install the idle gear B. 1. Crank Gear
Install the idle gear B in the direction given on the 2. Idle Gear A
figure and tighten up the fastening bolts with the
specified torque. Align the crankshaft gear (2) L mark and idle gear
A (1) 0 marks.
6HK1: 95 N m (70 lb ft) Tighten the installing bolt to the specified torque.
Name
1. Idle Gear
2. Thrust Collar
3. Bolt
3. Install the oil pump.

4. Install the idle gear A shaft. (6HK1)
5. Install the idling gear A.
Rotate the crankshaft to make the No.1 cylinder
meet the compression top dead center (TDC).
Name
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. PTO Gear 9. Idle Gear A
5. PTO Idle Gear
6. Install the flywheel housing. 4HK1

Clean the rear side of the cylinder block. In
particular, remove overflow liquid gasket
thoroughly when the crankcase is installed.
As the figure shows, apply the liquid gasket

(ThreeBond 1207B or equivalent) inside a hole of
the bolt (except the bolt holes indicated with an
arrow) evenly.
6HK1 Align with the knock pin of the cylinder block and
install the flywheel housing.
Tightening torque of the flywheel housing (4HK1):

N m (lb ft)
1 = 96 (71) 2 = 77 (57) 3 = 38 (28)
Tighten up the Mark 3 from the cylinder block side.
4HK1
Tightening torque of the flywheel housing (6HK1):

N m (lb ft)
1 = 96 (71) 2 = 86 (63) 3 = 119 (88)
4 = 53 (39) 5 = 73 (54) 6 = 26 (19)
6HK1

 








7. Install the PTO idle gear.

Apply engine oil over the part where the gear of the
idle gear shaft is to be put together.
Put the idle gear and the shaft together and install
it on the location given on the figure and tighten up
with the specified torque.
Tightening torque: 4HK1: 133 N m (98 lb ft)

6HK1: 119 N m (88 lb ft)
6HK1
8. Install the PTO idle gear cover.

Install the O-ring on the cover and install it on the 9. Install the oil pan.
flywheel housing and tighten up the tightening Apply the liquid gasket (ThreeBond 1207B or
bolts with the specified torque. equivalent) on a joint between the cylinder block,
the front cover and the flywheel housing with a
Tightening torque: 19 N m (14 lb ft) beat diameter of 3 mm.
4HK1 Install the oil pan within 7 minutes after applying

the liquid gasket.
4HK1
6HK1 6HK1

With the flywheel housing, the front cover and the

stud of the crankcase as a guide, put together the Name
gasket and put the oil pan on it. 1. Oil Pan
Then, put the rubber ASM on the oil pan and fix it 2. Gasket
by fastening bolts and nuts. Tightening
4HK1 4HK1
After fastening the oil pan at the respective points
of (1), (2), (3), and (4), fasten other parts.

6HK1
Fastening the oil pan from the part of A or B in
clock wise order.
It tightens again by specified torque.
Tightening torque: 24.5 N m (18 lb ft) 



After pressing in the slinger, make sure that the

distance between crankshaft end surface and the
slinger is A as specified.
4HK1
10. Install the rear slinger using installer, setting tool.

Special tool
4HK1
Oil seal installer kit: 5-8840-2703-0 (J-43282)
6HK1
Oil seal setting tool: 8-94396-856-0
Install the slinger (1) to the end of adapter (2).
Install the adapter to the crankshaft (3).
Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
Distance (A): 17.3 0.3 mm (0.7 0.01 in)

Distance (B): 10.8 0.1 mm (0.7 0.01 in)
6HK1

After pressing the oil seal, make sure that the

Distance (A): 17 0.3 mm (0.7 0.01 in) distance between crankshaft end surface and the
oil seal as specified.
Caution: 4HK1
Be sure to replace the slinger and oil seal as a set.
11. Install the rear oil seal using installer, setting tool.
Distance (A): 7.8 0.3 mm (0.7 0.01 in)
Special tool
4HK1
6HK1
Apply engine oil to the oil seal lip.
Caution:
Do not allow engine oil to come in contact with the
outside oil seal and felt ring.
Insert the oil seal (1) into the adapter (2).
Insert the oil seal sleeve (3) to the adapter.
Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
6HK1 13. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
14. Remove the oil drain adapter.
15. Install the O-ring on the fuel supply pump and
make the slits with an arrow meet and with the stud
bolt as a guide, install the fuel supply pump
tentatively.
Caution:
When removing the fuel supply pump, if the stud
bolt on the cylinder block side loosens, or the stud
bolt is replaced, apply the Loctite No. 262 on the
side where the stud bolt is to be buried before
assembly.

Distance (B): 7.5 0.15 mm (0.3 0.006 in)

12. Install the flywheel.
Along with the knock pin of the crankshaft, install
the flywheel and tighten up with the specified
torque according to the order given on the figure.
Tightening torque:
1st step = 78 N m (57 lb ft)
2nd step = 60
3rd step = 60

Check if the alignment mark of the gear painted
white is at the location given on the figure when
viewed from the plug hole and tighten up with the
specified torque.
Nut tightening torque: 50 N m (36 lb ft)
Bolt tightening torque: 76 N m (56 lb ft)

If the location of the teeth of the painted gear is not
in the right place, put it together all over again.
17. Install the cylinder head ASM.
18. Install the camshaft ASM.
19. Install the rocker arm shaft ASM.
20. Install the cylinder head cover.
Name
1. Plug Hole
2. Alignment Mark
16. Install the oil drain adapter ASM on the plug hole
and tighten with the specified torque.
Apply engine oil over the O-ring nice and thin and
install it.
Name
1. Adapter
2. O-Ring
 


Special Tool
5-8840-2230-0
EN-47680
Crankshaft stopper
1-8521-0027-0
Slinger remover
5-8840-2703-0
J-43282
Oil seal installer kit
8-94396-856-0
Oil seal setting tool
Rocker Arm Shaft ASM

Components

Name
1. Camshaft Bracket 5. Rocker Arm Bracket
2. Rocker Arm 6. Camshaft Bracket
3. Wave Washer 7. Rocker Arm Shaft
4. Rocker Arm
Removal
Along with the camshaft bracket, remove the
rocker arm shaft ASM.
Because the bolt(s) shown on the figure is are 6. Remove the camshaft bracket to take the shaft out.
designed to fix the rocker arm shaft, do not remove
it for now.
Name
Caution: 1. Camshaft Bracket
Pay full attention so as not to drop the bridge cap in the 2. Rocker Arm
gear case of the rear part of the cylinder head or the 3. Wave Washer
hole into which oil pours back in the front. 4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
Disassembly 7. Rocker Arm Shaft
1. Remove the camshaft bracket.
2. Remove the rocker arm. 7. Check if the oil hole is clogged of the camshaft
bracket (on the rear side).
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
Disassemble according to the order (2) (4)
thereafter.
8. Check if the rocker arm shaft is bent.

Place the rocker arm shaft on a V block.
Check if it is bent by rotating the shaft with a dial

gauge on the center of the shaft.
As a result of measurement, if its bend is slight,

press it to rectify it (while cold).
If the bend of the shaft exceeds the limit, replace 10. Inspect a clearance between the rocker arm and
the shaft. the rocker arm shaft.
Use a cylinder gauge to measure an inside
diameter of the bushing of the rocker arm to
Bend of the rocker arm shaft mm (in)
measure a clearance between the external
Limit 0.3 (0.012) diameter of the shaft.

rocker arm and the shaft.
Clearance between the rocker arm and mm (in)

rocker arm shaft
Standard 0.010 0.056 (0.0004 0.0022)
Limit 0.2 (0.0079)
9. Check if the rocker arm shaft is worn.

Use a micrometer to measure 8 places of the
vibrating part of the rocker arm.
If the measurement falls is the limit or less, replace

the shaft.
External diameter of the rocker arm shaft mm (in)

Standard 22.0 (0.866) 11. Inspect a clearance between the roller of the
Limit 21.85 (0.860) rocker arm and the rocker arm pin.
a. Pass a string, for instance, through an opening
between the rocker arm and the roller, pull it in
the direction indicated with an arrow strongly
and measure the gap between the rocker arm
and the roller with the roller stuck out. Figure 1
b. After marking the measuring point, pull the
string out and measure the gap of the marked
place with the roller pushed deep into the end.
Figure 2
c. The gap between the measurement taken
under a. and that under b. will be a clearance
between the roller and the rocker arm pin. If it
exceeds the limit, replace the rocker arm.
Clearance between the roller and the mm (in)

rocker arm pin
Standard 0.068 0.099 (0.0026 0.0038)
Limit 0.2 (0.0079)
3. Install the wave washer between the rocker arm.

Reassembly 4. Install the rocker arm bracket.
Pay attention to the direction in which the bracket
1. Install the camshaft bracket to one side of the
is put together and put it together with the rocker
rocker arm shaft tentatively first. When the rocker
arm shaft.
arm shaft ASM is installed on the cylinder head,
tighten them up fast. 5. Install the camshaft bracket.
Assemble in the reverse order of disassembly. Install the camshaft bracket on the rocker arm
shaft with the bolts indicated with an arrow
tightened tentatively. When the rocker arm shaft
ASM is installed on the cylinder head, tighten them
up fast.
2. Install the rocker arm.

Apply engine oil in an inside diameter of the rocker
arm, the roller and the rocker arm pin and install it
on the rocker arm shaft.

Name
Name 1. Bridge Cap
1. Camshaft Bracket 2. Bridge
2. Rocker Arm
3. Wave Washer Loosen an adjusting screw of the rocker arm, apply
4. Rocker Arm engine oil over the roller part of the rocker arm and
5. Rocker Arm Bracket install it on the cylinder head.
6. Camshaft Bracket
7. Rocker Arm Shaft Loosen the bolts indicated with an arrow a little, it
will become easier to install it.
Installation
If the bridge cap comes off, apply engine oil over
the inside of the bridge cap and put it together with
the bridge.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
Apply engine oil on a screw of the bolts and nuts.
Tighten up the tightening bolts of the rocker arm

ASM tentatively, and gradually tighten up the entire
rocker arm ASM horizontally according to the order
of the nut on the rocker arm side.
Tightening torque:
4HK1
Bolt (3) = 56 N m (41 lb ft)
Nut (1), Bolt (2), (4) = 27 N m (20 lb ft)
6HK1
Nut (1) (4) and Bolt (10) (13) = 27 N m (20 lb ft)
Bolt (5) (9) = 56 N m (41 lb ft)
       

   
Name
1. Camshaft Bracket Fixing Nut
2. Camshaft Bracket Fixing Bolt
3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
Adjustment of valve clearance
Refer to Function Check.

Camshaft ASM
Components
4HK1
Name
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
6HK1
Name
1. Bolt 7. Sub Gear
2. Washer 8. Dish Spring
3. Gear 9. Snap Ring
4. Pin 10. Pin
5. Spring 11. Camshaft
6. Pin
Removal Caution:
Put the removed bearings in order with a tag, for
example, by cylinder.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
6. Remove the bearing lower.
Name
Disassembly 1. Snap Ring
1. Remove the scissors gear ASM. (6HK1) 2. Dish Spring
3. Sub Gear
Fix the hexagon portion of the camshaft in a vise
4. Spring
using a mouth ring. Use snap ring pliers to remove
5. Camshaft Gear
the sub gear.
2. Remove the camshaft gear.
Caution:
Take care not to damage to the cam portion and the Remove the fastening bolts of the camshaft gear
journal portion of the camshaft. and put the block of wood in a puller to remove the
camshaft gear.
Name
1. Wood
3. Remove the knock pin.

4. Inspect the camshaft visually.
Check if the journal and cam parts of the camshaft
are worn or damaged, if so, replace it.
If the height of the cam lobe is the limit or less,
replace the camshaft.
Height of the cam lobe mm (in)

Intake air Exhaust
Standard 52.8 (2.08) 54.5 (2.15)
Limit 51.8 (2.04) 53.5 (2.11)
5. Check the axial play of the camshaft.

Use a thickness gauge to measure an end
clearance of the camshaft gear and the camshaft
bracket.

camshaft gear or the camshaft.
End clearance of the camshaft mm (in)

Standard 0.085 0.205 (0.033 0.008) 7. Check if the camshaft journal is worn.
Limit 0.25 (0.009) Use a micrometer to measure wear which is not
even with a diameter of the camshaft journal.
Caution:
If the measured uneven wear exceeds the limit,
Measure an end clearance of the camshaft before
disassembling.
External diameter of the camshaft journal mm (in)

part
Standard 39.950 39.975 (1.5728 1.5738)
Limit 39.850 (1.5688)
Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0019)
6. Check if the cam lobe is worn.

Use a micrometer to measure the height of the
cam lobe.
Clearance of the journal part mm (in)

Standard 0.020 0.087 (0.0008 0.0034)
Limit 0.15 (0.0059)
8. Check for bent of the camshaft.

Place the camshaft on a V block to measure a
bend with a dial gauge.
Rotate the camshaft slowly to measure how much

the dial indicator shook. If it exceeds the limit,
Reassembly
Bent of the camshaft mm (in) 1. Install the knock pin.
Limit 0.05 (0.0019) 2. Install the camshaft gear.
With the side of the camshaft gear center boss part
stuck out being on the camshaft side, install the
camshaft gear along with the knock pin.
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft
bearing with a dial gauge.
b. Read the difference between the inside
diameter of the camshaft bearing and the
diameter of the camshaft journal.
If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
3. Install the scissors gear ASM. (6HK1)
Fix the hexagon portion of the camshaft in a vise Before installing the camshaft to the cylinder head,
using a mouth ring. Assemble the spring with its rotate the sub gear using the special tool to
left end contacting the pin of camshaft main gear to prevent the spring force which acts on the sub
make a gap on the right. gear from affecting. Align the hole of the sub gear
Assemble the sub gear so that its pin is inserted with the camshaft main gear and install the phase
into the gap between the right side of pin of the alignment pin from the sub gear side to match the
camshaft main gear and the right end of the spring. teeth.
Special tool
Scissors gear spring wrench: 5-8840-2674-0
Name
1. Snap Ring Assemble onto the cylinder head.
2. Dish Washer
3. Sub Gear
4. Spring
5. Camshaft Gear
Use snap ring pliers to assemble the snap ring and

the dish washer securely.
Fixing torque


Special Tool
5-8840-2674-0
Scissors gear spring
wrench
Installation 4HK1
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
4HK1
6HK1
6HK1
4. Install the baring upper to the bearing cap.

5. Install the bearing cap.
Apply engine oil on the bearing upper.
2. Install the camshaft bearing lower.
Direct the front mark of the bearing cap toward the
Apply engine oil over the camshaft bearing lower front of the engine and put it together with the
and install it on the cylinder head. cylinder head in numerical order.
Put together the camshaft ASM so as to make the
B (4HK1) or (6HK1) mark meets the upper
face of the cylinder head.
Apply engine oil over the screw part and tighten up

the bearing cap with the specified torque.


Valve Stem Seal, Valve Spring

Components

Name
1. Camshaft Bearing Cap 6. Valve Spring
2. Camshaft Bearing 7. Spring Upper Seat
3. Camshaft 8. Split Collar
4. Rocker Arm Shaft ASM 9. Bridge
5. Valve Stem Oil Seal 10. Valve Spring Seat
Removal 5. Remove the bridge (2).

1. Remove the cylinder head cover. Caution:
Refer to Cylinder Head Cover. Keep the removed bridge and bridge cap properly so
2. Remove the rocker arm shaft ASM. that they may be put back to the original place.
4. Remove the bridge cap (1).
8. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
9. Remove the valve stem oil seal.
Use pliers to remove the oil seal.
10. Remove the valve spring seat.
Name
1. Bridge Cap
2. Bridge
Caution:
hole into which oil pours back in the front. Caution:
Do not reuse the removed oil seal.
6. Remove the split collar.
Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home Inspection
position.
Check the valve spring.
Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool 1. Free length
Valve spring replacer: 5-8840-2621-0 (J-43263)
Measure free length of the spring and if it is shorter
Pivot: 8-9439-6862-0 (EN-46721)
than the specified limit, replace the spring.
4HK1
Free length of the valve spring mm (in)

Intake air Exhaust
Standard 65.9 (2.59) 68.1 (2.68)
Limit 62.9 (2.48) 65.1 (2.56)
6HK1
Free length of the valve spring mm (in)

Intake air Exhaust
Standard 59.9 (2.36) 68.1 (2.68)
Limit 58.7 (2.31) 66.7 (2.63)
7. Remove the spring upper seat.

Remove the special tool to remove the upper seat.
4HK1
Tension of the valve spring N (lb)

Intake air Exhaust
Installation
46.0 (1.81) 46.0 (1.81)
length mm (in)
Standard 348 (78) 383 (86)
Limit 330 (74) 356 (80)
6HK1
Tension of the valve spring N (lb)

Intake air Exhaust
Installation
46.0 (1.81) 46.0 (1.81)
length mm (in)
Standard 348 (78) 378 (38.5)
2. Valve spring squareness
Use a surface plate and a square to measure the Limit 309 (31.5) 329 (33.5)
valve spring squareness.
If the measured value exceeds the specified limit,
the valve spring must be replaced.
4HK1
Valve spring squareness mm (in)

Limit 3.0 (0.12)
6HK1
Valve spring squareness mm (in)

Limit 3.4 (0.13)
Installation
1. Install the valve stem oil seal.
Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a valve
stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
3. Tension
Use a spring tester to compress the spring to the
installation height. Measure tension of the
compressed spring. If the measurement is lower
than the limit, replace the spring.
Special tool 3. Install the spring upper seat.
4HK1 4. Install the split collar.
Valve stem seal installer: 8-9439-6815-0 (EN-47685) Apply compressed air over the cylinder from the
6HK1 glow plug holes to keep the valve at the home
Valve guide oil seal installer: 5-8840-2625-0 (J- position.
43267)
Use a replacer to compress the valve spring and
install the split collar.
Special tool
Pivot: 8-9439-6862-0 (EN-46721)
2. Install the valve spring.

Install it with the paint mark or the narrow side of
the spring pitch being the lower side (cylinder head
side).
Paint mark 5. Apply engine oil over the bridge and install it.
Intake air Light blue Caution:

Move it up and down to check if it moves smoothly.
Exhaust Yellow
6. Apply engine oil over the bridge cap and install it.
Caution:
hole into which oil pours back in the front.
Name
1. Spring Pitch
2. Paint Mark
Special Tool
5-8840-2621-0
J-43263
Valve spring replacer
8-9439-6862-0
EN-46721
Pivot ASM
Name
1. Bridge Cap
2. Bridge
7. Install the camshaft ASM. 8-9439-6815-0

Refer to Camshaft ASM. EN-47685
8. Install the rocker arm shaft ASM. Valve stem seal installer
Refer to Rocker Arm Shaft ASM. (4HK1)
5-8840-2625-0
J-43267
Valve guide oil seal
installer
(6HK1)
Cylinder Head
Components

Name
1. Bridge Cap 9. Idle Gear C Cover
2. Bridge 10. Idle Gear C
3. Bridge Guide 11. Glow Plug
4. Split Collar 12. Intake And Exhaust Valves
5. Spring Upper Seat 13. Cylinder Head
6. Valve Spring 14. Valve Spring Seat
7. Valve Stem Oil Seal 15. Thermostat
8. Valve Guide 16. Water Outlet Pipe
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the OFF position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Disconnect the front exhaust pipe.
4. Remove the turbocharger.
Refer to the Turbocharger and Exhaust Manifold.
5. Remove the left-hand EGR adapter and right-hand
EGR pipe.
6. Remove the EGR water feed pipe.
7. Remove the EGR water return pipe.
8. Remove the EGR cooler.
9. Remove the water feed pipe for coolant water for
the EGR cooler and the water return pipe.
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal Nut
4. Nozzle Leak-Off Pipe
17. Remove the fuel leak-off hose.

18. Remove the fuel leak-off pipe (2).
* 4HK1 is shown for illustration. 4HK1
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
10. Remove the fan guide bracket.

11. Remove the left-hand intake pipe between the
inter-cooler and the inlet duct.
13. Remove radiator upper hose.
14. Loosen the fuel injector terminal nuts alternately to
the same level, and remove the terminal.
15. Loosen the fuel injector harness bracket bolt,
remove the inside connector, and remove the
harness bracket.
Name
16. Remove the nozzle leak-off pipe (4).
1. High Pressure Pipe
2. Leak-Off Pipe
6HK1 6HK1

 

Name Name
1. High Pressure Pipe 1. Water Bypass
2. Leak-Off Pipe
20. Remove the EGR valve and EGR valve connector.
19. Remove the water bypass hose from the cylinder 21. Remove the cam angle sensor connector.
head side.
Remove the engine coolant temperature sensor Refer to Rocker Arm Shaft ASM.
connector.
4HK1 Refer to Camshaft ASM.
24. Remove the bridge cap carefully so that it does not
fall into inside the engine.
25. Remove the bridge.
Caution:
Store the removed bridge and bridge cap so that they
can be placed in their original locations.
26. Remove the glow plug connector.
27. Remove the glow plug.
Name
1. Water Bypass
28. Remove the injection pipe clip, and remove the 31. If you have difficulty in removing the fuel injector,
injection pipe. set the fuel injector remover in the fuel injector,
4HK1 tighten the attachment part on the joint of the leak-
off pipe and pull out the fuel injector upward.
Special tool
Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)
Caution:
When removing an fuel injector ID code, be sure to
attach the cylinder number.
When pulling out the fuel injector using a special tool,
check that the fuel injector sleeve does not come off.
Name
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
6HK1
Name
1. Sliding Hammer
2. Fuel Injector Remover
3. Fuel Injector ASM

Name
1. Fuel Injection Pipe Caution:
2. Fuel Injection Pipe Clip Attach a cylinder number to the removed fuel injector
when storing it.
29. Remove the common rail. Be sure not to make the nozzle touch something.
Remove the common rail pressure sensor
connector.
30. Remove the fuel injector bracket.

6HK1
32. Remove the lower head cover. 

Loosen the cylinder head bolts in the order Disassembly
described in the drawing.
1. Remove the case ASM.
Caution: Be sure not to lose the gasket.
Be sure not to overlook (1) and (2) because they are
attached with the flywheel housing with M10 bolts. 2. Remove the inlet cover.
Remove the cylinder head gasket. Remove liquid gasket adherent to the removed
inlet cover.
Caution:
Replace the head gasket with a new one once it was
removed.
4HK1

3. Remove the A/C compressor bracket.
4. Remove the exhaust manifold.
Remove the heat protector and remove the
exhaust manifold.
5. Remove the exhaust gasket.

6. Disconnect the water outlet pipe.
7. Remove the thermostat.

Name
8. Remove the idle gear C cover. 1. Idle Gear C
Put the edge of a driver on the outer circle of the 2. Shaft
sealing cup as shown in the drawing, tap it lightly,
reverse it, then pull it out with pliers or other 10. Remove the split collar.
equipment. 11. Remove the spring upper seat.
12. Remove the valve spring.
Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Pivot: 8-9439-6862-0 (EN-46721)
Remove the special tool, then remove the upper
sheet and springs.
Sort the removed valve springs by cylinder

number.
9. Remove the idle gear C.
13. Remove the intake and exhaust valves.

Sort the removed valves according to cylinders by
using tags and others.
Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)
14. Remove the valve stem oil seal.

Use pliers to remove the oil seals.
16. Put the nozzle sleeve remover on the nozzle
sleeve from the bottom side of the cylinder head,
then pull out the nozzle sleeve.
Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)
Caution:
Be sure not to scratch the bottom side of the
cylinder head.
Do not reuse the removed nozzle sleeve.
Carefully remove sawdust in the screw groove.
15. Remove the valve guide.

Use the valve guide replacer to press out the
valve guides from the bottom side of the cylinder
head.
Name
1. Nozzle Sleeve
17. Remove the bridge guide.

Electrically weld the nut on the head of the bridge
guide, attach the sliding hammer and pull it out.
Check the following causes in the case of leak of
the seal surface of the cylinder head, corrosion, air
leak and defective gasket.
Improper installation
Defective tightening of the cylinder head.
Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening torque
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
Check whether there is a crack between the
valve seats and in the cylinder head of the
exhaust port part, and replace the cylinder head
if there is serious damage or crack. Check the
collar if necessary.
Name
1. Nut
18. Remove the oil seal.

Press the tool against the oil seal. Strike the tool to
remove the seal from the inside of the cylinder
head.
c. Flatness of the under surface of the cylinder

head
Use a straight edge ruler and sickness gauge to
measure the four sides and diagonal lines as
shown in the drawing, and replace if they
exceed the limit.
Distortion of the under surface of the mm (in)

cylinder head
Inspection Standard 0.05 (0.002) or less
1. Check the cylinder head ASM. Limit 0.20 (0.0079)
Remove varnish, soot and others adhered on the
metal surface completely. Use metal brush and
others so that the seal surface of the surface
where the gasket is installed is not hurt.
Distortion of the exhaust manifold mm (in)

Standard 0.3 (0.0118) or less
Limit 0.5(0.0197)

d. Flatness of the surface where the exhaust
manifold and inlet cover are installed
measure the four sides and diagonal lines as
shown in the drawing, and replace if they
exceed the limit.
2. Bridge cap
Distortion of the surface where the mm (in) Inspect abrasion and deformation of the surface
manifold and cover are installed where the cap and the rocker arm adjust bolt
Standard 0.05 (0.002) or less contact.
Limit 0.2 (0.0079) If the amount of abrasion is 0.1 mm (0.0039 in) or

larger, or if it abrades away in a zonal shape,
replace it.
Abrasion of the bridge cap mm (in)

Limit 0.1 (0.0039)

e. Flatness of the exhaust manifold
measure the flatness. If it exceeds the limit,
replace the exhaust manifold.
3. Bridge 6HK1
Make sure the bridge moves smoothly along the
bridge guide. The external diameter of the valve stem mm (in)
Standard Limit
Measure the gap between the bridge and bridge
guide. Intake valve 8 (0.315) 7.88 (0.3102)
Exhaust valve
Gap mm (in)
Assembly standard 0.020 (0.00079)
0.057 (0.00224)
Usage limit 0.1 (0.0039)
Measure the gap between the valve guide and

valve stem within 10 mm (0.39 in) from the
valve guide, using a dial gauge.
If the measured value exceeds the limit, replace
the valve guide and valve altogether.
4HK1
Name
1. Bridge Gap between the valve guide and mm (in)
2. Bridge Guide valve stem
Standard Limit
4. Check the valve guide.
Intake valve 0.038 (0.00150) 0.20 (0.00787)
Caution: 0.071 (0.00280)
If there is a scratch or abnormal abrasion in the valve
stem and the inner diameter part of the valve guide, Exhaust valve 0.064 (0.00252) 0.25 (0.00984)
replace it with new one along with valve guide. 0.096 (0.00378)
a. Measure the valve guide clearance.
6HK1
Measure the diameter of the valve stem with a
micro meter. Gap between the valve guide and
If the diameter of the valve stem is smaller than mm (in)
valve stem
the limit, replace the valve and valve stem
altogether. Standard Limit
4HK1 Intake valve 0.039 (0.00153) 0.20 (0.00787)
0.062 (0.00244)
The external diameter of the valve stem mm (in)
Exhaust valve 0.064 (0.00252) 0.25 (0.00984)
Standard Limit 0.096 (0.00378)
Intake valve 8.946 (0.3522) 8.88 (0.3496)
8.962 (0.3528)
Exhaust valve 8.921 (0.3512) 8.80 (0.3465)
8.936 (0.3518)
4HK1
Thickness of valve mm (in)

Standard Limit
Intake valve 1.8 (0.0709) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
6HK1
Thickness of valve mm (in)

Standard Limit
Intake valve 1.88 (0.074) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
5. Inspect abrasion of the bridge gap.

Measure the contact surface of bridge cap and the
rocker arm, using a dial gauge.
If the abrasion exceeds the limit, or there is an

abnormal abrasion (zonal abrasion), replace the
bridge cap.
Abrasion of the bridge cap mm (in)

Limit 0.1 (0.00394)
Valve seat
Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If the value exceeds the limit, replace the valve
insert or the cylinder head ASM.
4HK1
Depth of the valve mm (in)

Standard 0.7 (0.0276) 1.2 (0.0472)
6. Check the valve. Limit 2.5 (0.0984)
Thickness of valve
Measure the thickness of the valve. 6HK1
Depth of the valve mm (in)
the valve and valve guide altogether.
Standard Limit
Intake valve 1 (0.039) 2.5 (0.098)
Exhaust valve 1.3 (0.051) 2.8 (0.11)
Measure the contact width of the valve seat. If Repair of the seat surface
the seat contact surface has a scratch or is
Remove carbon from the surface of the valve
rough, or if the abrasion of the contact surface
seat.
exceeds the limit, modify or replace it.
Use a seat cutter to minimize the scratch and
Contact width of the valve seat mm (in) other roughness (15/45/75 -blade), thereby
returning the contact width to the standard
Standard Limit value.
Intake valve 2.5 (0.0984) 3.0 (0.1181)
Exhaust valve 2.0 (0.0787) 2.5 (0.0984)
Caution:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Contact surface of the valve seat
Do not let the valve cutter pilot waver inside the valve
If the contact surface of the valve seat is guide.
defective, modify it or replace the valve, valve
guide and valve seat altogether.
Angle of the contact Exhaust side of 4HK1 and
surface: 6HK1: 45
Intake side of 6HK1: 30
Remove the valve seat insert
Arc-weld the entire inner diameter of the valve
seat insert.
Cool the valve seat insert for two to three
minutes. Contraction fur to cooling makes it
easier to remove the valve seat insert.
Remove the valve seat insert, using a screw
driver. Be sure not to hurt the cylinder head.
Attach compound in the valve insert seat.

Insert the valve into the valve guide.
Attach compound on the valve seat surface,
rotate the valve and hit it lightly to grind them,
and confirm that it has even contact all round.
Caution:
Remove compound completely after grinding.
Name
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
Install the valve seat insert

Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
Caution:
Do not apply too much pressure with the press.
Attach compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm that it
Replace the valve seat insert has even contact all round.
Name Name
1. Press 1. Cylinder Head
2. Attach Compound 2. Oil Seal Installer
3. Valve Seat
2. Install the bridge guide.
Apply engine oil on the outer diameter of the guide,
Reassembly then use the installer to hammer it into the depth of
the finishing part of the hole of the cylinder head.
1. Install the oil seal. (Note: the height of the bridge guide is about
Install on the surface of injection pipe insert. 37.5 mm (1.48 in) from the upper surface of the
head)
Hammer it in so that the seal does not incline.
Special tool
Caution: Bridge guide installer: 5-8840-2626-0 (J-43268)
Be sure not to hurt the rip. Engine oil
Special tool
Oil seal installer: 5-8840-2627-0 (J-43269)
3. Nozzle sleeve
Install the O-ring on the nozzle sleeve, apply
engine oil.
Apply seal material on the taper section.
Loctite No. TL620

Special tool
Nozzle sleeve installer: 5-8840-2624-0 (J-43266)
Name
1. Apply Seal Material
2. O-Ring Name
1. Punch Bar
Install the nozzle sleeve on the cylinder head, 2. Ball
insert the guide sleeve. 3. Guide Sleeve
4. Nozzle Sleeve
Use the guide sleeve to push in so that the nozzle 5. Bracket
sleeve fully contacts with the under surface of the 6. Bolt
cylinder head.
4. Install the valve guide.
Insert the sleeve and fix it with the tighten and bolt.
Hammer in the valve guide from the upper surface
Insert the ball (bearing steel ball 9.525 mm of the cylinder head, using the valve guide
0.375 in) into the guide sleeve, attach the punch replacer.
bar and hammer out the ball.
Caution:
Leave the cylinder head floating so that the ball
comes off from the under surface.
Special tool Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272) 4HK1
Valve stem seal installer: 8-9439-6815-0 (EN-47685)
6HK1
Valve guide oil seal installer: 5-8840-2625-0 (J-
43267)
Height from the upper surface of the cylinder head

to the edge surface of the valve guide: 13.9 mm
(0.5472 in) 14.3 mm (0.5630 in)
Caution: 6. Install the intake and exhaust valves.

When replacing the valve guide, it must be replaced Apply engine oil on the valve stem part and install
together with the valve. the valve.
5. Install the valve stem oil seal. 7. Install the valve spring.
Apply engine oil on the outer diameter of the valve Install the valve spring with the paint mark or the
guide, use the valve stem seal installer to install narrower side of the spring pitch on the under side
the oil seal. (the cylinder head side).
Caution:
After installation of the valve stem seal, confirm that the Paint mark
oil seal is not inclining and the garter spring is in place.
Intake side Light blue
Exhaust side Yellow
Name
1. Spring Pitch
2. Paint Mark Name
1. Idle Gear C
8. Install the spring upper seat. 2. Shaft
9. Install the split collar.
11. Install the idle gear C cover.
Use a replacer to compress the valve spring and
install the split collar. Apply liquid gasket (Loctite 262 or 962T) on the
outer diameter of the idle gear C cover, use the
Special tool sealing cup setting tool to hammer it in so that the
Valve spring replacer: 5-8840-2621-0 (J-43263) measurements follow the drawing.
Pivot: 8-9439-6862-0 (EN-46721)
Special tool
Sealing cup installer: 5-8840-2222-0 (EN-47690)
10. Install the idle gear C. 

Apply engine oil on the idle gear C shaft and the 12. Install the thermostat.
inner diameter of the idle gear, install the idle gear
C so that the side with gear groove is on the side of Install the thermostat on the position shown in the
the rear surface of the engine. drawing.
Tighten the idle gear C to the specified torque.
Do not use impact wrench and like.

4HK1 4HK1
6HK1
Name
1. Thermostat
6HK1

14. Install the exhaust gasket.

15. Install the exhaust manifold.
 Install the distance tube conical spring and the nut
on the stud of the cylinder head in this order.
Name
1. Thermostat
13. Connect the water outlet pipe.

Tighten the water outlet pipe to the specified
torque.
Tighten it up together with the fan shroud bracket.

6HK1

Name Install the heat protector.
1. Distance Tube
2. Conical Spring
3. Nut
16. Install the inlet cover.
Tighten the exhaust manifold in the order Apply liquid gasket (ThreeBond 1207C or
described in the drawing. equivalent) in accordance with the groove of the
inlet cover, with the bead diameter of 2.5 mm
Tightening torque: 34 N m (25 lb ft) (0.0984 in) ~ 5.5 mm (0.2165 in).
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
4HK1

Tighten in the order described in the drawing.
Tighten the stud bolts (6) and (9) jointly with the
common rail.

4HK1

6HK1
Installation
1. Install the cylinder head gasket.
Select the cylinder head gasket. (4HK1 only)
Clean the head of the piston and the upper surface

of the cylinder block.
      
Use a dial gauge to measure the extrusion of the
piston. Measure at two points of each cylinder.
The following drawing shows the measurement

      
points and the standard point of the cylinder block.

17. Install the inlet pipe.

Measurement Head of the piston (2) and (3)

points:
Standard point: Upper surface of the (1)
cylinder block
Caution: 4HK1 only
Note that there are three options for the head gasket
according to the amount of extrusion of piston shown in
the following table. (4HK1 only)
Calculate the average piston extrusion amount of
each cylinder. (4HK1 only)
Calculate the maximum amount of the average

amount of each cylinder. (4HK1 only)
Select a gasket of an appropriate grade based on

the maximum protrusion amount. (4HK1 only)
Name
1. Grade Recognition Hole
Apply liquid gasket
Apply liquid gasket (ThreeBond 1207B or

equivalent) on the joint (1) of the cylinder block and
the flywheel housing with the bead diameter of
3 mm (0.118 in).
Install the cylinder head within seven minutes after

applying liquid gasket.
Gasket Recognized Piston protrusion mm (in)
Grade amount
0.539 (0.2122)
A (no hole)
0.618 (0.02433)
0.619 (0.02437)
B (1 hole)
0.698 (0.02748)
0.699 (0.02752)
C (2 holes)
0.779 (0.03067)
(4HK1 only)
Install the cylinder head gasket.
Install the cylinder head gasket with the parts

number upside, along with the cylinder head rear
gear case and knock pin.
Tightening torque:
M14 bolt (4HK1: 1 ~ 18, 6HK1: 1 ~ 26)
2nd step = 147 N m (108 lb ft)
3rd step = 30 ~ 60
M10 bolt (4HK1: 19, 20; 6HK1: 27, 28)
4th step = 38 N m (28 lb ft)
Use a stud bolt for (4HK1: 16).
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
4HK1

Install the cylinder head, adjusting the knock pin of
the cylinder block.
Caution:
Be sure not to hurt the head gasket when installing it.
6HK1

Apply molybdenum disulfide on the screw part and
setting face of the head bolt of M14, and apply
engine oil on the screw part and setting face of the
head bolt of M10.
Use a torque wrench and angle gauge to tighten 

the head bolts in the order described in the
3. Install the fuel injector on the cylinder head.
drawing.
4. Apply molybdenum disulfide on the screw part and
setting face of the fuel injector tighten bolt and
tighten it tentatively.
Important:
Reinstall each fuel injector to the original cylinder from
which it was removed during the disassembly
procedure.
Name
2. Fuel Injector Tighten Bolt

Tightening torque: 19 N m (14 lb ft) * 4HK1 is shown for illustration.
Install the common rail pressure sensor. Name

6. Install the injection pipe. 2. Fuel Injection Pipe Clip
Apply a thin coat of engine oil on the outer
diameter of the sleeve nut on the side of the fuel 7. Final tighten the injection clamp bolts to the
injector and install the injection pipe. specified torque.
Use a spanner to tighten the sleeve nut until it
completely contacts both on the fuel injector and 8. Tighten the injection pipes to the specified torque.
common rail. Tightening torque: 44 N m (32 lb ft)
Tighten the injection pipe clip with the designated
torque.


Name
Name 1. Bridge Cap
1. Injection Clamp Bolt 2. Bridge
2. Injection Pipe Sleeve Nut
9. Install the glow plug. Refer to Camshaft ASM.
Tightening torque: 20 N m (15 lb ft) 14. Install the rocker arm shaft ASM.
10. Install and tighten the glow connector with the
15. Install and tighten the camshaft speed sensor with
designated torque.
the designated torque.
Tightening torque: 1.2 N m (10.5 lb in)
11. Apply engine oil over the bridge and install it.
Caution:
Move it up and down to check if it moves smoothly.
12. Apply a thin coat of engine oil inside the bridge
cap, install it.
16. Connect the water bypass hose.

Install the engine coolant temperature sensor on
the thermostat housing.
17. Install the leak off pipe.

Leak off pipe tightening torque:
18. Install the fuel leak-off hose.
Install the fuel leak-off hose on the fuel leak-off 4HK1
pipe and fix it with a clip.
19. Clip a new gasket to the fuel nozzle leak-off pipe

and install the fuel leak-off pipe.
6HK1
21. Install the terminal nuts on the fuel injector.

Caution:
Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
20. Install the fuel injector harness connector from
unified.
inside, tighten the harness bracket with the
designated torque. Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
26. Connect the exhaust pipe.
Connect the front exhaust pipe and tighten to the
specified torque.
Exhaust manifold side

Exhaust brake side

27. Install the engine harness.
28. Replenish the coolant.
Name
1. Fuel Injector
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut

23. Connect the radiator upper hose.
24. Install the EGR valve & EGR cooler.
For details of installation, refer to EGR Valve and
EGR Cooler of the section of exhaust system.
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
25. Install the oil level gauge and guide tube.

Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
8-9439-6815-0
5-8840-0019-0
EN-47685
J-23907
Valve stem seal installer
Sliding hammer
(4HK1)
5-8840-2625-0
5-8840-2628-0 J-43267
J-43272 Valve guide oil seal
Valve guide replacer installer
(6HK1)
5-8840-0266-0
5-8840-2621-0
J-45059
J-43263
KM470-B
Valve spring replacer
Angle gauge
5-8840-2624-0 8-9439-6862-0
J-43266 EN-46721
Nozzle sleeve installer Pivot ASM
5-8840-2626-0 5-8840-2222-0
J-43268 EN-47690
Bridge guide installer Sealing cup installer
5-8840-2627-0
J-43269
Oil seal installer
5-8840-2623-0
J-43265
Nozzle sleeve remover
5-8840-2826-0
EN-46720
Fuel injector remover
Piston, Connecting Rod

Components
Name
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
Refer to Oil Pan.
5. Remove the cylinder head.
6. Remove the connecting rod cap.
Caution:
Sort the removed bearings according to cylinders by
using tags.
7. Remove the piston and connecting rod.

Remove carbon on the upper side of the cylinder
liner with a scraper.
Pull out the piston and connecting rod towards the

cylinder head.
Caution:
Be sure not to damage the oil jet and cylinder liner
when pushing out the connecting rod.
2. Remove the snap ring.

3. Remove the piston pin.
Caution:
Sort the disassembled piston pins, pistons and
connecting rods together in the order of cylinders.
8. Remove the connecting rod bearing.
Caution:
Sort the bearings in the order of cylinders when reusing
them so that they will not be confused with the bearing
of other cylinders.
Disassembly
1. Remove the piston ring.
Use ring pliers to remove the piston ring.
Caution:
Sort the piston rings in the order of cylinders when
reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
4. Remove the connecting rod from the piston.
5. Piston
Clean carbon carefully that is adhered to the head
of the piston and the groove of the piston ring.
Caution:
Do not use wire brush to clean the piston because it
scratches the piston.
Inspect the piston with eyes for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6. Measure the gap between the piston and the inner
diameter of the cylinder liner.
Cylinder liner inner diameter Gap between the piston and the inner mm (in)
Use a cylinder bore dial indicator to measure the diameter of the cylinder liner
liner inner diameter both in the thrust and radial
directions in the designated position. Standard 0.082 0.130
(0.0032 0.0051)
Measurement position (from the upper surface of
the cylinder block) 6HK1
1. 20 mm (0.79 in) 2. 110 mm (4.33 in)
3. 190 mm (7.48 in) Piston diameter mm (in)
Measure the liner inner diameter based on the Standard 114.974 114.989
average value of the actual measurement values (4.52652 4.52711)
on 6 positions.
Gap between the piston and the inner mm (in)
Cylinder liner inner diameter mm (in) diameter of the cylinder liner
115.021 115.050 (4.52838 4.52952) Standard 0.042 0.066
(0.00165 0.00259)
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
Name
1. 20 mm (0.79 in)
2. 110 mm (11.00 cm)
3. 190 mm (19.00 cm)
7. Piston replacement
Piston outside diameter
You do not need to select grades because there is
Use a micrometer to measure the outside diameter
only one grade for each of the piston and the
of the piston in the right angle to the piston pin in
cylinder liner inner diameter.
the designated position.
If you replace the cylinder liner, you must select
Measurement position (from the upper surface of the cylinder block (1, 2, 3) because there are two
the piston) 82 mm (3.2 in). types of the liner outer diameter.
Refer to Cylinder Block if you replace the cylinder
4HK1 liner.
Piston diameter mm (in) Caution:

Standard 114.920 114.949 The head of piston has a marking of grade B or C when
(4.52440 4.52554) it is shipped from the factory.

Name piston ring.
1. Front Mark Cut
8. Inspect the piston ring. Piston ring gap mm (in)

Measure the joint of the piston ring (remove carbon
on the ring joint) Standard Limit
Insert the piston ring into the cylinder liner. Top ring 0.2 0.3 1.2
(0.0079 0.0118) (0.047)
Use the piston to push the ring to reach the under
Second ring 0.3 0.45 1.2
edge of the cylinder liner.
(0.0118 0.0177) (0.047)
Oil ring 0.2 0.04 1.2
(0.0079 0.0157) (0.047)
Measure the clearance between the piston ring

groove and the piston.
Remove carbon on the piston ring groove
completely.
Put the piston ring in the piston ring groove, use a

sickness gauge to measure the gap between
them.
If the clearance between the piston ring groove

and the piston exceeds the limit, replace the piston
and the piston ring.
Piston ring and piston ring groove mm (in)

Use a sickness gauge to measure the gap of the clearance
ring joint.
Piston ring Standard Limit
Top ring 0.067 0.087 0.20
(0.0026 0.0034) (0.0079)
Second ring 0.03 0.07 0.15
(0.0012 0.0028) (0.0059)
Oil ring 0.01 0.03 0.15
(0.0004 0.012) (0.0059)
9. Inspect the piston pin. Inspect to make sure that there is a resistance to
Inspect the piston pin with eyes for cracks, the extent which the piston can push the piston pin
scratches and other damages, replace it if lightly in normal temperatures.
necessary.
If it feels a large looseness or instability in normal
Use a micrometer to measure the outer diameter temperatures, replace the piston or piston pin.
of the piston pin. If the measured value exceeds
the limit, replace the piston pin.
4HK1
Piston pin outer diameter mm (in)

Standard 35.995 36.000 (1.4171 1.4173)
Limit 35.970 (1.4161)
6HK1
Piston pin outer diameter mm (in)

Standard 4.0 (1.5748)
Limit 39.95 (1.5728)
Measure the bush of the small edge of the

connecting rod. If the clearance between the
bushing inner diameter and the pin diameter
exceeds the limit, replace the bushing or
connecting rod ASM, and the pin.
Piston pin and connecting rod small end mm (in)

bushing clearance
Standard 0.012 0.027
(0.0005 0.0011)
Limit 0.05(0.0020)
10. Measure the clearance between the piston and the

piston pin. Name
1. Setting Bar
Apply engine oil on the piston pin. Use your finger 2. Connecting Rod
to push it in the piston hole and rotate it. If the pin 3. Nut
smoothly rotates without instability, the clearance 4. Collar
is normal. If there is instability, measure the 5. Bushing
clearance. If the clearance exceeds the limit, 6. Collar
replace the piston and the piston pin.
Place the connecting rod bushing replacer base on
Piston pin and piston pin hole clearance mm (in) the bench press, tighten the fixation bolt.
Standard 0.004 0.017 (0.00016 0.00067) Use the bench press to replace the bush.
Limit 0.04 (0.0016)
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
11. Remove the bushing. (EN-47682)
Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
Tighten the nut.
Name
1. Bolt
2. Connecting Rod Bushing Replacer
12. Measure the connecting rod alignment.

Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole and
the small end hole. If the measured value exceeds
the limit, replace it.
Connecting rod alignment mm (in)

(per length of 100 mm (3.94 in))
Standard Limit
Distortion and 0.05 (0.002) 0.20 (0.008)
Parallelism
Remove the cap.

Measure the largest width of the plastigauge to
calculate the oil clearance. If the clearance
exceeds the limit, replace the bearing ASM.
Crank pin and bearing clearance mm (in)

Standard 0.036 0.077 (0.0014 0.0030)
Limit 0.10 (0.0039)
Remove the plastigauge from the bearing and

crank pin.
13. Measure the bearing oil clearance.
Measure the oil clearance between the connecting
rod bearing and the crank pin with the following
method.
Remove the connecting rod cap. Sort the

removed caps according to the cylinder
number.
Clean the bearing and the shaft pin.
Check the bearing. If it is damaged or worn
seriously, replace the bearing ASM.
Place the plastigauge on the crankshaft pin.
Install the bearing cap and tighten the bolt with the
designated torque.
the bearing surface.
Connecting rod bearing cap bolt torque: N m (lb ft) 14. Select the connecting rod bearing.
1st step 39 (29) Refer to the bearing selection table when installing
a new connecting rod or replacing bearings in use.
2nd step 60
3rd step 30 Select and install the bearing, paying attention to
the large edge hole diameter of the connecting rod.
Caution:
Do not rotate the crankshaft.
Reassembly
1. Install the bush
Place the connecting rod bushing replacer base on
the bench press, set the connecting rod and
tighten the fixation bolt.
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
(EN-47682)
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
Bearing selection table

Big end hole Bearing Oil clearance
diameter recognition
mm (in)
Grade color
Name
A Green 0.036 0.077 1. Bolt
(0.0014 0.0030) 2. Connecting Rod Bushing Replacer
B Yellow 0.036 0.077
(0.0014 0.0030) Set the collar, new bushing and collar on the
setting bar as shown in the drawing.
Tighten the nut.
Adjust the oil hole of the connecting rod and the oil
hole of the bush, and use the bench press to install
the bush.
Name
1. Grade Identification Color
Name Name
1. Setting Bar 1. Snap Ring
2. Connecting Rod 2. Front Mark
3. Nut 3. Forging Mark (Projecting)
4. Collar
5. Bushing 4. Apply enough engine oil on the piston pin, push it
6. Collar in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
After installing the new bush, use a grinder to
machine the pin hole so that the pin clearance Caution:
equals the standard value. Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
2. Install the piston.

3. Install the connecting rod.
Install it so that the front mark of the head of the 6. Use piston ring setting tool to install the piston ring.
piston and the connecting rod forging mark Install the oil ring so that the joint angle of the ring
(projecting) on the connecting rod face the same and coil expander is in the opposite 180 direction.
direction.
Install the top ring and second ring in this order so
Use snap ring pliers to install the snap ring of one that the marks 1Nand 2N face upward.
side.
Special tool Make sure that there is not gap in the position indicated
Piston ring setting tool: 1-8522-1029-0 in the drawing when the oil ring coil expander was
installed.
Name
1. Oil ring
2. Second Ring Installation
3. Top Ring 1. Install the connecting rod bearing.
Install the bearing on the connecting rod, apply
6HK1
engine oil on the bearing.
2. Install pistons and connecting rod ASM.

Apply enough engine oil on the piston ring, ring
groove and piston side surface.

Dislocate the piston ring joint so that (1) is top ring,

(3) is 2nd ring and (2) is oil ring, as shown in the
drawing.
 Face the piston front mark cut to forward, use the
piston ring compressor to insert the piston in the
cylinder liner.
Caution:
 Be sure not to make the connecting rod touch the
oil jet when pushing in the piston.
Be sure not to hurt the inside of the liner when
pushing in the piston.
Name
1. Oil ring
2. Second Ring
3. Top Ring
Caution:
Note that the shapes are different for top ring and
second ring. (Second ring has undercut)
Special tool Special tool
Piston ring compressor: 5-8840-9018-0 (J-8037) Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Make sure that the crankshaft rotates smoothly.
3. Install the connecting rod cap.

Install the bearing on the connecting rod cap and
apply engine oil.
4. Install the cylinder head.
Install the cap, matching the numbers (1, 2, 3, 4) of Refer to the Cylinder Head.
the caps and connecting rods. 5. Install the camshaft ASM.
8. Install the oil pan.
Refer to Oil Pan.
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number

the setting face of the tightening bolt and tighten it
with the designated torque.
Tightening torque:
2nd step = 60
3rd step = 30
Special Tool
5-8840-2340-0
EN-47682 1-8522-1029-0
Connecting rod bushing Piston ring setting tool
replacer
5-8840-0266-0
5-8840-9018-0
J-45059
J-8037
KM470-B
Piston ring compressor
Angle gauge
Flywheel
Components
Name
1. Flywheel Housing 3. Washer
2. Flywheel ASM 4. Crankshaft Position Sensor
Removal 4HK1
1. Remove the starter motor.
Remove the ground cable of the starter motor.
Remove the two nuts on the upper side and lower

side that fix the starter, remove the starter from the
fly wheel housing.
6HK1 Special tool
2. Remove the crankshaft position sensor.

Remove to prevent contact damage when the Gradually loosen the flywheel installation bolts in
flywheel is removed. the order shown in the drawing so that the flywheel
does not rotate.
Do not throw or drop because it is vulnerable to
shock. After loosening all the bolts, remove the stopper to
* 4HK1 is shown for illustration. remove the flywheel.
3. Remove the washer and flywheel. 4. Take out the ring gear.
Install the crankshaft stopper to the starter Put a bar on the ring gear and hit it with a hammer
installing portion of the flywheel housing. to remove it.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
Inspection Installation
1. Visual check 1. Install the ring gear.
Inspect the flywheel friction surface for cracks and After heating the ring gear with a gas burner
damages, and replace it if it has abnormality. equally, install it in the flywheel.
Inspect the tooth part of the ring gear, replace the In the case of shrinkage cooling of the ring gear,
ring gear if it has damage or serious wear. maintain the flatness by applying weight of 68.6 kN
(15,400 lbf).
2. Measurement of the friction surface
Measure the depth of the flywheel friction surface. Caution:
Install the ring gear so that the side with a pattern
Adjust it if the measured value is within the faces forward.
standard value and the limit. Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
complete.
the flywheel.
Depth of the friction surface of the flywheel mm (in)

Standard 19 (0.75)
Limit 20 (0.79)
Depth = From the pressure installation surface to the

friction surface.

3. Install the washer.
Install the flywheel to match with the knock pins of
the crankshaft, tighten them in the order shown in
the illustration.
Apply molybdenum disulfide on the screw part and 4HK1
setting face of the bolt.
Install the crankshaft stopper to the starter

installing portion of the flywheel housing.
Tightening torque:
2nd step = 120 150
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
6HK1
Install the ground cable of the starter motor.
4. Install and tighten the crankshaft position sensor

with the designated torque.
5. Install the starter motor on the flywheel housing
with nuts and tighten them with the designated
torque.

 

Special Tool
5-8840-2230-0
EN-47680
Crankshaft stopper
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Front Cover
Components
4HK1
6HK1
  


  

Name
1. Adjusting Plate 7. Crankshaft Pulley
2. Generator 8. Water Pump ASM
3. Front Cover 9. Fan Belt
4. Oil Pan Gasket 10. Water Pump Pulley
5. Oil Pan 11. Spacer
6. Front Oil Seal 12. Fan ASM
Removal
1. Remove the front oil seal.
Refer to Crankshaft Front Oil Seal.
Refer to Oil Pan.
3. Remove the water pump.
Refer to the Water Pump in the cooling system
section.
4. Remove the front cover.
Remove the generator adjust plate.
Install within seven minutes after applying liquid
gasket.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
4HK1
Remove the oil relief valve (arrow), loosen the front

cover installation bolts and remove the front cover.
Name
1. O-Ring
6HK1
Installation
1. Install the front cover.
Clean the cylinder block front surface. In particular,
remove liquid gasket leaked during installation of
the crankcase.
Install two O-rings and apply liquid gasket 

(ThreeBond 1207B or equivalent), or each
equivalent along with the groove of the front cover Name
installation surface. 1. O-Ring
Align with the knock pin of the cylinder block and

Beat width 1.5 5mm (0.059 0.20 in) install the front cover.
Beat height 0.3 mm 1.5 mm
(0.012 0.059 in) from the joint Caution:
surface Along with the front cover, install the water pump ASM
(before liquid gasket hardens).
4HK1
Tightening torque
Front cover bolt: 24 N m (18 lb ft)
Tighten bolt with (*) mark together with the adjust
plate of the generator.
Tighten the oil relief valve (5) to the specified


torque.
Tightening torque
Oil relief valve: 39 N m (29 lb ft)

2. Install the water pump.

Refer to the Water Pump of the section of the
Cooling System
Refer to Oil Pan.
4. Install the front oil seal.
Name
1. Bolt: L = 35
2. Bolt: L = 25
3. Bolt: L = 65
4. Bolt: L = 30
5. Oil Relief Valve
6HK1
Tightening torque
Front cover bolts (13 bolts): 18N m (13 lb ft)
Tighten bolt with (*) mark together with the adjust
plate of the generator.
When you remove the stud bolt (1), install in

original position.
Tightening torque
Stud bolt for water pump: 12.7 N m (9.4 lb ft)
4HK1





6HK1






Crankshaft Front Oil Seal

Components

Name
1. Crankshaft Pulley 2. Crankshaft Front Oil Seal
Removal 4HK1
1. Drain coolant.
2. Remove the starter.
Disconnect the starter ground cable.
Unscrew two mounting nuts, upper and lower, from

the starter to dismount the starter from the flywheel
housing.
6HK1 Special tool
3. Disconnect the upper radiator hose on the engine

side. 10. Remove the crankshaft front oil seal.
4. Disconnect the coolant reserve tank hose on the Remove the oil seal off with a screwdriver or the
radiator side. like avoiding damage to the oil seal contact surface
5. Disconnect the lower radiator hose on the engine on the front cover and the shaft.
side.
6. Remove the radiator (with the fan guide) detaching
right and left brackets.
7. Remove the fan ASM.
Remove the fan ASM unscrewing four mounting
bolts.
8. Remove the fan belt.

9. Remove the crankshaft pulley.
Loosen the pulley nut blocking the crankshaft from
turning by placing a crankshaft stopper on the
starter mounting position on the flywheel housing.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
Name
1. Felt
2. Slinger
3. Oil Seal
Caution:
11. Remove the front slinger.
Use the slinger remover to remove the front
slinger.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
8-9439-6858-0 (For 6HK1)




After pressing in the slinger, make sure that the

distance between crankshaft end surface and the
slinger is A as specified.
4HK1
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
6HK1
Install the slinger (1) to the end of adapter (2).
Distance (A): 40.5 0.3 mm (1.6 0.01 in)

Distance (B): 34 0.1 mm (1.3 0.004 in)
6HK1 Special tool
4HK1
6HK1
(Use the parts listed below for the front oil seal.)
No. Part Name Oil seal

1 Sleeve (front)

2 Adapter (front)
3 Adapter ring (front)
4 Washer (front)
5 Center bolt
6 Fixing bolt
Mount the adapter onto the crankshaft with fixing

bolts.
Distance (A): 18 0.3 mm (0.7 0.01 in)
Caution:
2. Install the crankshaft front oil seal.
Press fit the oil seal using an oil seal installer,
setting tool.
Name
1. Adapter
Apply engine oil to the lip of the oil seal and place it
on the front side adapter.
Put the front side adapter ring in the sleeve and fix
the sleeve on the adapter with the center bolt and
Name a washer.
1. Oil Seal
2. Adapter (Front) Tighten the bolt until the sleeve touches the
3. Adapter Ring (Front) adapter to press fit the front oil seal.
4. Fixing Bolt
5. Sleeve (Front)
6. Washer (Front)
7. Center Bolt
4HK1
Name
1. Oil Seal Name
2. Adapter Ring 1. Adapter Ring
3. Sleeve 2. Sleeve
4. Bolt and Washer 3. Adapter
4. Oil Seal
6HK1
After you have press-fitted the front oil seal,

confirm the measurement shown (depth from the
end surface of the crankshaft to the oil seal) and
check for deflection of the oil seal. Distance (B): 8.5 0.15 mm (0.33 0.006 in)
3. Install the damper to the crankshaft pulley. (6HK1)
Tighten in the sequence shown.


4. Install the crankshaft pulley.

Name
Apply engine oil to the threads of the fastening 1. Crankshaft Pulley
bolts. 2. Generator
3. Fan Pulley
Install the crankshaft pulley aligning with the knock
pins on the crankshaft.
b. Fan belt adjustment
Tighten in the sequence shown. Loosen the adjustment bolt (1) of the AC
generator and adjust the fan belt moving the
Tightening torque: 200 N m (148 lb ft) generator.
Tightening torque: (2) = 24 N m (18 lb ft)
(3) = 40 N m (30 lb ft)
5. Install the fan belt.

a. Inspection of fan belt deflection
Check with a scale if the belt deflection is within Name
the specified limits when pressure of 98 N 1. Adjusting Bolt
(22 lb) is applied mid-way along the belts 2. Fixing Bolt
longest run. Also check the belt for damage. 3. Fixing Bolt
Amount of fan belt deflection mm (in)
6. Tighten the fan ASM to the specified torque.
for new belt 5.0 5.8 (0.19 0.23)
for reused belt 6.1 6.9 (0.24 0.27)
7. Install the radiator.
8. Connect the lower radiator hose.
9. Connect the coolant reserve tank hose.
10. Connect the upper radiator hose.
11. Install the starter in the flywheel housing with nuts
and tighten to the specified tightening torque.
Connect the starter ground cable.

12. Fill the radiator with coolant.
Special Tool
5-8840-2703-0
5-8840-2230-0
J-43282
EN-47680
Crankshaft stopper
(4HK1)
8-94396-856-0
1-8521-0027-0
Slinger remover
(6HK1)
Crankshaft Rear Oil Seal

Components
Name
1. Flywheel 2. Crankshaft Rear Oil Seal
Removal
Refer to the Flywheel.
2. Remove the crankshaft rear oil seal.
Remove the oil seal off with a screwdriver or the
like avoiding damage to the oil seal contact surface
on the flywheel housing and the shaft.
Name
1. Felt
2. Slinger
3. Oil Seal
3. Use the slinger remover to remove the slinger.
Caution:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
8-9439-6858-0 (For 6HK1)



Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
6HK1 After pressing in the slinger, make sure that the
Oil seal setting tool: 8-94396-856-0 distance between crankshaft end surface and the
Install the slinger (1) to the end of adapter (2). slinger is A as specified.
4HK1
Name
Distance (A): 17.3 0.3 mm (0.7 0.01 in) 1. Adapter (Rear)
Distance (B): 10.8 0.1 mm (0.4 0.004 in) 2. Fixing Bolt
6HK1 3. Center Bolt
4. Sleeve (Rear)
5. Collar (Rear)
6. Adapter Ring (Rear)
7. Oil Seal
Special tool
4HK1
6HK1

No. Part Name Oil seal

1 Sleeve (rear)
2 Adapter (rear)
3 Collar (rear)
4 Adapter ring (rear)
5 Center bolt
Distance (A): 17 0.3 mm (0.7 0.01 in) 6 Fixing bolt
Caution:
Put a collar on the fixing bolt and mount the
adaptor onto the crankshaft.
2. Install the crankshaft rear oil seal.
Press-fit the rear oil seal using an oil seal installer,
setting tool.
* 4HK1 is shown for illustration. * 4HK1 is shown for illustration.

After you have pressed in the rear oil seal, confirm
Name
the measurement shown (depth from the end
1. Collar
surface of the crankshaft to the oil seal).
2. Fixing Bolt
3. Adapter
Apply engine oil to the lip of the oil seal and place it
in the rear side adapter.
Put the rear side adapter ring in the sleeve and put
the sleeve on the adapter and fix with the center
bolt.
Name
1. Rear Part of The Crankshaft
2. Oil Seal
3. 4HK1: 7.8 0.3 mm (0.31 0.012 in),
6HK1: 7.5 0.15 mm (0.3 0.006 in)
4. Collar
5. Adapter Ring
6. Sleeve
* 4HK1 is shown for illustration. 7. Adapter
Name
1. Sleeve
2. Adapter Ring
Tightening the center bolt until the sleeve touches

the adapter to press fit the oil seal.
Special Tool
1-8521-0027-0
Slinger remover
5-8840-2703-0
J-43282
(4HK1)
8-94396-856-0
(6HK1)
Crankshaft
Components

Name
1. Upper Bearing 5. Lower Bearing
2. Upper Thrust Bearing 6. Lower Thrust Bearing
3. Gear 7. Crankcase
4. Crankshaft
Removal 4. Remove the cylinder head.

Refer to Cylinder Head Cover. 5. Remove the fuel supply pump.
Refer to Fuel Supply Pump in the fuel system
2. Remove the rocker arm shaft.
section.
6. Remove the crankshaft front oil seal.
3. Remove the camshaft.
7. Remove the crankshaft rear oil seal. 6HK1
Refer to Oil Pan.
9. Remove the water pump.
Refer to the Water Pump in the Cooling System             
Section.
Refer to the Front Cover.
      
11. Remove the timing gear train.
Refer to the Timing Gear Train.       
12. Remove the oil pump.

Refer to the Oil Pump.
13. Remove the piston and connecting rod.            
Refer to the Pistons and Connecting Rod.
14. Remove the crankcase.
Gradually loosen crankcase mounting bolts in the
sequence shown and remove the crankcase using 
the replacer holes (arrowed holes in the figure). 15. Remove the lower thrust bearing.
4HK1 16. Remove the lower crankshaft bearings.

17. Remove the crankshaft ASM.
18. Remove the upper thrust bearing.
19. Remove the upper crankshaft bearings.
Special tool
Crankshaft gear puller: 8-9439-6819-0 (EN-41222)
Disassembly
Name
1. Remove the gear.
1. Alignment Mark
Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-6818-0 (EN-47684) Inspection
1. Thrust clearance
Set a dial gauge as shown and measure the
crankshaft thrust clearance.
If the thrust clearance exceeds the limit, replace

the thrust bearings in a pair.
Axial play of the crankshaft mm (in)

Standard 0.104 0.205 (0.0041 0.0081)
Limit 0.35 (0.0138)
Caution:
Measure the thrust clearance before dismounting.
Reassembly
1. Install the gear.
Heat the gear to 170 250 C (338 482 F) and
install it aligning the groove on the gear with the
pin on the crankshaft.
Insert the gear at one push into the flange with its
end side with the alignment mark S facing
outward. If you are fitting the gear while it is cold,
beat the gear in until it impinges on the end using
the installer.

2. Main bearing clearance Place Plastigauge on the crankshaft journal as
Remove the crankcase. shown.
Set out disassembled main bearings in the order of
the numbers. Place the lower bearings at original positions on
the crankcase.
Remove the crankshaft. Remove the main bearing.
Clean the crankshaft journal and the upper and

lower bearings.
Check the bearings for damage or excessive wear.
If you find damage or excessive wear in the check,

replace the bearings in pairs.
Place the upper bearings and the crankshaft on

the cylinder block. Install the crankshaft so that it
becomes horizontal.
Caution:
Turn the crankshaft about 30 to allow the bearings to
settle in.
Install the crankcase and tighten bolts to the

specified tightening torque.
Tighten the crankcase in the sequence shown

using a torque wrench and an angle gauge.
Tightening torque:
M14 bolt 4HK1: (1 10), 6HK1: (1 14)
2nd step = 132 N m (97 lb ft)
3rd step = 30 60
M10 bolt 4HK1: (11 27), 6HK1: 15 39)
Tighten bolts from 1 to 10 (M14) and confirm that
they are tightened to a torque of 142 N m (105
lb ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Do not rotate the crankshaft after tightening the
crankcase.
Loosen the bolts and gently remove the
crankcase.
4HK1
Measure the widest part of the Plastigauge
flattened by tightening the crankcase to determine
the clearance.
4HK1
Journal oil clearance mm (in)

Standard Limit
No.1, 2, 4, 5 0.037 0.072 0.11
(0.0015 0.0028) (0.0043)
No.3 0.051 0.086 0.11
(0.0020 0.0034) (0.0043)
6HK1
Journal oil clearance mm (in)

Standard Limit
6HK1 No. 1, 2, 3, 5, 6, 0.063 0.094 0.14
7 (0.0025 0.0037) (0.0055)
No. 4 0.093 0.124 0.14
(0.0037 0.0049) (0.0055)
           
      
      
           

If the journal oil clearance exceeds the limit, 4. Measure the journal and the crank pin diameters
replace the main bearings altogether or the and uneven wear.
crankshaft. Measure outer diameters of the journal and the pin
and calculate differences between the maximum
Remove the plastigauge from the bearing and and the minimum values. Take measurements at
crank pin. four positions for both the journal and the pin.
Inspection of crankshaft
Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil seal
contact surface for excessive wear and damage.
Check the oil port for clogging.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
4HK1
Crankshaft run-out mm (in)

Standard 0.05 or less (0.0020 or less)
Limit 0.30 (0.012)
4HK1
6HK1 Crankshaft outside diameter mm (in)
Crankshaft run-out mm (in) Standard Limit
Standard 0.06 or less (0.0024 or less) Journal #1, 2, 4, 5 81.905 81.925 81.85
(3.22460 3.22538) (3.222)
Limit 0.45 (0.018)
Journal #3 81.891 81.911 81.85
(3.22408 3.22483) (3.222)
Pin 65.902 65.922 65.850
(2.59456 2.59535) (2.5925)
6HK1
Crankshaft outside diameter mm (in)

Standard Limit
Journal No. 1, 2, 3, 81.905 81.925 81.85
5, 6, 7 (3.22460 3.22538) (3.222)
Journal No. 4 81.875 81.895 81.85
(3.22341 3.22421) (3.222)
Pin 72.902 72.922 72.850
(2.87015 2.87093) (2.8681)
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
shall not polish the surface of the crankshaft.
Selection of crankshaft bearing

When installing new crankshaft bearings or Caution:
replacing bearings in use, make reference to the Be careful about difference in the shape of the bearings
Bearing Selection Table. when installing them.
Select and install new bearings paying close
attention to the cylinder block journal internal
diameter grade and the crankshaft journal
diameter grade.
Journals are numbered from 1 to 5 (4HK1) or 1 to
7 (6HK1) from left to right when viewed so that the
numbers are in normal reading orientation.
Name
1. Upper Bearing
2. Oil Gallery
4. Oil Groove
5. Lower Bearing
Bearing selection table
4HK1
Combination of grades Oil clearance mm (in)

Cylinder block Crank journal Bearing identification #1, 2, 4, 5 #3
Grade Grade color
1 1 Black 0.039 0.070 0.053 0.084
(0.00154 0.00276) (0.00209 0.00331)
1 2 Brown 0.037 0.068 0.051 0.082
(0.00146 0.00267) (0.00201 0.00323)
2 1 Blue 0.041 0.072 0.055 0.086
(0.00161 0.00283) (0.00217 0.00339)
2 2 Black 0.039 0.070 0.053 0.084
(0.00154 0.00276) (0.00209 0.00331)
6HK1
Combination of grades Oil clearance mm (in)

Cylinder block Crank journal Bearing identification #1, 2, 3, 5, 6 #4
Grade Grade color
1 1 Black 0.065 0.092 0.095 0.122
(0.00256 0.00362) (0.00374 0.00480)
1 2 Brown 0.063 0.089 0.093 0.119
(0.00248 0.00350) (0.00366 0.00469)
2 1 Blue 0.067 0.094 0.097 0.124
(0.00264 0.00370) (0.00382 0.00488)
2 2 Black 0.065 0.091 0.095 0.121
(0.00256 0.00358) (0.00374 0.00476)
Installation
1. Install the crankshaft upper bearing.
Install the upper bearing in the cylinder block and
apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Crankshaft Bearing Grade Selection.
Do not apply oil to the bearing installation surface on
the cylinder block and external surface of the bearing.

2. Install the upper thrust bearing.
Install the upper thrust bearing in the front side of 5. Install the lower thrust bearing.
the cylinder block journal No.5 (4HK1) or No.7 Install the lower thrust bearing in the rear side of
(6HK1). In doing this, you may attach the upper the crankcase journal No.5 (4HK1) or No.7
thrust bearing to the cylinder block with grease. (6HK1).
Then, be sure to wipe up excess grease.
Install the thrust bearing so that the oil groove
Caution: contacts the crankshaft.
Install the thrust bearing so that the oil groove contacts
the crankshaft.

6. Install the crankcase.
3. Install the crankshaft ASM.
Apply liquid gasket (ThreeBond 1207B or
Apply engine oil to the crankshaft journal and
equivalent) to the crankcase forming beads with
gently place the crankshaft on the cylinder block.
diameters of 3 4 mm (0.12 0.16 in).
Press the crankshaft to the rear and insert the
Install the crankcase within 7 minutes after you
upper thrust bearing in the rear side of the cylinder
have applied the liquid gasket.
block journal No.5 (4HK1) or No.7 (6HK1).
Gently place the crankcase on the cylinder block.
Caution:
Install the thrust bearing so that the oil groove contacts
the crankshaft.

4. Install the lower crankshaft bearing.
4HK1
6HK1












Apply Molybdenum Disulfide to M14 bolts threads 6HK1
and setting faces and tighten them to the specified
tightening torque in the sequence shown.
You need not apply engine oil to M10 bolts.

           
Tightening torque:
M14 bolt 4HK1: (1 ~ 10), 6HK1: (1 ~ 14)
2nd step = 132 N m (97 lb ft)       
3rd step = 30 ~ 60
M10 bolt 4HK1: (11 ~ 27), 6HK1: (15 ~ 39)       

Tighten the bolts (M14) from 1 to 10 (4HK1) or 1 to
14 (6HK1) and confirm that they are tightened to a            
torque of 142 N m (105 lb ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B) 
7. Install pistons and connecting rods.

Caution: Refer to the Pistons and Connecting Rod.
Confirm that the crankshaft turns smoothly. 8. Install the oil pump.
4HK1 Refer to the Oil Pump.
9. Install the timing gear train.
Refer to the Timing Gear Train.
10. Install the front cover.
Refer to the Water Pump in the Cooling System
Section.
Refer to Oil Pan.
15. Install the fuel supply pump.
Refer to the Fuel Supply Pump.
Special Tool
8-9439-6818-0 8-9439-6819-0
EN-47684 J-41222
Crankshaft gear puller Crankshaft gear installer
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Cylinder Block
Components

Name
1. Cylinder Liner 2. Cylinder Block
Removal 5. Remove the fuel supply pump.

section.
6. Remove the crankshaft front oil seal.
7. Remove the crankshaft rear oil seal.
4. Remove the cylinder head.
Refer to Oil Pan.
9. Remove the water pump. If the cylinder liner cannot be pulled free by hand,
Refer to the Water Pump in the Cooling System tap around the lower side of the liner with a
Section. hammer grip or similar object loosen it.
Inspection
11. Remove the timing gear train.
Refer to the Timing Gear Train. 1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
12. Remove the oil pump.
Refer to the Oil Pump. Be careful not to damage the cylinder block.
13. Remove the piston and connecting rod. 2. Carefully remove the liquid gasket on the
Refer to the Pistons and Connecting Rod. crankcase mounting surface.
14. Remove the crankshaft. 3. Clean up the cylinder block.
Refer to the Crankshaft.
4. Visually inspect the cylinder block.
15. Remove the piston oil jet
Conduct color check and hydraulic (or pneumatic)
test and if you find crack or other damage, replace
the cylinder block.
5. Cylinder liner wear measurement

Check the internal surface of the liner for flaw or
damage.
Measure the liner bore diameter at the most worn

part (it wears more in the rotation direction) at 15
20 mm (0.59 0.79 in) from the top end of the liner
with the liner installed in the cylinder block. If the
wear is over the application limit, replace it.
16. Remove the cylinder liner.


Cylinder liner bore diameter mm (in)
Standard 115.021 115.050
(4.52837 4.52952)
Limit 115.20 (4.5354)
Caution:
You need not select cylinder liner bore grade since the
liners are only available in one size.
6. Cylinder block upper face warpage
Pull out the cylinder liners and remove water stains
on the cylinder block.
Measure four sides and two diagonals of the top

surface of the cylinder block using a straight edge
(1) and a thickness gauge (2).
Replace the cylinder block if the measurements

exceed limit values.
Cylinder block upper face warpage mm (in) Installation

Standard 0.05 or less (0.002 or less) 1. Cylinder liner grade selection
Select liner outer diameter grades according to the
Limit 0.20 (0.079)
cylinder block bore grades stamped on the cylinder
block at arrowed positions in the figure.
The cylinder liner grade is stamped on the outside

of the cylinder liner (1).
Matching the grades of the cylinder block and the

liner outer diameter
Cylinder block (stamp) 1, 2 3

Liner outside diameter 1X 3X
Cylinder block bore and liner grade mm (in)

(Reference)
Grade (1, 2) / (1X) (3) / (3X)
Cylinder 118.001 118.020 118.021 118.030
block (4.64699 (4.64649
Bore 4.64654) 4.64684)
diameter
Liner 117.991 118.000 118.001 118.010
outside (4.64531 (4.64570
diameter 4.64566) 4.64605)

(Reference)
When replacing liners, a liner set let you obtain a
piston of proper grade for a given liner bore
 diameter only by specifying a liner outside
diameter grade.
4HK1 2. Install the cylinder liners.
Install the cylinder liners perpendicular to the
cylinder block.
Do not hammer the liner or apply excessive forth to

insert it.
Caution:
Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
6HK1
3. Amount of the cylinder liner extrusion

Measure the amount of the cylinder liner extrusion
using a dial gauge.
Difference of the amount of the extrusion between
adjacent two cylinders should be within 0.03 mm
(0.0012 in).
Amount of the cylinder liner extrusion mm (in)

Standard 0.05 0.10 (0.0020 0.0039)
Caution:
Be sure to measure the cylinder liner extrusion
whenever you have replaced cylinder liners.
5. Install the crankshaft.

Refer to the Crankshaft.
6. Install pistons and connecting rods.
4. Install the piston oil jet. Refer to the Pistons and Connecting Rod.
Align the knock pin of the oil jet with the pin hole of 7. Install the oil pump.
the cylinder block and tighten with the check valve. Refer to Oil Pump.
8. Install the timing gear train.
Tightening torque: 21 N m (15 lb ft) Refer to the Timing Gear Train.
Caution: 9. Install the front cover.
Be careful not to deform or damage the oil jet nozzle. Refer to the Front Cover.
Refer to the Water Pump in the Cooling System
Section.
Refer to Oil Pan.
Refer to Fuel Supply Pump in the Fuel System
section.
Lubrication System
Precautions on Service Work Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton Always, the start and end of the application should
and apply the specified new fluid gasket at each be overlapped.
location.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
Function Check 7. Stop the engine.
Oil pressure check 8. Remove the oil pressure gauge.
1. Check whether the engine oil is contaminated with 9. Install the oil pressure switch.
dirt, light oil, or water. If contaminated with dirt, 10. Start the engine and check for oil leakage.
light oil, or water (after examining the cause and
taking the appropriate measures for light oil or Engine oil
water contamination), replace the oil. Ensure the engine is at a level ground. Before
2. Check the engine oil level. The oil level should be starting the engine or when 5 minutes or more
between the two holes of the level gauge. If the oil have elapsed after stopping the engine, check the
level is insufficient, replenish it. engine oil volume using the level gauge. The
3. Remove the oil pressure switch on the oil filter volume is appropriate if the engine oil is between
body. the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lower
4. Install the oil pressure gauge on the oil filter body.
limit. Also, check for contamination of the engine
oil.
Special tool
Oil pressure gauge: J43620-20
Hose: J43630
Connector (4HK1 only): J43630-14
Oil pressure testing adapter (4HK1 only): EN-46333
Name
1. Oil Pressure Testing Adapter (4HK1 only)
2. Connector (4HK1 only)
3. Hose
4. Oil Pressure Gauge
Name
5. Warm the engine. 1. Upper Limit
6. Measure the oil pressure, to check whether it is 2. Lower Limit
more than 343 kPa (50 psi) at 2000 rpm.
Engine oil leakage
In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
Special Tool
J-43620-20
Oil pressure gauge
J-43630
Hose
J-43630-14
Connector
(4HK1)
J-46333
Oil pressure testing
adapter
(4HK1)
Oil Port Cover ASM

Components
Name
1. Oil Pressure Switch 3. O-Ring
2. Oil Port Cover
Removal
1. Remove the oil pressure switch.
2. Remove the oil port cover.
3. Remove the O-ring.
Installation
1. Install the O-ring on the oil port cover.
Name
1. O-Ring
2. O-Ring
2. Install the oil port cover on the cylinder block and
tighten it to the specified torque.
Tightening torque:
4HK1 48 N m (35 lb ft)
6HK1 39.2 N m (29 lb ft)
Name
1. Bolt M10X L = 80
2. Bolt M10X L = 25
3. Install the oil pressure switch to the oil port cover.

Apply the liquid gasket (Loctite 262) on 2 to 3
peaks from the tip of the threaded part of the oil
pressure switch and install it at the position shown
in the figure.
Tightening torque: 41.2 N m (30 lb in)

Oil Cooler
Components
4HK1
Name
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Common Rail
6HK1
    
Name
1. EGR Cooler Water Return Pipe 4. Fuel Supply Pump
2. Oil Cooler 5. Suction Pipe
3. Common Rail
Removal
1. Remove the common rail.
section.
2. Remove the fuel supply pump.

3. Remove the EGR cooler water return pipe.
Remove the brackets to the water pipe at two
locations to make the pipe unsupported.
4. Remove the EGR cooler water feed pipe. (4HK1) Screw the removed fixing bolt of the oil cooler into
5. Remove the clip on the head side of the water the replacer hole at the location 1 of the figure and
bypass hose (4HK1) and remove the hose from remove the oil cooler.
the suction pipe ASM.
4HK1

Name
1. Bypass Hose Disassembly
2. EGR Cooler Water Return Pipe 1. Remove the element mounting bolts.
3. EGR Cooler Water Feed Pipe
2. Remove the element.
4. Suction Pipe
6HK1
 
Name Name
1. Suction Pipe 1. Element
2. EGR Cooler Water Return Pipe 2. O-Ring
6. Remove the oil cooler ASM with glow plug

controller bracket (4HK1 only). Reassembly
1. Install the O-ring on the oil cooler case.
2. Install the element.
3. Tighten the element fixing bolts using the specified
torque.
Name
1. O-Ring
* 4HK1 is shown for illustration. 2. O-Ring
3. Liquid Gasket
Name
1. Element Align the oil cooler holes with the cylinder block
2. O-Ring studs.
Install the oil cooler and glow plug controller
bracket to the cylinder block.
Installation Tighten the bolts to the specified torque in the
1. Install the oil cooler ASM. order shown in the illustration.
Apply liquid gasket (ThreeBond 1207B or Tightening torque: 24 N m (18 lb ft)
equivalent) to the flange surface groove (cylinder Liquid gasket quickly hardens.
block). Bead diameter must be between 2 and 4 Make it complete within 7 minutes after
mm (0.008 and 0.16 in). applying the liquid gasket.
Refer to the illustration for the offset position (no
more than 1 mm (0.04 in)). 4HK1
Install the O-rings (1) and (2) to the oil passage
inlet and outlet. Do not allow the liquid gasket to
contact the O-ring.
6HK1 6HK1
2. Connect the water suction pipe.

Name
Apply liquid gasket (ThreeBond 1207B) to the 1. Gasket
flange of the water suction pipe. Bead diameter 2. Suction Pipe
must be between 2 and 5 mm. Refer to the
illustration for the offset position (no more than
1 mm). (4HK1) Caution:
The water suction pipe must be installed immediately
Install the water suction pipe to the oil cooler. Refer after the oil cooler (the pipe and cooler use the same
to the illustration. liquid gasket).
4HK1
Tighten the bolts to the specified torque.

6HK1: 20 N m (15 lb ft)
4HK1
3. Install the EGR cooler water feed pipe. (4HK1)

Install the O-ring on the EGR cooler water feed
pipe.
Install at the position shown in the figure and

tighten using the specified torque.
Name
1. Liquid Gasket
4HK1
4. Install the EGR cooler water pipe.

(4HK1)
5. Install the body cover ASM LH on the surface of
the oil cooler and cylinder block and tighten it using
the specified torque. (4HK1)
6. Remove the oil drain adapter. (4HK1)
section.

section.
Oil Pan
Components

Name
1. Oil Pan Gasket 2. Oil Pan
Removal Installation
1. Drain engine oil. 1. Install the oil pan.
2. Remove the oil pan. At the seam between the cylinder block and the
front cover with the flywheel housing, apply the
liquid gasket (4H: ThreeBond 1207B or 6H:
1207C) to a bead diameter of 3 mm.
Apply the liquid gasket and install the oil pan within
7 minutes.
4HK1 4HK1
6HK1 6HK1

Install the gasket using the studs of the crankcase,

flywheel housing, and front cover as guide and Name
mount the oil pan. 1. Oil Pan
Install the rubber ASM on the oil pan and secure it 2. Gasket
using nuts and bolts.
4HK1
Tighten the locations (1), (2), (3), and (4) as shown
in the figure and then tighten others. (In any
sequence)

6HK1
Fastening the oil pan from the part of A or B in
clock wise order.
It tightens again by specified torque.
Tightening torque: 24.5 N m (18 lb ft)
Oil Pump
Components

Name
1. Oil Pump ASM 5. Driven Gear And Shaft
2. Spring 6. Oil Pump Body
3. Ball 7. Gasket
4. Split Pin
Removal 9. Remove the rear oil seal of the crankshaft.

Refer to Rear oil seal of Crankshaft.
1. Drain engine oil.
2. Drain out the cooling water.
7. Remove the fuel supply pump ASM.
section.
11. Remove the flywheel housing.
Make sure you remove the bolts shown in the
figure.
Disassembly
* 4HK1 is shown for illustration. 1. Remove the driven gear and shaft.
12. Remove the idle gear A. 2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
13. Remove the oil pump ASM and gasket.
4. Apply engine oil on the driven gear and shaft and

mount them on the oil pump body.
Measure the clearance between the gear surface
and the upper surface of the oil pump body using
the thickness gauge and square.
If the gap between the gear and the body inner

wall exceeds the limit, replace the gear ASM or the
driven gear ASM.
Clearance between the gear side surface mm (in)

and the upper surface of the oil pump body
Standard 0.064 ~ 0.109 (0.0025 ~ 0.0043)
Limit 0.20 (0.0079)
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
Measure the clearance between the gear and oil
pump body using a thickness gauge.
If the gap between the gear and the body inner

wall exceeds the limit, replace the gear ASM or the
driven gear ASM.
Clearance between the gear and inner mm (in)

wall of the body
Standard 0.125 ~ 0.220 (0.0049 ~ 0.0087) 3. Measure the clearance between the driven gear
shaft and the bush.
Limit 0.30 (0.0118) Measure the outside diameter of the driven gear
shaft using a micrometer.
Outside diameter of the driven gear shaft mm (in)

Standard 15.989 ~ 16.000 (0.62949 ~ 0.62992)
Limit 15.900 (0.62598)
2. Measure the clearance between the gear side

surface and the upper surface of the oil pump
body.
3. Install the idling gear A.
Install the idling gear shaft at the position shown in
the figure and apply engine oil on the shaft.
Rotate the crankshaft clockwise and bring the

piston of the No.1 cylinder to the top dead center.
Measure the inside diameter of the bushes of the

oil pump body and cylinder block using the dial
gauge.
If the clearance between the driven gear shaft and

bushing exceeds the limit, replace the driven gear
ASM. * 4HK1 is shown for illustration.
Match the alignment marks of the crankshaft gear
Clearance between the driven gear shaft mm (in) and the idle gear A, and install them on the
and bush cylinder block.
Standard 0.04 ~ 0.07 (0.0016 ~ 0.0028)

Limit 0.20 (0.0079)

Tighten the mounting bolts using the specified
torque.

Installation 4. Install the flywheel housing.
1. Install the gasket. Clean the rear side of the cylinder block. Remove
the protruding fluid gasket thoroughly, especially,
2. Install the oil pump ASM.
when mounting the crankcase.
Apply the liquid gasket (ThreeBond 1207B) Tightening torque: (6HK1)
uniformly on the inside surface of the bolt holes
Bolt holes marked with 1 = 96 N m (71 lb ft)
(excluding the bolt holes indicated by arrows) as
shown in the figure.
After applying the liquid gasket, quickly install it. Bolt holes marked with 4 = 53 N m (39 lb ft)
4HK1 Bolt holes marked with 5 = 73 N m (54 lb ft)
The seal is tightened from the cylinder block side.
6HK1
Align with the knock pin of the cylinder block and

install the flywheel housing.
Tightening torque: (4HK1)

4HK1
6HK1

 









Refer to Oil Pan.
6. Install the rear seal of the crankshaft.
Refer to Rear Oil Seal of Crankshaft.
8. Install the fuel supply pump ASM.
section.
12. Tighten the cylinder head cover.
Oil Pressure Switch

Inspection
Check the continuity between the switch terminal and
the body grounding in the no-load condition.
If there is no connectivity, replace with normal parts.
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
Cooling System 1B-1
ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Precautions on Service Work . . . . . . . . . . . . . . . 1B-2
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
A List of Defective Phenomena . . . . . . . . . . . . . 1B-7
Main Data and Specifications. . . . . . . . . . . . . . . 1B-7
Water Pump (4HK1) . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-11
Water Pump (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1B-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1B-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
1B-2 Cooling System
Cooling System
Precautions on Service Work Explanations on functions and operation
WARNING: Cooling water system
Do not remove the radiator cap when the cooling water The cooling water system, which is the forced
is at high temperature. Steam or boiling water will gush circulation system, consists of a water pump,
out and you may be burnt. To open the radiator cap, thermostat, and radiator as its main components. The
cover the cap with a thick cloth when the cooling water oil in automatic transmission is cooled due to the
is cool, release the pressure by slowly turning the cap, cooling water in the radiator.
and then remove the cap.
4HK1
Name
1. Water Jacket 10. Reservoir Tank
2. Drain Plug 11. Air Bleeding Plug
3. Oil Cooler 12. Water Outlet Pipe
4. Water Pump 13. Thermostat (2 units)
5. Drain Cock 14. Thermometer Unit
6. Radiator 15. Bypass Route
7. Cooling Fan 16. Turbocharger
8. Radiator Cap 17. EGR Cooler
9. Heater Core
Cooling System 1B-3
6HK1

 
 



 
 

Name
1. Water Jacket 8. Radiator Cap
2. Drain Plug 9. Reservoir Tank
3. Oil Cooler 10. Water Outlet Pipe
4. Water Pump 11. Thermostat (2 units)
5. Drain Cock 12. Thermometer Unit
6. Radiator 13. Bypass Route
7. Cooling Fan 14. EGR Cooler
1B-4 Cooling System
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.

Name
1. Fan Center 3. Impeller
2. Bearing 4. Seal Unit
Cooling System 1B-5
Thermostat
The thermostat is a wax pellet type and consists of two
units, in which one unit (bottom bypass type) has an
valve initial opening temperature of 82 C (180 F) and
the second (inline type) has an valve initial opening
temperature of 85 C (185 F). It is designed such that
the water temperature can be adjusted finely and it is
mounted within the thermostat-housing unit.
Name
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve
Function Check 6HK1

Cooling water level check Standard value
Check the cooling water level within the reserve Cooling water 14.5 L (15.3 qts)
tank and the level is appropriate when the cooling level (Engine only)
water level is within the MAX (upper limit) and MIN
(lower limit) range. In case the volume of the
Inspection
cooling water is deficient, remove the reserve tank
cap and replenish with a mixture of tap water and Cooling water leak check
engine coolant in the ratio of 1:1 until the level Use the radiator cap tester and apply a pressure of
comes close to the MAX line. 200 kPa (28.4 psi) and check for leaks in the
4HK1 locations given below. Check that the radiator hose
and heater hose are not damaged or degraded
Standard value and the hose clamp is not loose.
Cooling water 14 L (14.8 qts)
level (between MIN and MAX levels)
1B-6 Cooling System
Inspection location
Radiator ASM, water pump ASM, radiator hose,
heater hose
Coolant
1. About the engine coolant concentration
Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the
concentration of the engine coolant.
Use only genuine Isuzu engine coolant.
Use engine coolant with a mix ratio in the range
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
Name
1. Antifreeze Hydrometer
2. Radiator
Fix the temperature of the cooling water being

measured in the range of 0 to 50 C (32 to 122 F).
Measure the temperature and specific gravity and
determine the concentration from the table given
below.
Freezing Mix ratio Concentration

temperature Liter (qts) of engine
guideline coolant
Engine Tap
coolant water
-18 C (-0.4 F) 4.2 (4.4) 7.8 (8.2) 35%
-25 C (-13 F) 5.0 (5.3) 7.0 (7.4) 42%
-35 C (-31 F) 6.0 (6.3) 6.0 (6.3) 50%
-40 C (-40 F) 6.4 (6.8) 5.6 (5.9) 53%
2. Engine coolant density measurement

Methods for measuring specific gravity
Measure the specific gravity and the temperature
of the cooling water using an anti-freeze specific
gravity meter and thermometer.
Take precautionary measures as the boiled cooling
water may gush out at high temperatures if the cap
is removed.
Use a deep container to suit the height of the Coolant scooping method
specific gravity meter. Measure the concentration using the coolant scoop.
Cooling System 1B-7
A List of Defective Phenomena
Engine overheats
Engine overcools
Engine overheats
Condition Possible Cause Correction

Engine overheats Cooling water volume is deficit. Replenish.
Thermometer unit is defective. Replace.
Thermostat is defective. Replace.
Radiator pump is defective. Replace.
Radiator is clogging. Clean or replace.
Radiator cap is defective. Replace.
Engine oil volume is deficient or Replenish or change the engine oil.
incorrect engine oil is used.
Cylinder head gasket is defective. Replace.
The fan belt is loose. Adjust.
Exhaust system is clogging. Clean or replace.
The fuel injection quantity is in surplus. Diagnose the engine control system.
Fuel injection timing is incorrect. Diagnose the engine control system.
Starting pressure of fuel injection is Diagnose the engine control system.
low.
Engine overcools

Engine overcools Thermostat is defective. Replace.
Water pump Centrifugal impeller system

Pulley ratio 0.950
Thermostat Wax pellet system
Valve opening temperature C ( F) With jiggle valve 85 (185)
Without jiggle valve 82 (180)
Temperature when fully open C ( F) With jiggle valve 100 (212)
Without jiggle valve 95 (203)
1B-8 Cooling System
Water Pump (4HK1)

Components
Name
1. Fan 4. Fan Belt
2. Spacer 5. Water Pump ASM
3. Water Pump Pulley 6. Gasket
Removal
2. Remove the four mounting bolts and then the fan
ASM and spacer, water pump pulley.
Cooling System 1B-9
Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 5. Remove the gasket.
4. Bolt
3. (2) and (3) that tighten the setting plate and water Inspection
pump together. Loosen the adjusting bolts (1) in 1. Appearance check
the generator and remove the fan belt. Check for cracks or damage in the pump body.
Check for cracks and corrosion in the impeller.
Check for water leakage from the seal unit.
If you find abnormalities, replace with the water
pump ASM.
2. Bearing nut check
Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
If you find abnormalities, replace with the water
pump ASM.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
4. Remove the water pump ASM while inserting and

scraping with the driver at the position shown in
the figure.
1B-10 Cooling System
Installation
1. Install the gasket.
2. Install the water pump ASM.
Mount the water pump to match with the studs
of the front cover.
3. Temporarily fit the bolts until the water pump pulley
and the spacer and fan are properly seated in the
water pump ASM.
4. Mount the fan belt, tighten the adjusting bolts of
the generator, and adjust the tension.
Refer to the Drive Belt.
5. After fan belt adjustments, tighten the generator
using the specified torque.
Tightening torque: 76 N m (25.40 kg ft)
Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt
7. Pour coolant.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
6. After the fan belt adjustments, tighten the

temporarily fitted fan pulley and spacer and fan
using the specified torque.
Cooling System 1B-11
Water Pump (6HK1)
Removal Loosen the mounting bolt (2) and the sliding

piece nut (1).
1. Loosen the fan fixing nuts to remove the cooling
fan. Pivot the alternator at the mounting bolt toward
the center of the engine.


2. Remove the fan guide.



Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
3. Loosen the fan pulley fixing bolts.

4. Remove the fan belt.
5. Remove the adapter and fan pulley.
 
Name
1. Adapter 4. Bypass hose
2. Fan pulley 5. Water duct
3. Water pump 6. Water duct
6. Disconnect the bypass hose.

7. Loosen the fixing nuts and bolts from the water
pump.
8. Remove the water pump from the front plate.
9. Discard the gaskets.
Installation 7. Install the fan pulley and adaptor to the water
pump.
1. Install the water pump with new gaskets to the
Tighten the fixing bolts to the specified torque.
front plate. Use the locating pin.
2. Tighten the fixing nuts and bolts to the specified Tightening torque: 52 N m (38 lb ft)
torque.
Tightening torque: Nut A: 39 N m (29 lb ft)
Bolt: 20 N m (14 lb ft)
8. Install the fan belt.

9. Adjust the fan belt tension.
Depress the drive belt midway between the
3. Install the water duct with new gasket to the alternator and fan pulley.
cylinder head.
Drive Belt Deflection: 8 - 11 mm (0.31 - 0.43 in)
Tightening torque: Bolt (1) : 221.6 N m (163 lb ft)
Bolt (2) : 24.5 N m (18 lb ft)




4. Install the water duct with new gasket to the oil

cooler and water pump.
5. Connect the bypass hose.
6. Clamp the bypass hose.
10. Install the cooling fan.
Tighten the fixing nuts to the specified torque.
11. Install the fan guide.

Tighten the fixing bolts to the specified torque.



Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide





 


Disassembly














Name
1. Center 9. Shaft
2. Dust cover 10. Water pump body
3. Snap ring 11. Dowel pin
4. Bearing 12. Seal unit
5. Bearing 13. Impeller
6. Spacer 14. Gasket
7. Bearing 15. Cover
8. Washer 16. Bolt
1. Remove the rear cover from the water pump body. Inspection and Repair
2. Use a remover 1-8521-0062-0 to remove the Make the necessary adjustments, repairs and part
impeller from the water pump. replacements if excessive wear or damage is
3. Use a puller to remove the water pump center. discovered during inspection.
4. Remove the dust cover and snap ring.
Water pump impeller
5. Remove the water pump shaft with ball bearings.
Use a plastic hammer to lightly tap on the water 1. Check the impeller for corrosion.
pump shaft from the impeller side.
Water pump shaft

6. Use a bench press to remove the bearing from the
shaft. 1. Measure the water pump shaft and center or
impeller interference.
If the measured interference is less than the
specified limit, the pump shaft and / or the center
and impeller must be replaced.
Pump shaft and center interference:
Limit: 0.048 0.078 mm (0.0019 0.0031 in)
Pump shaft and impeller interference:
Limit: 0.022 0.062 mm (0.0009 0.0024 in)
7. Remove the seal unit.

2. Carefully wipe away any bearing grease. Use a bench press to gradually press the water
3. Listen for excessive bearing operating noise. pump shaft down until the bearings are seated
correctly.
Excessive bearing operating noise indicates

severe bearing wear. 2. Install the water pump shaft with bearings to the
water pump body.
Repack the bearings with multipurpose grease.
Reassembly
1. Install the ball bearing to the water pump shaft.
Apply engine oil to the water pump shaft.
Place the water pump shaft and the bearings
on the base plates.
Install the washer (4), ball bearing (3), spacer
(2), and bearings (1).
Place the water pump body on bench press

 base plate.
NOTE :
 To prevent damage to the water pump shaft, place soft
brass or copper sheets between the base plates and
the water pump shaft.
Position the pump shaft with bearings to the 4. Install the seal unit to the water pump body.
water pump body. Press in the seal unit to the specified position
Use a bench press to gradually press the water using a bench press and installer 1-85220-047-
pump shaft into the water pump body. 0.
Seal unit installation position A:
NOTE :
Do not drive the bearing into position with a hammer or 11.0 11.6 mm (0.433 0.457 in)
similar object. Bearing damage will result.
5. Install the water pump impeller to the water pump

3. Install the snap ring and dust cover. shaft.
Use pliers to install the snap ring into water Use a bench press to press in the impeller.
pump body groove. The impeller must be flush with the water pump
Install the dust cover with the flange facing out. shaft end.
6. Use a bench press to gradually press the water
pump center onto the water pump shaft to the
specified dimension.
Dimension A: 202.9 mm (7.988 in)

7. Install the rear cover with new gasket to the water
pump body.
Special tool
1-8521-0062-0
Impeller remover
1-8522-0047-0
Seal unit installer
Thermostat
Components

Name
1. Water Outlet Pipe 3. Gasket
2. Thermostat
Removal
1. Drain the coolant. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
2. Disconnect the water outlet pipe.
3. Remove the thermostat.
4. Remove the gasket from the thermostat.
Inspection
Place the thermostat in water and increase the
temperature while stirring it sufficiently.
Measure the temperature when the valve is just
opened and when it is fully open.
Installation 6HK1
1. Mount the gasket on the thermostat and mount it at
the position shown in the figure.
The thermostat with the jiggle valve (A) is
installed to the left side of the engine. The jiggle
valve faces the rear of engine.
Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.

Name
1. Thermostat
 2. Connect the water outlet pipe.


4HK1

3. Replenish the cooling water stored during the
discharge, and check the volume of the cooling
water.
Name
1. Thermostat
2. Cylinder Head
Drive Belt
Components
Name
1. Crankshaft Pulley 5. Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Adjusting Plate
4. Generator 8. Water Pump Pulley
Inspection Drive Belts Adjustment

Check for the presence of wear or damage in the drive Adjustment procedure
belt and renew the parts if necessary. Adjust simultaneously the generator drive belt for
Check the tension of the belt and adjust if necessary. adjustment of belt.
Inspection procedure 1. Loosen the adjusting plate lock nuts and the
Apply a pressure of 98 N (22 lb) at the center of the mounting bolts of generator on the underside of
long span of each belt and check the deflection of the the generator.
belt. 2. Rotate the adjusting bolts of generator and adjust
the belt (remove and fit).
Deflection of generator drive belt
When replacing the belt, you must always
When the belt is new replace both the belts.
8 to 12 mm (0.315 to 0.472 in) 3. After adjustments, tighten the adjusting plate lock
When the belt is reused nuts and the mounting bolts of generator on the
10 to 14 mm (0.394 to 0.551 in) underside of the generator using the specified
torque.
Tightening torque: 76 N m (25.40 kg ft)

Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt

Fuel System 1C-1
ENGINE
Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2
Precautions on Service Work . . . . . . . . . . . . . . .1C-2
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Fuel Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16
Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-20
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-21
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .1C-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-24
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-28
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-29
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-31
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32
1C-2 Fuel System
Fuel System
Precautions on Service Work Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
Parts of the fuel system such as the internal part of the
exposed ends of the hose or pipe.
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy. If parts are to be replaced (fuel hose, fuel pipe,
They are therefore highly sensitive to foreign matter etc.) do not open the new part packaging until
and the entry of foreign matter could cause damage to installation.
the fuel passage. Therefore, effective measures should Discard gaskets and O-rings and replace them with
be taken to prevent the entry of foreign matter. new ones.
If water removal agent is used in the fuel then it will Work procedure
absorb moisture in the light oil and may cause rust. The fuel opening must be quickly sealed when
Therefore, do not use water removal agent in the fuel removing the fuel pipe, injection pipe, fuel injector,
tank. fuel supply pump, and common rail.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the The eyebolts and gasket must be stored in a clean
system. parts box with a lid to prevent adhesion of foreign
matter.
Before beginning the service procedure, wash the
fuel line and the surrounding area. Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
Perform the service procedures with clean hands. out and make sure there is no fuel leakage after
Do not wear work gloves. starting the engine.

Fuel system diagram
 




 
 

Name
1. Common Rail 5. Fuel Tank
2. Fuel Filter 6. Supply Pump
3. Electromagnetic Pump 7. Fuel Injector
4. Pre-fuel Filter 8. Leak-Off Pipe
Fuel System 1C-3
Caution:
Be careful foreign material does not into the fuel
system, because the precise fuel system is used.
Common rail
4HK1
Name
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
1C-4 Fuel System
6HK1

Name
1. Flow Damper 3. Fuel Inlet
2. Pressure Limiter 4. Pressure Sensor
Fuel System 1C-5
Fuel supply pump
4HK1
Name
1. Fuel Temperature Sensor 4. Camshaft Key
2. Suction Control Valve 5. Camshaft Nut
3. High Pressure Pipe
1C-6 Fuel System
6HK1
 
Name
1. Fuel Temperature Sensor 3. High Pressure Pipe
2. Suction Control Valve 4. Camshaft Key
Fuel System 1C-7
Fuel injector Fuel filter
Name Name
1. Terminal Stud 1. Priming Pump
2. Part for Mounting Leak Off Pipe 2. Air Bleed
3. O-ring 3. Case
4. Part for Mounting Injection Pipe 4. Drain Plug
5. Parts Number
6. ID Code Plate
Function check
Air bleeding
1. Before starting the engine
a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
near the plug overflows.
c. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
After waiting for approximately a minute, loosen
the plug and bleed out the air in the fuel filter.
(This work must be repeated a minimum of
three times until no more air comes out from the
plug.)
d. Tighten the plug firmly and wipe the fuel in the
surrounding area. Operate the priming pump
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine.
1C-8 Fuel System
2. After starting the engine
a. Start the engine by rotating the starter without
depressing the accelerator pedal.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum. (Repeat
this operation several times)
e. Rotate the idling knob counterclockwise and
return to idling mode.
Caution:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.
Water drain
It is designed that the float inside of the water
sedimenter floats when water accumulates.
When the float level goes up to the aluminum body
section, be sure to drain the water.
Water draining procedure

Loosen the air bleed plug at the top of the water
sedimenter. Then loosen the drain plug to drain the
water inside of it. After draining, tighten each plug
Name
securely. Then bleed air from the fuel.
1. Fuel Pressure/Vacuum Gauge ASM
2. Fuel Pipe (Discharge Side)
Fuel system vacuum check
3. Fuel Pressure/Vacuum Gauge Adapter (4HK1
Use this procedure to measure the vacuum (negative only)
pressure) discharge side the fuel system.
4. Loosen the air bleeding plug on the supply pump.
Important:
5. Use your hand to operate the fuel filter priming
The fuel pressure/vacuum gauge ASM (gauge (1)) and
pump. Operate the pump until all the air has been
the fuel pressure/vacuum gauge adapter (adapter (5))
bled from the system.
must be cleaned before connecting to the fuel line.
Otherwise, foreign material adherent to the tools may 6. Start the engine and allow it to idle.
damage the fuel supply pump. 7. Note the gauge (1) reading. If the reading is
normal, go to Step 8. If the fuel vacuum is greater
1. Disconnect the fuel hose from the fuel filter than the specified value, there is a problem in the
housing. (fuel supply pump side). fuel system. Perform the procedures outlined
below.
2. Install the adapter.
Standard fuel vacuum Less than 17 kPa (170 mbar)
Special tool Replace the cartridge fuel filter element.
Fuel pressure/vacuum gauge adapter (4HK1 only):
EN-47667 Check the fuel delivery pipe. If it is clogged, it must
be replaced.
3. Connect the gauge (1) with hose to the adapter
(3). Remove the fuel pipe at the fuel filter inlet. Use
high-pressure air forced through the fuel pipe to
Special tool clean the fuel system.
Fuel pressure/vacuum gauge ASM:
Caution:
J-44638
Remove the fuel filler cap before applying high-
pressure air.
Fuel System 1C-9
Do not perform this procedure if the fuel tank is
nearly full (fuel approaching or flowing into the fuel
filler neck). The forced air will spray fuel from the
fuel filler neck.
8. Remove the gauge (1) and hose from the adapter
(3).
9. Remove the adapter (3).
10. Connect the fuel hose.
11. Use your hand to operate the fuel filter priming
pump. Operate the pump until all the air has been
bled from the system.
12. Start the engine and allow it to idle.
13. Inspect the fuel system for fuel leakage.
Special Tool
EN-47667
Fuel pressure/vacuum
gauge adapter
(4HK1)
J-44638
Fuel pressure/vacuum
gauge ASM
1C-10 Fuel System
Fuel Filter ASM

Components
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Removal
1. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
2. Remove the bolts for mounting the fuel filter.
3. Remove the fuel filter ASM.
Installation
1. Install the fuel filter ASM.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Bleed out the air.
Refer to Fuel System.
Fuel System 1C-11
Fuel Filter Element

Removal Special tool
Main filter wrench: 8-9801-3170-0
1. Remove the case using the filter wrench.
Special tool Special Tool

Main filter wrench: 8-9801-3170-0
2. Remove the Fuel Filter element. Illustration Tool Number/Description
8-9801-3170-0
Main filter wrench
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Installation
1. Assemble the Fuel Filter element.
2. To simplify air bleed, fill light oil in the case.
3. Tighten the case by hand. During this process take
adequate care that the light oil that is inside does
not flow out.
4. Use the filter wrench and tighten rotating by 1/3 to
2/3.
1C-12 Fuel System
Fuel Injector
Components
4HK1
Fuel System 1C-13
6HK1





 



Name
1. Fuel Injection Pipe Clip 7. EGR Adapter
2. Fuel Injection Pipe 8. EGR Cooler
3. Fuel Injector Leak-Off Pipe 9. EGR Valve
4. Fuel Injector 10. Cylinder Head Cover
5. Fuel Injector Clamp 11. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 12. Fuel Injector Terminal
The fuel system consists of many tiny holes and Caution:

spaces that allow the movement of fuel from one place To avoid electric shock;
to another. These holes and spaces are milled to Set the switch to the OFF position and disconnect
extremely high precision. This is especially true of the battery negative cable before checking or repairing the
fuel injectors. fuel injector, wiring or/and connectors.
The fuel injector is very sensitive to foreign material. Removal
Foreign material will result in fuel system breakdown.
1. Remove the engine harness, the EGR valve, the
Exercise great care not to allow the entry of foreign
pressure sensor, and all of the fuel injector
material into the fuel system or fuel injectors during the
connectors.
removal and installation procedure.
2. Remove the EGR valve and the EGR adapter.
1C-14 Fuel System
3. Tape the EGR case holes shut to prevent the entry
of foreign material.
4HK1
Name
6HK1 1. Cylinder Head Cover
5. Alternately loosen the fuel injector terminal nuts a


little at a time in sequence. Several loosening
cycles should be required before the nuts are
loose.
6. Loosen the fuel injector harness bracket bolts.
Remove the inside connector and the harness
bracket.
7. Remove the fuel injector leak-off pipe.
 8. Remove the lower cover.

Name
1. EGR Adapter
2. EGR Valve
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak Off Pipe
Fuel System 1C-15
9. Remove the fuel injection pipe clips and the
injection pipes.
4HK1
6HK1
Name
1. Sliding Hammer
2. Remover
11. Mark each fuel injector with the number of the

cylinder from which it was removed. Store the fuel
injectors in a safe place. Position the fuel injector
so that the nozzle is protected.
Caution:

Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
Name will result in injector failure.
2. Pipe Clip Recording Fuel Injector Flow Rate Information from
the QR plate on the replaced injector housing;
10. Loosen the fuel injector clamp fixing bolts and Record all numbers of replaced fuel injector's from QR
remove the fuel injectors. plate.
If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the
leak-off pipe attachment part on the fuel injector. Use a
sliding hammer to force the fuel injector clamp off the
fuel injector.
Caution:
Do not remove the fuel injector sleeve.
Special tool
Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019 (J-23907)
1C-16 Fuel System
3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown
in the illustration.
7. Use a spanner to carefully the sleeve nuts until the
fuel injector pipes contact the fuel injector and
common rail.
8. Tighten the fuel injection pipe clips to the specified
torque.
Name
1. QR Plate
2. Fuel Injector Flow Rate
3. Fuel Injector
Installation
Important:
Install each of the fuel injectors on its original position.
(the cylinder from which it was removed)
1. Install a new gasket and O-ring to each of the fuel
injector clamps. Refer to the illustration.
Name
2. Pipe Clip
9. Final tighten the injection clamp bolts to the

specified torque.

10. Tighten the injection pipes to the specified torque.
Name
1. Gasket
2. Fuel Injector
3. Bolt
4. Fuel Injector Clamp
2. Apply molybdenum to the threads and seating

surfaces of the clamp bolts.
Fuel System 1C-17
4HK1

6HK1
Name
1. Clamp Bolt
2. Sleeve Nut
11. Install the nozzle leak off pipes together with the
new gaskets. Tighten the pipes to the specified
torque.
14. Install the fuel injector terminal nuts to the injector.

15. Alternately tighten each nut 2 or 3 turns at a time
until the specified torque is reached.
Caution:
Do not overtighten the nuts. Damage to the terminal
studs will result.
12. Install the fuel injector harness connectors. Work
from the inside out.
13. Install the harness bracket and tighten the bolts to
the specified torque.
6HK1: 22 N m (16 lb ft)
1C-18 Fuel System
Name
1. Fuel Injector * 4HK1 is shown for illustration.
2. Harness
Name
3. Terminal Nut
1. EGR Adapter
2. EGR Valve
16. Install the gasket to the cylinder head cover.
17. Install the cylinder head cover and tighten the bolts 20. Attach the engine harness connectors. Each
to the specified torque. composite connector should make a loud click
Tightening torque: 4HK1: 18 N m (13 lb ft) when it is securely attached.
6HK1: 13 N m (9.6 lb ft) Before Programming the Fuel Injector Flow Rate
Important:
DO NOT program the fuel injector flow rate unless you
are directed by a service procedure or you are directed
by a service bulletin. Programming the fuel injector at
any other time will not permanently correct a customers
concern.
Ensure the following conditions are met before
programming the ECM.
System voltage for machine
There is no charging system concern. All
charging system concerns must be repaired
before programming the ECM.
Battery voltage is greater than 12 volts but less
than 16 volts. The battery must be charged
before programming the ECM if the battery
voltage is low.
A battery charger is NOT connected to the
machines battery. Incorrect system voltage or
* 4HK1 is shown for illustration. voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
Name
1. Cylinder Head Cover Turn OFF or disable and system that may put a
load on the machines battery.
18. Install the gasket to the EGR valve and tighten the The ignition switch is in the proper position. DO
bolts to the specified torque. NOT change the position of the ignition switch
during the programming procedure, unless
Tightening torque: 24 N m (17 lb ft) instructed to do so.
19. Install the gasket to the EGR adapter and tighten All tool connections are secure.
the bolts to the specified torque. RS-232
Fuel System 1C-19
The connection at the data link connector
(DLC) is secure.
Voltage supply circuit
DO NOT disturb the tool harness while
programming. If an interruption occurs during the
programming procedure, programming failure or
ECM damage may occur.
Surrounding environment
Surrounding temperature must be between 0
and 50 C during the programming procedure.
Excessively low or high temperature may cause
the programming failure or ECM damage.
Electromagnetic interference (EMI) on the tool
harness and ECM may cause the programming
failure or ECM damage.
Fuel Injector Flow Rate Programming Procedure
1. Connect the scan tool to the data link connector.
2. Connect the RS-232 to the scan tool and PC.
3. Start TIS 2000 and select the Service
Programming System (SPS).
4. In the "Select Diagnostic Tool and Programming
Process" screen, select the following menu.
Diagnostic tool "Pass-Thru".
Select Programming Process "Reprogram
ECU".
ECU Location on the Machine.
Then, follow the SPS screen instructions.
5. Ensure that ALL programming contents are
entered correctly and were programmed
successfully by turning OFF the ignition for 30
seconds.
6. Using the scan tool to check each programmed
fuel injector flow rate.
7. Start the engine and let idle.
8. Inspect for a proper engine running condition and
for no DTCs. Refer to the Diagnostic System
Check Engine Control if needed.
1C-20 Fuel System





Fuel System 1C-21
Special Tool
5-8840-0019-0
J-23907
Sliding hammer
5-8840-2826-0
EN-46720
Fuel injector remover
1C-22 Fuel System
Fuel Supply Pump

Components

Name
1. Fuel Leak Off Pipe 5. Bracket
2. Fuel Pipe 6. Bracket O-ring
3. Fuel Supply Pump 7. Drive Gear
4. O-ring 8. Oil Drain Adapter
The fuel system consists of many tiny holes and

spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.
Fuel System 1C-23
Removal
1. Remove the intake pipe and case ASM.
2. Remove the fuel pipe and fuel leak-off pipe.
4HK1

6. Use a gear puller to remove the fuel supply pump
gear and the bracket O-ring.
6HK1

7. Loosen the 3 bolts holding the fuel supply pump
bracket. Remove the bracket and the O-ring.
3. Disconnect the fuel feed hose.
4. Disconnect the connector of fuel temperature Caution:
sensor and the common rail pressure regulator Do not hold the high pressure pipe, during the
from the fuel supply pump. supply pump removal procedure.
5. Remove the fuel supply pump. Do not grasp the high pressure pipe, when moving
the supply pump form one location to another.
Note:
A single bolt (1) secures the pump and the flywheel
housing.
1C-24 Fuel System
Name Name
1. Fuel Supply Pump 1. Fuel Supply Pump
2. O-ring 2. O-ring
3. Fuel Supply Pump Bracket 3. Fuel Supply Pump Bracket
3. Align the fuel supply pump shaft key and gear.

Install the gear and tighten the nut to the specified
Installation torque.
1. Install the O-ring to the fuel supply pump. There is a round alignment mark on the gear (white
2. Install the pump to the bracket and tighten the 3 paint).
bolts to the specified torque.
Caution:
Take care not to twist the O-ring.
Name
1. Fuel Supply Pump
2. Fuel Supply Pump Gear
3. Nut
Fuel System 1C-25
4. Apply white paint to the top of the fuel supply pump 6HK1
gear tooth directly above the stamped O mark.
Refer to the illustration.
6. Remove the oil drain adapter.

7. Install the O-ring to the fuel supply pump.
8. Align the slits as shown in the illustration.
5. Turn the crankshaft in the normal direction of
9. Insert the stud bolts into the guides and
engine rotation until the No. 1 or No. 4 cylinder is
temporarily tighten them.
at TDC on the compression stroke.
Refer to the illustration. Caution:
4HK1 If the stud bolts (cylinder block side) have been
loosened or replaced, apply Loctite 262 to the
recessed portion of the bolts.

Check that the round alignment mark (white paint)
is positioned as shown in the illustration when
viewed from the plug hole. If necessary, reposition
the gear.
Tighten the stud bolts and the nuts to the specified
torque.
Tightening torque Nut: 50 N m (37 lb ft)
Bolt: 76 N m (56 lb ft)
1C-26 Fuel System
14. Install the case ASM.
Apply the liquid gasket and mount within 7
minutes.

4HK1
Name
1. Plug Hole
2. Alignment Mark
10. Apply a light coat of engine oil to the O-ring.

6HK1
11. Install the oil drain adapter to the plug hole.
15. Install the fuel pipe and fuel leak-off pipe.

16. Start and idle the engine.
Important:
In order to make the fuel supply pump characteristic
Name learn into the ECM, let the engine idle until warm-up. If
1. Oil Drain Adapter the fuel system DTC' stored in the meantime, once
2. O-ring clear DTD and warm-up the engine again.
12. Connect the fuel temperature sensor and the

suction control valve connectors to the fuel supply
pump.
13. Connect the fuel feed hose.
Fuel System 1C-27

1C-28 Fuel System
Common Rail
Components
4HK1
Name
1. Fuel Leak Off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Common Rail
4. EGR Cooler 9. Common Rail Bracket
5. EGR Adapter
Fuel System 1C-29
6HK1

Name
1. Fuel Leak Off Pipe 5. EGR Adapter
2. Fuel Pipe 6. Injection Pipe Clip
3. EGR Valve 7. Injection Pipe (#1 to #6)
4. EGR Cooler 8. Common Rail
Parts of the fuel system such as the internal part of the Cover the removed fuel hose with a lid, keep it
fuel injector, holes and clearances that form passages facing upward and secure it using wire, etc.
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter Note:
and the entry of foreign matter could cause damage to Cover the areas exposed during part removal to
the fuel passage. Therefore, effective measures should prevent the entry of foreign material into the fuel
be taken to prevent the entry of foreign matter. system.
3. Disconnect the connected of common rail pressure
sensor, and all the connectors.
Removal
1. Remove the air intake pipe. 5. Tape the EGR case holes shut to prevent the entry
Disconnect the connector for the intake air of foreign material.
temperature sensor.
2. Remove the fuel leak off hose from the leak off
pipe.
1C-30 Fuel System
4HK1 4HK1
6HK1 6HK1
 

 
Name Name
1. EGR Adapter 1. Fuel Injection Pipe
2. EGR Valve 2. Pipe Clip
6. Remove the injection pipe clip and remove the 7. Remove the fuel pipe.
injection pipes.
Note:
Note: Cover the areas exposed during part removal to
Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel
prevent the entry of foreign material into the fuel system.
system. 8. Remove the clip and the fuel leak off pipe.
Note:
Cover the areas exposed during part removal to
prevent the entry of foreign material into the fuel
system.
Fuel System 1C-31
4HK1
Name Name
1. Fuel Leak Off Pipe 1. Common Rail Bracket (4HK1)
2. Common Rail
6HK1
Disassembly
1. Remove the fuel pressure limiter.
4HK1
Name
1. Fuel Leak Off Pipe
9. Remove the common rail and the common rail

bracket.
Caution:
Do not grasp the pressure sensor, during the
common rail removal procedure.
Take care not to damage the connector unit of the
pressure sensor.
1C-32 Fuel System
6HK1 6HK1
 
 
 
 
Name Name
1. Common Rail 1. Common Rail
2. Pressure Sensor 2. Pressure Sensor
3. Pressure Limiter 3. Pressure Limiter
Reassembly Installation
1. Install the fuel pressure limiter. 1. Tighten the common rail bracket to the specified
Tightening torque: 172 N m (127 lb ft) torque. (4HK1)
4HK1
2. Tighten the common rail to the specified torque.
6HK1: 25 N m (18 lb ft)
Caution:
Do not grasp the pressure sensor, during the
common rail removal procedure.
Take care not to damage the connector unit of the
pressure sensor.
Fuel System 1C-33
6HK1
 

* 4HK1 is shown for illustration. 
5. Tighten the injection pipe and the clip using the

Name specified mounting torque.
1. Common Rail Bracket (4HK1)
Injection pipe sleeve nut
2. Common Rail
3. Tighten the fuel leak off pipe (1) using the
Injection pipe clip
mounting eyebolt and the clip using the specified
torque. Tightening torque: 6 N m (52 lb in)
Tightening torque 4HK1 (2): 18 N m (13 lb ft) Apply a thin coat of engine oil on the periphery of
6HK1 (2): 10 N m (7.4 lb ft) the sleeve nut on the fuel injector side and
4HK1 (3): 12 N m (104 lb in) assemble.
6HK1 (3): 14.2 N m (125 lb in) 4HK1
4HK1 (4): 8 N m (69 lb in)
4HK1 (7): 6 N m (52 lb in)
6HK1 (7): 8.8 N m (78 lb in)
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the specified torque.
Tightening torque (6): 44 N m (33 lb ft)
(8): 44 N m (33 lb ft)
4HK1
1C-34 Fuel System
6HK1 6HK1
 

 
Name Name
1. Fuel Injection Pipe 1. EGR Adapter
2. Pipe Clip 2. EGR Valve
6. Install the gasket to the EGR valve and tighten the

bolts to the specified torque.

7. Install the gasket to the EGR adapter and tighten
the bolts to the specified torque.

4HK1
Fuel System 1C-35
4HK1
1C-36 Fuel System
6HK1


 








Engine Electrical 1D-1
ENGINE
Engine Electrical
TABLE OF CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . .1D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . .1D-2
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .1D-3
General Description . . . . . . . . . . . . . . . . . . . . . .1D-3
Generator (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6
Torque Specifications . . . . . . . . . . . . . . . . . . . . .1D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-7
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .1D-14
General Description . . . . . . . . . . . . . . . . . . . . .1D-14
On-vehicle Service: Starting System . . . . . . . .1D-15
Starter (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Torque Specifications . . . . . . . . . . . . . . . . . . . .1D-17
Main Data and Specifications. . . . . . . . . . . . . .1D-18
Preheating System . . . . . . . . . . . . . . . . . . . . . . .1D-26
Glow Plug Replacement. . . . . . . . . . . . . . . . . .1D-26
Precautions on Service Work . . . . . . . . . . . . . .1D-27
A List of Defective Phenomena . . . . . . . . . . . .1D-27
Main Data and Specifications. . . . . . . . . . . . . .1D-28
Starter (6HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-29
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-29
Sectional view (reference) . . . . . . . . . . . . . . . .1D-30
Output Characteristic (reference). . . . . . . . . . .1D-31
Disassembly and Inspection of Starter. . . . . . .1D-32
Assembly of Starter . . . . . . . . . . . . . . . . . . . . .1D-38
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . .1D-42
Generator (6HK1) . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-44
Disassembly and Inspection of Generator . . . .1D-45
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-51
Bench Testing. . . . . . . . . . . . . . . . . . . . . . . . . .1D-52
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . .1D-53
1D-2 Engine Electrical
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound will be called out. The correct torque value
must be used when installing fasteners that require it. If
the above conditions are not followed, parts or system
damage could result.
Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a 120-amp,
selfrectifying type with a built-in regulator. The battery
discharge indicator light is mounted in the instrument
panel.



 



Name
1. Generator 8. Plate
2. Lower Mount Bolt 9. Bolt
3. Nut 10. ACG Adjust Bolt
4. Spring Washer 11. Sliding Piece
5. Washer 12. Washer
6. Bracket 13. Adjust Nut
7. Bracket Mount Bolt
Maintenance Electrical Tests
The most common indication of charging system Before performing the following generator electrical
troubles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, the first step not defective and generator belts are not slipping. Also,
should be to check its condition as described under the battery must be fully charged for a valid test of the
Diagnosis of Battery. In the case of an undercharged charging system.
battery, check for battery drain caused by grounds or Notice:
by accessories left turned on. To avoid damage to the vehicle electrical system,
Keep the generator and all other electrical system always observe the following precautions:
terminals clean and tight. A loose or badly corroded Do not polarize the generator.
terminal connection will create excessive resistance in
Do not short across or ground any of the terminals
the system and result in hard starting, dim lights etc.
in the charging circuit except as specifically
Inspect the generator system at regular intervals and
instructed herein.
correct any potential causes of trouble before machine
performance is affected. NEVER operate the generator with the output
terminal open-circuited.
Diagnosis of Charging System
Be sure the generator and battery have the same
Trouble in the charging system will be evidenced as ground polarity.
one or more of the following three conditions:
When connecting a charger or booster battery to
1. The battery discharge warning light will stay on. the vehicle battery, connect negative to negative
2. An undercharged battery as evidenced by slow and positive to positive.
cranking. 1. With the engine control switch ON and engine not
3. An overcharge, or overvoltage, condition. running, connect a voltmeter from terminal E to
ground. The voltmeter should show 0 volts.
Undercharged Battery 2. With the engine control switch ON, and engine
Inspection not running, connect a voltmeter from terminal B
1. Accessories to be sure none were left on for to ground. The voltmeter should read at least 24
extended periods. volts.
2. Drive belt for proper tension. Refer to Generator 3. With the engine control switch ON and the engine
Drive Belt later in this section. not running, connect a voltmeter from white wire
side of the connector to ground. The voltmeter
3. The ECM main relay has been ON stuck at the should show 24 volts.
ignition switch OFF position. (Battery voltage is
consumed.) 4. With the engine control switch ON and the engine
not running, the charge light should be on. This
4. Refer to Diagnosis of Battery earlier in this shows that the other circuit in the connection is
section. working.
5. Wiring and connections for corrosion or looseness. 5. With the engine running and the headlight high
Overcharge (or Overvoltage) condition beams turned on, read the voltage at the B post
A charging rate in excess of 29.5-volts for a prolonged on the generator. The voltmeter should read at
period may cause early electrical system failure. least 24 volts.
Blown fuses. light bulbs burned out, and even battery 6. If steps 1 through 4 are not OK, check connectors
failure may result. If this condition exists, test the in the harness for looseness or corrosion and
generator as described under Generator Output Test retest.
later in this section. 7. If step 5 voltage is low, substitute a known good
regulator and test again. If the voltage is still low,
Noisy Generator bench test the generator.
Inspection
1. Drive pulley for looseness.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
Generator noise may also be caused by worn or
damaged diodes and/or starter.
Generator (4HK1)
Removal
Battery negative cable.
1. Electrical wiring at the generator.
2. Loosen the adjust nut.
3. Loosen the ACG adjust bolt.
4. Loosen the lower mount bolt.
5. Drive belt
6. Generator. 2. ACG Adjust bolt.
3. Adjust nut.
Installation Tightening torque:
Lower Mount Bolt 76 N m (56 lb ft)
1. Generator.
Tightening torque: 4. Electrical wiring at the generator.
Lower Mount Bolt 127 N m (94 lb ft) Battery negative cable.


Specifications Connector terminal
Isuzu Part No. 8973750170 Wire

Terminal symbol Lead wire color
specifications
Nominal output (V-A) 24-50
R R AEX 0.75f
Rated speed (rpm) 5000
L L AEX 0.75f
Regulator-type IC type
Regulated voltage (V) 28.5 1
Weight (kg) 9.5
 
Name
1. R Terminal
2. L Terminal
Internal connections
 



Disassembly of generator




 

 













Disassembly Procedure
1. Screw 13. Collar
2. Cover 14. Ball Bearing
3. Through Bolt 15. Rotor Assembly
4. Rotor, Front Bracket Assembly 16. Screw
5. Nut, Washer 17. Field Coil Assembly
6. Pulley 18. Stator Assembly
7. Fan 19. Holder
8. Collar 20. Regulator Assembly
9. Screw 21. Bolt (B terminal)
10. Retainer 22. Condenser
11. Ball Bearing 23. Rectifier Assembly
12. Front Bracket Assembly is the reverse order of disassembly.
Inspection and repair of generator 3. Diode for initiating excitation, Resistor
Check the continuity between connector terminals
1. Diode
R and L with a tester (at 100 range). Normal
Check the continuity of forward and inverse
diodes and resistors show low resistance in
directions with a tester. Normal diodes show low
forward direction and high resistance in inverse
resistance in forward direction and high resistance
one.
in inverse one.
Judge that they are faulty other than those above.
4. Field coil
2. Condenser
Charge the condenser with a tester (at 1000 To judge the insulating condition of field coil,
range), and connect a tester lead inversely. Judge measure between the protrusion portions and core
it as normal if the needle on a meter deflects a little of the coil with a tester (at 1000 range). Judge
and returns to the original position. as faulty if it has continuity.
Measure between the protrusion portions of field Judge as normal if there is continuity between N
coil with a tester, and judge as normal if the lead of stator coil and three leads.
resistance is about 6.7 (20 C).
6. Bearing
5. Stator coil Check if the bearing rotates smoothly or has no
To judge the insulating condition of stator coil, noise.
measure between the stator coil and core with a If the result of the inspection is unsatisfactory,
tester (at 1000 range). Judge as faulty if it has replace the bearing.
continuity.
Performance test
In the performance test of generator, connect as
follows and measure the regulated voltage and output
current.
Actual wiring diagram for performance test of IC regulator built-in generator
   
    
1. Voltmeter 5. Clamp Tester Ammeter
2. R Terminal 6. Battery 24 V
3. L Terminal 7. Variable Resistor
4. Charging Lamp 24 V-3 W
Regulated voltage measurement of regulator Measurement of the output current

Close SW1 switch, and warm-up five to ten minutes at Close SW1 and SW2 switches, and raise the generator
approx. 1500 rpm in generator until an ammeter shows speed to 5000 rpm. While keeping the voltmeter
6 A or less. showing 27 V, measure the maximum value of output
After confirming that an ammeter shows between 2 and current with a variable resistor.
6 A, set the generator between approx. 3000 to 4000 In this time, judge as normal if the output current is 50
rpm. If an voltmeter shows between 27.5 and 29.5 V, A or more.
the regulated voltage of regulator is normal.
If the ammeter shows 6 A or more, charge the battery Caution:
for a while or replace it with full-charged battery. Do not cut off battery circuit during generator
Replace the regulator if the voltmeter shows out of rotating.
range between 27.5 and 29.5 V. Do not connect to L terminal if the charging lamp
(24 V-3 W) is not used.
Specified value of regulated voltage
Never connect L terminal and B circuit directly.
27.5 V 29.5 V (+25 C) Diode for excitation may be broken.
Handling of generator
Be careful with the following when handling a
generator.
Connecting the polarities of battery inversely
causes generator diode to be broken.
While the engine runs, NEVER disconnect the
wiring of battery terminal and charging circuit.
Wiring connection to terminal must be performed
properly according to terminal symbol.
Do not perform megger test on semiconductor
device.
Be sure to disconnect the battery terminal ( )
before inspection on equipment.
Do not open/close the battery relay switch while
the engine runs.
Disconnect the battery terminal when charging
from external source such as quick charge.
Do not pour steam cleaner or water directly on it.
After connecting to B terminal and E terminal,
tighten them to the following torque.
B terminal 4.9 N m {50 kgf cm}
E terminal 4.9 N m {50 kgf cm}
Refer to Belt Adjustment for tension adjustment
of V-belt.
Trouble and Action
Action to be
Trouble symptom Trouble location Trouble cause
taken
Charging is Wiring and Open or short circuit, disconnection
Repair
impossible. ammeter
Generator. Open circuit, short to ground, short circuit in each coil Replace
Broken diode Replace
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Insufficient Wiring Open or short circuit, looseness in connection Repair
charging
Generator. Looseness of generator driven belt Repair
Layer or short circuit in field coil Replace
Layer or short circuit in stator coil Replace
Defective diode Replace
Poor contact in each terminal Repair
Excessive Regulator Defective regulator.
Replace
charging
Unstable charging Wiring Intermittent contact or nearly disconnected connection
Repair
current in wiring
Generator. Looseness of generator driven belt Repair
Short circuit or nearly disconnected connection in field
Repair
coil
Short circuit or nearly disconnected connection in stator
Repair
coil
Poor contact in each terminal Repair
Noisy generator Generator. Improper installation of generator Repair
Defective bearing Replace
Contact of rotor core and stator core Repair
Defective diode Replace
Short circuit in stator coil Replace
Starting System
General Description
Starter and Glow Plug Relays

The starter is a 5 kilowatt, non-reduction drive model. The starter circuit starts at the batteries. The battery
The gear housing and armature end bearing housings cable goes to the large terminal on the starter.
are aluminum. The brush ASM has replaceable From that terminal wires lead to the engine control
brushes. The commutator bars are mica insulated and switch and the starter relay.
are undercut.
Name
1. Starter 3. Ground Cable
2. Nut 4. Bolt
Maintenance
Keep the starters exterior clean. Remove corrosion
from the terminals, leads, and connectors.
Tighten the starter to engine mounting bolts and the
electrical cable retaining nuts.
Diagnosis of Starting System If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the
No Cranking, No Sound voltage is 18 volts or more, repair the starter. If the
Discharged batteries. Turn on the headlights and voltage is less than 18 volts, clean and tighten the
check the brightness. If the headlights are dim, positive cable connections. If the voltage is still less
charge the batteries. Check for the cause of the than 18 volts, replace the positive cable.
discharged batteries.
Sulfated battery terminals. Turn on the headlights. On-vehicle Service: Starting System
The headlights will be bright. Attempt to start the
engine. The headlights will be very dim or go out. Maintenance
Clean all the battery terminals and cable ends.
Keep starter terminals and all other terminals in the
A starter that draws too much current. electrical system clean tight. A loose or corroded
Starter relay wont work. Attempt to start and listen connection or terminal will cause excessive resistance
for a click at the starter relay. If there is no click, in the system that will result in hard starting. At regular
check the starter relay control terminals with a test intervals, inspect the starting system to locate and
light. If the test light shows that power is getting to correct potential causes of trouble before the system
the starter relay, check the ground circuit with the performance is affected. Starting motors do not require
test light. If the ground circuit is OK, replace the lubrication.
starter relay.
Engine control switch start circuit wont close.
With the engine control switch turned to start,
check the starter relay with a test light. If the test
light doesnt come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
Starter relay power circuit isnt closing. Attempt to
start. The starter relay clicks. Check the
secondary terminals with a test light. If the test light
lights on the battery side only, replace the starter
relay. If the test light lights on both terminals, check
for an open at the starter.
Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
cranking the engine. If voltage is OK, replace the
starter.
Slow Cranking, Solenoid Clicks or Chatters

Discharged batteries. Turn on the headlights and
check the brightness. If the headlights are dim,
charge the batteries. Check for cause of
discharged batteries.
Check the battery terminal for corrosion. Hint: Test
for warm terminals. Clean all the battery terminals
and connectors.
Loose or dirty connections. Measure the cranking
voltage at the battery terminals. If the voltage is
less than 18 volts, load test the battery. If the
battery is bad, replace the battery. If the battery is
good, repair the starter.
If the voltage is 18 volts or more, measure the voltage
from the battery NEGATIVE terminal to the engine
block. If the voltage is 0.5 volt or more, repair the
ground cable and connections.
Starter (4HK1)
Removal
1. Battery negative cable from the battery.
2. Cables and electrical leads from the starter.
3. Two mount nuts.
4. Starter.
Installation 3. Cables and electrical leads to the starter.
1. Starter 4. Battery negative cable to the battery.
2. Two mount nuts.
Tightening torque:
Mount nuts 82.4 N m (60 lb ft)

Model (Manufacturer) Nikko Electric Industry Co., Ltd

Rating Voltage V 24
Power output kw 5
Time Sec. 30
Number of pinion teeth 11
Revolution direction (viewed from pinion side) Clockwise
Weight (approx.) N {kg} 78.4 {8}
No load Current/Voltage A/V 85 or less/24
characteristic
Speed/Voltage rpm/V 3300 or more
Load characteristic Current/Voltage A/V 500 or less/18.5
Torque N m {kgf m} 28.4 {2.9} or more
Speed rpm 1250 or more
Locking Current/Voltage A/V 1400 or less/9
characteristic
Torque N m {kgf m} 88.2 {9.0} or more
Connections (Nikko Electric Industry Co., Ltd)




 


 



  
Name
1. Starter Relay 3. Motor
2. Battery 4. Magnetic Switch
S.S Starter switch

Ar Armature
Fc Field coil
C1 Pressure coil
C2 Holding coil
C3 Starter relay coil
P1 Sub contactor
P2 Main contactor
Disassembly of starter
24 V 5.0KW (Nikko Electric Industry Co., Ltd)


 

  
 

 

 










Name
1. Clip Ring 15. Ball
2. Pinion Stopper, Pinion, Spring 16. Rubber Bushing
3. Lead Wire 17. Plate
4. Bolt 18. Spring
5. Magnetic Switch 19. Pin
6. Screw 20. Holder
7. Bolt 21. Shift Lever
8. Rear Bracket 22. E Clip
9. Brush Holder ASM 23. Overrunning Clutch ASM
10. Yoke ASM 24. Internal Gear
11. Armature 25. Washer
12. Cover 26. Drive Shaft ASM
13. Packing 27. Front Bracket ASM
14. Idle Gear Assembly is the reverse order of disassembly.
Inspection and repair of starter Contact Point Check
Service limit of contact point is judged by damaged
1. Magnetic switch
condition on contact surface in the following procedure.
Never perform operational check on magnetic
Measure the load current on starter. Replace it if
switch as single unit.
voltage drop between terminals B and M is 0.3 V or
Inspection of coil more per 100 A.
Check the pressure coil C1 and holding coil C2 for
open circuit using a tester. Caution:
Check the continuity between magnetic switch and Use a digital voltmeter to measure voltage drop. Using
M terminal. It has open circuit if no continuity. an analog voltmeter may damage itself.
(Resistance approx. 1.6 )
2. Armature
Supply 24 V between M terminal of magnetic Bentness measurement of shaft
switch and case, push the plunger by hand, and Measure with a dial gauge, and repair or replace if
then release it. It is normal if it is not sucked. Coil is bentness is 0.05mm or more.
defective if it is sucked.
Caution:
Perform this while the magnetic switch is set up.
Inspection of commutator Inspection of armature coil
Check the surface of commutator. File the Using a growler tester, put probe on a armature
surface smooth with No.400 to 600 sand paper core. It is normal if probe does not vibrates.
if it is rough. Repair with a lathe if deflection is Check with a tester. It is normal if there is no
0.1mm or more. continuity between commutator and shaft.
Measure the depth of undercut and repair if it is 3. Field Coil

0.2mm or less.
Check the field coil for open circuit with a tester. It
is open circuit if there is no continuity between M
terminal in field coil and lead wire on brush side.
Check between field coil and yoke with a tester. It
is normal if there is no continuity between them.




Name
1. Repair is needed
2. Improper repair
3. Good
4. Overrunning clutch
Outside diameter of commutator
Measure the outside diameter of commutator with Rotate the pinion by hand. It is normal if it is
a slide-caliper. If the measured value is less than rotated smoothly in one direction only.
the limit, replace it. Check the pinion tooth surface. Replace if it has
worn or damage.
mm
Caution:
Standard Limit If the entire overrunning clutch is soaked in liquid when
32.4 31.4 washing it, internal grease flows out, causing seizure.
6. Bearing
Check if the bearing outer race rotates smoothly by
hand.
5. Reduction gear
Check the reduction gear. It is normal if it has no
wear.
7. Brush height
Measure the brush height. If it is less than the limit,
replace the brush.
mm
Standard Limit
17 18 10
Handling of starter
1. Precautions on handling
Improper gap between pinion and ring gear causes
faulty mesh. (Gap 2 Ñü 5mm)
Also, the front bracket is installed on the engine
side securely.
Be sure to turn off the battery switch before
removal/installation of stater.
Tightening/inserting wiring must be performed
properly. Improper work causes starting trouble
due to high contact resistance.
2. Precautions on starting
Be careful with charging status of battery.
Insufficiently-charged battery causes starting
trouble.
After checking engine starting, turn off the stater
switch immediately.
One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.
If the starter does not stop rotating when the starter
switch is turned off, turn off the battery switch
immediately. In this case, check the wiring, switch,
etc.
Trouble countermeasure
Trouble symptom Trouble cause

Starter does not operate when 1. Full discharge of battery
starter switch is turned on. 2. Open circuit, poor contact
3. Poor contact in starter switch or improper tightening of terminal
4. Poor contact in starter relay or plug terminal
5. Short or open circuit in magnetic switch coil
Pinion moves forward but it does not 1. Insufficient capacity of battery
engage with ring gear. 2. Improper gap of pinion and ring gear
3. Wear of pinion or ring gear tooth edge
4. Dust on pinion shaft
5. Insufficient auxiliary rotation of armature due to insufficient thrust gap
of motor
Pinion engages and rotates motor 1. Slippage of clutch
but it does not run engine. 2. Breakage of reduction gear
Pinion engages but it does not run 1. Insufficient capacity of battery
engine. 2. Too high rotational resistance of engine
3. Improper tightening of wiring circuit terminal
4. Short circuit of armature or field coil
5. Contamination of commutator
6. Fatigue or wear of brush spring
7. Locking of bearing
8. Poor contact in magnetic switch
When turning starter switch off, 1. Retuning failure of starter switch contact
starter does not stop after engine 2. Retuning failure of starter relay contact
starts.
3. Short circuit in magnetic switch coil
Preheating System
Glow Plug Replacement
Precautions during maintenance

Adequate care should be taken as over-tightening the
glow plug could lead to damage.
Removal Procedure
1. Remove the engine harness, the EGR valve, the
pressure sensor, and all of the fuel injector
connectors.
3. Tape the EGR case holes shut to prevent the entry
of foreign material.
Installation Procedure
1. Install the glow plug.
2. Install and tighten the glow connector with the
designated torque.
Tightening torque: 1.2 N m (9 lb ft)
3. Install the EGR valve and the EGR adapter.
Name
1. EGR Adapter
2. EGR Valve
4. Remove the glow plug connector.

5. Remove the glow plug.
Name
1. EGR Adapter
2. EGR Valve
4. Attach the engine harness connectors. Each

composite connector should make a loud click
when it is securely attached.
Precautions on Service Work
Adequate care should be taken as over-tightening the
glow plug could lead to damage.
The preheating system consists the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and make the engine easy to start.
Function check
Refer to the 6E section (Glow control system check).
Except the glow plug.
Glow plug check
Use the circuit tester and measure the resistance
of the glow plug.
If the measured value deviates from the specified
value, then replace the glow plug.
Resistance value of glow plug is approximately
less than 5 .
Caution:
Use a set of four glow plugs from the same
manufacturer.

The glow indicator lamp does not light up.
Preheating does not work.
Preheating time is too long or too short.
Trouble Shooting
The glow indicator lamp does not light up.

The glow indicator lamp does not Slow blow fuse has blown. Replace the slow blow fuse.
light up. Fuse is unavailable. Replace the fuse.
Indicator valve is burnt out. Replace the indicator valve.
Engine control system is faulty. Refer to the 6E section.
Preheating does not work.

Preheating does not work. Slow blow fuse has blown. Replace the slow blow fuse.
Defective or faulty glow plug relay Re-mount or replace the glow plug
connector contact. relay.
Preheating time is too long or too short.

Preheating time is too long or too Thermo-sensor fault and break in Replace the thermo-sensor. Repair
short. circuit or short circuit. the circuit.
Fault in glow plug. Replace or tighten the glow plug.
Item Model
Preheating device model Glow plug
Glow plug rated voltage/ current (V-A) 23 3.5
Starter (6HK1)
Specifications
Manufacturer Mitsubishi Electric Co.

Isuzu Part No. 181100-4140
Manufacturer code No. M008T60971
Power output (V-kw) 24-5.0
Rating (Sec) 30
Outside diameter of yoke (mm) 85
Revolution direction Right
Protection Dust-proof, drip-proof
Reduction mechanism Internal gear
Weight (kg) 7.2
Pinion Module 3
Pressure angle 14.5
The number of teeth 11
Gear ratio {ring gear/pinion gear} 12.8 {129/11}
No load Voltage (V) 23
Current (A) 85 or less
Revolution speed (rpm) 3,300 or more
Restraint Voltage (V) 9
Current (A) 1,400 or less
Torque N m {kgf m} 88 {9} or more
Pinion engagement voltage (V) 16.0 or less
Sectional view (reference)
 


   

Name
1. Through Bolt 8. Pinion
2. Bearing 9. Bearing
3. Rear Bracket 10. Front Bracket
4. Brush Holder 11. Gear
5. Magnetic Switch 12. Yoke
6. Shift Lever 13. Armature
7. Gear Shaft
Output Characteristic (reference)
   

  
   
   
 
   


   
   
   

   
   
        


Disassembly and Inspection of Starter

Disassembly diagram: disassemble in the order of the numbers.


 







 

  

  
 
 
 



1. Snap Ring 16. Plate
2. Stop Ring 17. Packing
3. Pinion 18. Packing
4. Pinion Spring 19. Plate
5. Lead Wire with Terminal 20. Planetary Gear
6. Screw 21. Lever
7. Magnetic Switch 22. E-shaped Retaining Ring
8. Screw 23. Overrunning Clutch
9. Through Bolt 24. Internal Gear
10. Rear Bracket 25. Washer
11. Yoke Assembly 26. Gear Shaft
12. O-Ring 27. Front Bracket
13. Brush Holder 28. Bearing
14. Armature 29. Washer
15. Ball 30. Brush
Disassembly
Caution:
Before disassembling the starter, put alignment 
marks on each magnet switch, yoke front bracket
and rear bracket to facilitate re-assembly. 
In normal condition, if tap the pinion or stop ring 

toward the front bracket side, the front bracket will 

be broken. Therefore, tap the stop ring when the


pinion come out to cranking position.
1. Connect the starter to battery as shown in the
illustration.
When closing the switches SW1 and SW2, the
pinion move forward to the cranking position and
the armature rotates.
Then, open the switch SW2 to stop the armature
rotating.
Caution:
Remove the pinion within 10seconds since heat is Name
generated during electric discharge. 1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
5. Pipe

6. Pinion Spring


 3. Remove the nut on M terminal of magnet switch

 and remove the lead wire with terminal.

 Caution:
 Tightening screw is tight. Use a shock driver to loosen.

4. Remove the brush holder-tightening screw and
through bolt.
Then, remove the rear bracket and O-ring

together.
Caution:
Do not reuse the removed O-ring.
 Also, do not reuse also O-ring on tightening screw.
2. Apply the pipe, which just fits the stop ring, on the 5. Apply a socket (outside diameter 32mm) on a
ring and tap the pipe with a hammer to remove the commutator of armature.
stop ring toward the pinion side once. Then, slide the brush on the socket to yoke
Then, remove the snap ring and remove the stop assembly and O-ring.
ring, pinion and pinion spring. This facilitates to re-assemble.
Caution: Caution:
Do not reuse the snap ring. Do not reuse the removed O-ring.
6. Remove the brush from brush holder by pulling up
the brush spring, and then remove the brush
holder.
7. Remove the armature.
Remove a bearing using a general puller.
8. Remove the plate in planetary gear and remove
the packing.
Then, remove the packing and plate on the lever
support.
9. Remove the internal gear, gearshift, overrunning
clutch and lever as a unit from front bracket.
10. Remove the lever. Check the armature coil for grounding (faulty
insulating) with a circuit tester.
Caution: Replace the armature if grounding is present.
Remember the direction of lever.
11. Remove the two E-shaped retaining ring.
To remove the overrunning clutch, rotate the spline
by one tooth to remove it from gearshift assembly.
Caution:
Do not reuse removed E-shaped retaining ring.
12. Remove the internal gear.
In this time, take out one washer which adjusts
axial play of gearshift.
Inspection and maintenance

1. Armature
Check the armature coil for internal short circuit
with a growler tester.
Replace the armature if internal circuit is present.
Check the outside of commutator for wear.

Replace the armature if wear exceeds limit.
Check the depth (undercut) of insulating mold of Check the coil for grounding (faulty insulating) with
commutator. a circuit tester.
Remove abrasion powder on brush, and repair if Repair or replace the yoke assembly if grounding
faulty. is present.


3. Brush
Name
1. Good Measure the length of the brush.
2. Insulating If it is worn to the limit, replace the brush holder
3. Commutator Segment assembly on the brush holder as a unit and only
4. Defective brush on the yoke assembly side.
Make sure the brush moves smoothly in the brush
Check the gears for wear or damage. holder. Also, check the brush spring pressure.
Replace the armature if fault is present.
Check the bearings for noise, rattle or grease
leakage.
2. Field coil
Check the coil for open circuit with a circuit tester.
Replace the yoke assembly if open circuit is
present.
Check the brush holder for grounding (faulty
insulating) with a circuit tester.
Clean the brush holder before checking.
Replace the brush holder assembly if the
continuity is present when putting one probe of
circuit tester to brush holder plate (metal part) and
another one to insulated holder.
5. Front bracket
Check the bearing and oil seal, and replace the
front bracket assembly (including bearing, oil seal)
if faulty.
6. Internal gear and planetary gear
Check the internal gear and planetary gear, and
replace them if excessive wear or damage is
Name present.
1. Brush Length 7. Lever
2. Insulated Holder It the portion which contacts the overrunning
switch is worn, the protruded position of pinion will
4. Overrunning clutch and pinion be faulty.
Hold the housing of overrunning clutch by hand. (Refer to 4. Assembly section to adjust the
Make sure that the pinion can be rotated by hand protruded position of pinion.)
with a light resistance in one direction and cannot
be in the opposite direction. Replace the
overrunning clutch if faulty.
Check the pinion, and replace it if wear or scratch
is present.
Caution:
Grease is present in overrunning clutch. Do not use
wash oil or cleaning agent for cleaning.
Wipe off stain on overrunning clutch with a cloth.
Name
1. Worn Part
8. Magnetic switch
Check the continuity between the M terminal and
the body, and replace the magnet switch if no
continuity is present.
Then, make sure that no continuity is present
between B terminal and M terminal. Replace the
magnet switch if continuity is present.
 
Name
1. M Terminal
2. S Terminal
3. B Terminal
Assembly of Starter
Assembly diagram: Assemble in the order of the numbers.



 







 

  

  
 
 
 



Assembly Procedure
1. Brush 16. Ball
2. Washer 17. Armature
3. Bearing 18. Brush Holder
4. Front Bracket 19. O-Ring
5. Gear Shaft 20. Yoke Assembly
6. Washer 21. Rear Bracket
7. Internal Gear 22. Through Bolt
8. Overrunning Clutch 23. Screw
9. E-shaped Retaining Ring 24. Magnetic Switch
10. Lever 25. Screw
11. Planetary Gear 26. Lead Wire with Terminal
12. Plate 27. Pinion Spring
13. Packing 28. Pinion
14. Packing 29. Stop Ring
15. Plate 30. Snap Ring
1. Lubricant locations and tightening torque
  
 
 
 


   

Lubricant locations
Shown in
the Lubricant locations Lubricant agent
illustration
A Sleeve bearing and ball Molycote AG650
B Clutch shaft sliding surface MULTEMP 6129
C Spline portion and sliding portion of gearshift MULTEMP 6129
D Sliding portion of lever and overrunning clutch Molycote AG650
E Armature shift gear, planetary gear, internal gear Molycote AG650
F Under pinion MULTEMP 6129
G Outer surface of armature bearing (tiny amount) MULTEMP 6129
H Oil seal MULTEMP 6129
I Surface of plunger (tiny amount) MULTEMP 6129
2. Axial play of armature shift Pass the gear shaft through washer, internal gear
Adjustment is unnecessary (assemble the ball into and overrunning clutch. Then move the
a tip of shaft.) overrunning clutch by one tooth of spline to make
3. Axial play of gear shaft sure that the clutch cannot be pulled out.
Adjustment is unnecessary Assemble the E-shaped retaining ring.
Appropriate gap will be obtained automatically
when one washer (removed in step 12 of Caution:
disassembly procedure) is inserted between Do not reuse removed E-shaped retaining ring.
internal gear and gearshift.
4. Assembly of gearshift
If assembling the E-shaped retaining ring prior to
the overrunning clutch, the clutch cannot be
assembled. Be careful with it.



 


Name
1. Pinion
2. Clutch Shaft
Name 3. Snap Ring
1. Overrunning Clutch 4. Stop Ring
2. Washer 5. Pinion Spring
3. Gear Shaft
4. E-shaped Retaining Ring 6. Check of the pinion protruded position
5. Internal Gear After assembling the starter, check the protruded
position of pinion.
5. Assembly of pinion How to measure and adjust
Assemble the pinion spring, pinion and stop ring to Connect the starter to battery.
clutch shaft in this order, then assemble the snap When closing the switches SW1 and SW2, the
ring to the groove of clutch shaft at the end. pinion move forward to the cranking position
Then, pull strongly the stop ring toward the snap and the armature rotates.
ring side with a gear puller and fix both of them. Then, open the switch SW2 to stop the
armature rotating.
Caution:
Assemble the pinion before assembling the
magnet switch to front bracket.
Do not reuse the removed snap ring.
Push into or pull back a tip of the crankshaft
lightly by hand and measure the moving
distance of it.
Adjust by using one or two packings (0.5mm) of
magnet switch and front bracket so that this
measurement value is between 0.5 2.0mm.
If this adjustment cannot be done, replace the
lever.
 
 


Name
1. Battery 24 V





No Load Test
1. After adjusting the protruded position of pinion,
connect the starter as shown in the illustration
above.
Caution:
Use a thick electric wire and tighten the connected    
portion securely. 
2. Close the switch and read the speed, current and 
voltage.
  
If the measured values are out of specified value,

disassemble and inspect again.
Name
1. Battery 24 V
2. Ammeter
3. Voltmeter
Specifications
Item Standard value or limit

No load Voltage (V) 23
characteristic
Current (A) 85 or less
Speed (rpm) 3,300 or more
Commutator Outside diameter (mm) 32
Limit (mm) 31.4
Commutator Undercut (mm) 0.5
Limit (mm) 0.2
Brush Length (mm) 18
Limit (mm) 11
Brush spring Pressure (N) 29 39
Limit (N) 13.7
Protruded position of pinion (mm) 0.5 2.0
Generator (6HK1)
Specifications
Manufacturer Mitsubishi Electric Co.

Isuzu Part No. 1-81200-633-0 1-81200-603-2
Model by manufacturer A009TU3782 A004TU6285
Nominal voltage (V) 24
Output current (A) 90 50
Rated speed (rpm) 5000
Output current/Voltage (A/V/rpm) 114/27/5000 50/27/5000
No load voltage (V/rpm) 24/900
Revolution direction Clockwise
Polarity ( )
Pulley diameter (P. C. D) (mm) 90 80
Charging Circuit

  

 
 
 



Name
1. Field Coil 5. Key Switch
2. Stator Coil 6. Battery 24 V
3. Diode Trio 7. IC Regulator
4. Charging Lamp 8. Generator
Charging circuit and internal circuit are shown in the illustration above.
Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.
Structure
 






Name
1. Rear Bracket 6. Rotor
2. IC Regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front Bracket
5. Stator 10. Coil Assembly (Field Coil)
This generator has no brush. terminal (for direct current output), L terminal and R
Main parts are a rotor, stator, rectifier assembly, front terminal.
bracket, rear bracket, IC regulator, bearing, pulley and The L terminal is connected to field coil. Therefore, as
so on. well as R terminal, it becomes input terminal for
Moving parts are a rotor and pulley. A field coil is initiating excitation current until the generator starts to
secured to rear bracket. generate electric power.
Six main diodes and two additional diodes are used to It also provides function as output terminal. (Current
convert three-phase alternating current, generated in capacity is 1 A.)
stator coil, into direct current. Among six main diodes, The charging lamp will be off if the voltage on L
there are three positive diodes and three negative terminal reaches battery voltage.
diodes. Both bearings are sealed, therefore periodic lubricant is
In addition, three tiny diodes, called trio diode, are used not necessary.
to supply field current. IC regulator cannot be disassembled. Handle it as
This generator has three terminals, which are B assembly.
Disassembly and Inspection of Generator

 


 





Name
1. Nut Washer 9. Ball Bearing
2. Pulley, Fan 10. Screw
3. Collar 11. Cover
4. Through Bolt 12. Rectifier Assembly
5. Front Bracket 13. Regulator Assembly
6. Ball Bearing 14. Stator Assembly
7. Retainer 15. Field Coil Assembly
8. Rotor Assembly


 




 







Name
1. Nut Washer 10. Ball Bearing
2. Pulley, Fan 11. Field Coil Assembly
3. Key 12. Connector Set
4. Collar 13. Screw
5. Through Bolt 14. Terminal Set
6. Front Bracket 15. Cover
7. Ball Bearing 16. Rectifier Assembly
8. Retainer 17. Regulator Assembly
9. Rotor Assembly 18. Stator Assembly
Disassembly 2. Hold the rotor with a vise without deforming the

rotor ball.
Caution: Remove the nut which fixes pulley, and remove the
To facilitate re-assembly, put alignment marks on front pulley, fan, spacer and front bracket.
bracket and rear bracket before disassembly.
1. Remove out the four through-bolts. Caution:
Pry between stator and front bracket with a tip of Do not lose a half-moon key when removing the pulley.
flathead screwdriver and separate the front bracket
Caution:
pulley rotor assembly from stator rear bracket
To hold the rotor with a vise, grip the portion A. Portion
assembly carefully.
B is not strong enough to be gripped.
Caution:
Take care not to damage the stator coil.
5. To remove the coil assembly from rear bracket,
firstly remove the screw A (which fixes coil terminal
portion to IC regulator).
Removing a screw B (which fixes the coil assembly
to rear bracket) prior to screw A may cause

damage to terminal portion.
Hold the coil assembly by hand not to damage to
terminal portion.
Then, remove the screw B and remove the coil
assembly.
 


Name
1. Ball
3. If the front bearing needs to be removed, remove

the screw which fixes retainer, and push out the
bearing using appropriate socket.

Caution:
Do not remove it if not necessary. Do not reuse the
removed bearing.
4. If the rotor bearing needs to be removed, it can be Name
done by a general bearing puller. 1. Connector
Caution: 6. Disconnect the connector.

Do not remove it if not necessary. Do not reuse the 7. Remove the cap and nut from terminal bolt of
removed bearing. rectifier.
Pry between rear bracket and B terminal assembly
to remove the B terminal. A tube remains on rear
bracket.
Caution:
Do not lose the tube.
 








Name
1. IC Regulator 8. Cap
2. Rectifier 9. Nut
3. B terminal 10. Terminal Bolt
4. Terminal Bolt 11. Terminal Bolt
5. B terminal 12. Terminal Bolt
6. Cap 13. Rectifier
7. Nut




Name
1. IC Regulator 4. B terminal
2. Terminal Bolt 5. Tube
3. Nut 6. Rectifier
8. Remove two screws which fix rectifier and two

screws which fix regulator.
Remove the stator and rectifier assembly from rear
bracket as a unit.
Then, remove the IC regulator.
9. Disconnect four lead wires of stator coil and
remove the stator from rectifier.

Caution:
Lead wires of stator coil are soldered (melting point:
230 C) on rectifier terminal.
Disconnect them quickly (within five seconds) not to
heat the rectifier causing damage to diode.
Inspection
1. Stator
Check visually for damage, loose connection and
discoloration of coil.
Check the continuity between two lead wires of Name
stator coil with a circuit tester. Replace the stator if 1. Stator Coil Lead
no continuity is present.
Check the continuity between lead wire of stator
coil and core with a circuit tester. Replace the
stator if continuity is present.
2. Rotor 4. Rectifier assembly
Check the bearings for noise, rattle or grease Check the continuity between positive diode,
leakage (wipe off if tiny amount of grease). additional diode positive heat sink on positive side
Replace it if faulty. It is easier to check for noise and four diode terminals with a circuit tester.
and rattle when it is press-fitted into shaft than The positive diode has short circuit if continuity is
when it is a single unit. present in both directions. Replace the rectifier
assembly.
The positive diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
Negative diode and additional diode on negative
side

Check the continuity between negative heat sink
and four diode terminals with a circuit tester.
The negative diode has short circuit if continuity is
present in both directions. Replace the rectifier
assembly.
The negative diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.

Diode trio (three tiny diodes)
Check the continuity in both directions with a circuit
tester.
The diode is faulty if continuity is present in both
directions or no continuity is in both directions.
Name Replace the rectifier assembly.
1. Stator Coil Lead
2. Core
3. Coil assembly
Measure the resistance between terminal portions 
with a circuit tester.
Replace the coil assembly if the value is out of
specified value.
 

Name

1. Diode Terminal Portion
2. Positive Diode
3. A Part of Negative Diode
5. Front bearing
Check the bearings for noise, rattle or grease
leakage (wipe off if tiny amount of grease).
Name Replace them if faulty. It is easier to check for
1. Terminal noise and rattle when the bearing is press-fitted
2. Terminal Portion into bracket than when it is a single unit.
6. Regulator
The regulator cannot be checked with a circuit
tester. After re-assembling the generator, check it
to make sure that regulator controls the voltage for
generator.
Assembly
Assembly can be performed in the reverse order of
disassembly. However, be careful with the following.
1. Lubrication is not necessary. Bearing is filled with
grease and is sealed.
Caution:
Keep a bearing with resin band for rotor shaft away
from oil. Wipe off oil on bearing box area of rear
bracket. Oil may cause creep.
2. Use a high temperature solder (melting point:
230 C).
Using a soldering iron (with 180 270 watt),
soldering must be performed quickly (within five
seconds) not to heat the rectifier.
3. Tightening torque
Pulley fixing nut:
132 162 N m {13.5 16.5 kgf cm}
Through bolt:
12.8 18.6 N m {1.3 1.9 kgf cm}
Bearing retainer fixing screw:
2 5.3 N m {20 54 kgf cm}
Coil assembly fixing screw:
2 5.3 N m {20 54 kgf cm}
Rectifier fixing screw:
2 5.3 N m {20 54 kgf cm}
Regulator fixing screw:
2 5.3 N m {20 54 kgf cm}
Nut for B terminal bolt:
4.9 8.7 N m {0.5 0.9 kgf cm}
4. Assembly of rear bracket to stator assembly and
front bracket to rotor assembly
The rotor bearing and rear bracket are engaged
tightly. Heat the bearing box area of rear bracket to
50 60 C prior to assembly.
After re-assembling the generator, rotate the pulley
to confirm that the rotor rotates smoothly.
Bench Testing 4. Set the generator speed to approx. 5000 rpm and
read an ammeter. If the value is 5 A or less, read
Bench testing is performed as follows.
indication on a voltmeter. This is regulated voltage.
If an ammeter shows 5 A or more, keep charging
Regulated voltage check
for a while until it shows below 5 A or replace the
1. Wire as shown in the illustration. battery with full-charged one.
Use an ammeter with 100 A rating and a voltmeter If regulated voltage is out of specified value,
with 30 V rating. replace the regulator.
Output current test

Output current test is performed to check if the
generator generates rated output.
1. After checking regulated voltage, decrease the
 
generator speed until it stops.
 2. Close the switch 1. The lamp should come on.
  3. Set the value of no load resistance to maximum

 (minimum current) and close the switch 2.
  
 4. Increase the generator speed to 5000 rpm and
 
keep it. Adjust the load resistance so that output
current becomes maximum.
Keep this condition 15 minutes and increase in
temperature of the generator.
15 minutes later, set the generator speed to the
specified speed (2500 and 5000 rpm) and then
adjust the load resistance so that output current
becomes maximum in this condition.
Name In this time, if indication of ammeter is within
1. Voltmeter specified value, the generator is normal.
2. Ammeter If it is less than specified value, check the
3. Lamp (24 V, 3 W or less) generator again according to Inspection on page
4. Key Switch 1 4.
5. Battery (24 V)
6. Key Switch 2
7. Load Resistance
2. Close the switch 1. Leave the switch 2 open.

In this time, the lamp comes on.
If it does not, check the voltage on L terminal.
If the voltage is almost the same as battery
voltage, check the generator.
If the voltage is low, lamp or the circuit is open.
3. Increase the generator speed gradually.
Make sure that the lamp goes off before the speed
reaches approx. 1300 rpm.
Notice the voltage. If the voltage is not controlled
and exceeds 30 V, the IC regulator may be faulty.
If the voltage does not exceed battery voltage, the
generator does not generate electric power.
Check the generator again.
If the lamp does not go off, check the generator
again.
Trouble Diagnosis
Symptom Trouble cause

No generation of a. Defective IC regulator
electric power b. Open circuit in field coil
Low output a. Defective diode
b. Defective stator coil
c. Defective rectifier
d. Internal short circuit in field coil
Too high regulated a. Defective IC regulator
voltage
Noise a. Defective bearing
b. Defective rectifier
c. Foreign material in generator
Specifications
Item Standard value and limit

Isuzu Part No. 1-81200-633-0 1-81200-603-2
Manufacturer code No. A009TU3782 A004TU6285
Rated output (V-A) 24-90 24-50
Output Voltage (V) 27 27
characteristic (hot)
Current (A) 105 or more 42 or more
Revolution speed (r/min) 2,500 2,500
Voltage (V) 27 27
Current (A) 114 or more 50 or more
Revolution speed (r/min) 5,000 5,000
Field coil resistance ( : at 20 C) 4.3-5.0 4.4-5.1
Regulated voltage by regulator (V) 28-29 28-29
Revolution direction (viewed from pulley side) Clockwise Clockwise
Exhaust System and Turbocharger 1F-1
ENGINE
Exhaust System and Turbocharger
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2
Precautions on Service Work . . . . . . . . . . . . . . . 1F-2
Explanations on Functions and Operation . . . . . 1F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . . 1F-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 1F-5
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
A List of Defective Phenomena . . . . . . . . . . . . . 1F-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
Table of Specifications. . . . . . . . . . . . . . . . . . . . . . 1F-7
Turbocharger Structured Diagram. . . . . . . . . . . . . 1F-8
Disassembly and Inspection of Turbocharger . . . . 1F-9
Assembly of Turbocharger . . . . . . . . . . . . . . . . . 1F-15
Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . 1F-20
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-20
1F-2 Exhaust System and Turbocharger
EGR System
Precautions on Service Work Explanations on Functions and Operation
Perform EGR related assembly according to the usual Re-circulate a part of the exhaust gas of the EGR
procedure of temporarily fitting and then permanently system in the intake manifold. Reduce the combustion
tightening the parts so that unnecessary stresses are temperature and inhibit NOx generation since inert
not applied on the parts. gases may be mixed up in the intake air.
An electronic control system is used in this EGR to
balance the requirements of operability and low
emissions. A DC motor is operated using the control
current of the Engine Control Module (ECM) to control
the EGR.
Refer to the chapter on Engine Control System for
details on fault diagnosis of the EGR system.
Name
1. EGR Cooler 3. EGR Valve DC Motor
2. Engine Control Module (ECM)
EGR Valve and EGR Cooler

Components
Name
1. EGR Adapter 4. EGR Pipe
2. Cooling Water Pipe (out) 5. Cooling Water Pipe (in)
3. EGR Cooler 6. EGR Valve
Removal
2. Disconnect the EGR valve connector.
3. Remove the EGR pipe.
2. Install the EGR cooler.
Temporarily fit the EGR cooler to the bracket.
Notice:
Temporarily tighten the bolts.
3. Install the EGR adapter.
Temporarily fit the EGR adapter between the EGR
cooler and exhaust manifold.
Notice:
4. Install the EGR pipe.
Insert the gasket between the two ends of the EGR
pipe and temporarily fit it.
Notice:
During temporary assembly, tighten the nuts
* 4HK1 is shown for illustration. and bolts to the specified torque in the order
shown in the illustration.
Name
1. EGR Adapter
2. Cooling Water Pipe (out)
3. EGR Cooler
4. EGR Pipe
5. Cooling Water Pipe (in)
4. Remove the cooling water pipes.

5. Remove the EGR adapter.
6. Remove the EGR cooler.
7. Remove the EGR valve.
Caution:
After removing the EGR valve and EGR adapter, seal
so that foreign matter does not enter.
Inspection
Gas leak check

Check for gas leak in various parts of the EGR gas
line.
If the results of the check show abnormalities, repair or
replace the defective parts.
EGR valve check

Refer to the chapter on Engine Control System for
details on the method of checking the EGR valve.
Installation Name
1. Mount the EGR valve. 1 ~ 9 Show the Order of Tighten Bolts and Nuts.
Insert the gasket and temporarily fit the EGR valve. Tightening torque
Notice: 1, 2: 28 N m (21 lb ft)
Temporarily tighten the bolts. 3, 4, 5, 6: 24 N m (17 lb ft)

Exhaust System
Vibration or rattling noise from the exhaust system
Clogging of exhaust system
Exhaust leakage or noise
Troubleshooting
Vibration or rattling noise from the exhaust system

Vibration or rattling noise Loose or misaligned components Match the joints and then re-tighten.
from the exhaust system Or, check for damage in the hanger,
mounting brackets and clamps.
Clogging of exhaust system

Clogging of exhaust system Clogging or deformation of the exhaust Repair or replace the exhaust piping.
piping
Exhaust leakage or noise

Exhaust leakage or noise Defect or misalignment in mounting Match the joints and then re-tighten.
Damage or burn-out of exhaust piping Replace the damaged part.
or silencer
Defective components in the exhaust Replace the defective part.
system (clamps, pipes, silencer)
Internal damage to silencer Replace the silencer
Table of Specifications
Nominal Assembly
Item Service limit
dimension specifications
Turbine shaft Axial play (mm) 0.06 0.09 0.11
Radial play (mm) 0.10 0.17 0.205
Journal outside diameter (A) (mm) 11.380
Sealing groove width (B) (mm) 1.33
Runout (mm) 0.11
Sealing Turbine side (bearing housing) (F) (mm) 17.03
insertion part Compressor side (seal plate) (H) (mm) 14.05
Oil thrower Sealing groove width (G) (mm) 1.52
Bearing Bearing housing inner diameter (B) (mm) 16.11
housing Thrust bearing inside diameter for (L) (mm)
23.020
press-fit portion
Thrust Bearing pad height at compressor side (J) (mm) 0.0 0.060
bearing
Thrust collar thickness (K) (mm) 2.950

 
 

 
Turbocharger Structured Diagram
 
 
 
 
Name
1. Turbine Housing 6. Seal Plate
2. Heat Protector 7. Compressor Impeller
3. Floating Metal 8. Seal Ring
4. Oil Thrower 9. Seal Ring
5. Compressor Housing 10. Turbine Shaft
Disassembly and Inspection of Turbocharger

Disassembly diagram: disassemble in the order of the numbers.
 
















1. Compressor Housing 10. Seal Ring
2. Nut 11. Gasket
3. Compressor Impeller 12. Heat Protector
4. Seal Plate 13. Thrust Bearing
5. Oil Thrower 14. Thrust Collar
6. Seal Ring 15. Snap Ring
7. G Coupling 16. Floating Metal
8. Turbine Housing 17. Thrust Bearing
9. Turbine Shaft 18. Bearing Housing
Disassembly 1. Compressor housing
Put alignment marks between the compressor
Inspection Prior to Disassembly housing and the seal plate, and tap the
Measurement of axial play of turbine shaft compressor housing to drive it out.
Liquid gasket is applied to the mating surfaces of
Axial play mm the compressor and the seal plate.
Assembly specifications 0.06 0.09
Caution:
Service limit 0.11
Take care not to damage the impeller during removal of
the compressor housing.
If it exceeds the service limit, check the thrust
metal, the thrust bushing, and the oil thrower.
Name
Measurement of radial play of turbine shaft 1. Alignment Mark
Radial play mm 2. Nut

Assembly specifications 0.10 0.17 The nut is left-hand screw.
Service limit 0.205 3. Compressor impeller
Attach the box spanner to the turbine-side shaft
If it exceeds the service limit, check the floating end of the turbine shaft, and remove the nut.
metal. Remove the impeller from the turbine shaft.
Washing of impeller
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic scraper
or hard brush.
Caution:
Do not use a wire brush.
Washing of turbine housing
Soak in the cleaning solvent to remove the foreign
matters.
Name
1. Left-hand Thread
9. Turbine shaft
4. Seal plate
Hold the heat protector lightly by hand, and take
Loosen the pot small screw.
out the turbine shaft.
Lightly tap the bearing housing in the seal plate
If it is hard to remove, lightly tap the compressor-
with a wooden hammer.
side shaft end with a wooden hammer.
Liquid gasket is applied to the mating surfaces of
Washing of turbine shaft
the seal plate and the bearing housing.
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic scraper
or hard brush.
Caution:
Do not use a wire brush.
Foreign matters remaining on the surface causes
the unbalance of weight. Therefore, wash it
thoroughly.
Take care not to damage the floating metal contact
surface of the shaft and the seal ring groove.
5. Oil thrower
Remove the oil thrower from the seal plate.
6. Seal ring; oil thrower
7. G coupling
Loosen the nut and remove the G coupling from
the turbine housing and the center housing.
8. Turbine housing
Remove the center housing from the turbine
housing.
10. Seal ring Impeller
Remove the seal ring from the turbine shaft. Check the impeller for scratch, dent or crack.
11. Gasket
12. Heat protector
Remove the heat protector from the bearing
housing.
13. Thrust bearing (compressor side)
Loosen the Plate small screw with a screwdriver,
and remove the thrust bearing and the thrust collar.
14. Thrust collar
15. Snap ring
Remove the turbine-side snap ring with snap ring
pliers.
16. Floating metal
Draw out the floating metal from the bearing
housing.
17. Thrust bearing (turbine side)
Using a brass bar, push out the compressor-side
floating metal from the turbine-side bearing
housing, together with the thrust bearing. Heat protector
Check the heat protector for damage, thermal
Caution: deformation or corrosion.
while pushing out with a bar, take care that they do
not run on to damage the snap ring.
Removal of snap ring (also to be done after step
17.)
Remove the 2 snap rings from the bearing housing
with snap ring pliers.
18. Bearing housing
Inspection
Compressor housing
Check the compressor housing for crack or
damage, and replace if defective.
Turbine shaft
Measure the journal outer diameter of the turbine
shaft, and the groove width of the seal ring
insertion part.
Journal outer diameter mm

Service limit 11.38
Groove width of the seal mm

ring insertion part
Service limit 1.33
Name Oil thrower

1. Journal outer diameter Inspection of damage on the oil thrower sliding
2. Ring groove width surface, measurement of the seal ring groove
width
Measurement of turbine shaft runout
Seal ring groove width G mm
Turbine shaft runout mm
Service limit
Service limit 0.011
G 1.52
Thrust collar
Measure the thrust collar thickness (K), and
replace with new one if it exceeds the service limit.
Seal plate
Inspection of damage on the seal plate,
measurement of inner diameter of the seal ring
insertion part
Thrust bearing
Inner diameter of the seal mm Replace the compressor-side and the turbine-side
ring insertion part thrust bearings with new ones.
Service limit
Floating metal
H 14.05
Replace the floating metal with new one.
Bearing housing
Check the casting surface for peeling from
oxidation-deterioration, dent or crack. Replace with
new one if faulty.
mm
Location Service limit
Bearing housing inner diameter (B) 16.11
Turbine-side seal ring insertion (F) 17.03
part
Turbine-side thrust bearing (L) 23.02
press-fit part inner diameter
  
G coupling
Replace with new one.
Seal ring
Replace with new one.
Others
Check the bolts for deformation, and replace with
new ones if faulty. Also, replace the Plate small
screw with new one.
Assembly of Turbocharger
Assembly diagram: Assemble in the order of the numbers.

 















Assembly Procedure
1. Bearing Housing 10. Gasket
2. Snap Ring 11. Turbine Housing
3. Floating Metal 12. G Coupling
4. Thrust Bearing 13. Seal Ring
5. Seal Ring 14. Oil Thrower
6. Heat Protector 15. Seal Plate
7. Turbine Shaft 16. Compressor Impeller
8. Thrust Collar 17. Nut
9. Thrust Bearing 18. Compressor Housing
Assembly
1. Bearing housing
Check that the bearing housing is free of damage
and foreign matters.
2. Snap ring
Install the 2 snap rings to the bearing housing with
snap ring pliers.
After assembling the floating metal (turbine side),
install the snap ring at the position shown in the 
figure.
Name
1. Apply Oil.
4. Thrust bearing
a. Press-fitting of turbine-side thrust bearing

Press-fit the turbine-side thrust bearing into the
bearing housing.
Position the pawl of the turbine-side thrust
bearing for more than 2 mm apart from the
existing press-fitting part.
Do not press the thrust bearing pad surface
Name
during press-fitting.
1. Turbine-Side Floating Metal
The press-fit pressure must be between 215.6
3. Floating metal N {22.0 kgf} and 1862 N {190 kgf}.
Apply oil to the floating metal, and assemble it to After press-fitting, remove the dust powder
the bearing housing. using vacuum.
After securing it with a snap ring, assemble the
compressor-side floating metal.
Caution:
Place the snap ring with its rounded-side facing to
the floating metal.
Assemble the inner snap ring with its end gap
facing to the oil outlet-direction of the housing, to
prevent it from blocking the oil path.
Assemble the turbine-side snap ring to the housing
with its end gap facing to the direction as shown in
the illustration.
Apply oil to the floating metal before assembly.
Besco super engine oil

b. After press-fitting, check the depth and flatness 8. Thrust collar
of the turbine-side thrust bearing. Apply engine oil to the thrust collar, and install ti to
(Depth 3.08 0.02, Flatness is below 0.01: See the turbine shaft.
illustration)







Name
Name 1. Apply Oil.
1. Common Tolerance
9. Thrust bearing
5.Seal ring
Apply engine oil to the metal portion of the thrust
Insert the seal ring to the turbine shaft. bearing, and insert it to the bearing housing.
Use new seal ring. Apply Loctite to the Plate small screw threads, and
6.Heat protector install it using torque screwdriver.
Install the heat protector to the bearing housing. Tightening torque: 3.7 N m (0.38 kgf m)
7.Turbine shaft
Apply engine oil to the journal portion of the turbine
shaft, and insert it from the turbine side of the
bearing housing.
Take care not to damage the floating metal with the
turbine shaft. Also, insert with the end gap of the
seal ring facing to the oil inlet side so that its core
matches with the turbine shaft.

Name
1. Apply Oil.
10. Gasket
Set the gasket to the turbine housing, and install it
to the bearing housing.
11. Turbine housing
Assemble by aligning the phase of the turbine
housing and the bearing housing with the turbine
housing positioning pin and the bearing housing 
hole.
  
 
 
Name
1. Approx. 60
2. Approx. 60
3. Torque Wrench
12. G coupling Hammering procedure
a. Check that it does not run on the turbine 1) Using a metal hammer (Approx. 250g in
housing or the bearing housing. weight), lightly tap 2 to 3 times (same place),
b. Tighten temporarily to the specified torque from the outer portion toward the center.
using a torque wrench. 2) Do not hammer the G coupling directly. Place
Tightening torque: 83 N m (8.5 kgf m) brass bar between as shown in the illustration.
c. Hammering: Perform the hammering of (1) to

(6) in the numerical order, using the following
procedure.
d. Tighten to the specified torque using a torque
wrench.
Tightening torque: 83 N m (8.5 kgf m)
   
e. Perform (c) and (d) of the above step again.

 
Name
1. Approx. 13
2. Hammer
3. G Coupling
4. Bearing Housing
5. Gasket
6. Heat Shield Plate
7. Turbine Housing
13. Seal ring 17. Nut
Install the seal ring to the oil thrower. Attach the box spanner to the turbine-side shaft
Use new one. end of the turbine shaft, and tighten the nut.
14. Oil thrower The nut is left-hand thread. Make sure the turning
direction.
Insert the oil thrower into the seal plate.
Insert with the end gap of the seal ring facing to the Tightening torque: 7.8 N m (0.80 kgf m)
oil inlet side. 18. Compressor housing
15. Seal plate Apply liquid gasket to the compressor-side flange
Apply liquid gasket to the turbine-side flange surface of the seal plate. Illustration shown in the
surface. Application thickness 0.1 0.2 mm (B) previous page (A)
Application thickness 0.1 0.2 mm
ThreeBond No. 1207
ThreeBond No. 1207
Install the seal plate to the bearing housing.
Apply Loctite (B) to the Pot small screw threads, Align the alignment marks that marked during the
and install it using torque screwdriver. disassembly, and assemble the compressor
housing to the seal plate.
Tightening torque: 23 N m (2.3 kgf m)
Tightening torque: 7.9 N m (0.81 kgf m)


16. Compressor impeller

Insert the compressor impeller to the turbine shaft.
Measurement Tool
Shape Name Part number Usage

Caliper Measurement of the seal ring groove width
Measurement of inner diameter of the seal ring
insertion part
Measurement of turbine shaft journal outer
diameter
Measurement of thrust bushing groove

clearance
Measurement of thrust bearing thickness
Measurement of floating metal inner/outer
diameter
Measurement of inner diameters of the center
housing metal portion and ring portion
Dial gauge Measurement of turbine shaft axial gap, radial
gap and runout
Other Material
Name Usage
Besco super engine oil Floating metal sliding portion
Thrust bushing sliding portion
Thrust bearing sliding portion
Turbine shaft journal portion
ThreeBond No. 1207 Housing installing surface of the seal plate
Flange of the compressor housing
Loctite No. 242 Seal plate tightening screw thread
Introduc tion
This Troubleshooting Manual describes the structure and the troubleshooting of
electronic control fuel injection system (common rail type) in 4HK1 and 6HK1
industrial engines.
Use this manual sufficiently to perform service work properly and quickly.
Isuzu Motors Limited

Off-highway Powertrain
Operation Dept.
Control System
Engine Control
(Electronic control fuel injection system (Common rail type))
Table of Contents
How to use this manual. . . . . . . . . . . . . . . . . . . .10D-4 DTC: P0089 (Flash code 151) . . . . . . . . . . .10D-219
Table of abbreviation . . . . . . . . . . . . . . . . . . . .10D-5 DTC: P0090 (Flash code 247) . . . . . . . . . . .10D-224
List of parts according to engine control specifications DTC: P0107 (Flash code 71) . . . . . . . . . . . .10D-230
10D-6 DTC: P0108 (Flash code 71) . . . . . . . . . . . .10D-237
About colors of wirings . . . . . . . . . . . . . . . . . . .10D-7 DTC: P0112 (Flash code 22) . . . . . . . . . . . .10D-243
About wiring diagrams . . . . . . . . . . . . . . . . . . .10D-8 DTC: P0113 (Flash code 22) . . . . . . . . . . . .10D-249
Precautions on Service Work . . . . . . . . . . . . . . 10D-11 DTC: P0117 (Flash code 23) . . . . . . . . . . . .10D-257
Procedure of trouble diagnosis . . . . . . . . . . . . .10D-12 DTC: P0118 (Flash code 23) . . . . . . . . . . . .10D-263
Interview. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10D-14 DTC: P0182 (Flash code 211) . . . . . . . . . . .10D-270
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . .10D-16 DTC: P0183 (Flash code 211) . . . . . . . . . . .10D-275
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . .10D-16 DTC: P0192 (Flash code 245) . . . . . . . . . . .10D-282
How to read DTC . . . . . . . . . . . . . . . . . . . . . .10D-17 DTC: P0193 (Flash code 245) . . . . . . . . . . .10D-288
Confirmation after repair . . . . . . . . . . . . . . . .10D-19 DTC: P0201 (Flash code 271) . . . . . . . . . . .10D-295
List of final check items . . . . . . . . . . . . . . . . .10D-19 DTC: P0202 (Flash code 272) . . . . . . . . . . .10D-302
How to clear DTC. . . . . . . . . . . . . . . . . . . . . .10D-20 DTC: P0203 (Flash code 273) . . . . . . . . . . .10D-309
Trouble diagnosis with scan tool . . . . . . . . . .10D-21 DTC: P0204 (Flash code 274) . . . . . . . . . . .10D-316
How to use trouble diagnosis-related tool . . . . .10D-26 DTC: P0205 (Flash code 275) . . . . . . . . . . .10D-323
How to use Tech2. . . . . . . . . . . . . . . . . . . . . .10D-26 DTC: P0206 (Flash code 276) . . . . . . . . . . .10D-328
Rewrite setting of Q-key correction data by Tech2. . . DTC: P0219 (Flash code 543) . . . . . . . . . . .10D-333
10D-49 DTC: P0237 (Flash code 32) . . . . . . . . . . . .10D-335
How to use TIS 2000 . . . . . . . . . . . . . . . . . . .10D-69 DTC: P0238 (Flash code 32) . . . . . . . . . . . .10D-342
How to use injector checker . . . . . . . . . . . . . .10D-79 DTC: P0335 (Flash code 15) . . . . . . . . . . . .10D-349
How to use flush tool . . . . . . . . . . . . . . . . . . .10D-84 DTC: P0336 (Flash code 15) . . . . . . . . . . . .10D-355
How to use breaker box . . . . . . . . . . . . . . . . .10D-85 DTC: P0340 (Flash code 14) . . . . . . . . . . . .10D-361
Engine Control System . . . . . . . . . . . . . . . . . . .10D-88 DTC: P0341 (Flash code 14) . . . . . . . . . . . .10D-368
Description of function and operation. . . . . . .10D-88 DTC: P0380 (Flash code 66) . . . . . . . . . . . .10D-374
Engine Control Module (ECM) . . . . . . . . . . . .10D-98 DTC: P0381 (Flash code 67) . . . . . . . . . . . .10D-379
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 10D-119 DTC: P0487 (Flash code 44) . . . . . . . . . . . .10D-384
Engine harness location. . . . . . . . . . . . . . . .10D-135 DTC: P0488 (Flash code 45) . . . . . . . . . . . .10D-389
Connector list . . . . . . . . . . . . . . . . . . . . . . . .10D-145 DTC: P0522 (Flash code 294) . . . . . . . . . . .10D-395
List of function checks. . . . . . . . . . . . . . . . . . .10D-148 DTC: P0523 (Flash code 295) . . . . . . . . . . .10D-401
OBD system check. . . . . . . . . . . . . . . . . . . .10D-149 DTC: P0601 (Flash code 53) . . . . . . . . . . . .10D-408
Diagnosis lamp illumination circuit system check10D- DTC: P0603 (Flash code 54) . . . . . . . . . . . .10D-410
151 DTC: P0606 (Flash code 51/52) . . . . . . . . .10D-412
Diagnosis lamp blinking circuit system check . .10D- DTC: P0611 (Flash code 34) . . . . . . . . . . . .10D-414
153 DTC: P0612 (Flash code 34) . . . . . . . . . . . .10D-417
Scan tool power supply circuit system check10D-156 DTC: P0650 (Flash code 77) . . . . . . . . . . . .10D-420
Scan tool communication circuit system check .10D- DTC: P1093 (Flash code 227) . . . . . . . . . . .10D-425
158 DTC: P1095 (Flash code 225) . . . . . . . . . . .10D-434
Starting circuit system check . . . . . . . . . . . .10D-161 DTC: P1095 (Flash code 225) . . . . . . . . . . .10D-434
Starting system check . . . . . . . . . . . . . . . . .10D-167 DTC: P1112 (Flash code 295) . . . . . . . . . . .10D-443
Fuel system check . . . . . . . . . . . . . . . . . . . .10D-170 DTC: P1113 (Flash code 295) . . . . . . . . . . .10D-451
Intake system check. . . . . . . . . . . . . . . . . . .10D-172 DTC: P1173 (Flash code 542) . . . . . . . . . . .10D-458
Exhaust system check . . . . . . . . . . . . . . . . .10D-173 DTC: P1225 (Flash code 31) . . . . . . . . . . . .10D-464
EGR control system check. . . . . . . . . . . . . .10D-174 DTC: P1261 (Flash code 158) . . . . . . . . . . .10D-468
QOS system check . . . . . . . . . . . . . . . . . . .10D-177 DTC: P1262 (Flash code 159) . . . . . . . . . . .10D-478
List of diagnostic trouble code. . . . . . . . . . . . .10D-181 DTC: P1271 (Flash code 24) . . . . . . . . . . . .10D-488
DTC: P0087 (Flash code 227) . . . . . . . . . . .10D-206 DTC: P1277 (Flash code 24) . . . . . . . . . . . .10D-494
DTC: P0088 (Flash code 118) . . . . . . . . . . .10D-214 DTC: P1278 (Flash code 24) . . . . . . . . . . . .10D-499
10D-3 Electronic control fuel injection system (Common rail type)
DTC: P1282 (Flash code 24) . . . . . . . . . . . 10D-504
DTC: P1283 (Flash code 24) . . . . . . . . . . . 10D-509
DTC: P1345 (Flash code 16) . . . . . . . . . . . 10D-514
DTC: P1625 (Flash code 416) . . . . . . . . . . 10D-519
DTC: P1630 (Flash code 36) . . . . . . . . . . . 10D-526
DTC: P1631 (Flash code 55) . . . . . . . . . . . 10D-528
DTC: P1632 (Flash code 55) . . . . . . . . . . . 10D-531
DTC: P1633 (Flash code 55) . . . . . . . . . . . 10D-534
DTC: P1634 (Flash code 55) . . . . . . . . . . . 10D-537
DTC: P1635 (Flash code 55) . . . . . . . . . . . 10D-540
DTC: U2104 (Flash code 84) . . . . . . . . . . . 10D-543
DTC: U2106 (Flash code 85) . . . . . . . . . . . 10D-548
List of trouble symptom . . . . . . . . . . . . . . . . . 10D-553
Engine start failure . . . . . . . . . . . . . . . . . . . 10D-554
Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-558
Engine hunting, rough idling . . . . . . . . . . . . 10D-562
Engine output shortage . . . . . . . . . . . . . . . . 10D-566
Exhaust gas contains a lot of white smoke. 10D-570
Exhaust gas contains a lot of black smoke. 10D-573
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-576
Fuel consumption deteriorates.. . . . . . . . . . 10D-578
Oil consumption deteriorates. . . . . . . . . . . . 10D-581
Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-583
Difference by each machine manufacturer . . 10D-584
JCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-584
About wiring diagrams. . . . . . . . . . . . . . . . . 10D-590
Electronic control fuel injection system (Common rail type) 10D-4
How to use this manual
This manual describes about engine-related trouble diagnosis, and is closely related
to the machine trouble diagnosis. Always refer to both manuals for the trouble
diagnosis.
This manual consists of the following contents. This section How to use this manual
describes about abbreviations and instructions to use this manual. Therefore, if you
are familiar with Isuzu manuals, start with Precautions on service work and Basic
procedure of trouble diagnosis.
How to use this manual

Table of abbreviation
List of parts according to engine control specifications
Wiring color code
How to use wiring diagram
Precautions on service work
Procedure of trouble diagnosis
How to use trouble diagnosis-related tool

How to use scan tool
How to use TIS 2000
How to use injector checker
How to use flush tool
How to use breaker box
Engine control system
List of function checks
List of diagnostic trouble codes
List of trouble symptom

Table of abbreviation
Abbreviation Name Meaning and remarks

A/D Analog/Digital Analog/Digital
AP Accelerator Position Accelerator Pedal Position
CAN Controller Area Network Communication system used to communicate between
ECM and the machine control unit
CKP Crankshaft Position Crankshaft (the sensor is installed onto flywheel
housing) position
C/U Control/Unit Abbreviation of control unit
CMP Camshaft Position Camshaft (the sensor is installed onto the rear of
cylinder head) position
DLC Data Link Connector Connector for scan tool (also known as: Checker
connector)
EMPS Engine Module Programming System Rewriting of control program in ECM
DMM Digital Multi-Meter Diagnostic tester for electrical equipment system (5-
8840-2691-0)
DTC Diagnostic Trouble Code Self-diagnosis code numbers which indicate trouble
condition
ECT Engine Coolant Temperature Engine coolant temperature
ECM Engine Control Module Core of engine control in engine control computer
ECU Electronic Control Unit Computer for various control
EGR Exhaust Gas Recirculation Recirculation system which mixes exhaust gas from
engine with intake air again to lower the combustion
temperature resulting in reduction of NOx.
EMI Electro Magnetic Interference Electro magnetic interference
Exh Exhaust Exhaust
F/B Feed/Back Abbreviation of feedback
FT Fuel Temperature Fuel temperature (the sensor is installed onto supply
pump.)
GND Ground Ground/Earth
IAT Intake Air Temperature Intake air temperature
J/C Joint/Connection Connector which connects each harness
MIL Malfunction Indicator Lamp Warning lamp MIL (diagnosis lamp)
PC Pressure Control Pressure control/Common rail pressure
SCV Suction control valve Valve which controls fuel flow to common rail and is
installed onto supply pump
PCV Pressure Control Valve Valve which controls fuel flow to common rail and is
installed onto supply pump
PWM Pulse Width Modulation Pulse width modulated wave
QOS Quick On Start Warming-up device
RP Rail pressure Pressure in common rail
SBF Slow blow fuse Slow-blow type fuse which protects circuits of battery,
motor, etc.
Abbreviation Name Meaning and remarks

SIG Signal Signal
VSS Vehicle Speed Sensor Sensor used to detect vehicle speed to control meters
or engine
W/S Weld/Splice Joint of each harness without connector
List of parts according to engine control specifications
Engine
Function
6W 6U 6H 4H 4J
PCV Controls the fuel pressure feed of supply pump.
SCV Controls the fuel pressure feed of supply pump.
CMP sensor Detects camshaft position of engine (used for identifying cylinder.)
G sensor Detects cam position of supply pump (used for identifying cylinder.)
CKP sensor Detects crankshaft position (used for engine control in general.)
About colors of wirings
All harnesses are identified by using different colors of
claddings. The harness for the main circuit in a certain
electrical system is identified by using a single color,
while the harness for the sub circuit uses a color in
stripes. Sizes and colors coding in a wiring diagram are
as follows.





Name
1. Single color
2. Color stripe
Symbol Color Symbol Color

B Black BR Brown
W White LG Light green
R Red GR Grey
G Green P Pink
Y Yellow SB Sky blue
L Blue V Violet
O Orange
About wiring diagrams


 
   

  

 
  
  

                 
         


  

        
   
   
              


  
  

    
  

 
 

  
 
 


    
 




 


 
 


1. Sections surrounded by long broken lines are used

to indicate the units, such as ECM.
2. Sections surrounded by dotted lines are used to
classify or differentiate the specifications of
machines. Confirmation of specifications is
needed.
3. Sections surrounded by dotted lines and marked
with a symbol (A in example) on the upper left are
used to classify different wiring in the specifications
of machines. Confirmation of specifications is
needed.
4. Sections surrounded by heavy lines are used to
differentiate engine harnesses from other
harnesses. Heavy lines indicate engine harnesses,
other lines indicate machine harnesses.
How to read trouble diagnosis section
The following illustration is an example for trouble diagnosis section. See this illustration and description.

Description of DTC diagnosis section

The following numbers correspond to those shown in the illustration. They describe each item.
1. DTC:
This indicates trouble code.
2. Flash code
Trouble code indicated by lamp flashing
3. Description of trouble symptom
4. Conditions on system that establish the codes
5. Circuit diagram
Circuit diagram related to trouble code
6. Description of circuit
System circuit principle related to trouble
7. Main trouble symptom
Expected state of engine caused by system trouble
8. Preconditions when DTC is set
Judgment is not performed unless this condition is established.
9. DTC set condition
Condition for fault judgment when preconditions are met
10. Action taken when DTC is set
Behavior of diagnosis lamp, monitor display on the machine and engine control when trouble code is set.
11. Recovery from failure
Description of recovery from failure to normal state
12. Diagnostic aid
Expected trouble causes are listed. They are important information to perform diagnosis.
Be sure to read before trouble diagnosis.
13. Breaker box inspection procedure
There is an appropriate table in diagnostic chart. It describes detailed diagnostic procedure.
Precautions on Service Work

Use of tools for circuit test Caution:
If there are no special instructions according to the The following guidelines should be followed to
diagnostic procedure, test lights must not be used in prevent the damage caused by electrostatic
the diagnosis of electric system of powertrain. Use a discharge:
connector test adaptor kit 5-8840-0385-0 when a probe Do not touch the ECM connector pins or the
connector is required during the diagnostic procedure. electronic components soldered on to the
circuit board of the ECM.
Commercial electrical equipment Package of that part should not be opened until
Commercial electrical equipment means that the preparation of the installation of the
commercial electrical components installed to a replacement part is completed.
machine after shipment from factory. Be careful that no Connect that package to the normal grounding
special consideration for this equipment is taken in the on the machine before taking out the parts from
design process of the machine. the package.
If handling the parts with moving seats in
Caution: sliding, or sitting down from the standing
Connect commercial electrical equipment to the position, or walking for a certain distance, it is
circuit whose power supply and ground wires are required to touch the normal grounding before
not related to the electronic control system. the installation of the parts.
Commercial electrical equipment may cause Fuel pipe

malfunction of the electronic control system even if they
are installed properly. They include devices which are
not connected to the electrical systems on the machine,
such as mobile phones or radios. Therefore, in trouble
diagnosis of powertrain, first check if this commercial
electrical equipment is installed, and if so, remove it   
from the machine. If the trouble has not been solved

after the removal, diagnose it in usual procedures.
Welding work on the machine

If performing welding on the machine, remove the
battery in advance. Otherwise, the current during
welding may cause system trouble or damage.
Damage caused by electrostatic discharge

The electronic components used in the electronic 
control systems are easy to get damaged, caused by


electrostatic discharge because they are designed to
operate in a very low voltage. Some kinds of electronic 
components may get damaged by electrostatic in even Name

less than 100 V which human cannot feel. For 1. Injector pipe
reference sake, the voltage of 4,000 V is needed for 2. Flow damper
human to feel the flow of electrostatic discharge. 3. Common rail
There are several ways for human body to have 4. Fuel temperature sensor
electrostatic charged. The common way to be charged 5. Pressure limiter
is caused by friction or induction.
For example, a charging by friction is caused when Do not reuse the high-pressure pipe and injector
a person slides on the seat of the machine. pipe of the fuel system. Replace with new one if it
A charging by induction occurs when a person who is removed.
wears well-insulated shoes stands near the high- Never replace the pressure limiter, fuel
electrified object and then he grounds instantly. temperature sensor, flow damper alone. If faulty,
The same electric charge flows out and that person replace the common rail assembly and all the fuel
is charged in the high opposite electric charge. It is pipes.
important to be careful in handling or testing the
electronic components because electrostatic
causes damage.
Procedure of trouble diagnosis

The following diagnostic procedure is extremely important to solve the problems of all electric/electronic (E/E)
systems. Failure to perform this procedure may require unnecessary repair. Read carefully this procedure to
understand, and then perform trouble diagnosis.
In addition, use the effective function or a scan tool to perform trouble diagnosis and system check.




 




 



Step 1 Confirm the users complaint
Organize the trouble conditions using a check list.
Step 2 Perform pre-inspection

Perform an overall visual check.
Confirm the service history in the past.
Detect faulty such as noise, abnormal smell, etc.
Collect the diagnostic trouble code (DTC) information for effective repair.
Check for faults by comparing with the specified value.
Step 3 Check service information

Check service letters for the market.
Step 4 Check according to each DTC

Check the items indicated by the diagnostic trouble code (DTC)
Step 5 Perform fault inspection for each symptom

Check the items not indicated by the diagnostic trouble code (DTC)
Information:


 About types of system trouble diagnosis

 
 

 
 
 
System diagnostic method is a standardized method to
 
 
 
 
 
 
 
repair all the electric/electronic (E/E) systems. The
faults in E/E system often occur in the following stages,
  
 
 
 


 
 

   


 


 
 
  
different from general machine fault.
  


 
 
 
 
1. Early stage of fault;
  
As the fault occurs for a short period and singly,

  
    
   
a customer often does not notice and miss it. In
    
   
  
   
    
this stage, customers complaint is indefinite

    
 
    
  
 
and it is impossible to reproduce the trouble.

  
    
  
    
     
However, the engine control module (ECM)

   
   
  
may store the fault.

  
  
  
  
=Past fault (past trouble)

  
   
   
    
2. Middle stage of fault;

    
    
    
  
The fault occurs for a short period and singly,

   
    
  
but repeats intermittently and definitely occurs


Name under a specific condition. A customers

1. Diagnosis for each DTC complaint (contents of the fault) is clear but
2. List of trouble symptom description of condition of the fault is not clear.
Therefore, it is possible to reproduce the trouble
if a mechanic could figure out the conditions.
=Intermittent trouble (intermittent)
3. Stage that fault is real;
The fault occurs on a steady basis and a
customers complaint is realistic and clear.
Therefore, it is possible for a mechanic to
reproduce the fault. However, sometimes there
are multiple causes.
=Current fault (current trouble)
Interview 2. All of complaints from customers do not always
mean troubles.
Interview
3. Extra repair steps are caused if the trouble
1. Comprehend the contents of a customers condition is not correctly reported to a mechanic in
complaint using Check list (engine control charge.
system).
The check list helps to diagnose, repair, and
<Reference>
recheck after repair work in the maintenance shop.
Do not interview blindly. Interview about the trouble
presumed by symptoms (cases).
2. Evaluate the trouble information correctly.
Figure out specifically based on 5W1H.
Example: The temperature is low, at the time of
starting, constantly, in the vicinity of the engine
portion, metallic noise, etc.
Points for interview
What Trouble symptom

When Date, time, frequency of
occurrence
Where Road condition
In what condition Running condition,
operating condition,
weather
How Feeling about symptom
Check list for engine control system

It is necessary to confirm Trouble symptom and Data
of occurrence of a trouble based on check list (engine
control system) on receiving the machine from a
customer at a service shop.


Name
1. Trouble symptom
2. Frequency of trouble occurrence / trouble
conditions
Because:
1. It may be impossible to reproduce the trouble
symptom at a service shop.

Pre-inspection Trouble Diagnosis
Visual inspection of engine compartment About diagnostic trouble code (DTC)

Visual inspection of engine compartment should be Every time turning the key switch to ON, the ECM
carefully when performing the diagnostic procedure. performs self-test of most wiring and components and
This inspection can often solve the trouble with no extra stores the detected faults in memory. For some DTCs, it
steps. If performing visual inspection, follow the also performs the back-up control. If the fault which
guideline below. affects operation occurs, the diagnosis lamp comes on
Check all the air hoses etc. for punch hole, cut, to notify an operator.
disconnection or improper routing.
Inspect the hoses hidden behind other Basic knowledge for required tools
components. Important:
Check if all the harnesses of the engine If performing the diagnostic procedure, no basic
compartment are properly connected, if there are knowledge on this powertrain may lead to faulty
any burnout parts or worn parts, if harnesses are diagnosis or damage to powertrain components. If
pinched, if there are any contacts with sharp you do not have basic knowledge, do not perform
edges, or an exhaust manifold or pipes in high the diagnosis of the trouble relating to powertrain.
temperature, etc. Basic understanding on hand tools, such as scan
tools, is required to utilize service manual
Machine maintenance result check effectively.
If the maintenance of the machine is not properly
About on-board diagnosis test
performed, the diagnosis lamp comes on. Clogging in
oil filter or fuel filter caused by insufficient oil change or Types of trouble diagnosis results are the following.
improper oil viscosity and deposit in crankcase may 1. Past trouble
cause troubles on the machine, which were not found Trouble codes which occurred under the following
before on-board diagnosis (OBD) system check. conditions are called Past trouble.
Though improper maintenance of the machine is not Diagnostic test was completed at previous
classified as The trouble caused by other than a ignition cycle.
machine, a maintenance schedule should be more Diagnosis test has accepted at current ignition
strictly followed because of high sensitivity of the on- cycle.
board diagnosis (OBD) system check.
Faults found by the diagnostic test do not
currently exist.
Non-OEM parts
2. Current trouble
All the on-board diagnosis system checks are adjusted Trouble codes which occurred under the following
to be operated by genuine parts. Therefore, if a conditions are called Current trouble.
commercial general sensor or switch is installed, the
Diagnostic test was completed at previous
diagnosis lamp comes on due to faulty diagnosis.
ignition cycle.
If commercial electronic devices, such as mobile
phone, stereo, antitheft device, etc. are installed and The faults detected by the diagnostic test
their installation is not proper, EMI (electromagnetic currently exist.
interference) may be discharged to the control system. The faults exist at current ignition cycle.
That leads to the generation of fault sensor information
and the diagnosis lamp comes on. When performing
trouble diagnosis, turn the power of all commercial Description of terms
parts to OFF or remove those parts, and check for
faults again. Ignition cycle
Ignition cycle is defined as Key ON, Run and Key OFF
so that the machine can be operated under the
Information: specified diagnostic standard.
Fault in related system
Diagnosis lamp
Many on-board diagnosis (OBD) system checks enter
the back-up operating mode by instruction from engine Basically, the diagnosis lamp comes on when a fault is
control module (ECM) when the ECM detects the fault detected in electronic control, such as engine control
in related systems or components. In the back-up module (ECM).
operating mode, they lower output to protect the
machine.
Data link connector (DLC) How to read DTC
The data link connector is communication device with
control unit. The DLC is also used to connect a scan How to read DTC by diagnosis lamp
tool. General use of scan tool is described below. The diagnosis lamp blinks to indicate the current and
past trouble codes (DTCs) stored in ECM by
Note: connecting the diagnosis switch.
The location of DLC and existence of DLC vary
depending on each machine. Refer to the Note:
machines manual. Refer to the machines manual for the locations of
diagnosis lamp.
Identification of stored DTC
Reading of serial data Turn the key switch to ON and make sure the
diagnosis lamp illuminates. (Bulb check)
About ECM OFF Turn the key switch to ON, and the engine OFF.
The power of ECM is cut off 10 seconds after the key Connect the diagnosis switch (connector).
switch is turned to OFF, and then it will be ECM OFF Read the blinking pattern of the diagnosis lamp.
condition. Judge the contents of DTC by DTC table.
If a scan tool has been connected, it can be read using
Operation of comprehensive diagnosis for the tool.
monitors of components
It is necessary to comprehensively diagnose Indication with no DTC stored
components for the proper operation of the engine. The code 1, which indicates starting of code display, is
repeatedly displayed.
Input components:
Input components are confirmed to check if there are Indication with DTC stored
open circuit and the values exceed the range. Stored trouble code is displayed three times. If more
Though the following does not include all input than one trouble code are stored, they are displayed in
components, these sensors are included. the ascending order for three times each. After taking a
Crankshaft position (CKP) sensor round, codes are repeatedly displayed in the ascending
Camshaft position (CMP) sensor order. This will last as long as the diagnosis connector
Engine coolant temperature (ECT) sensor is connected.
Vehicle speed sensor
Boost pressure sensor
Common rail pressure sensor
Accelerator position (AP) sensor
Output components:
Output components are diagnosed if their responses to
commands from control units are relevant. Check
whether there are open circuit and the values exceed
the range.
Though the following does not include all the output
components to be confirmed, these circuits are
included.
Suction control valve (SCV)
Lamp, relay control
Magnetic valve
Diagnosis lamp


 



 



  
About DTC indicated by blinking of diagnosis lamp If there is intermittent (intermittent trouble)
While the engine stops, both the current and past DTCs The trouble situation not occurring constantly is called
are displayed. intermittent (intermittent trouble). Perform the following
While the engine is operated, the lamp illuminates only steps to solve the intermittent trouble.
if the current DTC occurs. 1. Check the DTC information and data display.
2. Evaluate symptom and situation explained by the
How to read DTC by trouble display monitor
customer.
When a DTC occurs, it is displayed on trouble display 3. Check the circuits or the electric system
monitor on the machine. components using check sheet or other methods.
How to read DTC by a scan tool
If the trouble is not detected
DTC can be read using a scan tool.
In this case, the machine is judged as it operates
Note: properly. The condition explained by the customer may
Refer to Trouble diagnosis with scan tool, be the normal condition. Confirm the customers
Operation procedure for work procedure. complaint comparing with the condition of the machine
to that of another machine. That condition may mean
If the DTC (diagnostic trouble code) is stored an intermittent trouble. Confirm the complaint in the
situation the customer explains before returning the
Perform service correctly according to the specified machine to the customer.
DTC chart.
1. Confirm the complaint again.
If the complaint can not be fully detected or
If there is no DTC
identified, the machine must be diagnosed again.
Select symptom from the diagnostic chart according to Confirm the complaint one more time. The
symptom. Complete the service following diagnostic complaint may be an intermittent trouble as
procedure. You may also perform inspection by defined in If there is intermittent, but it may also
referring function diagnosis. be possible that the machine is normal.
2. Repair and confirm.
If there is no applicable symptom If the problem is confirmed, repair it. Confirm that
1. Confirm the complaint in detail. the machine operates properly and the symptoms
2. Create diagnostic plan. are corrected. This includes test on the machine or
3. Use wiring diagram and principle of operation. other procedures to confirm that the trouble is
Ask for technical support when repair history is solved under following conditions:
available for similar case. Connect technicians Confirm by testing in the situation that the
knowledge with the effective usage of available service customer described.
information. If DTC is diagnosed, reproduce the situation
found while the DTC is set, and confirm the
repair by checking a scan tool data.
Confirmation after repair About confirmation of machine repair
It is effective for confirmation of machine repair to use
Confirmation of machine repair on-board diagnosis (OBD) system check. Mechanic
If an electronic control system is repaired, it is should perform the following steps to diagnose the
necessary to confirm that repair is properly performed machine after repair.
after the repair work. If this confirmation is not properly 1. Review and record the DTC (diagnostic trouble
performed, it may happen that the diagnosis lamp code) or scan tool data used in diagnosis.
comes on again or a trouble in operability occurs in the 2. Clear the DTC.
course of delivering the machine to the customer. 3. Operate the machine based on scan tool data.
Especially as for intermittent (trouble), it is needed to
4. Confirm the DTC status information of specified
reproduce and confirm the situation according to the
DTC used in diagnosis until the diagnostic test
customers complaint.
relating that DTC is performed by control unit.
In the case of confirmation of repair by on-board
diagnosis (OBD) system check, performing these steps
is extremely important. Failure to perform these steps
may require unnecessary repair.
List of final check items
No. Item Purpose Method

1 Check of DTC Confirm the DTC display after Clear previous DTC. To gain a test environment,
repair. warm-up sufficiently with idling and raise the
engine speed to No Load Max. to race.
2 Confirmation of To check whether the idling Check whether the idle speed after warm-up is
idle speed after control is normal or not. stable under no load condition. If the trouble is
the engine is detected, refer to Unstable idling in symptom
warmed-up. diagnosis.
3 Check the scan Check the engine control and Monitor the scan tool data list and use a typical
tool data list. communication status for data sheet to perform the check.
faults at standard condition. Confirm the typical data of scan tool data list.
4 Confirmation of To check whether the starting Confirm that after the engine is warmed up.
ability of control is normal. Confirm that the engine starts after less than 5
restarting second of cranking time and becomes stable.
5 Confirmation of If an electric wave transmitting Check if idling engine speed changes due to ON
powerful electric equipment such as and OFF of an electric wave transmitter such as
wave transmitter. transceiver is additionally transceiver. If a fault is found, inform a customer
installed, confirm whether of necessity to change the location and output of
interfering electric wave is an electric wave transmitter.
consequently transmitted or
not.
Confirmation of powerful electric wave transmitter; if Do not install mobile communication equipment
faults are found in these items, inform a customer of the with high output.
following check items as required.
An antenna should be installed as far away from Caution:
control unit/sensors or electrical systems on the If confirming repair using on-board diagnosis
machine as possible. system check, perform the following steps. If not
following these steps, unnecessary repair may be
Antenna codes should be installed more than 20
needed.
cm away from control units/sensors or electrical
systems on the machine as possible. Review and record the scan tool data related to
DTC which is diagnosed.
Do not put the antenna codes and other wire
together. Keep the antenna codes as far away from Clear the DTC.
other wire as possible. Operate the machine while checking the
When installing an additional equipment, follow its relevant scan tool data.
installation manual to install it securely.
How to clear DTC Clear with ECM (intermittent trouble)
The DTC stored in ECM will be cleared if the same one
Clear of DTC is not valid within 20 ignition cycles.
The DTC, which have been stored in the engine control
module (ECM) upon trouble occurrence, will not be
erased even if the faulty parts are repaired, unless it is
compulsory cleared in the following procedure.
Clear with a scan tool

If a scan tool (Tech2 or scan tool with KW
communication) has been connected, it can be cleared
by clear operation of the scan tool (Tech2 or scan tool
with KW communication).
If a scan tool with CAN communication has been
connected, clear with the memory clear switch.
Clear with memory clear switch

1. Turn the key switch to ON.
2. Turn the diagnosis switch to ON.
3. Turn the memory clear switch to ON.
4. Leave as it is ON for 3 seconds.
5. Turn the memory clear switch to OFF.
6. Turn the diagnosis switch to OFF.
7. Turn the key switch to OFF.
8. Leave as it is for 10 seconds.
10. Turn the diagnosis switch to ON.
11. Make sure that memory is cleared.
       
       

Note:
Refer to the machines manual for the locations
of memory clear switch and diagnosis switch.
Perform the same procedure to clear memory
regardless of forms of switches (switches,
connectors). (ON = Connection, OFF =
Disconnection)
Trouble diagnosis with scan tool
About scan tool
There are scan tools for each machine manufacturer
and the scan tool (Tech2) for Isuzu, and they have
different display method respectively.
The scan tools for the machine manufacturer with CAN
communication display only the physical value in data
parameters.

Isuzu scan tool (Tech2) and the scan tools with KW

communication can display both the physical value and
voltage value.
In some diagnostic charts, both the voltage value and
physical value may be shown. Refer to the voltage
value for Tech2 and the scan tools with KW
communication or the physical value for the scan tools
with CAN communication.


Name
1. Tech2 and scan tool with KW communication
2. Scan tool with CAN communication
About scan tool display
Refer to the relevant page by each machine manufacturer for the difference of data display in KW or CAN viewed
from ECU.
Tech2, KW display CAN display

Engine Model (EEPROM) Engine Model
Engine Serial Number (EEPROM) Engine Serial Number
ECM Part No. (EEPROM) ECM Parts Number
Software ID (EEPROM) Software Identification
Q Resistance (EEPROM) Q adjustment data
QR Code (EEPROM) QR code
Starter Switch (On)
Starter Switch (ST)
EGR BLDC Position 1
EGR BLDC Position 2
EGR BLDC Position 3
Glow Relay Switch
Glow Signal
Accelerator Sensor 1 Act Accel position
System Voltage
Main Relay Voltage
Battery Voltage
Intake Air Temperature Sensor
Fuel Temperature Sensor
Engine Coolant Temperature Sensor
Idle Up Volume Sensor
Barometric Pressure Sensor
Differential Fuel Rail Pressure
Differential EGR Valve Position Sensor
Engine Speed Act. Engine Speed
Request Engine Speed
Intake Air Temperature Intake Air Temperature
Boost pressure
Boost Temperature
Engine Coolant Temperature Coolant Temperature
Fuel Temperature Fuel Temperature
Barometric Pressure Barometric Pressure
Engine Oil Pressure
Fuel Flow
Engine Torque
Trip used fuel
Total used fuel
Differential EGR Position (BLDC Motor)
SCV Duty
EGR BLDC Motor Duty
Tech2, KW display CAN display

EGR DC Motor Duty
SCV F/B
Desired Idle Speed
Common Rail Pressure F/B Mode
Engine Mode
Target Fuel Flow
Main Fuel Injection Timing
Pre-fuel Injection Amount
Main Fuel Injection Amount
About scan tool (Tech2)
This is an useful tool to diagnose the electric faults and
the system check of the engine control system. The
Tech2 is small and light tester. It can communicate with
each control unit to perform various types of diagnosis
and test by connecting it to DLC equipped to the
machine using Tech2 adapter.

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 


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
 



Function of Tech2 Utilizing this mode, reproduce and record the
conditions claimed by the customer to identify the
Data display data fault.
This displays conditions recognized and controlled by The trigger type allows to record the data of the
ECM at each items. time when DTC is displayed.
The values of display items is described in typical data The stored data can be replayed with a domestic
of Tech2 data list. power supply.
The contents of display items describe about data.
Programming
Confirm the data history before replacement of ECM.
(Data confirmation) Then, upload the data to the Tech2.
After replacement of ECM, download data from Tech2
to new ECM.


 Actuator test

 Perform each test to check the operation or function of
 appropriate parts for faults.
 When giving instruction to ECM from test screen, set
 the select switch of the Tech2 adapter to 2 position.
Caution:
Each test may not performed if the machine, engine
operation status, coolant temperature, vehicle
speed, switch status, gear position, etc. does not
meet conditions or if DTC is detected.

This menu can be used to display the current data.

The display synchronizes with the status of the
machine or equipment.
If the data display menu cannot be selected:
Trouble occurs on the cable between ECM and
DLC.
The position of select switch on Tech2 adapter is
wrong.
If the abnormal fixed value is displayed:
[Example] The data display value of engine speed,
each sensor, etc. is fixed and different from actual
one. Move the connector or harness by hand. If the
display changes from fix to release, connection of
the connector is faulty, pin tip length is uneven, or
open or short circuit exists in the harness where
you have moved. Therefore, repair is necessary.
When asterisk mark (*) is displayed in place of

numeric display;
The Tech2 software has problem.
If asterisk mark (*) is found on any of the data,
PCMCIA card must be version-upgraded.
Snapshot
To find the cause of trouble, perform this snapshot to
review the data.
The snapshot can record the data list menu and
plot a graph.
How to use trouble diagnosis-related tool
How to use Tech2
Components of Tech2
 
 

Name
1. PCMCIA card 4. DLC cable
2. SAE 16/19 adapter 5. Tech2
3. Power cable
Each part of Tech2
Name
1. Softkeys 10. Fastening bar of VCI module
2. Selection keys (Arrow keys) 11. Connector of DLC cable connection
3. Action keys (YES, NO, ENTER, EXIT) 12. Connector for AC adapter connection
4. Function keys (F0 F9) 13. PCMCIA card insertion slot with cover
5. Help key (?) 14. PCMCIA card release button
6. Control keys (PWR / SHIFT) 15. Connector for external communication (RS-232
7. Wide stand port)
8. Display area (LCD) 16. Connector for external communication (RS-485
9. Machine communication interface (VCI) module port)
1. Softkeys 3. Action keys (YES, NO, ENTER, EXIT)

While operating the Tech2, selection boxes appear They are used to execute the operation of Tech2,
on the upper part of the screen. The softkeys respond to instruction/question, and switch/move
correspond the selection boxes. They cannot be to each menu screen.
used unless the selection boxes are displayed. 4. Function keys (F0 F9)
2. Selection keys (Arrow keys) They are used to execute a menu function in the
They are used to select the menu or switch the screen. These keys also correspond to F numbers,
display on the screen of Tech2. Selected part is such as F0, when they are displayed on the
highlighted in the screen. menu screen.
5. Help key (?) Handling
Explanation of Tech2 function, which is being used The Tech2 is precision electronic device. Handle
at the time when the key is pressed, is displayed with extreme care.
6. Control keys (PWR / SHIFT) Operating voltage of Tech2 is DC 12 V. Do not
The PWR key turns on/off the power to the Tech2. energize 24 V to it.
The SHIFT key is used to adjust the screen
contract. When the SHIFT key is active, the orange
LED illuminates. In this case, all the keys except
selection keys and functions are locked. When the
power is on, the green LED illuminates.
7. Wide stand
Use this as a stand. The stand opens angle of 0
180 .
8. Display area (LCD)
This is liquid crystal display (LCD) with contrast
adjusting function. It displays ECM information and
various instructions.
9. Machine communication interface (VCI) module
This is a module to communicate between the
machine and Tech2.
10. Fastening bar of VCI module
The bar is used to install/fasten/remove the VCI.
11. Connector of DLC cable connection
This is used to connect the Tech2 to the machine.

Connect the DLC cable. Do not have an impact on it by dropping. It causes

12. Connector for AC adapter connection internal faults even no damage on appearance.
This is used to connect the attached AC adapter
when using Tech2 with other than the machine.
13. PCMCIA card insertion slot with cover
Open the cover when inserting the PCMCIA card
into Tech2. Insert the PCMCIA card with the cover
opened. Never insert/remove the PCMCIA card
when the Tech2 is powered on.
14. PCMCIA card release button
This is used to remove the PCMCIA card from
Tech2. Press the button to remove the PCMCIA
card. Never remove the PCMCIA card when the
Tech2 is powered on.
15. Connector for external communication (RS-232
port)
This is used to connect the Tech2 to a computer.
16. Connector for external communication (RS-485
port)
This is a connector for phone line connection,

however it is not currently used. Do not connect
the phone line etc. to this connector. Be sure to turn off the power of Tech2 when
installing/removing the PCMCIA card. Avoid
Precautions on handling Tech2 repetition of installing/removing the card as
possible. Otherwise, the card may be deteriorated.
Ventilation Before turning on the Tech2, make sure that the
If performing inspection and test with engine running in cables and adapters are connected securely.
badly ventilated area, such as garage, ventilate Do not disconnect the cables and adapters
sufficiently. In badly ventilated area, poisoning may connected to Tech2 while the key switch is ON or
occur due to inhaling colorless, odorless carbon the engine is starting.
monoxide included exhaust gas.
Do not connect the phone jack to communication
port on the side of Tech2.

Avoid using and storing it in a place with extreme


high or low temperature. Especially in summer, do
Avoid using and storing it in dusty area. When not not leave it in the machine exposed to direct
using it, always put it in its case to prevent the sunlight.
adapter from getting dust.


Avoid using and storing it in a place with rapid

changes of temperature. If bringing it from cold
outside into warm indoor suddenly, dew
condensation may occur resulting in malfunction or
trouble.
Avoid using and storing it in a place that it may Power supply
contact water or chemicals. When cleaning, use
cloth with mild detergent, not highly-volatile solvent About power supply
such as thinner, and wipe out using dry cloth. Its The power supply method for the Tech2 varies
display is easy to get dirty, clean periodically using depending on the voltage of the machine, shape of
antistatic cloth. DLC and the situation in which the unit is used.
Therefore the user will have to gain good
understanding of the relevant connecting procedure.
Notice that machine data and DTC will not be able to be
checked if the connection is not established in
accordance with the power supply of the machine.
Note:
Use of the external power (AC power) does not
allow to utilize the applications.

Connection of power

Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Battery cable Caution:
This cable should be used, in the case where no power If the card is not inserted properly and the unit is
is supplied even when the Tech2 is connected to the switched on, NO PCMCIA CARD INSERTED will
machine through the machine DLC cable, or where the appear. If that is the case, turn off the power and
machine works with a higher voltage than the operating redo the insertion of the PCMCIA Card.
voltage of the unit. When connecting the cable, pay
Connection
heed to the polarities of the clamps. (The black clip of
the cable is to be connected to the negative terminal of Check to see whether the DLC cable is fitted with an
the battery and the red clip to the positive terminal.) adapter compatible with the machine.
Caution: Note:
In the case of a 24-V machine, connect to battery on Before connecting the cable to the machine, verify
the body ground side to take out 12 V. that the key switch is in the OFF position.
Caution:
In the case of a 24-V machine, connect to battery on
the body ground side to take out 12 V.
How to connect Tech2

1. Insert the PCMCIA Card with the latest version of
ISUZU system into the Tech2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech2.
4. Make sure that the key switch is OFF.
5. Connect the SAE 16/19 adapter of Tech2 to the
machine DLC.
Caution:
Connecting method varies depending on each
machine. Refer to the machines manual. The
following description is for the machine with DLC.

Power socket cable (AC/DC adapter)

This is used to check the captured data by operating
Tech2 away from the machine.
Caution:
Be sure to use the power socket cable adapted to
local standards. Otherwise, it may result in failure
of Tech2 or power socket cable due to different
voltage and current depending on regions.
Check items before use
VCI
Check to see whether the VCI module is securely
inserted and whether the fastening latch bar of the VCI
module is located on the left-hand end.
Attach the DLC cable and fasten it by tightening the two 
lock screws.
PCMCIA Card
Check to see whether the slot (upper side) has this card
inserted with its Tech2 label side up.
6. Turn the ignition switch to ON and press the PWR Display of POST results:
key of the Tech2. If the test ends normally, Pass will appear and one
7. Check the display of the Tech2. short sound will be heard.
If the test ends abnormally, Fail will appear and three
short sounds will be heard.
Note:
If the LED fails to come on, it means a
malfunction of the LED, not a malfunction of
the SHIFT key.
Absence of sound means a malfunction of the
Sound Transducer*1, but the unit can be used
as is, without any problem.
*1. Sound Transducer: The sound is intended
to indicate the completion of a data setup or an
error in a setup.

Caution:
Be sure to turn off the power of Tech2 when
installing/removing the PCMCIA card.
Operation procedure
Start-up
The Tech2 is designed to automatically conduct a self-
function test every time it is started. Immediately after
the unit has been switched on, the SYSTEM
INITIALIZING message will appear. During this period,
POST (Power-On Self Test) is carried out, and if the
test ends normally, a sound will be issued at the 
completion of the test. Simultaneously, the LED of the
SHIFT key will momentarily come on. This is also Pass: Normal
meant to check the normality of the LED. Fail: Abnormal
Note:
Only for UART, SCI, RTC, and CLKMEM in
particular, the test result may appear as Fail
without this meaning any trouble. For Fail above,
refer to Tech2 Self Test in Tool Options.
IRAM: Internal RAM

ERAM: External RAM
UART: Universal Asynchronous Receiver and
Transmitter

MCU: MC68332 Microcontroller
QSPI: Queued Serial Peripheral Interface
SCI: Serial Communication Interface
TPU: Time Processor Unit
RTC: Real-Time Clock
CLKMEM: Clock Memory
KEYPAD: Keypad

Main Menu Screen composition:
If all the functions are normal after the Tech2 has been The screen for data display is composed in the
switched on, the Start Up screen will open, displaying following manner.
the Version No. and the applicable model year, stored
on the PCMCIA card, to allow the user to verify the
information. After the Start Up screen has opened,
pressing the [ENTER] key will cause the Main Menu
to appear. The Main Menu offers 4 different
applications to select from. The desired menu can be 
executed moving the highlight bar to it with the relevant 
function key or selection keys and pressing the 
[ENTER] key. 





Name
1. TITLE AREA
2. MESSAGE AREA
3. DISPLAY AREA
4. Highlight bar
5. FULL TEXT AREA
6. SOFT KEY AREA

TITLE AREA: Shows the item currently selected.

MESSAGE AREA: Shows a supplementary
explanation or instruction.
DISPLAY AREA: Displays data parameters and
values (9 lines x 23 characters).
FULL TEXT AREA: Shows details of the parameter
under the highlight bar.
SOFT KEY AREA: The softkeys below the function
item display boxes are valid.
Main Menu
F0: Diagnostics
Allows the user to check data, including Tech2-
compatible DTC (Diagnostics Trouble Codes), Data
Display, Snapshot, Miscellaneous Tests, etc., by
selecting a machine ID and System.
DTC: Shows the contents and situation of DTC

stored in the controller of the system.
Data Display: Shows the input/output data to/from
the machine controller under test. Since the
displayed data varies from a system to another, and
besides, most of the items do not have their
guidance standard values installed, it is necessary
to first check what the displayed data means.
Snapshot: Allows to record and display the data of Tech2 Self Test: Performs troubleshooting on the
malfunctions occurred. The displayed data not only functions of the main unit.
includes the one corresponding to the moment when
a malfunction occurred, but also those that existed Caution:
before and after the occurrence of the malfunction. It While this function is under execution, do not
also provides the function (Plot) to draw graphs. connect the unit to the machine!
F1: Service Programming System (SPS) Set Clock: Sets the internal clock of the Tech2.
Set Unit: Switches between the Metric system and
Note:
the English system.
Except industrial engine.
Set Contrast: Adjusts the brightness of the display.
F2: View Capture Data F4: Down Load Up Load Help
Allows to review data recorded under Snapshot of F0: The function to upload/download data (DTC, Snapshot,
Diagnostics. etc.) acquired through the Tech2 to/from a PC, and the
F3: Tool Options Help function to render assistance in case the operation
Offers the function to make settings for the Tech2 main encounters a hitch.
unit, to display POST (Power On Self Test) results, and
to perform detailed tests (PCB, VCI).
List of functions of Tech2

Diagnostic procedure
1. When the Tech2 is switched on, the software
version and the model year applicable to the
software will also be shown. Confirm the display
and press [ENTER].

4. Select the Vehicle Type on the Vehicle

Identification screen and press the [ENTER] key.

2. Press the function key [F0] or bring the cursor to

[F0: Diagnostics] on the Main Menu screen by
operating the selection keys ( ). And then,
press the [ENTER] key.


3. Select the Model Year corresponding to the

desired diagnostic action on the Vehicle
Identification screen and press the [ENTER] key.
Note:
Select the model year of the relevant machine by
checking VIN of each machine.
5. Press the function key [F0] or bring the cursor to
[F0: Engine] by operating the selection keys ( ).
And then, press the [ENTER] key.

8. The following illustration shows the state in which

the Tech2 is waiting for communication with the

machine controller. If the softkey Next is pressed
6. Select Powertrain (Eng. name) on the Vehicle with the ignition key in OFF, this display will stay
Identification screen and press the [ENTER] key. forever. (State of communication disabled)
However, turning the ignition key ON to START
in this condition will place the unit in the waiting
state for communication.

7. The items chosen in steps 3 to 6 are shown in the

Message Area display section. If the identification 
of the machine is OK, turn the ignition key ON to
START and press Next by following instructions 9. Once the communication is established, the unit
given on the screen. will show the part No. and DDI (Diagnostic Data
Identification) (which varies from a system to
Note: another). Press the softkey Confirm and go on to
If you make any mistake, pressing the [EXIT] key the application. If any mistake was made in the
will return you to the Main Menu. selection of the vehicle type, despite that the
communication is enabled, a message to that
effect will appear flashing. If that is the case, check
the vehicle type again and redo the operation from
step 1.
F1: DTC Clear
Depending on a machine, DTC is not clearing by
Tech2. (The memory clear harness on the machine side
needs to be connected to ground.)
DTC application menu display screen

[Example] Industrial Engine
F0: DTC Display
If no DTC stored


Pressing [EXIT] key in the steps 3 to 9 will return you to
the Main Menu screen.
DTC check
1. Select F0: Diagnostic Trouble Codes on the
Engine screen.

If DTC stored

F0: Diagnostic Trouble Codes

This function allows the user to analyze the
information on the Trouble Code related to the
system currently under test. 
2. Choosing F0: Diagnostic Trouble Codes, the
following menu is displayed.
F0: DTC Display
F1: DTC Clear
F0: DTC Display
Loads and displays the DTC information stored in the
machine controller in a priority order.
Data Display Softkey functions
1. Select F1: Data Display on the Engine screen. A maximum of 5 data parameters can be fixed on the
F1: Data Display Data Display screen. The 5 fixed parameters will be
Displays the information concerning various parts retained at the upper part of the screen, even when the
of the engine and transmission as data on the display is scrolled up or down. To fix parameters, bring
screen of the Tech2. the highlight bar to the desired parameter on the
screen, which appears as you select the softkey Select
Items, and press the [ENTER]. The selected item can
be identified by the asterisk (*) which will be placed
atop the parameter. Move the highlight bar with the
selection keys ( ), and once you have chosen all the
parameters you want fixed, press the softkey Accept.
Data Display screen is displayed again. To modify the
fixed parameter list, choose Select Items, move the
highlight bar to the parameter you want changed, and
press the [ENTER] key. The parameter will be cleared.
Choosing Clear All will clear all the fixed parameters.
If you select the softkey DTC while the Data Display

function remains active, DTC will be displayed on the
Data Display screen.
Snapshot can be used while the Data Display function
remains active. For this, choose Quick Snapshot.
Choosing the softkey More allows to use additional
 functions.
For Quick Snapshot, refer to Snapshot.
2. F1: Choosing Data Display, the engine data is
displayed.









 
 
 
 
 
 
 
 

Snapshot Snapshot
1. Select F2: Snapshot on the Engine screen. Snapshot is intended to save information received by
the machine controller during its execution. It provides
an effective means to analyze data generated when the
machine encounters a trouble. Use of this function
enables the user to focus on the situation in which the
trouble took place, without having to view all the data
for suspected malfunctions. The Tech2 is capable of
holding two different Snapshot data. This ability of
storing two different Snapshot data allows to compare
Good and Bad machine states with each other. Since
these data are saved on a first-in, first-out basis, the
first Snapshot data (of older date/time) stored on the
PCMCIA card will be lost as it is overwritten when a
third data comes in. Therefore, be sure to set the
internal clock of the Tech2 precisely before starting the
Tech2. If a given data must not be erased, highlight that
data and choose the softkey Write Protect. This
prevents the data from being overwritten. Pressing the
softkey Clear cancels the protect.

Snapshot is available in the following 2 types:
2. Choosing F2: Snapshot, the following menu is
Snapshot: To be chosen in the Snapshot Menu.
displayed.
F0: Manual Trigger Quick Snapshot: To be chosen through the softkey
F1: Any Code on the Data Display screen.
F2: Single Code The Snapshot Data will not be lost even when the
F4: Beginning Tech2 is switched off, because the data is saved on the
F5: Center PCMCIA card.
F6: End
About trigger type:
Choosing the Trigger Type Menu allows to check the
cause that triggered [Snapshot]. [Snapshot] is executed
when there is one of the three causes of occurrence.
F0: Manual Trigger:
Pressing the softkey Trigger saves data.
F1: Any Code: 2. Move the highlight bar to the data you want
Data is saved in case any trouble code is issued. replayed, and press the [ENTER] key. The data will
be replayed.
F2: Single Code:
Data is saved in case the specified trouble code is
issued.
About trigger point:

Trigger Point corresponds to the point in time where
triggering is originated by a code issued or by Manual
Trigger activated. This information is useful to know the
time point of Snap Point and to investigate changes in
the data parameter. Trigger Point can be set up at
Beginning, Center, or End.
F4: Beginning
Starts saving data from Trigger Point, and keeps on
saving it, until the Snapshot recording area is filled up.
This selection is effective when the trouble that
constitutes the cause is foreseeable.
F5: Center
This function is commonly utilized, since it saves not

only the data after Trigger Point, but also those prior to
that. This selection allows to compare data that existed Note:
before the occurrence of a trouble, those present at the Flashing Trigger means that data is being
time of occurrence of the trouble, and those after the recorded. Pressing the [EXIT] key in this condition
trouble, among themselves. will abort the recording. The recording will also be
F6: End cancelled when the memory capacity is filled up. In
Saves only the data prior to Trigger Point. This either case, the data is saved in memory.
selection is useful when it is desired to terminate
Snapshot after the occurrence of a trouble. Plot
Snapshot can also be replayed in View Captured
Snapshot data replay Data.
1. Press the softkey Review Data on the Snapshot
Options screen. Plot setup procedure
1. Pressing the softkey Plot switches the Data
Display screen.










2. Bring the highlight bar to the parameter you want Explanation of Plot data displayed
plotted in a graph, as with Select Items, and
press the [ENTER] key.
3. The selected parameter can be identified by the

asterisk that appears at its top. No more than 3

parameters can be displayed. 


A: Maximum values of selected parameters

B: Minimum values of selected parameters
C: Values of selected parameters and Center Point (E)
in frame

D: Number of frames/time
4. Choosing the softkey Accept changes the display E: Center point of graph indication
screen and shows a graph after a while.

1. Denotes recognition of DTC.


Plot cancel A vertical line appears in abscissa, if there is a

Trouble Code issued in the Snapshot Data loaded.
To close the graph display screen, press the [ENTER] When plotting a graph, it is advisable to check for
key and you will be returned to the Data Display DTC through Over View.
screen.
2. DTC-recognized frame 236 (Actually issued in
Frame 235.)
Softkey functions
Choose the More on the snapshot graph display
screen.
Move : Allows to view changes of data preceding
the display screen.
Move : Allows to view changes of data following 2. Pressing the softkey Select Frame causes the
the display screen. following screen.
Trigger Frame: Displays a trigger point.
More: Switches the displayed softkeys.
Choose the More on the plot display screen.
Zoom In: Shows the abscissa by enlarging it (each
press doubles the display).
Zoom Out: Shows the abscissa by reducing it
(each press halves the display).
Over View: Shows the entire frame.
Choose the More on the plot display screen.
Time / Frame conversion: Switches the value in
abscissa.
Select frame
Select frame setup procedure

1. Press softkey Select Frame.
First Frame: First frame No. and data acquisition
time from Trigger Point (calculated backward).
Last Frame: Last frame No. and data acquisition
time from Trigger Point (integrated).
 Go To Frame: Entering a frame No. allows to view
 its data.
+/ : Only the sign is displayed.
 3. 1 entered via keys in the Go To Frame area.















Frame No. 1 and recording time displayed, and data

values in Display Area represent those of Frame 1.
Actuator test 4. Select the Rail Pressure Test.
 
Common rail pressure control test

This test is performed to check the operation of RPCV.
The Tech2 must be used in this test.
Test procedure
1. Connect the Tech2 to the machine DLC.
2. Start the engine and run it at idle.
3. Select the Common Rail System.


5. Send the instruction to RPCV and check the data 5. Send instruction to each injector (set to OFF by
list. softkey on Tech2 screen) to stop the injector, and
check the variation of engine speed.

 








6. If variation of data list is proper value, RPCV is
judged as normal. 6. If the engine speed varies when the injector stops,
electrical circuit of that injector is judged as normal.
Injector balance test If the engine speed does not vary when the injector
This test is performed to confirm that proper electric stops, electrical circuit of that injector or injector
signal is sent to injector while the engine is running. body is judged as faulty.
Note: Injector control test

At test, the engine is controlled to low idle speed, in This test is performed to confirm that proper electric
order to clarify the variation of engine speed. signal is sent to each injector. The Tech2 must be used
in this test.
Test procedure Test procedure
1. Connect the Tech2 to the machine DLC. 1. Connect the Tech2 to the machine DLC.
2. Start the engine and run it at idle. 2. Turn the key switch to ON (engine is standstill).
3. Select the Common Rail System. 3. Select the Common Rail System.
4. Select Injection Stop for Each Injector. 4. Select Compulsory Drive of Injector.


5. Send instruction to each injector (set to ON by 4. Select the Glow Plug Relay.
softkey on Tech2 screen), and check the operation
sound of injector.








5. Send the instruction to glow plug relay and check


whether the lamp on the machine operates.
6. If the operation sound is heard, electrical circuit of
that injector is judged as normal.
If the operation sound is not heard, electrical circuit
of that injector or injector body is judged as faulty.
Note:
After injector control test, the key switch must be
turned to OFF once to restart.
Glow time relay test

This test is performed to check the operation of QOS
lamp.
Test procedure
1. Connect the Tech2 to the machine DLC.
3. Select the Device Control.

6. If the lamp operates properly, it is judged as

normal.
EGR regulating valve test

This test is performed to check the operation of EGR
valve.

Test procedure Sample use of snapshot data replay
1. Connect the Tech2 to the machine DLC. 1. Turn on the power.
2. Start the engine and run it at idle.
3. Select the Device Control.
4. Select the EGR Control.

2. Press [ENTER].

5. Send the instruction to EGR valve and check the

data list.





6. If variation of data list is proper value, EGR valve is

judged as normal.
View captured data.

The Snapshot data acquired through the application
menu F2: Snapshot under the Main Menu, F0:
Diagnostics can be replayed.
Since the data is saved on the PCMCIA card, it can be
viewed after disconnecting the Tech2 (DLC) from the
machine. Two data items can be saved there. The
internal clock of the Tech2 needs to be set precisely,
since the data are identified with dates and times.
3. Choose F2: View Capture Data and press the 6. Snapshot Replay Screen appears.
[ENTER] key. View Captured Data appears.
4. Choose Snapshot Data with selection keys ( )
and press the [ENTER] key.









Softkey functions
 1. Choose the softkey More on the Snapshot
Replay screen
5. Press the softkey Continue on the display screen.
Select Items: Chosen to fix and display a
parameter (up to 5 parameters).
Plot: Draws a graph (Up to 3 parameter items).
Select Frame: Allows to specify a frame No.
and to move a parameter to the specified frame.
2. Choose More out of the 4 softkeys on the display
screen.
Auto Reverse: Allows to view changes of data
of each frame.
Stop: Stops a frame in motion.
Auto Forward: Allows to view changes of data
of each frame.
screen.
First Frame: Allows to view the top data frame.
 Trigger Frame: Allows to view a triggered
frame.
Last Frame: Allows to view the last data frame.
screen.
Units: Changes the unit (speed/temperature).
Previous Frame: Allows to view changes of
data by reversing it, frame No. by frame No.
Next Frame: Allows to view changes of data by
feeding it forward, frame No. by frame No.
5. Choose More out of the 4 softkeys on the display Tech2 self test menu
screen. F0: Automated Main PCB and VCI
DTC: Shows the frames in which a Trouble Automatically executes function tests on the Main PCB
Code was issued, in the range from the top and VCI modules.
frame to the displayed frame.
F1: Automated Main PCB
Previous DTC-Chg: Shows the frames in which
Automatically executes function tests on the Main PCB
a Trouble Code was issued, in the range before
module.
the displayed frame.
Next DTC-Chg: Shows the frames in which a F2: Automated VCI
Trouble Code was issued, in the range after the Automatically executes function tests on the VCI
displayed frame. module.
More: Switches the displayed softkeys. F3: Selectable Main PCB
6. Choose More out of the 4 softkeys on the display Allows to check detailed information on the PCB
screen. module test items.
The Snapshot Replay screen is restored. F4: Selectable VCI
Allows to check detailed information on the VCI module
Difference in operation of Snapshot Data Replay:
test items.
The operations of Snapshot Data Replay under F2:
View Captured Data are somewhat different from F5: Power On Self Test Results
those of Replay (softkey function Review Data) under Displays POST test results again.
F2: Snapshot. Be careful not to confuse them.
Set clock
Tool options Operation procedure:
Tool Options is the function to conduct a detailed test, in 1. Choose the F2: Tool Options and press [ENTER].
case communication cannot be established with the 2. Choose the F1: Set Clock and press [ENTER].
machine at the time of setup of the Tech2 or at the time 3. Display the Set Real-Time Clock screen. Move
of Power On Self Test (POST). the cursor to the item you want changed by
operating the selection keys ( ), and press the
Tool option menu [ENTER] key.
F0: Tech2 Self Test
Allows to conduct a test that assists with the Note:
diagnostics of the Tech2 itself. Normally the Self Test Each press on the [ENTER] key will increment the
function need not be executed, since the Tech2 numeric value one by one, but it will not exceed the
conducts the Power On Self Test (POST) every time it preset maximum value.
is switched on. If the POST demonstrates any trouble,
4. After all the values have been entered, press the
the results of the POST can be checked choosing the
softkey Set Clock and the changes will be saved.
Self Test menu.
F1: Set Clock
Resets the date and time of the Tech2. Before exiting
this menu, press the softkey Set Clock to save the
settings.
F2: Set Unit
Switches the unit between the English and the Metric
system.
F3: Set Contrast
Changes the screen contrast (lighter or darker). The
change will be saved even after the Tech2 is switched
off.

Set units Rewrite setting of Q-key correction data by
Operation procedure: Tech2
1. Choose the F2: Tool Options and press [ENTER]. Q-key, Injector code label is attached to the cylinder
2. Choose the F2: Set Unit and press [ENTER]. head cover. It is used for rewriting and registering the
3. Display the Set Unit screen, and move the cursor ID.
to the item you want changed by operating the
selection keys ( ), and press [ENTER] key.
4. When the setup is complete, press the [EXIT] key
to save the current setting.
Note:
It will take effect next time the Tech2 is switched on.    

Name
1. Engine number
2. Typical engine model
3. Q-key information
4. Injector information

There is the injector code on the top of injector as well.
When replacing the injector, register its code.
* Metric
Temperature: C Speed: km/h
* English
Temperature: F Speed: MPH
1. Refer to the following instruction for how to setup

the Q-key correction data.
Step 1 Step 3
Press [ENTER]. Choose the menu (5) 2005 with , (up/down)
keys, and press the [ENTER] key.
* Applicable for 2000MY or later.

Step 2 
Choose the menu F0: Diagnostics with , (up/
down) keys or F0 (function) key, and press Step 4
[ENTER]. Choose the menu (Off-Road) Industrial Engine
with , (up/down) keys, and press the [ENTER]
key.


Step 5 Step 7
Choose F0: Engine in Menu with , (up/down) Press the softkey Confirm.
keys or F0 (function), and press [ENTER]. The ignition is ON at this time.
 
Step 6 Step 7-1

Choose 6HK1-TC (C/Rail_TIER3) with , (up/
down) keys, and press [ENTER].


Step 8 Step 10
Press the softkey Confirm. Choose the menu F0: Q-key correction with ,
This displays the ECU ID information. (up/down) keys or F0 (function) key, and press
[ENTER].


Step 9
Choose the menu F4: Programming with , (up/ Step 11
down) keys or F4 (function) key, and press Choose the menu F2: Service mode with , (up/
[ENTER]. down) keys or F2 (function) key, and press
[ENTER].
F0: Uploads the three-point Q-key data stored
in the ECM to the Tech2.
* Registers the data when replacing ECM.
F1: Writes the three-point Q-key data
temporarily stored in the Tech2 to the ECM.
* Registers to the ECM after replacing
ECM.
F2: Any data can be written. However,
password and ID are required.


Step 12 Step 12-2
Password input screen If the password you have entered is correct, press
This procedure will end automatically if the the softkey [Okay].
registration is not completed within 30 seconds. Enter the password within 30 seconds. Failure to
The message Time Over appears. enter the password within 30 seconds will return to
Step 11.


Step 12-1
After entering the password, press [ENTER] key. Step 13
The password for 04/6H is SLN6HU2. After completing the password registration, ID
Entering the password other than SLN6HU2 will registration will be performed.
return to the previous menu. The value +5+ appeared in the screen below will
be counted down. Press the function key [ENTER]
before the value becomes +4+. This changes the
value to +0+.
* If the value becomes +3+, the registration will
be invalid.


Step 13-1 Step 15
Ask the machine manufacturers service center or Isuzu Displays the three-point Q-key data in the ECM.
Industrial Engine Dept. service section for a password.
1. To modify the Q-key data, press the softkey
Note: Change.
The clock of Tech2 must be correctly set.
After entering, press [ENTER] key.

Step 15-1
If the Q-key correction data you have entered is

correct, press [ENTER] key.
Step 14 1. The entry conditions are as follows.
When the ID code matches, the following screen Conditions:
will appear. C/Rail system entry setting is 1 15.
Press the softkey Next. TIS system entry setting is 1 8.
This step can be performed only when the engine
speed is 0 rpm.


Step 15-2 Step 15-4
If the Q-key correction data you have entered is To go to Step15-5, modify the Q-key data within the
correct, press the softkey Program. set value and press the softkey Program.
 
Step 15-3 Step 15-5

If the Q-key correction data you have entered is off If the entered values meet the conditions in Step
the set value, the message shown as Step 15-4 15-1 and 15-3, the status display of data
appears. registration (writing) from the Tech2 to ECM as
shown below will appear.


Step 17 Injector ID code (No. 1 cylinder No. 6
When the writing of data completes, the following cylinder) registration setting using Tech2
screen will appear.
Q-key, Injector code label is attached to the cylinder
This indicates that the result of comparison of
head cover. It is used for rewriting and registering the
entered data with that written in the EEPROM of
ID.
the ECM is in good condition.
   


Name
Step 17-1
1. Engine number
If the entered Q-key data in Step 15-1 does not 2. Typical engine model
correspond to that written in the EEPROM of the 3. Q-key information
ECM, the following message will appear. 4. Injector information
Pressing the softkey [End] returns you to Step 11.
There is the injector code on the top of injector as well.
When replacing the injector, register its code.

1. Refer to the following instruction for how to register

Injector ID code.
Step 1 Step 3
Press [ENTER]. Choose the menu (5) 2005 with , (up/down)
keys, and press the [ENTER] key.


Step 2
Choose the menu F0: Diagnostics with , (up/ Step 4
down) keys or F0 (function) key, and press Choose the menu (Off-Road) Industrial Engine
[ENTER]. with , (up/down) keys, and press the [ENTER]
key.


Step 5 Step 7
Choose F0: Engine in Menu with , (up/down) Press the softkey Confirm.
keys or F0 (function), and press [ENTER]. The ignition is ON at this time.
 
Step 6 Step 7-1

Choose 6HK1-TC (C/Rail_TIER3) with , (up/
down) keys, and press [ENTER].


Step 8 Step 10
Press the softkey [Confirm]. Choose the menu F1: Injector ID code with ,
This displays the ECU ID information. (up/down) keys or F1 (function) key, and press
[ENTER].


Step 9
Choose the menu F4: Programming with , (up/ Step 11
down) keys or F4 (function) key, and press Choose the menu F1: ID code registration with ,
[ENTER]. (up/down) keys or F1 (function) key, and press
[ENTER].
F0: Displays the Injector ID codes (hereinafter
called ID code) of Cyl.1-Cyl.6.
Allows you to confirm the ID code after
registration.
F2: Uploads (transfers) the ID code (No. 1
cylinder No. 6 cylinder) registered in the
ECM to Tech2 to store in its memory.
F3: Allows you to download (batch registration)
the uploaded ID codes from Tech2 to the
ECM.


Step 12 Step 12-2
Press the softkey [Next].
As an example, the vehicle will be checked
whether it is in the condition (engine stopped) that
the ECM requests during ID registration.

Step 12-3
You need to enter the ID on the following display.
ID code is number of year. The following conditions

must be met.
Step 12-1 Conditions:
The following display appears while checking if the 1. The time setting of Tech2 matches with the
engine speed is 0 rpm. calendar.
When the engine speed is 0 rpm, it will take you to 2. Press the function keys (F0 F9) to enter.
Step 13.


Step 13 Step 15
Choose the cylinder (No. 1 cylinder No. 6 ID code registration (data entry)
cylinder) you want to register the ID code with , 1. The cursor is positioned at M (model code) in
(up/down) keys, and press the [ENTER] key. the default setting.
As an example, this describes about No. 1 cylinder. MCD0 D1D2
2. At this point, enter the model code (MC) and ID
code (D0) in this order.
Entering with the function keys (F0 F9) will
automatically move the cursor to the right.
However, if you enter with , (up/down)
keys, you need to move the cursor with the
arrow (left/right) keys.
3. Entered data must be within $00 $FF.
You can enter 0 9 with the function keys (F0
F9), or 0 Z with , (up/down) keys.
4. For VC17 (China), BCC code needs to be
entered. NK3 request
Tech2 calculates the entered data and displays
the following message.
When entered ID code (QR) is out of the set
value:
Writing unable
 When entered BCC code is out of the set
Step 14 value:
Writing unable
To register the ID code, press the softkey
When the ID code (QR) does not correspond
[Change].
to BCC code:
The ID code for Cylinder1 (No. 1 cylinder) selected Writing unable
at Step 13 is shown here.


Step 15-1 Step 15-3
1. The model code (MC) for VC25 is $5A, the Tech2 If you have entered incorrectly (D7:$EG), do the
specifies to register (write) $5A automatically. following.
However you may also enter. 1. After pressing [ENTER] key as with Step 15-1,
Tech2 calculates the BCC code (BC) and registers press the softkey [Program]. This cause the
automatically. error message Invalid data Try again! to
Therefore, you do not need to enter. appear.
2. After entering the ID code input data byte (MC-D9), 2. Set the data entry limit judgment.
press [ENTER] key. Judgment condition: Data (1 byte) meets the
following condition.
MSB:$F Data LSB:$F
The following error message will be displayed
until the value that meets the condition is
entered.

Step 15-2
If the ID code you have entered is correct, press
the softkey [Program].
If you want to quit the program (registration), press
the softkey [Abort] or press [EXIT] key. 
Quitting the registration or pressing [EXIT] key Step 16

returns you to Step 11. If the entered values meet the conditions in Step
15-1 and 15-3, the status display of data
registration (writing) from the Tech2 to ECM as
shown below will appear.


Step 17 Step 18
When the ID code entered in Steps 15-1 and 15-3 Pressing [EXIT] key returns you to Step 11.
corresponds to that registered in the ECM, the
following message will appear. Also, if you want to
register ID again, press the softkey [Yes]. This
returns you to Step 13, and allows you make
registration as before. Pressing the softkey [No]
will take you to Step 18.
This completes the ID code registration.


Step 17-1
When the ID code entered in Steps 15-1 and 15-3
does not correspond to that registered in the ECM,
the following message will appear.
Pressing the softkey [End] returns you to Step 11.

ID code upload (Tech2) Step 12
Step 11 Pressing the softkey [Yes] updates the ID codes of
No. 1 cylinder No. 6 cylinder stored in the ECM,
This step 11 describes ID code registration
to the Tech2.
continued from the step right before.
Pressing the softkey [No] returns you to Step 11
1. Choose the menu F2: ID code upload (Tech2) without uploading the data.
with Å£, Å (up/down) keys or F2 (function) key, Upload is the function to transfer the registered ID
and press [ENTER]. code from ECM to Tech2 to store the data in it.


Step 11-1
Step 12-1


Step 12-2 Step 12-4
When the ID code registered in the ECM Pressing the softkey [Confirm] returns you to Step
corresponds to that uploaded to the Tech2, the 11.
following message will appear.
Upload is completed.
Pressing the softkey [Confirm] returns you to Step
11.


Step 12-3
When the ID code registered in the ECM does not
correspond to that uploaded to the Tech2, the
following message will appear.
11.
In this case, the uploaded ID code will be erased.
Therefore, perform upload again. The message
shown in Step 12-4 will appear.

ID code download (Tech2) Step 12
Step 11 Press the softkey Confirm.
This step 11 describes ID code registration As an example, the vehicle will be checked
continued from the step right before. whether it is in the condition (engine stopped) that
the ECM requests during ID registration.
1. Choose the menu F3: ID code download (ECM)
with Å£, Å (up/down) keys or F2 (function) key,
and press [ENTER].

Step 12-1
 The following display appears while checking if the
engine speed is 0 rpm.
Step 11-1
When the engine speed is 0 rpm, it will take you to
Step 13.


Step 12-2 Step 13-1
The following display appears when the engine Registration is started from No. 1 cylinder (INJ.#1)
speed is not0 rpm. to No. 2 cylinder (INJ.#5) and the ECM in the order.
In this case, stop the engine as instructed in the The status for registration (writing) of data to ECM
message, and try again from Step 1. will appear.
The message in the screen changes in the order of
No. 1 cylinder (INJ.#1) and No. 2 cylinder (INJ.#5).
When it is abnormal, the registration repeats 3
times.

Step 13
Pressing the softkey [Yes] downloads (registers)
the uploaded ID codes (Cyl.1-Cyl.6) to the ECM. 
Pressing the softkey [No] returns you to Step 11.
Download is the function to register (write) the Step 13-2
stored (uploaded) ID codes (No. 1 cylinder No. 6 When the downloaded ID code corresponds to that
cylinder) in the Tech2 to the ECM. ID is registered registered (written) in the ECM, the following
from No. 1 cylinder to No. 6 cylinder in the order. message will appear. Download (registration) is
completed.
11.


Step 13-3
When the downloaded ID code does not
correspond to that registered (written) in the ECM,
the following message will appear.
11.

How to use TIS 2000
TIS 2000 installation procedure

(Time needed: 30 minutes)
System Requirements 1. PC Free hard disk space: 150MB or more

OS: Windows 95 or higher RS-232C connector
CD-ROM drive
2. Distribution CD-ROM
* Internet Explorer version 4.01 or later is required to use TIS 2000.

* If Internet Explorer prior to version 4.01 is installed, or it is not installed on your PC, Internet Explorer version 4.01
(English version) will be installed automatically.
1. Turn on the power to start-up Windows. 5. Select the language to be used, and click the
2. Insert the distribution CD-ROM into the CD-ROM Next.
drive of PC.
3. The following screen will appear in approx. 10
seconds.
* If the screen does not appear, open the file of
Autorun.Exe in the CD-ROM.
4. When the Welcome screen appears, click the
Next.
6. Usually, leave the Destination Directory as it is,

and click the Next.
7. On the Choose serial port for Techline. screen,
select the serial port of the serial cable to connect
Tech2 to the PC.
Normally, select the COM1 and click the Next.
10. On the TIS 2000 installation mode, select the

Standalone and click the Next.
8. On the Set HARDWARE_KEY screen, select the

LPT and click the Next.
9. On the Salesmake screen, select either the

Isuzu - General Export (General Export VIN) or
Isuzu US (US VIN) and click the Next.
[Example (UBS 6VE1 engine)]
General VIN: JACUBS26GY7100001
US VIN: JACDJ58X3Y7100001
11. On the TIS 2000 Update screen, click the OK. This describes about how to transmit and display Tech2
snapshot data using the Snapshot Upload function of
TIS 2000. Snapshot data can be displayed with the
Snapshot Upload function of TIS 2000. The trouble
symptom can be checked by analyzing snapshot data
with various methods. To display the snapshot data,
perform the following 3 steps;
A. Record the snapshot data in Tech2.
B. Transmit the snapshot data to PC.

After recording the snapshot data to Tech2, transmit the
data from Tech2 to PC in the following procedure.
1. Startup TIS 2000.
2. Choose the Snapshot Upload/Display on the
initial screen of TIS 2000.
3. Either select the Upload from diagnostic tool or
click the appropriate icon on the tool bar.
4. Select the Tech2 and transmit the saved
snapshot data.
5. Select the Transmitted Snapshot.
12. If the installation is completed, the TIS 2000 icon
6. When the snapshot data transmission is
is displayed on the desktop.
completed, the data parameter list will appear on
* An error message may appear when restarting the screen.
the PC at Step 12.
In this case, install the following file in the CD-
ROM.
~cosids\Diag\Mdac_type.ex_
Copy this file on your hard disk, change the file
name into mdac.exe, and double-click
mdac.exe.
After this work, install TIS 2000 again.
How to display snapshot
Fig. 2: Data display (sample)
Fig. 1: Application Selection screen

C. Display snapshot data with the Snapshot
Upload function of TIS 2000.
Snapshot data are stored in the PC hard disk or floppy
disk, and they can be displayed any time. Stored
snapshot can be displayed in the following procedure.
1. Startup TIS 2000.
2. Choose the Snapshot Upload/Display on the
initial screen of TIS 2000.
3. Either select the Open file or click the relevant
icon on the tool bar.
4. Select the Transmitted Snapshot.
5. When the snapshot data opens, the data
parameter list will appear on the screen.
Icons to be displayed
The following icons are used for data display.
Transmits the snapshot from Tech to PC.
Uploads the snapshot data from the floppy disk or hard disk.
Saves the snapshot data on the floppy disk or hard disk.
Displays the data parameters in one frame.
Displays the data parameters in two frames.
Changes the unit.
Displays the data parameters in graph and list (up to 3 parameter items for graph display).
Selects/cancels the parameter.

Displays the data parameters in graph only (up to 6 parameter items).
Prints (data parameter print out).
Snapshot data replay

Snapshot data can be replayed using icons in the bottom of the screen.
1st record: Displays the first record of the snapshot.
Previous record: Displays the previous record of that currently displayed.
Regeneration in reverse direction: Replays in the reverse direction.
Trigger of record: Moves to the trigger position and displays the snapshot.
Regeneration in forward direction: Replays all the snapshot in the forward direction.
Next record: Displays the next record of that currently displayed.
Last record: Displays the last record of the snapshot.
End of regeneration: Clicking the snapshot ends the replay of record.

Graph display 6. Graph display can be moved with the navigation
Numeric value and graph (up to 3 for graph display): icons.
1. Clicking the icon for graph display opens Graph 7. If you wish to view the graph with different
Parameters window. parameter, drag the parameter in the list onto the
display screen. (Click the parameter and move the
2. Click the 1st graph icon in the top of the window,
cursor with the mouse button pressed, and then
and select one parameter from the list in the
release the mouse button in the display screen.)
bottom of the window. Selected parameter is
New parameter appears to replace the old one. To
shown next to the graph icon. Graph category can
view the graph in full screen, move the cursor to
be selected with the field located in the right hand
the top of the screen, and click the screen where
of the parameter.
the cursor changes to magnifying glass icon. This
3. Perform the same procedure for the 2nd and 3rd will display the graph in full screen.
graph icons.
4. After selecting all the parameters (up to 3 Graph display in one frame (up to 6 for graph
parameters) you wish to view, click the [OK] button. display)
1. Click the Six graph icon. This opens Graph
Parameters window.
Fig. 4: Graph Parameters window (sample)
5. Selected parameter is shown in graph form, in the Fig. 6: Graph Parameters window
right hand of the data parameter on the screen.
2. Click the graph icon, and select the parameter you
wish to view from the list. Change the graph
category as required.
3. Perform the same procedure for the 2nd to 6th
parameters with graph icons.
4. Clicking the [OK] button displays the graph.
Fig. 5: Graph display screen (sample)

5. In this case, parameters are available only in graph
form. All the parameters are shown in one frame.
Fig. 8: Parameter selection
Fig. 7: Graph display screen (sample) Directory to save data

Normally data is saved in C:\Program
6. Graph display screen can be moved with the Files\cosids\DATA\SNAPSHOT\ folder. This directory
navigation icons. is different if you changed installation directory when
installing the application. Two sample files
Selects/cancels the parameter. (10000000SUR, 10000001.SUR) are already stored
when installing the application.
Use of parameter select/cancel function allows to select
particular parameter from the list and to display it
instantly. First click the parameter you want to view to
mark it, then click Select/Cancel Parameters.
Selected parameter is shown in the upper area of [Lock
line] on the top of the data list. Other parameters can be
added in the same procedure. Use of parameter
[LOCK] allows the parameters to be displayed
continuously for data comparison. To eliminate a
parameter from the list, click the parameter you want to
eliminate to put mark on it, then click Select/Cancel
Parameters. When quitting the [Snapshot Display]
application, Do you want to save this file? dialog box
appears automatically. The file can be saved on the PC
hard disk or floppy disk.
TIS 2000 navigation
TIS 2000 application can be operated using the following icons.
[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.
[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently
used. The applications currently used run in the background.
[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.
[Executed applications end]: Quits the application currently used to return to the initial page of
TIS 2000.
[Session]: Allows to register and display user information.
[Print]: Prints the screen.
[Help]: Launches the integrated help function of TIS 2000.
Software download
Herein, it is described about how to update Tech2

software using Software Download function of TIS
2000.
Updating Tech2 (Software download)

Update the Tech2 software to the latest version using
Software Download function of TIS 2000.
Tech2 software is updated on a regular basis to
correspond to the change in vehicle specifications and
diagnostic methods. Updated information includes new
vehicle system, amendment of diagnostic method,
update from previous version, addition of new
diagnostic method, etc.
There are two kinds of download mode; Standard and

Custom.
Fig. 1: Application Selection screen

Standard update (This mode is not used this time. 8. When the transmission is completed,
Select the Custom.) Transmission is completed will appear on the
Description: Standard mode can be used only when the screen. Click the Close button to quit the
old version of software is installed and registered in the application. The latest software has been
database. Only Custom mode can be used in any transmitted to the diagnostic tool.
other cases. In Standard mode, the latest version will
be installed for the language and the model Custom update
(manufacturer) which are set in Tech2 at that time. Use custom update when installing the old version
software, software other than Isuzu software or
The procedure of Tech2 Standard update, using software with different language, or when the database
Software Download function, is as follows. cannot identify the software version being installed.
1. Connect the Tech2 to the PC with RS-232C cable. After selecting Custom on the selection screen (See
2. Connect the standard accessory power cable to Fig. 2), perform the following procedure.
Tech2.
3. Startup TIS 2000 on the PC. 1. The Application Selection appears on the screen.
4. Choose Software Download icon on the initial The list of the software release No. appears on the
screen of TIS 2000. left hand of the screen. Clicking [+] mark allows to
5. Check the selected location on the Select view the list of available language of each release.
Diagnostic Tool for Download screen, and go to
next.
Fig. 3: Selection of application for Custom mode
Fig. 2: Selection of diagnostic tool to be updated and 2. Either double-click the relevant software version
update mode and language, or click the Select button to select.
The software you have chosen appears on the
Check the selected location and click Next. An right hand of the screen. To compare current
explanation appears as Reading information of software with selected software of the diagnostic
diagnostic tool. tool, click the mark on the right hand of the screen.
3. Clicking the [Download] button starts updating.
6. The Software Update Confirmation screen 4. Transmitting Software appears on the screen to
appears on the PC. tell the transmission status.
Also, the stored contents of the current Tech2 and 5. When the transmission completes, Transmission
stored data after transmitting diagnostic software is completed will appear on the screen. Click the
appear on the screen. Click the [Continue] to go Close button to quit the application. The selected
on. software has been transmitted to the diagnostic
7. Transmitting Software appears on the screen to tool.
tell the transmission status.
TIS 2000 navigation
TIS 2000 application can be operated using the following icons.
[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.
[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently
used. The applications currently used run in the background.
[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.
[Executed applications end]: Quits the application currently used to return to the initial page of
TIS 2000.
[Session]: Allows to register and display user information.
[Print]: Prints the screen.
[Help]: Launches the integrated help function of TIS 2000.

How to use injector checker

Name
1. Injector checker body 3. Test harness for 4-cylinders
2. Test harness for 6-cylinders
* To prevent wrong connection, the end of corrugate Name

tube of connection harness for 6-cylinders is wrapped 1. Main switch
by identification tape (red) for 4-5-6 cylinder side 2. Battery lamp
harness. 3. Operation lamp
4. Cylinder selection switch
Each part of injector checker 5. Start button
Main switch
This is used to switch ON and OFF of injector checker
function.

Note:
Be sure to turn it to OFF before removing/installing
harness.
  Battery lamp
This comes on when the battery (9V) in the body gets
low (7.2V or less).

If the battery lamp comes on, replace the battery as
soon as possible. (Refer to Battery Replacement)

Note:
When using the main switch, it comes on
momentarily due to voltage change. If the battery
lamp does not come on when using the main
switch, check the battery. Replace it if it gets low
(7.2V or less).
Cylinder selection switch

This is used to switch a cylinder to be checked. Turn it
left fully before check, and then start to check clockwise
(1 2 3 4 5 6).
Note:
One rotation of cylinder selection switch allow
to check twice for each cylinder. At the third
time or later, turn the selection switch left back
to the original position and start to check.
Do not turn the selection switch excessively 
after it is turned to stopper.
Precautions on handling the body
Start switch The body is a precision equipment. Do not drop
This is used to stop the cylinder selected by the cylinder it or make a high impact on it.
selection switch. Injection of selected cylinder stops The body is drip-proof type. However, avoid
approx. 2.4 seconds. using it in rainy day or operating with wet
hands to prevent water from entering through
Operation lamp connector connection.
This comes on while injector is checked (approx. 2.4 Power for the body must be supplied from
seconds) after starting button is pressed. internal battery, not from external one.
Prevent foreign matter from entering into the
Note: body while replacing battery.
Do not use any switches and operate the machine Do not use screws to tighten battery holder
while the lamp comes on. Otherwise, diagnosis except original ones. This may cause body
result is not correct. damage or battery damage and electric
leakage.
Holder
Do not disassemble the body in any
Holders are used to hang or fix the body. They are circumstances. Contact the machine
tightened on the body. To use the holders, loosen the manufacturer or ISUZU Industrial Engine
screws to move. Service Dept. if it is faulty.
Note: Injector test
When using or storing holders, be sure to
1. Check the DTC.
tighten them to fix.
If DTC unrelated to injector is detected, repair or
Be careful not to tighten screws excessively.
check to eliminate the faults before test.
This may damage the body.
2. Turn the key switch to OFF. Note:
3. Disconnect the injector connector from engine on Be careful not to let the metal parts of connector
the machine. (4-cylinder: one, 6-cylinder: two) contact glow plug connector while connecting the
harness.

* 4HK1 is shown for illustration. 
4. Connect the test harness to the engine side. 5. Connect the test harness to the body.
Note:
Be careful not to let the metal parts of test
harness and connector contact glow plug
connector. Protect it with cloth to prevent short
during test of key switch.
Do not connect wrong connector. (Confirm the
identification tape (red) before connecting.)
DTC will be detected if disconnecting or
connecting the harness with the key switch to
ON. Turn it to OFF during work.

6. Start the engine.

7. If the machine has function to lower idle speed,
lower the speed to clarify the engine reaction.
8. Set the selection switch to 1.
9. Press the start button and check the engine
vibration level and change in exhaust noise.
Note:
Do not operate the body and the machine while the
 operation lamp comes on.

10. Confirm that the lamp goes off and repeat check of 2. Pull out the battery holder.
the remaining cylinders as steps 8 and 9.
11. Replace the injector in the cylinder of which engine
vibration level and exhaust noise did not change.
Note:
For work procedure, refer to Engine section in
the service manual.
12. Remove the test harness and restore the injector

harness.
Note:
DTC will be detected if disconnecting or connecting
the harness with the key switch to ON. Turn it to
OFF during work.
13. Start the engine and return the idle speed at

specified one.
14. Clear the DTC.

15. Perform a test drive, and check that there are no
faults. 3. Remove the battery from the holder.
Battery Replacement
1. Remove the two screws on the side of the body.


4. Disconnect the connector from battery, and replace
the battery.

5. Restore in the reverse order.
Note:
Prevent foreign matter from entering in while
removing the battery.
Do not tighten the battery holder screws
excessively.
Do not replace the battery holder screws with
other than original ones.
Be sure to use specified battery.
How to use flush tool
Description of function and operation

How to use breaker box Important:
When inspecting or measuring the voltage and
Breaker box inspection procedure continuity of ECM, be sure to use a adapter harness
The breaker box is a tool to easily check open or short which is appropriate to the breaker box and the
circuit in connector pin and harness between ECM and inspected machine
each sensor or actuator, which used to be difficult to Before inspection and measurement of ECM
check. Voltage and continuity on pins of ECM can be are performed, confirm the pin position.
measured through breaker box using digital multi-meter Otherwise the ECM may get damaged.
(5-8840-2691-0). If a scan tool is also used, more
precise inspection and service can be performed. Note:
The pin No. of ECM in diagnostic procedure
matches with the pin No. of breaker box.
 


Name
1. Breaker box 2. Adapter harness
How to connect breaker box
Caution:
Be sure to turn off the key switch before the
connectors are disconnected.
1. Disconnect the ECM connector from ECM.

2. Connect the connector of adapter harness to ECM.
3. Connect the ECM connector to adapter harness.
4. Connect the adapter harness to breaker box.



Name
1. Breaker box 3. ECM
2. Adapter harness 4. To machine-side harness
Caution: Example of use for breaker box

Take care with the following items when connecting 1. Inspection and measurement of voltage
the adapter harness to breaker box. Failure to
Accelerator position sensor
connect may damage the ECM.
Engine coolant temperature sensor
Connect the connector on adapter harness Intake air temperature sensor etc.
side to the connector of breaker box with the
same No. each other.
When the connecting the connector, align the
cutouts of connector and breaker box each 
other.
 


Name
1. Breaker box
2. ECM
3. Digital multi-meter

Name 2. Inspection and measurement of resistance

1. Connector No. (Adapter harness) Crankshaft position sensor
2. Connector No. (Breaker box) Camshaft position sensor
3. Cutout SCV etc.

Name
1. Breaker box
2. ECM
3. Digital multi-meter
3. Inspection and measurement with oscilloscope

Vehicle speed sensor signal
Crankshaft position sensor signal
Camshaft position sensor signal etc.

Name
1. Breaker box
2. ECM
3. Oscilloscope
Caution:
During inspection and measurement, interference
of measurement lead on breaker box or mistaking
terminal to be measured may cause damage to
ECM or sensors. Work with extreme care.
Engine Control System
Description of function and operation
About engine control (common rail) system EGR (Exhaust gas recirculation)
General and detailed description in engine control Idle speed control
system The engine control system also has the following
system control functions other than engine control.
The engine control system is electronic control system
which maintains optimum combustion status of engine QOS (Quick On Start) system
all the time according to operating conditions. It Engine speed signal output
consists of the following components. Self-diagnosis function
Electronic control fuel injection system (Common CAN (Controller Area Network) communication
rail type) (SAE J1939/21, SAE J1939/11)
System control schematic diagram

(*: Specifications vary depending on each machine. Refer to the machines manual.)


 





 




 
 

 









About fuel injection correction
ECM calculates the basic injection amount based on
the signals from accelerator position sensor, boost
pressure sensor, CKP sensor, CMP sensor, etc. It
regulates the opening/closing period of SCV or electric
conduction of injector according to the common rail
pressure, engine coolant temperature, etc. at this time,
to correct the optimum injection timing and injection


amount.
About starting Q correction
ECM performs starting Q correction when the engine
speed is less than the starting Q threshold value at
engine starting.
Also, ECM cannot perform starting Q correction or start
the engine when the engine speed is less than the
lowest speed that system can recognize, since it does 
not recognize engine rotation. 






About high-altitude correction

ECM calculates the current altitude based on the
barometric pressure sensor signal.
It corrects the optimum fuel flow according to the
altitude etc. at this time.
Table of Input/Output


 





 
 





 













 
 
 


Electronic control fuel injection system (Common Injection pressure control

rail type) The system controls the injection pressure by
The engine control module (ECM) gets information, controlling fuel pressure in common rail. It calculates
such as engine speed, engine load, etc. (signals from the appropriate pressure in common rail on the basis of
various sensors), and sends electrical signals, based engine speed, fuel injection amount, etc., and
on the information, to the supply pump, injector, etc. in discharges the proper amount of fuel by operating
order to properly control the fuel injection amount, supply pump resulting in pressure feed to common rail.
injection timing, etc. in each cylinder. Injection timing control
Injection amount control This is substitute for a timer function. The system
The system controls the injector, mainly based on the calculates the fuel injection timing on the basis of
signals from engine speed and accelerator opening mainly engine speed, injection amount, etc. and
angle or the designated speed of machine control unit, controls the injector.
to maintain the optimum injection amount. Injection rate control
To improve combustion in cylinders, the system injects
a little fuel (pre-injection) and ignites it at the beginning,
then perform the second injection (main injection) after
the first ignition. It controls these injection timing and
injection amount by operating the injector.
Control during overheat
In overheating, ECM begins to limit fuel flow when the
engine coolant temperature exceeds 108 C, for engine
protection. It limits fuel flow further as the engine
coolant temperature goes up. Fuel flow is limited to a
certain level at around 120 C. (* Setting varies
depending on the machine manufacturer)
The system raises an alarm from 105 C for some
machines. In addition to alarm, by reducing the load to
the machine, it enables to avoid such conditions that
the fuel flow is limited.




System schematic diagram
4HK1
 
  
 









 

6HK1
 
  
 









 

Fuel system
Fuel is supplied from fuel tank to supply pump, then
supplied to common rail after pressurized by the pump.
At this time, the system operates the suction control
valve (SCV) by the signal from ECM to control fuel
amount supplied to common rail.
 




 

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
EGR (Exhaust gas recirculation) On 4HK1-TC and 6HK1-TC machines, the EGR system
Exhaust Gas Recirculation system is abbreviated to has the check valve to stop backward flow of EGR gas
EGR system. It recirculates part of exhaust gas into and flows it in one way direction, leading to increase the
intake manifold to mix an inert gas with intake air. This amount of EGR.
leads to lower the combustion temperature to limit
emissions of nitrogen oxide (NOx).
It controls amount of EGR by opening/closing the EGR
valve installed between exhaust manifold and intake
manifold. It determines amount of EGR, based on the
engine speed and load rate on engine (fuel injection
amount), and operates the EGR valve to control the
amount of EGR.
The cooling system (EGR cooler) equipped on the EGR
gas passage allows to cool down high temperature
EGR gas and mix it with new air to lower the
combustion temperature further, resulting in limiting
NOx effectively (Cooled EGR).
EGR control
ECM operates the motor according to engine speed,
engine load, etc. to control amount of EGR valve lift.
Amount of valve lift is detected by EGR position sensor.
The dark color area in the figure shows that the valve
lift amount is large, and the darkest color area shows
that the valve lift amount is almost 100%.




EGR system schematic diagram
 













Idling control UP
At warm-up operation, using the Idling control selector While pressing the UP side of switch, the engine
switch allows to control the lowest idling speed. Also, speed increases, resulting in increasing the idling
using the Idling control selector switch allows to speed.
automatically set the lowest idling speed to the DOWN
optimum value according to engine coolant While pressing the DOWN side of switch, the engine
temperature. speed decreases, resulting in decreasing the idling
speed. However, the idling speed does not decrease
Note: below the lowest speed.
Since specifications vary depending on each The engine speed controlled by idling control switch is
machine. Available functions also vary. stored in ECM when the key switch is turned to OFF.
The same speed can be achieved at the next operation.
Idling control selector switch
Using the Idling control selector switch allows to Speed limit control
switch the idling control function.
Speed limit control means that the engine control
Idling control switch module (ECM) controls fuel injection amount, based on
vehicle speed signal and engine speed, so that the
Using the Idling control switch allows to control the machine speed does not exceed the setting value.
idling speed. The vehicle speed signal is sent from vehicle speed
sensor to pulse matching box. The pulse matching box
Note:
corrects the signal to match with the machine, and
Refer to the machines manual for the locations of
sends it to ECM, meter, etc. The ECM recognizes the
idling control selector switch and idling control
engine speed by the signal from crankshaft position
switch.
(CKP) sensor.
The highest speed varies depending on engine
model, machine specifications and warm-up
condition of engine.


  




Check for speed limit control
To check whether the speed limit control on the
machine is active, check blinking of diagnosis lamp.

1. Turn the key switch to OFF. 
2. Turn the key switch to ON. 

3. Diagnosis lamp illuminates for 15 seconds and
then blinks three times.









Note:
If it does not blink, the speed limit control is not
active.
Engine speed output to tachometer

The engine control module (ECM) outputs the engine
speed pulse (4 pulses per engine revolution) as a
tachometer output to tachometer. Tachometer shows
the engine speed using the engine speed pulse sent
from ECM.
 
   
  
 

Preheating control
QOS (Quick On Start) system
The ECM determines the period required for glow (pre-
glow, glow, after-glow), and operates the glow relay and
QOS indicator lamp. QOS system allows to make the
starting at cold weather easier and reduce white smoke
and noise at starting. When turning the key switch to
ON, the ECM detects the engine coolant temperature
by signal from engine coolant temperature (ECT)
sensor and changes the period for glow so that the
proper starting conditions can be achieved all the time.
Also, after-glow function allows to stabilize idling
immediately after starting.






 

Engine Control Module (ECM) The ECM monitors the information sent from various
sensors all the time and controls each system of the
About functions of ECM
powertrain. The ECM performs the diagnostic function
Note: of the system, detects operational problems of the
Refer to the machines manual for the locations of system, gives a warning through diagnosis lamp to a
ECM. driver and stores DTC (diagnostic trouble code). The
area where the trouble occurred can be identified by
the DTC to assist a mechanic to perform repair work.
The ECM sends the voltage of 5 V to supply the power
to various sensors or switches. The ECM controls the
output circuits by controlling the ground or power
supply circuit through a certain device.
ECM and components

The ECM is designed to maintain the level of emission
as the emission control regulations and get a good
performance and fuel efficiency at the same time. The
ECM monitors various functions of the engine through
the sensors such as crankshaft position (CKP) sensor
etc.

ECM voltage Removal of ECM
The ECM energizes standard voltage to various 1. Turn the key switch to OFF.
switches and sensors. The resistance value of the ECM 2. Disconnect the battery cable from negative
is quite high so that the ECM can energize a voltage terminal.
like this. The voltage actually applied to the circuit is 3. Remove the parts (relay etc.) around the ECM to
low, and it does not sometimes comes on even if the facilitate removal of it.
test light is connected to the circuits. The voltmeter
4. Disconnect the ECM connector from ECM. (81-pin,
usually used in a service shop may not indicate a
40-pin connectors)
correct reading because the input impedance is too low.
A digital multi-meter which has an input impedance of 5. Loosen the installing bolts (nuts) and remove the
10 M (e.g. 5-8840-2691-0) should be used to get an ECM.
correct reading of the voltage.
Note:
Installation method and locations vary depending
Electrically erasable programmable read only
on each machine. Refer to the machines manual.
memory (EEPROM)
EEPROM has programs which is necessary for ECM to Installation of ECM
control the operation of powertrain and information for
Install the ECM in the reverse order of removal.
calibration.
EGR valve position learning is required after replacing
If fault is found in the EEPROM, replace the ECM.
the ECM.
Examples of programs to control powertrain and
information for calibration in ECM are the following 1. Turn the key switch to ON.
items. 2. Turn the key switch to OFF.
Engine model 3. Leave as it is for 10 seconds.
Engine number Failure to perform the EGR valve position learning may
result in detection of DTC for EGR.
ECM part number
DTC About ECM power off
Learning value for interval correction of cylinders
The power supply inside the ECM does not go off for
QR about 10 seconds after turning the key switch OFF. If
Q-key the ECM power needs to be off such as for memory
Learning value for EGR correction clear, wait for more than 10 seconds after turning the
key switch OFF.
Precautions on ECM service work
Note:
Be sure to use the ECM with the part number
corresponding to the machine.
If performing welding on the machine,
disconnect the battery cable from the negative 

terminal beforehand.
The ECM is designed to sustain normal consumption of

current relating to the operation of the machine. Circuits

should not be overloaded. In case of testing of open 
and short circuits, the circuits of the ECM must not be
connected to the ground or be supplied with voltage 
except that there is such an instruction. Be sure to use

a digital multi-meter (5-8840-2691-0) when performing
the tests of these circuits.

Engine component location diagram
(Component location, its form and parts to be used vary
depending on each machine.)
4HK1
   
 




 

6HK1
   
 


 

Name
1. Engine coolant temperature (ECT) sensor 8. Suction control valve (SCV)
2. Overheating switch 9. Fuel temperature (FT) sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR valve
Supply pump SCV (suction control valve)
4HK1 4HK1
 
 
6HK1 6HK1


 
Name Name
1. SCV 1. SCV
2. Fuel temperature (FT) sensor
3. Feed pump The SCV (suction control valve) is installed onto supply
pump section and controls pressure feed of fuel
The supply pump pressurizes fuel using engine output, (discharge amount) to common rail. The engine control
and pressure-feeds fuel to common rail. Supply pump module (ECM) regulates period of electric conduction
has also SCV (suction control valve), fuel temperature of SCV to regulate the fuel discharge amount.
(FT) sensor and feed pump.
Removal
Note: Do not replace the SCV.
If it is faulty, replace it as supply pump ASM.
the service manual.
4HK1 Fuel temperature (FT) sensor
 
6HK1 The fuel temperature (FT) sensor is installed onto the

supply pump, and the thermistor changes the
resistance according to the temperature. The
resistance is low when the fuel temperature is high, and
is high when the temperature is low. The engine control
module (ECM) energizes the voltage (5 V) to the FT
sensor through pull up resistance, and calculates fuel
temperature based on change of voltage to use for
various controls such as supply pump control etc. If the
resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is
low), the voltage becomes high.
Removal
Do not replace the FT sensor.
If it is faulty, replace it as supply pump ASM.


Common rail Flow damper
4HK1 4HK1
 
 
   
 
6HK1 6HK1
 
 
   
 
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The common rail receives fuel from supply pump, holds The flow damper is installed onto outlet port to each
the common rail (fuel) pressure and distributes fuel to injector of common rail, limits pressure pulsation in
each cylinder. The common rail has common rail common rail and prevents over-injected fuel from
pressure sensor, flow damper and pressure limiter. injector. When the flow damper operates, fuel supply to
injector is stopped.
Note:
For work procedure, refer to Engine section in Removal
the service manual. Do not replace the flow damper.
If it is damaged, replace it as common rail ASM.
Pressure limiter Common rail pressure sensor
4HK1 4HK1
 
 
   
 
6HK1 6HK1
 
 
   
 
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The pressure limiter operates to release the pressure in The common rail pressure sensor is installed onto
common rail when the pressure becomes extremely common rail, detects fuel pressure in common rail,
high. converts the pressure into the voltage signal and sends
it to engine control module (ECM). Voltage becomes
Removal higher as pressure becomes higher, and lower as one
Do not replace the pressure limiter. does lower. ECM calculates the actual common rail
If it is damaged, replace it as common rail ASM. pressure (fuel pressure) based on the voltage signal
sent from sensors and uses it for fuel injection control
etc.
Removal
Do not replace the common rail pressure sensor.
If it is damaged, replace it as common rail ASM. Injector
4HK1

The injector is installed onto cylinder head section and
6HK1 is controlled by engine control module (ECM) to inject
fuel. The ECM raises the voltage for operating injectors
internally, energizes to injector, and regulates period of
electric conduction of injector to control fuel injection
amount and injection timing.
Note:
the service manual.
Engine coolant temperature (ECT) sensor


The engine coolant temperature (ECT) sensor is The crankshaft position (CKP) sensor is installed onto
installed onto engine block, and the thermistor changes flywheel housing and produces the CKP signal when
the resistance according to the temperature. the convex portion of flywheel passes the sensor. The
Resistance is low at high engine coolant temperature engine control module (ECM) distinguishes the
and high at low engine coolant temperature. The cylinders by the CMP signal input from CMP sensor,
engine control module (ECM) energizes the voltage (5 determines the crank angle and uses it to control fuel
V) to the ECT sensor through pull up resistance, and injection and calculate the engine speed. These
calculates engine coolant temperature based on controls are performed, usually based on CKP signal.
change of voltage to use for various controls such as However it is done by CMP sensor if the CKP sensor is
fuel injection etc. If the resistance is low (temperature is faulty.
high), the voltage becomes low; if the resistance is high
(temperature is low), the voltage becomes high. Removal
Disconnect the connector, and remove the 10mm-
Removal mounting bolt and sensor.
Disconnect the connector and remove it with
19mm-wrench 4HK1




Installation 6HK1
Apply Loctite 572 before installing it.
Tightening torque: 19.6 29.4 N m {2 3 kgf m}
Crankshaft position (CKP) sensor


Installation
Tightening torque: 14.7 24.5 N m {1.5 2.5
 kgf m}
Camshaft position (CMP) sensor 4HK1
4HK1




6HK1
6HK1



Installation

The camshaft position sensor is installed onto the rear Apply a coat of engine oil to the O-ring.
of cylinder head and produces the CMP signal when Tightening torque: 7.8 2N m {0.8 0.2kgf m}
the cam portion of camshaft passes the sensor. The
engine control module (ECM) distinguishes the
cylinders by the CMP signal input from CMP sensor,
determines the crank angle and uses it to control fuel
injection and calculate the engine speed. These
controls are performed, usually based on CKP signal.
However it is done by CMP sensor if the CKP sensor is
faulty.
Removal
Scissors gear is installed to the cam gear of 6HK1
engine. When the cam gear has been removed,
ensure that the scissors gear is installed properly.
Disconnect the connector, and remove the 10mm-
mounting bolt and sensor.
Engine oil pressure sensor 6HK1

 
The engine oil pressure sensor is installed near the Installation

starter motor of the cylinder block; it detects engine oil
Tightening torque: 41 N m {4.2 kgf m}
pressure, converts the pressure into the voltage signal
and sends it to engine control module (ECM). Voltage
Accelerator position (AP) sensor
becomes higher as pressure becomes higher, and
lower as one does lower. The accelerator position (AP) sensor is installed onto
machine console panel and supplies the voltage signal,
Removal which changes according to the accelerator volume
Disconnect the connector and remove it with angle, to engine control module (ECM). The ECM
27mm-wrench calculates accelerator position by voltage signal and
use it for various controls such as fuel injection amount
control.
4HK1
Note:
Refer to the machines manual for the location of
accelerator position sensor.
Barometric pressure sensor



The barometric pressure sensor is installed onto the EGR position sensor
machine side and converts the barometric pressure into
voltage signal. The ECM calculates barometric
pressure by voltage signal and performs fuel injection
amount correction (high-altitude correction) etc. by
barometric pressure.
Note:
barometric pressure sensor.
Intake air temperature (IAT) sensor

It is installed in EGR valve and detects the valve lift

amount of EGR.
Note:
Do not disassemble the EGR position sensor. If it is
faulty, replace it as EGR valve ASM.
Removal
4HK1
The intake air temperature (IAT) sensor is installed onto

the machine side and detects the temperature of intake
air for optimum fuel injection control.
Tightening torque: 10.8 16.3N m {1.1 1.7 kgf m}
Note:
intake air temperature (IAT) sensor.

6HK1


Installation

Installation Tightening torque: 4 6 N m {0.4 0.6 kgf m}
Boost temperature sensor

Boost pressure sensor

The boost temperature sensor is installed onto the EGR
The boost pressure sensor uses the pressure hose
valve upstream side of intake manifold. The sensor is
between the boost pressure sensor and intake pipe,
thermistor type. The resistance in the sensor changes
detects boost (intake air pressure), converts the
as the temperature changes.
pressure into the voltage signal and sends it to engine
control module (ECM). Voltage becomes higher as Removal
pressure becomes higher, and lower as one does
Disconnect the connector and remove it with
lower. ECM calculates the boost (intake air pressure)
19mm-wrench
based on the voltage signal sent from sensors and
uses it for fuel injection control etc.
Removal
Disconnect the connector, and remove the two
10mm-mounting bolts, hoses and sensor.
4HK1 DLC (data link connector)

       
       
 
6HK1 The DLC (data link connector) is a connector for

communication and connection between the external
diagnostic device (scan tool) and each controller.
Note:
Refer to the machines manual for the locations of
DLC.
Diagnostic switch

The diagnosis switch shorts the DLC terminals No. 1
and No. 4 (or No. 5) to make the diagnosis lamp blink to
indicate DTC.
Note:
Refer to the machines manual for the locations and
form of diagnosis switch.
Memory clear switch

The diagnosis switch and memory clear switch are

used to clear the DTC stored in ECM.
Installation Note:
Tightening torque: 10.8 16.3N m {1.1 1.7 Refer to the machines manual for the locations of
kgf m} memory clear switch.
Diagnosis lamp Mode selector switch (1, 2, 3)

It indicates DTC by blinking after the diagnosis switch is The mode selector switch allows to operate at the
turned to ON. engine speed set by each mode.
Note: Note:
Refer to the machines manual for the locations of Refer to the machines manual for the locations of
diagnosis lamp. mode selector switch.
Wiring diagram of engine control module (ECM)
(*: Refer to the machines manual for fuse capacity.)
4HK1


  
 

 



 
  


 

  



 


  



  
 

 
 
 


 

 
 
 




 



 



  
  





  

 
 





  

 

 
  
 
 
 
   

  

  
  
 
 
 


  
 
  
  

  

6HK1

  
 

 



 
  
 




 



  

 
 







 

 
  


  
  
 


 
 






 



  
 





 
 

 



 

  
  

  
 
 
  

 


  
 
  
 
  

 
 


  
  
 
  


 

Pin arrangement of engine control module (ECM)

81-pin connector
Pin No. Terminal name Connection

1 PG-POWER GND
2 PS-+B Power supply
3 PG-POWER GND
4 PG-POWER GND
5 PS-+B Power supply
6 OS-DIAGL Diagnosis lamp
7 OS-BOOSTL Boost temperature sensor pilot lamp
8
9
10 OS-GLOWR Glow relay
11 OS-GLOWL QOS indicator lamp

12
13
14
15
16
17 OS-OILPL Engine oil pressure lamp
18 CC-CAN-H CAN-HIGH
19 IF-SPD Vehicle speed sensor signal
20 SG-SLD1 Accelerator position sensor 1 GND
21 OS-MAINR ECM main relay
22
23
24 IS-IGKEY Key switch ON signal
25
26
27
28
29
30
31
32 IS-MEMCL Memory clear switch
33
34
35
36
37 CC-CAN-L CAN-LOW
38 CC-KW2000 Data link connector
39
40 OS-MAINR ECM main relay
41 SG-5VRT1 Accelerator position (AP) sensor GND
42 SP-5V1 Accelerator position (AP) sensor power supply
43 PG-SIGN GND
44
45
46 IS-START Key switch start signal
47 ENGSTP Engine stop switch
48
49
50

51
52 IS-DIAG Diagnostic switch
53
54
55
56
57
58
59
60 SG-5VRT2 Barometric pressure sensor, intake air temperature (IAT) sensor GND
61 SP-5V2 Barometric pressure sensor power supply
62 PG-SIGN GND
63 IA-ACCEL1 Accelerator position (AP) sensor 1 signal
64 IA-ACCEL2 Accelerator position (AP) sensor 2 signal
65
66
67 IA-OILPRESS Engine oil pressure sensor signal
68
69
70
71 IA-BARO Barometric pressure sensor signal
72 IA-IAT Intake air temperature sensor signal
73
74 IA-THBST Boost temperature signal
75
76
77
78
79 SG-5VRT3 Engine oil pressure sensor, fuel temperature sensor, engine coolant
temperature sensor GND
80 SP-5V3 Engine oil pressure sensor power supply
81 PG-CASE GND
40-pin connector

82 IA-PFUEL Common rail pressure sensor signal
83 IA-THL Fuel temperature sensor signal
84 IA-THW Engine coolant temperature sensor signal
85

86
87 SP-5V5 Camshaft position (CMP) sensor power supply
88
89 IA-SCVLO PCVLO drive
90 IA-PFUEL Common rail pressure sensor signal
91 IA-BPRESS Boost pressure sensor signal
92 IA-EBMPOS3 EGR valve EGR position sensor W
93 IA-EBMPOS2 EGR valve EGR position sensor V
94 IA-EBMPOS1 EGR valve EGR position sensor U
95 SP-5V4 Boost pressure sensor power supply
96
97 IA-SCVLO PCVLO drive
98 IF-CAMHAL Camshaft position (CMP) sensor signal
99 SP-CAMHAL Camshaft position (CMP) sensor power supply
100 SG-SLD5 Camshaft position (CMP) sensor,
common rail pressure sensor shield
101 SG-5VRT5 Common rail pressure sensor GND
102
103 OM-EBM2 EGR valve DC servomotor power supply input V
104
105 OS-SCVHI SCVHI drive
106 IF-CRANK- Crankshaft position (CKP) sensor (-)
107 IF-CRANK+ Crankshaft position (CKP) sensor (+)
108 SG-SLD4 Crankshaft position (CKP) sensor shield
109 SG-5VRT4 Boost pressure sensor, engine coolant temperature sensor, fuel
temperature sensor GND
110 OM-EBM3 EGR valve DC servomotor power supply input W
111 OM-EBM1 EGR valve DC servomotor power supply input U
112
113 OS-SCVHI SCVHI drive
114 OS-INJ5 Injector 5 (4H: /6H: 2nd cylinder)
115 OS-INJ6 Injector 6 (4H: /6H: 4th cylinder)
116 OP-COM2 Injector power supply 2 (4H: 3rd, 4th cylinders/6H: 4th, 5th, 6th cylinders)
117 OS-INJ3 Injector 3 (4H: 4th cylinder/6H: 3rd cylinder)
118 OS-INJ4 Injector 4 (4H: 2nd cylinder/6H: 6th cylinder)
119 OS-INJ1 Injector 1 (4H: 1st cylinder/6H: 1st cylinder)
120 OS-INJ2 Injector 2 (4H: 3rd cylinder/6H: 5th cylinder)
121 OP-COM1 Injector power supply 1 (4H: 1st, 2nd cylinders/6H: 1st, 2nd, 3rd cylinders)
Circuit diagram
(Refer to Wiring diagrams for a way to read the diagram.)
Main relay circuit

(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

 

 




 




4HK1








Starter for ECM control, glow circuit

   

 


 
      
   
 
 
 
 
    

 



6HK1









   

 


 
      
   
 
 
 
 
    

 



Starter for safety relay, glow circuit
4HK1

 
 







 
 































6HK1


 

 
 
 

 


 
 
      
    

 
 
 
 

 







 



CAN, GND, DLC circuits
                   
   


   
 


 

   

   
  
  

Indicator lamp, tachometer circuit
 
 
 

 

             


   

   

 

4HK1
Injector circuit
       
   
   

   
 
     
               
               
       

       
           
           

    
   

 

6HK1
           
     
     

     
  
        
                   
                   
         
         
               

               
     
     

 


SCV circuit
 

 
 
 
   
       




 
   

   

   
   
                 
pressure sensor circuit
 
       
        

  

   

   
  
  
             
   



  



   
  


     

 




  





CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil



 




       
       

Boost temperature sensor, boost pressure sensor circuit
    

    
         



    
    
 

  
                         
           
           

CMP sensor, common rail pressure sensor, EGR circuit
  

          
       
               

   
   
            

 


 

 

  
   
   
 
 

   
                 


 
     
                     
  

 
Accelerator position sensor, barometric pressure sensor, intake air temperature sensor circuit




    

    
Idling selector switch, idle up switch, idle down switch, mode map switch circuit
           


     

     

Memory clear switch, engine stop switch circuit






 
















Engine harness location
4HK1

   
 




 

Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
7. EGR position sensor

 
   
      
    
    
       
     
   
  
             
           

    
       
   
   
        
      

 
   
  
   
      
      
 



 
  
      
        
       
   
  
   

   


   
   
   
  
     
     




 

   
       
    
   
       
       
       
           
 
            
   
                 
                   
              
            
   
              
        
 
   

E75 E98
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CKP +
2 Boost pressure sensor Vout 2 CKP GND
3 Boost pressure sensor Vcc
E112
E76 Terminal
Number
Terminal
Number 1 CMP shield
1 Engine oil pressure sensor GND 2 CMP GND
2 Engine oil pressure sensor Vout 3 CMP +
3 Engine oil pressure sensor Vcc
E113
E80 Terminal
Number
Terminal
Number 1 Common rail pressure sensor GND
1 EGR Vcc 2 Common rail pressure sensor Vout
2 EGR hall sensor W 3 Common rail pressure sensor Vcc
3 EGR hall sensor V
E161
4 EGR hall sensor U
5 EGR GND Terminal
Number
6 EGR motor W
1 SCV Hi
7 EGR motor V
2 SCV Lo
8 EGR motor U
E163
E90
Terminal
Terminal Number
Number
1 Boost temperature sensor GND
1 ECT GND
2 Boost temperature sensor +
2 ECT +
3 ECT meter E164
Terminal
E93
Number
Terminal 1 Overheating switch
Number
1 Fuel temperature sensor GND H1
2 Fuel temperature sensor + Terminal
Number
1 Glow
H6 H20
Terminal Terminal
Number Number
1 SCV Lo 1 CKP +
2 SCV Hi 2 CKP GND
3 Fuel temperature sensor + 3 CKP shield
4 ECT meter 4 CMP +
5 5 CMP GND
6 Overheating switch 6 CMP shield
7 ECT +
H8
Terminal 9 Engine oil pressure sensor Vcc
Number
10 Engine oil pressure sensor Vout
1 EGR hall sensor U
11 Engine oil pressure sensor GND
2 EGR hall sensor V
12 Common rail pressure sensor Vcc
3 EGR hall sensor W
13 Common rail pressure sensor Vout
4
14 Common rail pressure sensor GND
5 EGR motor U
6 EGR motor V
16 Boost pressure sensor Vout
7 EGR motor W
17 Boost pressure sensor GND
8
18
H12 19
Terminal 20
Number
H22
1
2 Terminal
Number
3 Injector power supply 2
1 Glow
5 OS INJ3 signal H94
6 OS INJ2 signal
Terminal
7 OS INJ4 signal Number
8 OS INJ1 signal 1 Injector power supply 1
9 2 Injector power supply 2
12 5 OS INJ1 signal
6 OS INJ4 signal
7 OS INJ2 signal
8 OS INJ3 signal
Cylinder head
   
 
 


6HK1

   
 


 

Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
7. EGR position sensor
   
     
  
   
   
   




   
     
  
   

    
        
       
     
    
        
        

 

    
   
   
        
      
 
    
    

  
    
  

  
     
   


  


  
    
   
  
     
     
 

 
      
         
     



   
       
    
   
       
       
       
           
       
              
                           
                       
               
                   
          
    

E75 E98
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CKP +
2 Boost pressure sensor Vout 2 CKP GND
E112
E76 Terminal
Number
Terminal
Number 1 CMP shield
1 Engine oil pressure sensor GND 2 CMP GND
2 Engine oil pressure sensor Vout 3 CMP +
3 Engine oil pressure sensor Vcc
E113
E80 Terminal
Number
Terminal
Number 1 Common rail pressure sensor GND
1 EGR Vcc 2 Common rail pressure sensor Vout
2 EGR hall sensor W 3 Common rail pressure sensor Vcc
3 EGR hall sensor V
E161
4 EGR hall sensor U
5 EGR GND Terminal
Number
6 EGR motor W
1 SCV Hi
7 EGR motor V
2 SCV Lo
8 EGR motor U
E163
E90
Terminal
Terminal Number
Number
1 Boost temperature sensor GND
1 ECT GND
2 ECT +
3 ECT meter E164
Terminal
E93
Number
Terminal 1 Overheating switch
Number
1 Fuel temperature sensor GND H1
2 Fuel temperature sensor + Terminal
Number
1 Glow
H6 H20
Terminal Terminal
Number Number
1 SCV Lo 1 CKP +
2 SCV Hi 2 CKP GND
3 Fuel temperature sensor + 3 CKP shield
4 ECT meter 4 CMP +
5 5 CMP GND
6 Overheating switch 6 CMP shield
7 ECT +
H8
Terminal 9 Engine oil pressure sensor Vcc
Number
10 Engine oil pressure sensor Vout
1 EGR hall sensor U
11 Engine oil pressure sensor GND
2 EGR hall sensor V
12 Common rail pressure sensor Vcc
3 EGR hall sensor W
13 Common rail pressure sensor Vout
4
14 Common rail pressure sensor GND
5 EGR motor U
6 EGR motor V
16 Boost pressure sensor Vout
7 EGR motor W
17 Boost pressure sensor GND
8
18
H12 19
Terminal 20
Number
H22
1
2 Terminal
Number
1 Glow
5 OS INJ3 signal H94
6 OS INJ2 signal
Terminal
7 OS INJ4 signal Number
8 OS INJ1 signal 1
9 2 OS INJ1 signal
11 OS INJ6 signal 4 Injector power supply 2
12 OS INJ5 signal 5
6 OS INJ3 signal
7 OS INJ5 signal
8
H95
Terminal
Number
1
2 OS INJ6 signal
5
6 OS INJ4 signal
7 OS INJ2 signal
8











Connector list
No. Connector Face No. Connector Face
E-27 E-75
  

#1 injector (Silver)
E-29 E-76   

#2 injector (Silver) (Black)
E-31 E-80
 
E-33 E-90


#4 injector (Silver) (Blue)
E-35 E-93
#5 injector (Silver) (Gray)
E-37 E-98
E-56 E-112
(Gray) (Black)
E-57 E-113
(Gray) (Gray)
E-114 H1
(Black) (Black)
E-161 H-6
(Brown) (Gray)
E-162 H-6
(Dark gray) (Gray)
E-163 H-8
(Gray) (Black)
E-164 H-8
(Black)
FB-124 H-12
(Black) (Gray)
       
FL-150         H-12

(Gray)
   
   
  
   
FL-269 H-20    
   
 
   
   
H-95
H-20 (ECM
   
   
    side)

(Gray)
H-95
H22 (Injector
side)
(White) (Gray)
H-95
H22 (Injector
side)
(White) (Gray)
H-94
(ECM
side)
(Gray)
H-94
(ECM
side)
(Gray)
H-94
(Injector
side)
(Gray)
H-94
(Injector
side)
(Gray)
H-95
(ECM
side)
(Gray)
List of function checks
Interview Inspection to comprehend the trouble symptom and diagnose properly based on a
customers complaint.
OBD system check Inspection to identify defective point of engine control system (inspection
procedure)
Diagnosis lamp illumination Inspection when diagnosis lamp does not come on when starter switch is turned
circuit system check ON.
Diagnosis lamp blinking circuit Inspection when diagnosis lamp does not blink (remains on) when diagnostic
system check switch is turned ON.
Scan tool power supply circuit Inspection when scan tool (Tech2) does not operate.
system check
Scan tool communication Inspection when scan tool (Tech2) cannot communicate with ECM.
circuit system check
Starting circuit system check Inspection when starter does not operate.
Starting system check Inspection when starter operates but engine does not start.
Fuel system check Inspection when relevant points to fuel system may be faulty (inspection
procedure).
Intake system check Inspection when relevant points to intake system may be faulty (inspection
procedure).
Exhaust system check Inspection when relevant points to exhaust system may be faulty (inspection
procedure).
EGR control system check Inspection when relevant points to EGR may be faulty (inspection procedure).
QOS control system check Inspection when relevant points to QOS (glow) may be faulty (inspection
procedure).
CAN communication check Inspection when fault relevant to machine control unit and CAN communication
between scan tool and ECM may exist.
Machine-side check Inspection when fault relevant to machine function (inspection procedure) may
exist.
In the subsequent part of this manual, scan tool indicates scan tools including Tech2.
OBD system check
About OBD system check Note for OBD system check
OBD system check is systematic method to check the Important:
problems which caused by engine control system If there is no complaint for operationality, never
malfunction. It is the first procedure of all complaint perform this diagnostic step unless otherwise
diagnosis for operationality. Use of this diagnostic step instructed in other items.
properly enables to shorten the diagnosis period and to Before the diagnosis, check the service
prevent unnecessary replacement of proper parts. information.
Never erase DTCs unless otherwise instructed
Test description
in the diagnostic step.
2. Communication disability with scan tool is caused by If fault is found in the engine starting system,
fault in the communication circuit between each ECU refer to Electrical system in the service
and scan tool. manual Engine section.
4. If DTC is detected, proceed to the relevant DTC
Ensure the battery is fully charged.
diagnosis by referring to the list of DTC. If more than
one DTC is detected, start with the one with smallest Make sure the battery cable is normal and
DTC number unless otherwise instructed in the securely connected.
diagnostic step. Make sure the ground cable of ECM is
connected to the proper position securely.
Step Action Value YES NO

2. Check the diagnosis lamp (on the machine
trouble display monitor). Go to Step 2 in
1 Diagnosis lamp
Does the diagnosis lamp (on the machine illumination circuit
trouble display monitor) come on? Go to Step 2. system check.
1. Connect the diagnosis connector.
2. Check the diagnosis lamp (on the machine
Go to Step 2 in
2 trouble display monitor). Diagnosis lamp
Does the diagnosis lamp (on the machine blinking circuit
trouble display monitor) blink? Go to Step 3. system check.
3 Is the scan tool available? Go to Step 4. Go to Step 6.
1. Connect the scan tool.
Go to Scan tool
4 3. Turn the power switch of the scan tool to
power supply
ON.
circuit system
Does the scan tool powered ON? Go to Step 5. check.
Communicate with ECM using scan tool. Go to Step 2 in
Scan tool
Does it communicate with ECM properly?
5 communication
circuit system
Go to Step 6. check.
Turn the key switch to START. Go to Starting
6 circuit system
Does the starter operate?
Go to Step 7. check.
Turn the key switch to START.
7 Go to Starting
Does the engine start? Go to Step 8. system check.
Check if DTC is detected.
8 Go to the relevant
Is DTC detected? DTC diagnosis. Go to Step 9.

1. Check for following troubles.
Engine stall
Engine hunting, rough idling
Engine output lowering, blow up fault,
engine breathing
Exhaust gas contains a lot of white
9 smoke.
Exhaust gas contains a lot of black
smoke.
Idling rotation cannot be adjusted.
Idling rotation cannot be reduced. Go to the relevant
trouble symptom
Is the trouble detected? diagnosis. Normal system
Diagnosis lamp illumination circuit system check

 



   
  
   
 
 
 

 
 

             




   
   

 

Description of circuit Following inspections are necessary to detect these

The power supply voltage is supplied to the diagnosis causes.
lamp via key switch, and the signal from ECM will turn Improper connection of harness connector and
the lamp on. The ECM turns the diagnosis lamp on ECM connector
during lamp check with the key switch ON and when Poor connection of terminal from connector
DTC is detected. Also when the diagnosis connector is Unmatched terminals are fitted.
connected, it blinks the diagnosis lamp according to the Damage of connector lock
DTC detected. A monitor circuit is provided inside the
Poor contact between terminal and wire
ECM to monitor the lamp operation.
Damaged harness
Diagnostic aid Visually check the harness for damage.
If the intermittent trouble is suspected, followings may Check the relevant items on the scan tool data
be the cause. display while moving the connector and the
harness which are related to the sensor. The
Improper connection of harness connector
variation of the display indicates the faulty part.
Defective harness routing
Worn harness cladding
Wire disconnection inside harness cladding

1 2. Check the diagnosis lamp. Go to Diagnostic
Does the diagnosis lamp come on? aid. Go to Step 2.
Remove the diagnosis lamp to check its
2 condition. Replace the
Is the trouble detected? diagnosis lamp. Go to Step 3.
Check for open/short circuit between the
diagnosis lamp and ECM and power supply
3 circuit using DMM.
Repair the
Is the trouble detected? harness. Go to Step 4.
4 Is EMPS available? Go to Step 5. Go to Step 6.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to How to use flush tool in this section
for check and rewriting of ECM.
Note:
5
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to Engine Control System, Engine
control module (ECM), Installation of ECM
in this section for learning of EGR. Check the repair,
and Go to OBD
Is the procedure completed? system check.
Replace the ECM.
Note:
6
in this section for learning of EGR. Check the repair,
and Go to OBD
Is the procedure completed? system check.
Diagnosis lamp blinking circuit system check


 

                   
   
 

   
 

Description of circuit Following inspections are necessary to detect these

The power supply voltage is supplied to the diagnosis causes.
lamp via key switch, and the signal from ECM will turn Improper connection of harness connector and
the lamp on. The ECM turns the diagnosis lamp on ECM connector
during lamp check with the key switch ON and when Poor connection of terminal from connector
DTC is detected. Also when the diagnosis connector is Unmatched terminals are fitted.
connected, it blinks the diagnosis lamp according to the Damage of connector lock
Damaged harness
Diagnostic aid Visually check the harness for damage.
If the intermittent trouble is suspected, followings may Check the relevant items on the scan tool data
be the cause. display while moving the connector and the

2. Connect the DMM between the diagnosis
connector (male-side) and the ground.
1 3. Turn the key switch to ON. 0V
Is the DMM indication more than the specified

value? Go to Step 2. Go to Step 3.
Check for installation condition of the ECM
connector and coupling connector.
1. Check for play or looseness in the
2 connection.
2. If the trouble is detected, repair as
required.
Is the trouble detected? Verify repair. Go to Step 3.
1. Check for followings in the circuit between
ECM and diagnosis connector using
breaker box or DMM.
Refer to Breaker box inspection
procedure.
3 Open circuit
High resistance
required.
1. Check for following in the circuit between
diagnosis connector and ground.
Open circuit
4 High resistance
required.
Check the diagnosis lamp blinking condition
again.
5 2. Connect the diagnosis connector.
3. Check the diagnosis lamp.
Go to Diagnostic
Does the diagnosis lamp blink? aid. Go to Step 6.
necessary.
7 Note:
in this section for learning of EGR.
Is the procedure completed? Verify repair. Go to Step 8.


Replace the ECM.
Note:
8
Is the procedure completed? Verify repair.
Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
3 Open circuit/ Resistance Key switch OFF 52 - Diagnosis 100 or 10M or
high measureme connector terminal less more
resistance nt
Short circuit to Resistance Key switch OFF 52 - Ground 10M or 100 or
ground measureme more less
nt
Scan tool power supply circuit system check


 

                   
   
 

   
 

Circuit description Improper connection of harness connector and

The ECM and other ECUs communicate with the scan ECM connector
tool via data link connector (DLC). Power supply Poor connection of terminal from connector
voltage for the scan tool is provided from the battery. Unmatched terminals are fitted.
Damage of connector lock
Caution:
Use a 12-V battery from the chassis ground side for
the power supply to the scan tool. Damaged harness
Visually check the harness for damage.
Diagnostic aid Check the relevant items on the scan tool data
If the intermittent trouble is suspected, followings may display while moving the connector and the
be the cause. harness which are related to the sensor. The
Defective harness routing Test description
Important:
Wire disconnection inside harness cladding Before starting this diagnostic step, check if the
Following inspections are necessary to detect these scan tool operates properly on other machine.
causes.

Check the voltage of battery on the machine
1 using DMM. 10V Charge or replace
Is the voltage more than specified value? Go to Step 2. the battery.
Check for poor contact in the scan tool-side
2 cable.
Is the trouble detected? Go to Step 3. Go to Step 4.
Correct the connection of the scan tool.
3
Is the procedure completed? Go to Step 4.
Check for open/short circuit in the cable Request for repair
between scan tool and battery. by referring to the
4
operation manual
Is the trouble detected? of the scan tool. Go to Step 5.
1. Connect the scan tool to the machine.
2. Turn the power switch of the scan tool to
5 ON. Check the repair,
and Go to OBD
Does the scan tool powered ON? system check. Go to Step 1.
Scan tool communication circuit system check


 

                   
   
 

   
 

Circuit description Improper connection of harness connector and

The engine control module (ECM) performs KW ECM connector
communication with the scan tool via 16-pin data link Poor connection of terminal from connector
connector (DLC). Unmatched terminals are fitted.
Diagnostic aid Poor contact between terminal and wire
If the intermittent trouble is suspected, followings may Damaged harness
be the cause. Visually check the harness for damage.
Improper connection of harness connector Check the relevant items on the scan tool data
Defective harness routing display while moving the connector and the
Worn harness cladding harness which are related to the sensor. The
Wire disconnection inside harness cladding variation of the display indicates the faulty part.
Following inspections are necessary to detect these
causes.

Perform the OBD system check.
1 Go to OBD
Is the procedure completed? Go to Step 2. system check.

connector and coupling connector.
2 connection.
required.
1. Check the DLC for following conditions.
Poor connection of terminal from
connector
3 Poor contact between terminal and wire
required.
ECM and DLC using breaker box or DMM.
procedure.
Open circuit
4 High resistance
Short circuit to ground
required.
5 3. Communicate with ECM using scan tool.
Go to Diagnostic
Does it communicate with ECM properly? aid. Go to Step 6.
necessary.
Note:
7
Is the procedure completed? Go to Step 9. Go to Step 8.

Replace the ECM.
Note:
8


9 3. Communicate with ECM using scan tool.
Does it communicate with ECM properly? Verify repair. Go to Step 2.

Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Key switch OFF 38 - DLC terminal 100 or 10M or
high measureme No. 3 less more
resistance nt
nt
Starting circuit system check
Starter ECM control









 
 

 


 
      
   
 
 
 
 
    

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  
 


Starter safety relay control


 

 
 
 

 

 
 
      
    

 
 
 
 

 







Circuit description Damage of connector lock

ECM turns the starter relay ON when the key switch is Poor contact between terminal and wire
turned to START position. When the starter relay is Damaged harness
ON, the starter operates to start the engine. Visually check the harness for damage.
Check the relevant items on the scan tool data
Diagnostic aid display while moving the connector and the
If the intermittent trouble is suspected, followings may harness which are related to the sensor. The
be the cause. variation of the display indicates the faulty part.
Defective harness routing Test description
Worn harness cladding Numbers below indicate step numbers in the diagnostic
Wire disconnection inside harness cladding chart.
Following inspections are necessary to detect these 4. If these DTCs are detected, engine may not start.
causes. 5. When the ECM does not recognize the START
position signal from the key switch, the starter cut relay
Improper connection of harness connector and
is set OFF. Therefore, the starter relay will not turn
ECM connector
ON.
Poor connection of terminal from connector
Unmatched terminals are fitted.

Is the emergency stop switch equipped? Turn the switch to
1 OFF, and Go to
Step 2. Go to Step 2.
2. Check the DTC.
2 Go to the relevant
Is the DTC P0340, P0341, P0615, P1345 or diagnosis of DTC
P1625 detected? detected. Go to Step 3.
1. Turn the key switch to START.
2. Check for Starter switch (ST) on the data
4 display using scan tool.
Is the Starter switch (ST) displayed ON? Go to Step 6. Go to Step 5.

key switch and ECM using breaker box or
DMM.
procedure.
5 Open circuit
High resistance
required.
2. Remove the starter cut relay.
6 3. Check for continuity between the starter
cut relay switch-side terminals.
Replace the starter cut relay.
7
2. Remove the starter relay.
3. Connect the battery to the starter relay
8 coil-side terminal.
4. Check for continuity between the starter
relay switch-side terminals.
Replace the starter relay.
9
Turn the key switch to START.
10 Go to Diagnostic
Does the starter operate? aid. Go to Step 11.

1. Check the following circuits for open circuit
or high resistance.
Between key switch and starter cut
relay
Between starter cut relay and starter
11 relay
Between starter relay and ground
Between starter relay and starter
required.
1. Inspect by referring to Electrical system
in the service manual Engine section
12 2. If the trouble is detected, repair as
required.
necessary.
Note:
14

Replace the ECM.
Note:
15

Turn the key switch to START. Check the repair,
16 and Go to OBD
Does the starter operate?
system check. Go to Step 1.
key switch and ECM using breaker box or
DMM.
procedure.
17 Open circuit
High resistance
required.

2. Remove the starter cut relay.
18 3. Check for continuity between the starter
cut relay switch-side terminals.
Replace the starter cut relay.
19
2. Remove the starter relay.
3. Connect the battery to the starter relay
20 coil-side terminal.
4. Check for continuity between the starter
relay switch-side terminals.

Name
1. Breaker box
2. DMM

5, 17 Open circuit/ Resistance Key switch OFF 46 - Key switch 100 or 10M or
high measureme START terminal less more
resistance nt
nt

6, 18 Open circuit/ Resistance Key switch OFF Starter cut relay 100 or 10M or
high measureme Relay alone Switch-side terminal less more
resistance nt
8, 20 Open circuit/ Resistance Key switch OFF Starter relay 100 or 10M or
high measureme Relay alone Switch-side terminal less more
resistance nt Relay ON
Starting system check
 

 
 
 
   
       




About starting system check Diagnostic aid

Starting system check is systematic method to detect If there is relevant DTC to CKP sensor and CMP
the cause of that engine does not start. Followings are sensor, the engine will not start until memory clear is
the preconditions for performing this diagnosis. performed.
Battery is fully charged, and battery cable is If the intermittent trouble is suspected, followings may
securely connected. be the cause.
Engine speed at cranking is normal. Improper connection of harness connector
Sufficient amount of fuel is supplied. Defective harness routing
No air mixed in the fuel. Worn harness cladding
Air cleaner element and fuel filter is normal. Wire disconnection inside harness cladding
Correct fuel is used. Following inspections are necessary to detect these
causes.
Important: Improper connection of harness connector and
Start with the DTC diagnosis relevant to fuel system ECM connector
if there is any. Poor connection of terminal from connector
Test description
Numbers below indicate step numbers in the chart.
4. If the SCV-LOW circuit is shorted to ground, the SCV
drive current will not be more than 900mA.
5. If the engine starts with the SCV connector
disconnected, SCV system may be faulty. Also, if the
engine does not start, the fuel system may be faulty.
6. Check the signal and operation of each sensor and
injector.

1 OFF, and Go to
2. Crank the engine for 15 seconds.
2 3. Check the DTC. Go to the relevant
diagnosis of DTC
Is DTC detected? detected. Go to Step 3.
Is the scan tool (KW communication)
3
available? Go to Step 4. Go to Step 11.
While cranking the engine, check for SCV F/
B on the data display using scan tool.
4 900mA
Is the SCV F/B more than the specified
1. Disconnect the SCV connector.
5 2. Crank the engine. Go to Fuel system
Does the engine start? Go to DTC P0090. check.
Repair the SCV-LOW circuit between the ECM
6 and the SCV.
1. Check the relevant items to the following
using scan tool to see if the values are
normal. (Refer to Tech2 data reference
value for specified value.)
Engine coolant temperature (ECT)
sensor
7 Common rail pressure sensor
EGR position sensor
Injector
2. If the trouble is detected, replace the
circuit or sensor as required.

1. Check for following faults.
Engine mechanical timing is off.
Improper installation position of
flywheel
8 Excessive clogging in intake system
Excessive clogging in exhaust system
required.
Is the trouble detected? Go to Step 9.
1. Clear the DTC.
Refer to How to clear diagnosis trouble
code (DTC) of Procedure of trouble
diagnosis in this section for how to clear
DTCs.
9
2. Turn the key switch to OFF for more than
10 seconds.
Check the DTC. Go to the relevant Check the repair,
10 diagnosis of DTC and Go to OBD
Is DTC detected?
detected. system check.
1. Repair the SCV-LOW circuit between the
ECM and the SCV.
11 2. If the trouble is detected, repair the circuit
as required.
1. Check for following faults.
Engine mechanical timing is off.
Improper installation position of
flywheel
12 Excessive clogging in intake system
Excessive clogging in exhaust system
required.
Is the trouble detected? Go to Step 9.
Fuel system check
 




 

Name
4. Pre-filter
About fuel system Worn harness cladding

Fuel system consists of the fuel tank, fuel filter, supply Wire disconnection inside harness cladding
pump, common rail, and injector each of which is Following inspections are necessary to detect these
connected by the fuel pipe. causes.
Diagnostic aid ECM connector
Followings are considered as the major possible cause Poor connection of terminal from connector
of the fault in fuel system. Unmatched terminals are fitted.
Air mixed in the fuel system. Damage of connector lock
Clogged fuel filter Poor contact between terminal and wire
Damage, clogging, improper connection of fuel
pipe
Fuel tank fault
Supply pump fault
Injector fault
Pressure limiter fault
If the intermittent trouble is suspected, followings may
be the cause.

Check the fuel quality.
1. Drain fuel from the fuel tank.
2. Add proper fuel.
1 3. Bleed air from the fuel.
Does the engine start? Go to Step 6. Go to Step 2.
Check the fuel quantity.
2 Supply fuel, and
Is sufficient amount of fuel supplied? Go to Step 3. Go to Step 3.
Check if there are additional filters or parts,
other than genuine fuel filter, pre-filter and
3 electromagnetic pump, in the machines fuel
pipe.
Are there any additional filters or parts? Go to Step 4. Go to Step 5.
1. Remove the additional filter and bleed air.
If the fuel resistance is increased, the
4 DTC P1093 or P1094 may be detected.
Does the engine start? Go to Step 6. Go to Step 5.
1. Check for excessive dirt or clogging in the
(main and pre-) fuel filters.
2. Check for excessive dirt or clogging in the
electromagnetic pump filter.
5 3. If the trouble is detected, clean or replace.
4. If air is entered in the main filter, examine
the cause and repair.
1. Check for damage, clogging, or improper
connection in the fuel pipe.
required.
1. Check for following troubles in the fuel
tank.
Foreign matter mixed in the fuel
Disconnection or damage in fuel supply
pipe
Crush or damage in tank
7 Wrong assembly of fuel pipe
Clogging at filler neck
Water mixed in fuel
required.
Bleed air from the fuel.
Note:
8 For work procedure, refer to Engine
section in the service manual.

Intake system check
About intake system
The intake system consists of the air cleaner, intake
pipe, turbocharger, etc. Intake air is supplied to the
engine through the air cleaner and intake manifold.

Check for excessive dirt or clogging in the air
1 cleaner.
Clean or replace the air cleaner.
2
1. Check for crush, breakage, or air leakage
in the intake pipe.
2. Make sure that the intake pipe is a
genuine part.
3 Check for bend or improper piping that
may cause increasing in intake air
resistance.
3. Check the reed valve for breakage.
Repair or replace the intake pipe or reed valve.
4
Check the turbocharger.
Check for abnormal rattling in the
turbine shaft.
Check for oil leakage.
5
Note:
For work procedure, refer to Engine

Repair or replace the turbocharger.
Note:

Repair the machine.
7
Reed valve check If the reed valve is broken, bypass of intake air
deteriorates air-fuel ratio (A/F), resulting in output
lowering.
Check the reed valve for deformation or breakage.

Name
1. Reed valve
2. EGR Valve
3. Exhaust side
4. Intake side
Exhaust system check
About exhaust system

The exhaust system consists of the exhaust pipe, tail
pipe, etc.

Check for crush, breakage, or exhaust leakage
1 in the exhaust pipe and tail pipe.
Repair or replace the exhaust pipe or tail pipe.
2
Repair the machine.
3
EGR control system check


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 

Circuit description
The ECM operates the EGR valve based on engine
speed, engine coolant temperature, intake air
temperature, fuel injection amount, and barometric
pressure. The EGR motor drives the EGR valve, and
the EGR position sensor detects the EGR valve
opening angle.

Go to the relevant
1 2. Check the DTC. diagnosis of DTC
2

2. Warm-up the engine until the engine
coolant temperature increases to 70 C.
3 3. Check the value for EGR position using 3%
scan tool.
Is EGR position within the specified value? Normal system Go to Step 4.
1. Perform EGR control test using scan
tool.
4 2. Press the Up Down soft key. 3%
3. Check the value for EGR position.
Is EGR position within the specified value? Go to Step 6. Go to Step 5.
Replace the EGR valve.
After replacing the EGR valve or ECM, the
EGR valve position learning must be
performed in the following procedure.
5 2. Turn the key switch to OFF.
Failure to perform above procedure may result
in detection of DTC for EGR.
1. Check for damage or gas leakage in the
EGR pipe.
required.
coolant temperature increases to 80 C.
7 3. Check the value for EGR position using 3%
scan tool.
Is EGR position within the specified value? Verify repair. Go to Step 3.
2. Check the EGR valve for anchoring,
clogging, etc.
required.
Is the trouble detected? Go to Step 9. Normal system
After replacing the EGR valve or ECM, the
EGR valve position learning must be
performed in the following procedure.
9 2. Turn the key switch to OFF.
Failure to perform above procedure may result
in detection of DTC for EGR.

1. Check for damage or gas leakage in the
EGR pipe.
required.
Go to the relevant
11 2. Check the DTC. diagnosis of DTC
EGR valve check

Push the EGR valve with finger to make sure it opens/

closes smoothly. Also, make sure that the valve closes
completely when the finger is released.
EGR hysteresis




QOS system check









 
 

 


 
      
   
 
 
 
 
    


  
 


Note: Test description

The QOS circuit is the same for both the starter Numbers below indicate step numbers in the chart.
ECM control specifications and the safety relay 7. The QOS indicator lamp turns on when the key
specifications. switch is ON using lamp check function, even if the
QOS is not operating.
Circuit description 12. The QOS indicator lamp goes off within maximum
The QOS (Quick On Start) system consists of the ECM, 10 seconds.
glow relay, glow plug, and QOS indicator lamp. When 13. When the QOS indicator lamp does not go OFF
the key switch is turned ON with low engine coolant after removing the connector from the meter, it can be
temperatures, the ECM determines the glow time and judged as meter fault.
operates the glow relay and QOS indicator lamp. After 19. When the glow relay indication does not change
a certain time has elapsed, the ECM will turn the glow during the glow plug test, it can be judged as ECM fault.
relay and QOS indicator lamp to OFF.

Perform the OBD check.
1 Go to OBD

2. Check the DTC.
2 Is relevant DTC to the engine coolant Go to the relevant
temperature sensor, QOS indicator lamp, or diagnosis of DTC
glow reply detected? detected. Go to Step 3.
Check the fuse.
Check for blown out fuse relevant to the QOS
3 system.

Check for short circuit between the fuse, ECM,
glow plug, and QOS indicator lamp.
1. Disconnect the harness from the fuse,
glow relay, ECM, glow plug, and QOS
indicator lamp. 10 M or
4
2. Measure the resistance between each more
glow relay terminal, each QOS indicator
lamp terminal, and the ground.
Is the resistance specified value? Go to Step 6. Go to Step 5.
Repair the short circuit between the fuse, ECM,
5 glow plug, and QOS indicator lamp.
1. Replace the fuse.
6 3. Make sure that the fuse is not blown.

7 3. Check the QOS indicator lamp.
Does the QOS indicator lamp come on? Go to Step 12. Go to Step 8.
2. Remove the QOS indicator lamp.
8 3. Check the QOS indicator lamp for blow
out.
1. Replace the QOS indicator lamp.
1. Disconnect the ECM connector.
2. Measure the resistance between the QOS
10 indicator lamp terminal and the harness 10M or more
between ECM and the ground.
Repair the QOS indicator lamp terminal-to-
11 ECM harness.

Does the QOS indicator lamp go OFF within 10
seconds? Go to Step 14. Go to Step 13.
necessary. If rewriting is not necessary, go
to step 3.
13 3. Replace the ECM.
1. Perform Glow plug relay test using scan
tool.
When the scan tool is not available,
14 remove the relay and test it by itself.
2. Press the ON and OFF softkeys.
Does the glow relay display (contact) ON and
OFF? Go to Step 15. Go to Step 13.
2. Remove all the glow plugs. 6
15 3. Measure the resistance between each (Normal
glow plug terminal and the ground. temperature)
1. Turn the glow relay ON using the Glow
plug relay test of the scan tool.
remove the glow relay and short between
the terminals.
16 2. Measure the voltage between each 18V
cylinder glow plug harness terminal and
the ground using DMM.
Are the voltages at all the cylinders more than
specified value? Go to Step 17. Go to Step 18.
1. Turn the glow relay OFF using the Glow
plug test of the scan tool.
remove the glow relay.
Are the voltages at all the cylinders specified
value? Normal system Go to Step 19.
Repair the open circuit between the glow relay
and the glow plug, or the short circuit to the
18 ground circuit.


Repair the power supply circuit between the
glow relay and the glow plug, or the short
19 circuit to the ignition power supply circuit.

Replace the glow plug.
20
1. Turn the glow relay ON using the Glow
remove the glow relay and short between
the terminals.
Are the voltages at all the cylinders more than
1. Turn the glow relay OFF using the Glow
remove the glow relay.
Are the voltages at all the cylinders specified
value? Verify repair. Go to Step 17.
List of diagnostic trouble code

List of diagnostic trouble codes
4HK1
Fault Recovery
Flash DTC Item to be Preconditions when Behavior when Diagnos
DTC DTC set condition judgment from
code description detected DTC is set trouble occurs is lamp
period failure
P0087 227 No pump Common rail 900 rpm or more Actual rail Approx. 3 Intense engine ON *1
pressure pressure pressure is sec. vibration, rough
feed (fuel does not 15Mpa or less. idling, output
leakage) increase to lowering, blow up
the required fault, black smoke
area. emitted, and
excessive output
are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80MPa)
P0088 118 Common rail Common rail Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or more than 185 sec. vibration, rough
fault abnormal more. MPa. idling, output
(1st stage) increase DTC P0088, lowering, blow up
P0192, P0193, or fault, black smoke
P1635 is not emitted, and
detected. excessive output
Actual rail are possible.
pressure is 2 MPa Back-up:
or more, and 70 Limited injection
rpm or more. amount 3 (multi-
injection stopped)
Target RP upper
limit (80MPa)
Common rail Common rail Key switch input Common rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure fault sec. vibration, rough
fault abnormal more. (1st stage) is idling, output
(2nd stage) increase DTC P0088, completed, and lowering, blow up
P0192, P0193, or rail pressure is fault, black smoke
P1635 is not more than 190 emitted, and
detected. MPa. excessive output
injection stopped)
Target RP upper
limit (80MPa)
P0089 151 Common rail Common rail Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure is 40 sec. vibration, rough
fault abnormal more. MPa or more idling, output
(Excessive increase DTC P0089, higher than target lowering, blow up
pressure P0192, P0193, or rail pressure. fault, black smoke
feed in P1635 is not emitted, and
pump) detected. excessive output
Coolant are possible.
temperature is Back-up:
60 C or more, and Limited injection
375 rpm or more. amount 3 (multi-
Duty to SCV is injection stopped)
40% or more, or Target RP upper
SCV target limit (80MPa)
pressure feed is 90
mm3/sec or less.
Fault Recovery
period failure
P0090 247 SCV drive Open/short Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/ 18V or more. specified value possible
short or harness DTC P1630 is not for 2 seconds or depending on the
ground short detected. more, or when condition of open/
SCV drive duty is difference short circuit.
between 10 between target Black smoke
90%. and actual emitted, excessive
current exceeds output
specified value Back-up:
for 2 seconds or Limited injection
more. amount 3 (multi-
injection stopped)
Target RP upper
limit (80MPa)
P0107 71 Barometric Open/short Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure circuit/ voltage is 18V or pressure sensor sec. equivalent to
sensor fault deterioration more. voltage is lower 2500m
(low voltage of sensor or DTC P1630 or than 0.5 V. Black smoke
fault) harness P1632 is not emitted at high
detected. altitude
Output shortage
at low altitude
Back-up:
Barometric
pressure default
setting (80 kPa)
EGR stopped
P0108 Barometric Short circuit Key switch input Barometric Approx. 4 Due to back-up ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. equivalent to
sensor fault harness more. voltage is more 2500m
(high voltage DTC P1630 or than 3.8 V. Black smoke
fault) P1632 is not emitted at high
detected. altitude
Output shortage
at low altitude
Back-up:
Barometric
pressure default
setting (80 kPa)
EGR stopped
P0112 22 Intake air Short circuit Key switch input Intake air Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or temperature sec. Back-up:
sensor fault harness more. sensor voltage is Intake air
(low voltage DTC P1630 or less than 0.1 V. temperature
fault) P1632 is not default setting
detected. (at starting: 10 C,
at running: 25 C)
EGR stopped
P0113 Intake air Open/short Key switch input Intake air Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault deterioration more. sensor voltage is Intake air
(high voltage of sensor or DTC P1630 or more than 4.95 V. temperature
fault) harness P1632 is not default setting
3 minutes or more at running: 25 C)
has elapsed after EGR stopped
starting engine.
Fault Recovery
period failure
P0117 23 Engine Short circuit Key switch input Engine coolant Approx. 4 Start ability ON *2
coolant in sensor or voltage is 18V or temperature sec. deteriorates at low
temperature harness more. sensor voltage is temperatures or
sensor fault DTC P1630 or less than 0.1 V. black smoke
(low voltage P1633 is not emission is
fault) detected. possible, output
lowering
depending on
conditions.
Back-up:
Coolant
temperature
default setting
(at starting: 20 C,
at driving: 80 C)
EGR stopped
P0118 Engine Open/short Key switch input Engine coolant Approx. 4 At normal ON *2
coolant circuit/ voltage is 18V or temperature sec. temperature: Black
temperature breakage of more. sensor voltage is smoke emission,
sensor fault sensor or DTC P1630 or more than 4.85 V. greater engine
(high voltage harness P1633 is not combustion noise
fault) detected. possible.
3 minutes or more During idling at low
has elapsed after atmospheric
starting engine. temperatures:
Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant
temperature
default setting
(at starting: 20 C,
at driving: 80 C)
EGR stopped
P0182 211 Fuel Short circuit Key switch input Combustion Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(low voltage DTC P1630 or less than 0.1 V. Fuel temperature
at running: 70 C)
P0183 Fuel Open/short Key switch input Combustion Approx. 4 Not in particular ON *2
sensor fault breakage of more. sensor voltage is Fuel temperature
(high voltage sensor or DTC P1630 or more than 4.85 V. default setting
fault) harness P1633 is not (at starting: 20 C,
detected. at running: 70 C)
3 minutes or more
has elapsed after
starting engine.
P0192 245 Common rail Short circuit Key switch input Common rail Nearly Engine blow up ON *2
pressure in sensor or voltage is 18V or pressure sensor simultane Back-up:
sensor fault harness more. voltage is less ous to Specified back-up
(low voltage DTC P1630 or than 0.7 V. fault value (depending
fault) P1635 is not occurren on the machine
detected. ce manufacturer)
P0193 Common rail Open/short Key switch input Common rail Nearly Engine stall ON *2
pressure circuit/ voltage is 18V or pressure sensor simultane possible
sensor fault breakage of more. voltage is more ous to Output lowering
(high voltage sensor or DTC P1630 or than 4.5 V. fault Back-up:
fault) harness P1635 is not occurren Specified back-up
detected. ce value (depending
on the machine
manufacturer)
Fault Recovery
period failure
P0201 271 Open circuit Open/short Main relay power No injector 1 Approx. 3 Intensive engine ON *1
in injection circuit in supply voltage is monitor input sec. vibration, rough
nozzle #1 electrical 18V or more. signal exists. idling, output
drive system wiring No. 1 70 rpm or more lowering, blow up
cylinder DTC P0611, P126 fault
injector or P0201 is not Back-up:
detected. Injection for
cylinder #1
stopped, EGR
stopped
cylinder DTC P0611, fault
injector P1261 or P0202 is Back-up:
not detected. Injection for
cylinder #2
stopped, EGR
stopped
cylinder #3
stopped, EGR
stopped
cylinder #4
stopped, EGR
stopped
P0219 543 Overrun Engine Key switch input When the engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed exceeds sec. Back-up:
abnormally more. setting value Limited injection
high (depending on amount 1
the machine Limitation is lifted if
manufacturer) the speed
decreases
P0237 32 Boost Open/short Key switch input Boost pressure Approx. 3 Operationality is ON *2
pressure circuit/ voltage is 18V or sensor voltage is sec. affected.
sensor fault breakage of more. less than 0.1V. Back-up:
(low voltage sensor or DTC P1630 or Specified back-up
fault) harness P1634 is not value (depending
detected. on the machine
manufacturer)
P0238 Boost Short circuit Key switch input Boost pressure Approx. 3 Black smoke ON *2
pressure in sensor or voltage is 18V or sensor voltage is sec. emitted
sensor fault harness more. more than 4.9V. Back-up:
(high voltage DTC P1630 or Specified back-up
fault) P1634 is not value (depending
manufacturer)
Fault Recovery
period failure
P0335 15 Crank Open circuit CMP sensor Cam signal exists When Output lowering, ON *1
sensor fault in sensor/ pulse is normal. but no crank trouble white smoke
(no signal) wiring DTC P0335, signal. occurs 14 emission, intense
P0336, P0340, out of 21 engine vibration
P0341 or P1345 is samples. possible
not detected. Engine stall
Engine is running. possible (restart is
possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank Broken CMP sensor Number of pulse When Output lowering, ON *1
sensor fault teeth/ pulse is normal. for crank signal is trouble white smoke
(signal fault) unnecessary DTC P0335, mismatched. occurs 14 emission, intense
signal mixed P0336, P0340, out of 21 engine vibration
(such as P0341 or P1345 is samples. possible
short circuit not detected. Engine stall
with other Engine is running. possible (restart is
wiring) possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0340 14 Cam sensor Open circuit Key switch input Crank signal When Behavior does ON *1
fault (no in sensor/ voltage is 18V or exists but no cam trouble not change during
signal) wiring more. signal. occurs 7 engine running.
Crank pulse is out of 8 After engine
normal. samples. stalls, engine will
DTC P0335, not start.
P0336, P0340, Back-up:
P0341, P1345, or Engine running
P1635 is not based on crank
detected. when it is normal
Engine is running. After engine stops:
Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken Key switch input Number of pulse When Behavior does ON *1
fault (signal teeth/ voltage is 18V or for cam signal is trouble not change during
fault) unnecessary more. mismatched. occurs 7 engine running.
signal mixed Crank pulse is out of 8 After engine
(such as normal. samples. stalls, engine will
short circuit DTC P0335, not start.
with other P0336, P0340, Back-up:
wiring) P0341, P1345, or Engine running
P1635 is not based on crank
detected. when it is normal
Engine is running. After engine stops:
Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short Key switch input No glow relay When Operationality is ON *1
fault circuit/ power supply monitor signal trouble not affected.
damage of voltage is higher exists against occurs 25 Back-up:
relay or than 16 V but lower glow relay drive out of 30 Back-up: No back-
harness than 32 V. indication. samples. up action
P0381 67 Glow lamp Open/short Key switch input Glow lamp drive When Operationality is ON
fault circuit/ voltage is 18 V or indication signal trouble not affected.
damage of more. is unmatched occurs 25 Back-up:
lamp or DTC P0381 is not with glow lamp out of 30 Back-up: No back-
harness detected. monitor signal. samples. up action
Fault Recovery
period failure
P0487 44 EGR Open/short Main relay input EGR position Approx. 3 Operationality is ON *1
position fault circuit/ voltage is 18V or output signal is sec. not affected.
(Brushless damage of more. abnormal. Back-up:
specification) sensor DTC P1630 or Instruction to fully
harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/ DTC P1630, Difference Approx. Operationality is ON *2
control fault open circuit P1635, P0487, between target 10 sec. not affected.
or valve P0488, or P1635 is valve lift and Back-up:
engage/ not detected. actual position is Instruction to fully
stuck in Main relay voltage more than 20%. close EGR valve
drive motor is between 20
side 32 V.
Difference
between target
EGR opening
angle and actual
one is 20% or less.
P0522 294 Engine oil Open/short Key switch input Engine oil Approx. 4 Operationality is ON *1
pressure circuit/ voltage is 18V or pressure sensor sec. not affected.
sensor fault breakage of more. voltage is less Back-up:
(low voltage sensor or DTC P1633 is not than 0.1V. Back-up: No back-
fault) harness detected. up action
P0523 Engine oil Short circuit Key switch input Engine oil Approx. 4 Operationality is ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. not affected.
sensor fault harness more. voltage is more Back-up:
(high voltage DTC P1633 is not than 4.85V. Back-up: No back-
fault) detected. up action
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is ON *2
fault fault faulty. not affected.
Back-up:
Back-up: No back-
up action
P0606 51 CPU fault CPU fault Sub-CPU detects Nearly Output lowering ON *2
main CPU fault in simultane Back-up:
100 msec after ous to Limited injection
key switch ON. fault amount 2 (multi-
(SUB-CPU resets occurren injection stopped)
CPU.) ce SUB-CPU stops
CPU.

Sub-CPU detects Nearly Unable to start ON Diagnose
main CPU fault in simultane Back-up: d for
100 msec after ous to Limited injection 100msec
key switch ON. fault amount 2 (multi- only after
(SUB-CPU resets occurren injection stopped) KEY-ON.
CPU.) ce SUB-CPU stops
CPU.
52 CPU Sub-CPU 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
monitoring fault has elapsed after does not change simultane Back-up:
IC fault key switch ON. for 20 msec or ous to Limited injection
Key switch input more. fault amount 1
power supply occurren
voltage is higher ce
than 16 V.
Fault Recovery
period failure
P0611 34 Charge ECU charge Main relay power When charge Approx. Intensive engine ON *2
circuit fault circuit 1 fault supply voltage is circuit bank 1 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 1 stop
(#1, #4 cylinders
stopped), EGR
stopped
P0612 Charge ECU charge When charge Approx. Intensive engine ON
circuit fault circuit 2 fault circuit bank 2 1.5 sec. vibration, rough
(bank 2) (internal voltage inside idling, output
etc.) are possible.
Back-up:
Common 2 stop
(#2, #3 cylinders
stopped), EGR
stopped
P0650 77 Check Lamp fault Key switch input No check engine Approx. Operationality is Does *2
engine lamp voltage is 18V or lamp monitor 1.5 sec. not affected. not
fault more. signal exists. Back-up: come
DTC P0650 is not Back-up: No back- on.
detected. up action
P1093 227 No pump Fuel leakage Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure (large voltage is 18V or pressure is 50 sec. vibration, rough
feed (fuel amount) more. MPa or more idling, output
leakage) 1200 rpm or more lower than target lowering, blow up
Duty to SCV is rail pressure. fault, black smoke
33% or less, or emitted, engine
pressure feed is stall, and
28000mm 3/sec or excessive output
more. are possible.
DTC P0192, Back-up:
P0193, P1093, Limited injection
P0090, P1291, amount 3 (multi-
P1292, or P1635 is injection stopped)
not detected. Target RP upper
limit (80MPa)
P1095 225 Pressure Pressure Key switch input Pressure limiter Approx. 1 Output lowering, ON *1
limiter open limiter is voltage is 18V or is opened. sec. hunting
opened. more. Back-up:
DTC P1095, Limited injection
P0192, P0193, amount 1
P1630, or P1635 is
not detected.
50 rpm or more
Fault Recovery
period failure
P1112 295 Boost Open/short Key switch input Boost Approx. 4 Operationality is ON *2
temperature circuit/ voltage is 18V or temperature sec. not affected.
sensor fault breakage of more. sensor voltage is Back-up:
(low voltage sensor or DTC P1634 is not less than 0.1 V. Back-up: No back-
P1113 Boost Short circuit Key switch input Boost Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. not affected.
(high voltage Coolant more than 4.95V. Back-up: No back-
fault) temperature is up action
50 C or more.
3 (or 5) minutes
have passed after
engine starting
(depending on the
machine
manufacturer)
DTC P1634 is not
detected.
P1173 542 Overheat Overheat Key switch input Coolant Approx. 5 Operationality is Does *2
condition voltage is 18V or temperature is sec. not affected. not
more. more than 120 C. Back-up: come
DTC P1630, Back-up: No back- on.
P1633, P0117, or up action
P0118 is not
detected.
Under operation
P1261 158 Injection Open/short Main relay power No injector 1 and Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 4 monitor input sec. vibration, rough
common 1 injector 18V or more. signal exists. idling, output
drive system common 1- 70 rpm or more lowering, blow up
fault side None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0611, P1261 and Back-up:
fault P0201; DTC Common 1 stop
P0611, P1261 and (#1, #4 cylinders
P0202; DTC stopped), EGR
P0611, P1261 and stopped
P0203.
P1262 159 Injection Open/short Main relay power No injector 2 and Approx. 3 Intensive engine ON *1
P0612, P1262 and (#2, #3 cylinders
P0206.
Fault Recovery
period failure
P1271 24 Accelerator Difference in Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between 2 system fault... come
fault between DTC P1630, accelerator Accelerator on.
accelerator P1631, P1271, sensors 1 and 2 opening angle is
sensors 1-2 P1277, P1278, is 45% or more. controlled to 0%.
is 45% or P1282, or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system fault...
Accelerator
opening angle is
controlled to 0%.
P1277 Accelerator Open/short Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system fault... come
voltage fault) sensor or DTC P1630, V. Accelerator on.
harness P1277, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system fault...
Accelerator
opening angle is
controlled to 0%.
fault (high breakage of more. is more than 4.9 2 system fault... come
Back-up:
1 system fault...No
back-up
2 system fault...
Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system fault...
Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system fault...
Accelerator
opening angle is
controlled to 0%.
Fault Recovery
period failure
P1345 16 Cam sensor Camshaft Key switch input Correct cam When Behavior does ON *1
out of phase gear/ voltage is 18V or pulse does not trouble not change during
crankshaft more. exist in crank gap occurs 7 engine running.
gear DTC P0335, position. out of 8 After engine
installing P0336, P0340, samples. stalls, engine will
angle is out P0341, P1345, or not start.
of phase, or P1635 is not Back-up:
damage in detected. Specified back-up
gear. CMP sensor value (depending
pulse is normal. on the machine
Crank pulse is manufacturer)
normal.
P1625 416 Main relay Open/ Key switch input Main relay Approx. 2 Engine does not ON *2
system fault ground short voltage is 18V or system voltage is sec. start.
(Not enter) circuit in more. 1V or less with Back-up:
harness, DTC P1630 is not main relay coil Back-up: No back-
relay OFF detected. output ON. up action
anchoring 3 seconds or
more has elapsed
after key switch
ON.
Main relay drive
indication ON
Harness +B DTC P1625 or Relay does not Approx. 5 Vehicle power ON *1
short, relay P0606 is not cut off despite of sec. supply cannot be
ON detected. main relay coil shut off.
anchoring output OFF Back-up:
indication. Back-up: No back-
up action
P1630 36 A/D A/D A/D conversion Immediat Output lowering, ON *2
conversion conversion failure ely Black smoke
fault fault emitted
Back-up:
Analog sensor
system default

processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80MPa)
Fault Recovery
period failure
P1631 55 Voltage fault Power DTC P1630 is not Key switch power Approx. Accelerator ON *2
in 5-V power supply detected. supply voltage is 0.5 sec. opening angle is
supply 1 wiring short Key switch input 5.5V or more, or controlled to 0%.
to sensor, or power supply 4.5V or less, Back-up:
breakage in voltage is between when battery Same to
element/ 16 32 V. voltage is accelerator sensor
circuit for between 16V fault
power 32V.
supply
P1632 Voltage fault DTC P1630 is not Key switch power Approx. Due to back-up ON *2
regulation
in 5-V power detected. supply voltage is 0.5 sec. equivalent to
supply 2 inside ECM. Key switch input 5.5V or more, or 2500m
power supply 4.5V or less, Black smoke
voltage is between when battery emitted at high
16 32 V. voltage is altitude
between 16V Output shortage
32V. at low altitude
Back-up:
Same to
barometric
pressure and
intake air
temperature
sensor fault
P1633 Voltage fault DTC P1630 is not Key switch power Approx. Startability ON *2
in 5-V power detected. supply voltage is 0.5 sec. deteriorates at low
supply 3 Key switch input 5.5V or more, or temperatures or
power supply 4.5V or less, black smoke
voltage is between when battery emission is
16 32 V. voltage is possible, output
between 16V lowering or
32V. operationality is
affected depending
on conditions.
Back-up:
Same to coolant
temperature, fuel
temperature, and
oil pressure sensor
fault
P1634 Voltage fault DTC P1630 is not Key switch power Approx. Operationality is ON *2
in 5-V power detected. supply voltage is 0.5 sec. affected.
supply 4 Key switch input 5.5V or more, or Back-up:
power supply 4.5V or less, Same to boost
voltage is between when battery pressure and boost
16 32 V. voltage is temperature
between 16V sensor fault
32V.
P1635 Voltage fault DTC P1630 is not Key switch power Approx. Engine blow up, ON *2
in 5-V power detected. supply voltage is 0.5 sec. output lowering,
supply 5 Key switch input 5.5V or more, or black smoke
power supply 4.5V or less, emission, engine
voltage is between when battery stall are possible.
16 32 V. voltage is Back-up:
between 16V Same to rail
32V. pressure sensor
fault and EGR
position sensor
fault
U2104 84 CAN Bus CAN Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault communicati voltage is 12V or detected. continuou Back-up:
on fault more. sly Running at 1500
rpm.
Fault Recovery
period failure
U2106 85 CAN timeout CAN DTC U2104 is not CAN data At 1 sec. Set to idle speed. ON *3
fault communicati detected. reception does continuou Back-up:
on fault Key switch input not complete at a sly Specified back-up
voltage is 12V or set time. value (depending
more. on the machine
manufacturer)
About recovery from failure *2

There are three modes for recovery from failure. When the DTC has recovered to normal condition in the
To clear the fault indication displayed on the monitor of ignition cycle that the DTC is detected, the diagnosis
the machine, one more ignition cycle may be needed lamp and back up mode will also be recovered.
after the following ignition cycle.
 
*1

Even if the DTC has restored normally, the diagnosis 
lamp and back-up mode are not restored in the ignition 
cycle that the DTC is detected. After turning the key 
switch OFF, DTC diagnosis is performed when the

vehicle starts again. If it is judged as normal, everything
will be recovered to normal from the next ignition cycle. 


  














Name
1. DTC is detected.
2. Returned to normal.





Name
1. DTC is detected.
2. Repair and inspection
*3
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
be recovered normally, but the diagnosis lamp does not
go off.
 













Name
1. DTC is detected.
6HK1
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0087 227 No pump Common rail 900 rpm or more Actual rail Approx. 3 Intense engine ON *1
pressure pressure pressure is sec. vibration, rough
feed (fuel does not 15Mpa or less at idling, output
leakage) increase to 900rpm or more. lowering, blow up
the required fault, black smoke
area. emitted, and
excessive output
are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80MPa)
P0088 118 Common rail Common rail Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or more than 185 sec. vibration, rough
fault abnormal more. MPa. idling, output
(1st stage) increase DTC P0088, lowering, blow up
P0192, P0193, or fault, black smoke
P1635 is not emitted, and
detected. excessive output
injection stopped)
Target RP upper
limit (80MPa)
Common rail Common rail Key switch input Common rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure fault sec. vibration, rough
fault abnormal more. (1st stage) is idling, output
(2nd stage) increase DTC P0088, completed, and lowering, blow up
P0192, P0193, or rail pressure is fault, black smoke
P1635 is not more than 190 emitted, and
detected. MPa. excessive output
injection stopped)
Target RP upper
limit (80MPa)
P0089 151 Common rail Common rail Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure is 40 sec. vibration, rough
fault abnormal more. MPa or more idling, output
(Excessive increase DTC P0089, higher than lowering, blow up
pressure P0192, P0193, or target rail fault, black smoke
feed in P1635 is not pressure. emitted, and
pump) detected. excessive output
Coolant are possible.
temperature is Back-up:
60 C or more, and Limited injection
375 rpm or more. amount 3 (multi-
Duty to SCV is injection stopped)
40% or more, or Target RP upper
SCV target limit (80MPa)
pressure feed is 90
mm3/sec or less.
Fault Recovery
DTC judgment from
period failure
P0090 247 SCV drive Open/short Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/ 18V or more. specified value possible depending
short or harness DTC P1630 is not for 2 seconds or on the condition of
ground short detected. more, or when open/short circuit.
SCV drive duty is difference Black smoke
between 10 between target emitted, excessive
90%. and actual output
current exceeds Back-up:
specified value Limited injection
for 2 seconds or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80MPa)
P0107 71 Barometric Open/short Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure circuit/ voltage is 18V or pressure sensor sec. equivalent to
sensor fault deterioration more. voltage is lower 2500m
(low voltage of sensor or DTC P1630 or than 0.5 V. Black smoke
fault) harness P1632 is not emitted at high
detected. altitude
Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa)
EGR stopped
P0108 Barometric Short circuit Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. equivalent to
sensor fault harness more. voltage is more 2500m
(high voltage DTC P1630 or than 3.8 V. Black smoke
fault) P1632 is not emitted at high
detected. altitude
Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa)
EGR stopped
sensor fault harness more. sensor voltage is Specified back-up
(low voltage DTC P1630 or less than 0.1 V. value (depending
fault) P1632 is not on the machine
detected. manufacturer)
P0113 Intake air Open/short Key switch input Intake air Approx. 4 Not in particular ON *2
sensor fault deterioration more. sensor voltage is Intake air
(high voltage of sensor or DTC P1630 or more than 4.95 temperature default
fault) harness P1632 is not V when 3 setting
detected. minutes or more (at starting: 10 C,
3 minutes or more has elapsed at running: 25 C)
has elapsed after after starting EGR stopped
starting engine. engine.
Fault Recovery
DTC judgment from
period failure
lowering depending
on conditions.
Back-up:
Specified back-up
value (depending
on the machine
manufacturer)
P0118 Engine Open/short Key switch input Engine coolant Approx. 4 At normal ON *2
coolant circuit/ voltage is 18V or temperature sec. temperature: Black
temperature breakage of more. sensor voltage is smoke emission,
sensor fault sensor or DTC P1630 or more than 4.85 greater engine
(high voltage harness P1633 is not V. combustion noise
fault) detected. possible.
3 minutes or more During idling at low
has elapsed after atmospheric
starting engine. temperatures:
Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant
temperature default
setting
(at starting: 20 C,
at driving: 80 C)
EGR stopped
(low voltage DTC P1630 or less than 0.1 V. Specified back-up
fault) P1633 is not value (depending
manufacturer)
P0183 Fuel Open/short Key switch input Combustion Approx. 4 Not in particular ON *2
sensor fault breakage of more. sensor voltage is Fuel temperature
(high voltage sensor or DTC P1630 or more than 4.85 default setting
fault) harness P1633 is not V. (at starting: 20 C,
detected. at running: 70 C)
3 minutes or more
has elapsed after
starting engine.
sensor fault harness more. voltage is less ous to Specified back-up
(low voltage DTC P1630 or than 0.7 V. fault value (depending
fault) P1635 is not occurren on the machine
detected. ce manufacturer)
fault) harness P1635 is not occurren Specified back-up
detected. ce value (depending
on the machine
manufacturer)
Fault Recovery
DTC judgment from
period failure
P0201 271 Open circuit Open/short Main relay power No injector 1 Approx. 3 Intense engine ON *1
cylinder DTC P0611, P126 fault, output
injector or P0201 is not lowering
detected. Back-up:
Injection for cylinder
#1 stopped, EGR
stopped
not detected. Injection for cylinder
#2 stopped, EGR
stopped
#3 stopped, EGR
stopped
#4 stopped, EGR
stopped
#5 stopped, EGR
stopped
#6 stopped, EGR
stopped
P0219 543 Overrun Engine Key switch input When the engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed exceeds sec. Back-up:
abnormally more. setting value Limited injection
high (depending on amount 1
the machine Limitation is lifted if
manufacturer) the speed
decreases
Fault Recovery
DTC judgment from
period failure
(low voltage sensor or DTC P1630 or Boost pressure
detected. (150kPa)
Boost pressure
correction/EGR
stopped
(high voltage DTC P1630 or Boost pressure
detected. (150kPa)
Boost pressure
correction/EGR
stopped
P0335 15 Crank Open circuit CMP sensor Cam signal When Output lowering, ON *1
sensor fault in sensor/ pulse is normal. exists but no trouble white smoke
(no signal) wiring DTC P0335, crank signal. occurs 14 emission, intense
P0336, P0340, out of 21 engine vibration
P0341 or P1345 is samples. possible
not detected. Engine stall
Engine is running. possible (restart is
possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank Broken CMP sensor Number of pulse When Output lowering, ON *1
sensor fault teeth/ pulse is normal. for crank signal trouble white smoke
(signal fault) unnecessary DTC P0335, is mismatched. occurs 14 emission, intense
signal mixed P0336, P0340, out of 21 engine vibration
(such as P0341 or P1345 is samples. possible
short circuit not detected. Engine stall
with other Engine is running. possible (restart is
wiring) possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
Fault Recovery
DTC judgment from
period failure
P0340 14 Cam sensor Open circuit Key switch input Crank signal When Behavior does not ON *1
fault (no in sensor/ voltage is 18V or exists but no trouble change during
signal) wiring more. cam signal. occurs 7 engine running.
Crank pulse is out of 8 After engine stalls,
normal. samples. engine will not start.
DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken Key switch input Number of pulse When Behavior does not ON *1
fault (signal teeth/ voltage is 18V or for cam signal is trouble change during
fault) unnecessary more. mismatched. occurs 7 engine running.
signal mixed Crank pulse is out of 8 After engine stalls,
(such as normal. samples. engine will not start.
short circuit DTC P0335, Back-up:
with other P0336, P0340, Engine running
wiring) P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
Engine is running. Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short Key switch input No glow relay When Operationality is not ON *1
fault circuit/ power supply monitor signal trouble affected.
relay or than 16 V but lower glow relay drive out of 30 Specified back-up
harness than 32 V. indication. samples. value (depending
on the machine
manufacturer)
P0381 67 Glow lamp Open/short Key switch input Glow lamp drive When Operationality is not
fault circuit/ voltage is 18 V or indication signal trouble affected.
damage of more. is unmatched occurs 25 Back-up:
lamp or DTC P0381 is not with glow lamp out of 30 Back-up: No back-
harness detected. monitor signal. samples. up action
P0487 44 EGR Open/short Main relay input EGR position Approx. 3 Exhaust gas is ON *1
position fault circuit/ voltage is 18V or output signal is sec. affected.
(Brushless damage of more. abnormal. Back-up:
specification) sensor DTC P1630 or Instruction to fully
harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/ DTC P1630, Difference Approx. Exhaust gas is ON *2
control fault open circuit P1635, P0487, between target 10 sec. affected.
or valve P0488, or P1635 is valve lift and Back-up:
engage/ not detected. actual position is Instruction to fully
stuck in Main relay voltage more than 20%. close EGR valve
drive motor is between 20
side 32 V.
Difference
between target
EGR opening
angle and actual
one is 20% or less.
P0522 294 Engine oil Open/short Key switch input Engine oil Approx. 4 Operationality is not ON *1
pressure circuit/ voltage is 18V or pressure sensor sec. affected.
sensor fault breakage of more. voltage is less Back-up:
(low voltage sensor or DTC P1633 is not than 0.098 V. Back-up: No back-
Fault Recovery
DTC judgment from
period failure
P0523 294 Engine oil Short circuit Key switch input Engine oil Approx. 4 Operationality is not ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. affected.
sensor fault harness more. voltage is more Back-up:
(high voltage DTC P1633 is not than 4.85 V. Back-up: No back-
fault) detected. up action
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
Back-up:
Back-up: No back-
up action
P0606 51 CPU fault CPU fault Sub-CPU Nearly Output lowering, ON *2
detects main simultane hunting
CPU fault in 100 ous to Back-up:
msec after key fault Limited injection
switch ON. occurren amount 2 (multi-
(SUB-CPU ce injection stopped)
resets CPU.) SUB-CPU stops
CPU.
Sub-CPU Nearly Unable to start Diagnose
detects main simultane Back-up: d for
CPU fault in 100 ous to Limited injection 100msec
msec after key fault amount 2 (multi- only after
switch ON. occurren injection stopped) KEY-ON.
(SUB-CPU ce SUB-CPU stops
resets CPU.) CPU.
52 CPU Sub-CPU 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
monitoring fault has elapsed after does not change simultane Back-up:
IC fault key switch ON. for 20 msec or ous to Limited injection
Key switch input more. fault amount 1
power supply occurren
voltage is higher ce
than 16 V.
P0611 34 Charge ECU charge Main relay power When charge Approx. Intensive engine ON *2
circuit fault circuit 1 fault supply voltage is circuit bank 1 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. voltage inside idling, output
etc.) are possible.
Back-up:
Common 1 stop
(#1, #2, #3 cylinders
stopped), EGR
stopped
P0612 34 Charge ECU charge When charge Approx. Intensive engine ON
circuit fault circuit 2 fault circuit bank 2 1.5 sec. vibration, rough
(bank 2) (internal voltage inside idling, output
etc.) are possible.
Back-up:
Common 2 stop
(#4, #5, #6 cylinders
stopped), EGR
stopped
P0650 77 Check Lamp fault Key switch input No check engine Approx. Operationality is not Does *2
engine lamp voltage is 18V or lamp monitor 1.5 sec. affected. not
fault more. signal exists. Back-up: come
DTC P0650 is not Back-up: No back- on.
detected. up action
Fault Recovery
DTC judgment from
period failure
P1093 227 No pump Fuel leakage Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure (large voltage is 18V or pressure is 50 sec. vibration, rough
feed (fuel amount) more. MPa or more idling, output
leakage) 1200 rpm or more lower than target lowering, blow up
Duty to SCV is rail pressure. fault, black smoke
33% or less, or emitted, engine
pressure feed is stall, and excessive
28000mm 3/sec or output are possible.
more. Back-up:
DTC P0192, Limited injection
P0193, P1093, amount 3 (multi-
P0091, P0092, injection stopped)
P1291, P1292, or Target RP upper
P1635 is not limit (80MPa)
detected.
P1095 225 Pressure Pressure Key switch input Pressure limiter Approx. 1 Output lowering ON *1
limiter open limiter is voltage is 18V or is opened. sec. Back-up:
opened. more. Limited injection
DTC P1095, amount 1
P0192, P0193,
P1630, or P1635 is
not detected.
50 rpm or more
P1112 295 Boost Open/short Key switch input Boost Approx. 4 Operationality is not ON *2
temperature circuit/ voltage is 18V or temperature sec. affected.
sensor fault breakage of more. sensor voltage is Back-up:
(low voltage sensor or DTC P1634 is not less than 0.1 V. Back-up: No back-
P1113 Boost Short circuit Key switch input Boost Approx. 4 Operationality is not ON *2
(high voltage Coolant more than Back-up: No back-
fault) temperature 50 C 4.95V. up action
or more, or 3 (or 5)
minutes have
passed after
engine starting
(depending on the
machine
manufacturer)
DTC P1634 is not
detected.
P1173 542 Overheat Overheat Key switch input Coolant Approx. 5 Operationality is not Does *2
condition voltage is 18V or temperature is sec. affected. not
more. more than Back-up: come
DTC P1630, 120 C while Back-up: No back- on.
P1633, P0117, or engine is up action
P0118 is not operated.
detected.
Under operation
P1261 158 Injection Open/short Main relay power No injector 1, 3, Approx. 3 Intensive engine ON *1
P0611, P1261 and (#1, #2, #3 cylinders
P0203.
Fault Recovery
DTC judgment from
period failure
P1262 159 Injection Open/short Main relay power No injector 2, 4, Approx. 3 Intensive engine ON *1
P0612, P1262 and (#4, #5, #6 cylinders
P0206.
P1271 24 Accelerator Difference in Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between 2 system fault... come
fault between DTC P1630, accelerator Accelerator opening on.
accelerator P1631, P1271, sensors 1 and 2 angle is controlled
sensors 1-2 P1277, P1278, is 45% or more. to 0%.
is 45% or P1282, or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system fault...
Accelerator opening
angle is controlled
to 0%.
voltage fault) sensor or DTC P1630, V. Accelerator opening on.
harness P1277, or P1631 is angle is controlled
not detected. to 0%.
Back-up:
1 system fault...
No back-up
2 system fault...
Accelerator opening
angle is controlled
to 0%.
Back-up:
1 system fault...No
back-up
2 system fault..
.Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system fault...
Accelerator opening
angle is controlled
to 0%.
Fault Recovery
DTC judgment from
period failure
P1283 24 Accelerator Open/short Key switch input Accelerator Approx. 1 1 system fault...No Does *1
Back-up:
1 system fault...
No back-up
2 system fault...
Accelerator opening
angle is controlled
to 0%.
P1345 16 Cam sensor Camshaft Key switch input Correct cam When Behavior does not ON *1
out of phase gear/ voltage is 18V or pulse does not trouble change during
crankshaft more. exist in crank occurs 7 engine running.
gear DTC P0335, gap position. out of 8 After engine stalls,
installing P0336, P0340, samples. engine will not start.
angle is out P0341, P1345, or Back-up:
of phase, or P1635 is not Specified back-up
damage in detected. value (depending
gear. CMP sensor on the machine
pulse is normal. manufacturer)
Crank pulse is
normal.
P1625 416 Main relay Open/ Key switch input Main relay Approx. 2 Engine does not ON *2
system fault ground short voltage is 18V or system voltage sec. start.
(Not enter) circuit in more. is 1V or less with Back-up:
harness, DTC P1630 is not main relay coil Back-up: No back-
relay OFF detected. output ON. up action
anchoring 3 seconds or
more has elapsed
after key switch
ON.
Main relay drive
indication ON
Harness +B DTC P1625 or Relay does not Approx. 5 Vehicle power ON *1
short, relay P0606 is not cut off despite of sec. supply cannot be
ON detected. main relay coil shut off.
anchoring output OFF Back-up:
indication. Back-up: No back-
up action
P1630 36 A/D A/D A/D conversion Immediat Output lowering, ON *2
conversion conversion failure ely Black smoke
fault fault emitted
Back-up:
Analog sensor
system default

processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80MPa)
Fault Recovery
DTC judgment from
period failure
P1631 55 Voltage fault Power DTC P1630 is not Key switch Approx. Accelerator opening ON *2
in 5-V power supply detected. power supply 0.5 sec. angle is controlled
supply 1 wiring short Battery voltage is voltage is 5.5V to 0%.
to sensor, or between 16V or more, or 4.5V Back-up:
breakage in 32V. or less. Same to accelerator
element/ sensor fault
circuit for
P1632 Voltage fault DTC P1630 is not Key switch Approx. Due to back-up ON *2
in 5-V power power detected. power supply 0.5 sec. equivalent to
supply
supply 2 Battery voltage is voltage is 5.5V 2500m
regulation
between 16V or more, or 4.5V Black smoke
inside ECM. 32V. or less. emitted at high
altitude
Output shortage at
low altitude
Back-up:
Same to barometric
pressure and intake
air temperature
sensor fault
P1633 Voltage fault DTC P1630 is not Key switch Approx. Startability ON *2
in 5-V power detected. power supply 0.5 sec. deteriorates at low
supply 3 Battery voltage is voltage is 5.5V temperatures or
between 16V or more, or 4.5V black smoke
32V. or less. emission is
possible, output
lowering or
operationality is
affected depending
on conditions.
Back-up:
Same to coolant
temperature, fuel
temperature, and oil
pressure sensor
fault
P1634 Voltage fault DTC P1630 is not Key switch Approx. Operationality is ON *2
in 5-V power detected. power supply 0.5 sec. affected.
supply 4 Battery voltage is voltage is 5.5V Back-up:
between 16V or more, or 4.5V Same to boost
32V. or less. pressure and boost
temperature sensor
fault
P1635 Voltage fault DTC P1630 is not Key switch Approx. Engine blow up, ON *2
in 5-V power detected. power supply 0.5 sec. output lowering,
supply 5 Battery voltage is voltage is 5.5V black smoke
between 16V or more, or 4.5V emission, engine
32V. or less. stall are possible.
Back-up:
Same to rail
pressure sensor
fault and EGR
position sensor fault
on fault more. sly Specified back-up
value (depending
on the machine
manufacturer)
on fault Key switch input not complete at sly Specified back-up
voltage is 20V or a set time. value (depending
more. on the machine
manufacturer)
About recovery from failure *2
There are three modes for recovery from failure. When the DTC has recovered to normal condition in the
To clear the fault indication displayed on the monitor of ignition cycle that the DTC is detected, the diagnosis
the machine, one more ignition cycle may be needed lamp and back up mode will also be recovered.
after the following ignition cycle.
 
*1
Even if the DTC has restored normally, the diagnosis


lamp and back-up mode are not restored in the ignition 
cycle that the DTC is detected. After turning the key 
switch OFF, DTC diagnosis is performed when the

vehicle starts again. If it is judged as normal, everything
will be recovered to normal from the next ignition cycle. 


  









 



Name
1. DTC is detected.



*3

When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
 be recovered normally, but the diagnosis lamp does not
go off.
Name
1. DTC is detected.  
2. Repair and inspection
3. Returned to normal. 












Name
1. DTC is detected.
DTC: P0087 (Flash code 227)
Common rail low pressure fault (No pressure feed in supply pump)
 




 

Name
4. Pre-filter


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 

Description of circuit
The engine control module (ECM) monitors the
pressure inside of common rail based on the signal
from common rail pressure sensor. If the pressure is
low, ECM controls the SCV of supply pump to increase
the pressure inside of common rail. If fuel supply to the
supply pump is insufficient or the supply pump is faulty,
the pressure inside of common rail cannot be
increased.
Main trouble symptom

Intense engine vibration
Rough idling
Output lowering
Black smoke emitted
Excessive output is possible.
Fuel system filter Target RP upper limit (80MPa)
Recovery from failure


 Refer to List of diagnostic trouble code and About
recovery from failure in this section for recovery from
failure.

The conditions to clear the MIL/DTC
The current trouble turns to past trouble (history)
when the condition is out of the range from DTC
set condition (recovery from failure).
 The check engine lamp will go off after the code
turns to past trouble and the key switch is turned
OFF then ON again.
Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
 Diagnostic aid
 Followings are suspected as the cause.
Name Injector internal trouble
1. Fuel pump strainer Supply pump internal trouble
2. Pre-fuel filter Fuel system pipe fault (fuel leakage, clogging,
3. Electromagnetic pump filter crush, etc.)
4. Main fuel filter Fuel filter fault (clogging)
5. Gauze filter Fuel tank fault (clogging)
Filter clogging in the fuel system may establish the DTC Pressure limiter trouble (operation under specified
set condition. Check as required. pressure, degradation of sealability)
ECM trouble
Preconditions when DTC is set Common rail pressure sensor trouble
900 rpm or more
Test description
DTC set condition
Actual rail pressure is 15MPa or less for 3 seconds or 5. When rise of fuel level or diesel fuel odor is
more. confirmed, fuel leakage in the injector portion may be
the cause of the DTC detection.
Action taken when DTC is set 9. If the Common rail pressure sensor displays more
Check engine lamp comes on. than the specified value when the common rail
pressure sensor connector is removed, the circuit
Back-up mode beyond the sensor is normal including ECM.
Limited injection amount 3 (multi-injection stopped)

1 Go to OBD

Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
pressure pipe for looseness in the
connection (fuel leakage), crush or
clogging.
2 2. Check the fuel pipe, fuel filter, and inside
of the fuel tank for freeze or waxing. (at
cold temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Is the fuel system normal? Go to Step 4. Go to Step 3.
Repair or replace the faulty part.
3
Check for rise of fuel level in the oil level gauge
4 or light oil odor.
Check the connection of the fuel pipe in each
injector, and replace the injector if oil leakage is
confirmed.
5 Note:

6
Check the injector.
1. Clear the DTC.
DTCs.
7 3. Select the Actuator test from the menu.
4. Select the Injection stop at each injector
in the Common rail system.
5. Press the OFF soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine sound did
not change when it is stopped? Go to Step 9. Go to Step 8.
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.
8 Note:


Check the common rail pressure.
2. Check for Common rail pressure on the
data display using scan tool.
At engine
3. Start the engine and run it at idle. stopped:
4. Check for Differential fuel rail pressure Differential
9 on the data display using scan tool. pressure
5. Race it quickly for about 5 times. -30 MPa; At
6. Check for Differential fuel rail pressure idling, racing:
on the data display using scan tool. 5 MPa
Is each value of Fuel rail pressure (at engine

stopped, idling and racing) around the
2. Disconnect the common rail pressure
sensor connector.
10 4.8V
4. Check for Common rail pressure sensor
on the data display using scan tool.
Is the Common rail pressure sensor more
than the specified value? Go to Step 13. Go to Step 11.
1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
11 using breaker box or DMM.
required.
necessary.
Refer to How to use flush tool in this
section for check and rewriting of ECM.
13 Note:


control module (ECM), Installation of ECM in
this section for learning of EGR. Replace the
ECM.
Note:
14 EGR valve position learning is required

Replace the common rail (common rail
15 pressure sensor).
1. Clear the DTC.
DTCs.
16 3. Select the Actuator test from the menu. 5MPa
4. Select the Rail pressure control in the
Common rail system.
5. Press the Up soft key to check the value
of Differential fuel pressure.
Is Differential fuel rail pressure within the
Replace the supply pump.
17
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
18 DTCs.
10 seconds.
4. Test run with the Preconditions when
DTC is set.
5. Check the DTC.
Is DTC P0087 detected? Go to Step 2. Go to Step 19.
19 Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Use the injector checker to stop injection in the
injector, and check the change in engine
20 sound.

stopped.
21 Note:

sensor connector.
3. Measure the voltage between the common
22 rail pressure sensor power supply terminal 4.8V
and the ground.
23 using breaker box or DMM.
required.
2. Clear the DTC.
24 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
About common rail pressure sensor Breaker box inspection procedure
  

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply Name
1. Breaker box
2. DMM
Characteristics of common rail pressure sensor


  


11, 23 Short circuit to Voltage Disconnect the 82 - Ground 0V 1V or more
other signal measureme sensor 90 - Ground
circuit nt connector.
Key switch ON
Common rail pressure is abnormally high (1st or 2nd stage).
 




 

Name
4. Pre-filter


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 

Description of circuit Rough idling

The common rail pressure sensor detects the common Output lowering
rail internal pressure. The common rail pressure sensor Engine blow up fault
is installed to the common rail. As the common rail Black smoke emitted
internal pressure changes depending on engine Excessive output possible
condition, output voltage of the common rail pressure
sensor will change (if the common rail internal fuel Preconditions when DTC is set
pressure is low, output voltage becomes low, if the
pressure is high, the output voltage becomes high as 1st step
well). The engine control module (ECM) reads this Key switch input voltage is 18V or more.
output voltage change, converting it into common rail DTC P0088, P0192, P0193, or P1635 is not
internal pressure, to utilize for control. Dedicated detected.
communication circuits are used for the sensor power Actual rail pressure is 2 MPa or more, and 70 rpm
supply (5V), SIG, and ground in the common rail or more.
pressure sensor, which are connected to the ECM. 2nd step
Also, the sensor circuit is shielded to avoid electrical Battery voltage is normal.
noise etc.
DTC P0088, P0192, P0193, or P1635 is not
detected.
Actual rail pressure is 2 MPa or more, and 70 rpm
Intense engine vibration or more.
DTC set condition Target RP upper limit (80MPa)
1st step
Rail pressure is more than 185MPa for 5 seconds
or more. Refer to List of diagnostic trouble code and About
Common rail pressure sensor voltage is 3.9 V or recovery from failure in this section for recovery from
more. failure.
2nd step
1st stage is completed, and rail pressure is more
than 190MPa for 5 seconds or more. The current trouble turns to past trouble (history)
Common rail pressure sensor voltage is 4.0 V or when the condition is out of the range from DTC
more. set condition (recovery from failure).
The diagnosis lamp will go off after the code turns
to history code and the key switch is turned OFF
then ON again.


 Diagnostic aid


be the cause.

 Defective harness routing

 Wire disconnection inside harness cladding
 Following inspections are necessary to detect these
causes.
ECM connector

Action taken when DTC is set
Fault indication* is displayed on the monitor of the
machine or diagnosis lamp comes on. (* Nothing is
displayed depending on the machine Damaged harness
manufacturer) Visually check the harness for damage.
Back-up mode display while moving the connector and the
Limited injection amount 3 (multi-injection stopped) harness which are related to the sensor. The

1 Go to OBD
2. Check the DTC.
3. Are the fuel-related parts only just
replaced?
Air bleeding may not be performed
2 sufficiently after replacing fuel-related
parts. Bleed air again. Check the DTC
after bleeding air.
Is any of the P0088, P0192, P0193, or P1635 Go to the relevant
detected? DTC detected. Go to Step 3.
3

30 seconds.
2. Start the engine. Differential
3. Check for Differential fuel rail pressure pressure
4
on the data display using scan tool. 5MPa
(at idle)
Is Differential fuel rail pressure within the Go to Diagnostic
specified value? Go to Step 5. aid.
1. Check the fuel return pipe between the
supply pump and the fuel tank for
breakage, twist, etc.
2. Check for clogging or twisting in the vent
5 hose of the fuel tank.
3. Check for foreign matter in the fuel tank.
required.
1. Replace the common rail (common rail
pressure sensor) since it seems that
abnormal value of the pressure sensor is
detected.
6 Note:
2. Check the DTC.

Note:

2. Clear the DTC.
8 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Check if other DTC is detected.
9 Go to each DTC
About common rail pressure sensor
  

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply


  

Common rail pressure fault (Excessive pressure feed in supply pump)
 




 

Name
4. Pre-filter


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 

Description of circuit Rough idling

rail internal pressure. The common rail pressure sensor Engine blow up fault
is installed to the common rail. As the common rail Black smoke emitted
internal pressure changes depending on engine Excessive output possible
sensor will change (if the common rail internal fuel Preconditions when DTC is set
pressure is high, the output voltage becomes high as Key switch input voltage is 18V or more.
well). The engine control module (ECM) reads this DTC P0089, P0192, P0193, or P1635 is not
output voltage change, converting it into common rail detected.
internal pressure, to utilize for control. Dedicated Coolant temperature is 60 C or more, and 375 rpm
communication circuits are used for the sensor power or more.
supply (5V), SIG, and ground in the common rail Duty to SCV is 40% or less, or target pressure feed
pressure sensor, which are connected to the ECM. to SCV is 90 mm3/sec or less.
Also, the sensor circuit is shielded to avoid electrical
noise etc. DTC set condition
Actual rail pressure is 40MPa or more higher than
target rail pressure for 5 seconds or more.
Action taken when DTC is set Diagnostic aid
Fault indication* is displayed on the monitor of the If the intermittent trouble is suspected, followings may
machine or diagnosis lamp comes on. (* Nothing is be the cause.
displayed depending on the machine Improper connection of harness connector
manufacturer) Defective harness routing
Back-up mode
Limited injection amount 3 (multi-injection stopped) Following inspections are necessary to detect these
Target RP upper limit (80MPa) causes.
Recovery from failure ECM connector
Refer to List of diagnostic trouble code and About Poor connection of terminal from connector
recovery from failure in this section for recovery from Unmatched terminals are fitted.
failure.
The conditions to clear the MIL/DTC Poor contact between terminal and wire
Damaged harness
when the condition is out of the range from DTC Visually check the harness for damage.
set condition (recovery from failure). Check the relevant items on the scan tool data
The diagnosis lamp will go off after the code turns display while moving the connector and the
to history code and the key switch is turned OFF harness which are related to the sensor. The
then ON again. variation of the display indicates the faulty part.

1 Go to OBD
2. Check the DTC.
2
Is any of the P0089, P0192, P0193, or 1635 Go to the relevant
detected? DTC detected. Go to Step 3.
3
30 seconds.
2. Start the engine. Differential
4 3. Check for Differential fuel rail pressure pressure
on the data display using scan tool. 5MPa
Is Differential fuel rail pressure within the Go to Diagnostic
specified value? aid. Go to Step 5.
2. Wait for 2 minutes before the common rail
internal pressure goes down.
3. Turn the key switch to ON. Do not start Differential
5 engine. pressure
4. Check for Differential fuel rail pressure -30MPa
Is Differential fuel rail pressure the specified

2. Disconnect the SCV connector.
3. Check the SCV harness connector
terminal for poor contact, intermittent
trouble, etc.
4. Disconnect the ECM harness connector.
6
5. Check the ECM harness connector
trouble, etc.
required.
sensor connector.
3. Check the common rail pressure sensor
harness connector terminal for poor
contact, intermittent trouble, etc.
7 4. Disconnect the ECM harness connector.
5. Check the ECM harness connector
trouble, etc.
required.
pressure sensor).
Note:
8

Note:

2. Clear the DTC.
10 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Is the DTC P1093 detected? Go to Step 2. Go to Step 11.

11 Go to each DTC
1. Visually check the harness between the
ECM and the common rail pressure
sensor for damage.
required.
About common rail pressure sensor On-board check of sensors
  
 
 
Name Name
1. Power supply 1. Coupling connector between engine the
2. Signal machine
3. GND 2. Machine harness
3. Sensor connector
4. Engine harness
1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
 the wiring of sensor connector.
 3. Check the harness from coupling connector for
open circuit.
If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
If only step 1 is faulty, replace the sensor.
  

SCV drive system open circuit, +B short or ground short
 

 
 
 
   
       




Description of circuit Preconditions when DTC is set

The suction control valve (SCV) controls the fuel feed Main relay power supply voltage is 18V or more.
pressure amount to the common rail. Once the SCV DTC P0090 is not detected.
installed to the supply pump receives the signal 300 rpm or more, or actual rail pressure exceeds
(voltage), the SCV closes the valve and pressure-feeds target rail pressure.
fuel from the supply pump to the common rail. The
engine control module (ECM) operates the SCV to DTC set condition
adjust the common rail pressure.
When SCV drive current exceeds specified value
Main trouble symptom for 2 seconds or more.
When the difference between target and actual
Engine stall and/or engine blow up are possible
current exceeds specified value for 2 seconds or
depending on the condition of open/short circuit.
more.
Black smoke emitted
Excessive output
Back-up mode
Limited injection amount 3 (multi-injection stopped) Following inspections are necessary to detect these
Target RP upper limit (80MPa) causes.
failure.
Damaged harness

1 Go to OBD
2
3. Check for SCV F/B on the data display
3 using scan tool. 50mA
Is the value of SCV F/B less than the

SCV and ECM using breaker box or DMM.
procedure.
4 Open circuit
High resistance
2. If the trouble is detected, repair or replace
as required.

SCV and ECM using breaker box or DMM.
procedure.
Short circuit between terminals
5 Short circuit to power supply circuit or
ignition power supply circuit
Short circuit to other signal circuit
as required.
Check the SCV body. Between
1. Turn the key switch to OFF. terminals:
2. Disconnect the harness from the SCV. 3.2 0.3 ;
6 Each terminal
3. Measure the resistance between the SCV
to SCV body:
connector terminals.
(at normal
Is the resistance specified value? temperature) Go to Step 8. Go to Step 7.
Replace the supply pump (SCV).
Note:

2. Clear the DTC.
8 DTCs.
10 seconds.
4. Start the engine, and test run with the
Preconditions when DTC is set.
5. Check the DTC.
Go to Diagnostic
Is the DTC P0090 detected? Go to Step 9. aid.
necessary.
Note:
10


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
5. Check the DTC.
13 Go to each DTC
About SCV
4HK1
Name
 1. SCV-HI
2. SCV-LO
6HK1



Name
1. SCV
Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Disconnect the 105 - SCV terminal 5 or less 10M or
high measureme SCV connector. 113 - SCV terminal more
resistance nt Key switch OFF 89 - SCV terminal
97 - SCV terminal
Short circuit to Resistance Disconnect the 105 - Ground 10M or 100 or
ground measureme SCV connector. 113 - Ground more less
nt Key switch OFF 89 - Ground
97 - Ground
5 Short circuit Resistance Disconnect the 105 - 89 10M or 100 or
between measureme SCV connector. 105 - 97 more less
terminals nt Key switch OFF 113 - 89
113 - 97
Short circuit to Voltage Disconnect the 105 - Ground 0V 18V or
power supply measureme SCV connector. 113 - Ground more
circuit nt Key switch ON 89 - Ground
97 - Ground
Short circuit to Voltage Disconnect the 105 - Ground 0V 1V or more
other signal measureme SCV connector. 113 - Ground
circuit nt Key switch ON 89 - Ground
97 - Ground
On-board check of sensors If both steps 1 and 2 are faulty, repair the
 If only step 1 is faulty, replace the sensor.
 

Name
1. Coupling connector between engine the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
Barometric pressure sensor circuit input is low (open circuit or ground short).
  

 
   
   
 
 

   
                 


 
     
                     
  

 

Description of circuit Output shortage at low altitude

The barometric pressure sensor detects the barometric
pressure. The barometric pressure sensor is installed Preconditions when DTC is set
to the machine. As the barometric pressure changes Key switch input voltage is 18V or more.
depending on altitude and weather condition, output DTC P1630 or P1632 is not detected.
voltage of the barometric pressure sensor will change
(if the barometric pressure is low, output voltage DTC set condition
becomes low, if the barometric pressure is high, the
Barometric pressure sensor voltage is 0.5V or less
output voltage becomes high as well). The engine
for 5 seconds or more.
control module (ECM) reads this output voltage
change, converting it into barometric pressure, to utilize
for optimizing the fuel injection control and for
calculating the relative boost pressure. Fault indication* is displayed on the monitor of the
Main trouble symptom displayed depending on the machine
manufacturer)
Due to back-up equivalent to 2500m
Black smoke emitted at high altitude
Back-up mode Following inspections are necessary to detect these
Barometric pressure default setting (80 kPa) causes.
EGR stopped Improper connection of harness connector and
ECM connector
Recovery from failure Poor connection of terminal from connector
Refer to List of diagnostic trouble code and About Unmatched terminals are fitted.
recovery from failure in this section for recovery from Damage of connector lock
failure. Poor contact between terminal and wire
Damaged harness
The conditions to clear the MIL/DTC Visually check the harness for damage.
The current trouble turns to past trouble (history) Check the relevant items on the scan tool data
when the condition is out of the range from DTC display while moving the connector and the
set condition (recovery from failure). harness which are related to the sensor. The
Using the scan tool, or memory clear switch and variation of the display indicates the faulty part.
Test description
Diagnostic aid Numbers below indicate step numbers in the chart.
If the intermittent trouble is suspected, followings may 2. In case of current trouble, the Barometric pressure
be the cause. sensor displays less than the specified value. If more
Improper connection of harness connector than the specified value, identify the cause by referring
Defective harness routing to Diagnostic aid.
4. If the Barometric pressure sensor displays more
than the specified value when terminals between the
Wire disconnection inside harness cladding barometric pressure sensor connector are shorted, the
circuit beyond the sensor is normal including ECM.

Perform the OBD system check. Perform OBD
1 system check, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
2
Check the value for barometric pressure
sensor using scan tool.
3 0.5V
3. Check the value for Barometric pressure
Is the Barometric pressure sensor less than Go to Diagnostic
the specified value? Go to Step 4. aid.
Check for installation condition of the
barometric pressure sensor, ECM and coupling
connector.
4 connection.
as required.

2. Disconnect the barometric pressure
sensor connector.
3. Short between the barometric pressure
sensor connector power supply terminal
5 and the signal terminal using jump cable. 4.8V
Is the Barometric pressure sensor more than
the specified value? Go to Step 8. Go to Step 6.
1. Check for followings in the power supply
circuit between ECM and barometric
pressure sensor using breaker box or
DMM.
procedure.
6
Open circuit
High resistance
as required.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
procedure.
Short circuit to barometric pressure
sensor ground circuit
7
Open circuit
High resistance
as required.
Replace the barometric pressure sensor.
8
necessary.
10 Note:


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
2. Check the display of barometric pressure. 127kPa
14 (Displayed
Does the display of Barometric pressure error value) Go to Diagnostic
show error value? Go to Step 15. aid.
connector.
(Check the barometric pressure sensor circuit
for open circuit or ground short.)
15 1. Check for disconnection, play or
looseness in the connection.
as required.
circuit between ECM and barometric
DMM.
procedure.
16
Open circuit
High resistance
as required.

procedure.
Short circuit to barometric pressure
17
Open circuit
High resistance
as required.
About barometric pressure sensor Characteristics of barometric pressure sensor

The output voltage of barometric pressure sensor
changes according to the barometric pressure.
The scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 40kPa or 127kPa is not changed.
When error occurs, error value (127kPa) is displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
  
Tech2 and scan tools with KW communication can
display both voltage and physical value.



Name
1. Power supply
2. GND
3. Signal

  

Name
1. Breaker box
2. DMM

6 Open circuit/ Resistance Disconnect the 61 - Sensor 100 or 10M or
high measureme sensor connector power less more
resistance nt connector. supply terminal
Key switch OFF
7 Short circuit to Resistance Disconnect the 71 - 60 10M or 100 or
ground circuit/ measureme sensor 71 - Ground more less
ground nt connector.
Key switch OFF
Open circuit/ Resistance Disconnect the 71 - Sensor 100 or 10M or
high measureme sensor connector signal less more
resistance nt connector. terminal
Key switch OFF
On-board check of sensors
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
If both steps 1 and 2 are faulty, repair the harness.
Barometric pressure sensor circuit input is high (+5V short circuit).
  

 
   
   
 
 

   
                 


 
     
                     
  

 

Description of circuit Output shortage at low altitude

The barometric pressure sensor detects the barometric
pressure. The barometric pressure sensor is installed Preconditions when DTC is set
to the machine. As the barometric pressure changes Key switch input voltage is 18V or more.
depending on altitude and weather condition, output DTC P1630 or P1632 is not detected.
voltage of the barometric pressure sensor will change
(if the barometric pressure is low, output voltage DTC set condition
becomes low, if the barometric pressure is high, the
Barometric pressure sensor voltage is 3.8 V or
output voltage becomes high as well). The engine
more for 4 seconds or more.
control module (ECM) reads this output voltage
change, converting it into barometric pressure, to utilize
for optimizing the fuel injection control and for
calculating the relative boost pressure. Fault indication* is displayed on the monitor of the
manufacturer)
Due to back-up equivalent to 2500m
Barometric pressure default setting (80 kPa) causes.
EGR stopped Improper connection of harness connector and
ECM connector
Damaged harness
The conditions to clear the MIL/DTC Visually check the harness for damage.
Test description
If the intermittent trouble is suspected, followings may 3. In the case of current trouble, the Barometric
be the cause. pressure sensor displays more than the specified
Improper connection of harness connector value. If less than the specified value, identify the cause
Defective harness routing by referring to Diagnostic aid.
5. If the Barometric pressure sensor displays more
than the specified value when the barometric pressure
Wire disconnection inside harness cladding sensor connector is removed, the circuit beyond the
sensor is normal including ECM.

1 system check, and
2
Check the value for barometric pressure
3 3.8V
Is the Barometric pressure sensor more than Go to Diagnostic
connector.
4 connection.
as required.

sensor connector.
5 0V
Is the Barometric pressure sensor less than
1. Check the signal circuit between ECM and
barometric pressure sensor for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
procedure.
6 Important:
If the barometric pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

required.
1. Check for followings in the ground circuit
procedure.
7 Open circuit
High resistance
as required.
Replace the barometric pressure sensor.
8
necessary.
Note:
10


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
2. Check the display of barometric pressure. 127kPa
14 (Displayed
Does the display of Barometric pressure error value) Go to Diagnostic
show more than error value? Go to Step 15. aid.
connector.
(Check the barometric pressure sensor circuit
for short to +5V line or battery power supply
circuit.)
15
connection.
as required.

barometric pressure sensor for short
box or DMM.
procedure.
16 Important:
If the barometric pressure sensor circuit is
may be broken.

required.
procedure.
17 Open circuit
High resistance
as required.
About barometric pressure sensor
  

Name
1. Power supply
2. GND
3. Signal
Characteristics of barometric pressure sensor Breaker box inspection procedure
The output voltage of barometric pressure sensor Perform the inspection in the following procedure if
changes according to the barometric pressure. there is such an instruction to use breaker box in the
The scan tool with CAN communication displays a fixed step. After inspection, return to the diagnostic step.
the value of 40kPa or 127kPa is not changed.


Name
1. Breaker box

2. DMM
  


6 Short circuit to Voltage Disconnect the 71 - Ground 0V 18V or
power supply measureme sensor more
Key switch ON
high measureme sensor connector ground less more
Key switch OFF
Intake air temperature sensor fault (low voltage fault, ground short, short circuit)
  

 
   
   
 
 

   
                 


 
     
                     
  

 


The intake air temperature (IAT) sensor is the Key switch input voltage is 18V or more.
thermistor type and the value of resistance changes DTC P1630 or P1632 is not detected.
according to the temperature. The resistance is low
when the intake air temperature is high, and is high DTC set condition
when the temperature is low. The ECM energizes 5 V to
IAT sensor voltage is 0.1V or less for 4 seconds or
the IAT sensor through the pull up resistance, and
more.
calculate the intake air temperature from the change in
voltage, to utilize various control such as fuel injection
control. If the resistance is low (temperature is high),
the voltage becomes low; if the resistance is high Fault indication* is displayed on the monitor of the
(temperature is low), the voltage becomes high. machine or diagnosis lamp comes on. (* Nothing is
displayed depending on the machine
Main trouble symptom manufacturer)
White smoke emission possible when starting at
Back-up mode
low temperatures
Intake air temperature default setting
(at starting: 10 C, at running: 25 C)
EGR stopped Wire disconnection inside harness cladding
Recovery from failure causes.
Refer to List of diagnostic trouble code and About Improper connection of harness connector and
recovery from failure in this section for recovery from ECM connector
failure. Poor connection of terminal from connector
The conditions to clear the MIL/DTC Damage of connector lock
The current trouble turns to past trouble (history) Poor contact between terminal and wire
when the condition is out of the range from DTC Damaged harness
display while moving the connector and the
Diagnostic aid
To make sure the correct performance of the IAT
sensor, check with various temperatures using the Test description
reckoner table between temperature and
resistance. If the sensor is faulty, operationality
3. In the case of current trouble, the Intake air
may be affected.
temperature sensor displays less than the specified
value. If more than the specified value, identify the
be the cause.
cause by referring to Diagnostic aid.
Improper connection of harness connector 5. If the Intake air temperature sensor displays more
Defective harness routing than the specified value when the IAT sensor connector
Worn harness cladding is removed, the circuit beyond the sensor is normal
including ECM.

1 system check, and
2
Check the value for IAT sensor using scan tool.
3 3. Check the value for Intake air 0.1V
temperature sensor using scan tool.
Is the Intake air temperature sensor less than Go to Diagnostic
Check for installation condition of the IAT
sensor, ECM and coupling connector.
4 connection.
as required.
2. Disconnect the IAT sensor connector.
5 4. Check the value for Intake air 4.8V
Is the Intake air temperature sensor more

between ECM and IAT sensor using
breaker box or DMM.
procedure.
6 Short circuit to IAT sensor ground
circuit
as required.
Replace the IAT sensor.
7
necessary.
Note:
9

Replace the ECM.
Note:
10

2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
12 Go to each DTC

2. Check the display of intake air 214 C
13 temperature. (Displayed
Does the display of Intake air temperature error value) Go to Diagnostic
(Check the IAT sensor circuit for ground short.)
14 connection.
as required.
breaker box or DMM.
procedure.
15 Short circuit to IAT sensor ground
circuit
as required.
About IAT sensor
Name
1. Signal
2. GND
Characteristics of intake air temperature sensor
The output voltage of IAT sensor changes according to
the intake air.
the value of 40 C or 120 C is not changed.
When error occurs, error value (214 C) is displayed.
Tech 2 and scan tools with KW communication can



 







                   


Name
1. Breaker box
2. DMM

Key switch OFF
On-board check of sensors Name

 machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
 
 If only step 1 is faulty, replace the sensor.

Intake air temperature sensor fault (high voltage fault, open circuit or short to power
supply circuit)
  

 
   
   
 
 

   
                 


 
     
                     
  

 


The intake air temperature (IAT) sensor is the Key switch input voltage is 18V or more.
thermistor type and the value of resistance changes DTC P1630 or P1632 is not detected.
according to the temperature. The resistance is low 3 minutes or more has elapsed after starting
when the intake air temperature is high, and is high engine.
when the temperature is low. The ECM energizes 5 V to
the IAT sensor through the pull up resistance, and DTC set condition
calculate the intake air temperature from the change in
voltage, to utilize various control such as fuel injection IAT sensor voltage is 4.95V or more for 4 seconds
control. If the resistance is low (temperature is high), or more.
the voltage becomes low; if the resistance is high
(temperature is low), the voltage becomes high. Action taken when DTC is set
Main trouble symptom machine or diagnosis lamp comes on. (* Nothing is
White smoke emission possible when starting at displayed depending on the machine
low temperatures manufacturer)
Back-up mode Defective harness routing
Intake air temperature default setting Worn harness cladding
(at starting: 10 C, at running: 25 C) Wire disconnection inside harness cladding
EGR stopped Following inspections are necessary to detect these
causes.
Recovery from failure Improper connection of harness connector and
ECM connector
Refer to List of diagnostic trouble code and About
recovery from failure in this section for recovery from Poor connection of terminal from connector
failure. Unmatched terminals are fitted.
The current trouble turns to past trouble (history) Damaged harness
Using the scan tool, or memory clear switch and display while moving the connector and the
diagnostic switch operation enables to clear DTCs. harness which are related to the sensor. The
Diagnostic aid
To make sure the correct performance of the IAT Test description
sensor, check with various temperatures using the Numbers below indicate step numbers in the chart.
reckoner table between temperature and 3. In case of current trouble, the Intake air temperature
resistance. If the sensor is faulty, operationality sensor displays more than the specified value. In this
may be affected. case, identify the cause by referring to Diagnostic aid.
If the intermittent trouble is suspected, followings may 5. If the Intake air temperature sensor displays less
be the cause. than the specified value when terminals between the
Improper connection of harness connector IAT sensor connector are shorted, the circuit beyond
the sensor is normal including ECM.

1 system check, and
2
Check the value for IAT sensor using scan tool.
3 3. Check the value for Intake air 4.95V/120 C
Is the Intake air temperature sensor more Go to Diagnostic
than the specified value? Go to Step 4. aid.
4 connection.
as required.

2. Disconnect the IAT sensor connector.
3. Short the IAT sensor connector signal
terminal to the ground terminal using jump
cable.
5 4. Turn the key switch to ON. 0V/ 40 C
5. Check the value for Intake air
Is the Intake air temperature sensor less than
IAT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
procedure.
6 Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

required.
breaker box or DMM.
procedure.
7 Open circuit
High resistance
as required.
breaker box or DMM.
procedure.
8 Open circuit
High resistance
as required.
Replace the IAT sensor.
9

necessary.
11 Note:

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC
2. Check the display of intake air
15 temperature. 40 C
Is the Intake air temperature more than the Go to Diagnostic
16 connection.
as required.

IAT sensor for short circuit to the power
procedure.
17 Important:
If the IAT sensor circuit is shorted to the power

required.
breaker box or DMM.
procedure.
18 Open circuit
High resistance
as required.
breaker box or DMM.
procedure.
19 Open circuit
High resistance
as required.
About IAT sensor Name

1. Signal
2. GND
Characteristics of intake air temperature sensor
The output voltage of IAT sensor changes according to
the intake air.
Tech 2 and scan tools with KW communication can



 







                   


Name
1. Breaker box
2. DMM

Key switch ON
Key switch OFF
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Engine coolant temperature sensor fault (low voltage fault, ground short)
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 

Description of circuit Main trouble symptom

The engine coolant temperature (ECT) sensor detects Deterioration of startability at low temperatures
the engine coolant temperature. The ECT sensor is Black smoke emitted
installed near the thermostat housing. The ECT sensor Output lowering depending on conditions
is the thermistor type and the value of resistance inside
the sensor changes according to the temperature. If the Preconditions when DTC is set
temperature is high, the resistance becomes low; if the
Key switch input voltage is 18V or more.
temperature is low, the resistance becomes high. The
DTC P1630 or P1633 is not detected.
engine control module (ECM) is connected to the ECT
sensor via signal circuit and ground circuit, and
DTC set condition
energizes +5 V power supply to the signal circuit. ECM
recognizes the applied voltage, which varies with ECT sensor voltage is 0.1V or less for 4 seconds
change in the resistance of ECT sensor according to or more.
temperature (If the temperature is high, the voltage
becomes low; if the temperature is low, the voltage
becomes high), as an input signal.
Action taken when DTC is set If the intermittent trouble is suspected, followings may
Fault indication* is displayed on the monitor of the be the cause.
machine or diagnosis lamp comes on. (* Nothing is Improper connection of harness connector
displayed depending on the machine Defective harness routing
manufacturer) Worn harness cladding
Coolant temperature default setting causes.
(at starting: 20 C, at driving: 80 C) Improper connection of harness connector and
EGR stopped ECM connector
Recovery from failure Unmatched terminals are fitted.
Refer to List of diagnostic trouble code and About Damage of connector lock
recovery from failure in this section for recovery from Poor contact between terminal and wire
failure. Damaged harness
The current trouble turns to past trouble (history) display while moving the connector and the
when the condition is out of the range from DTC harness which are related to the sensor. The
set condition (recovery from failure). variation of the display indicates the faulty part.
diagnostic switch operation enables to clear DTCs. Test description
Diagnostic aid
3. In case of current trouble, the Engine coolant
DTC may be set at a overheat condition. temperature sensor displays more than the specified
After starting the engine, the thermostat begins to value. In this case, identify the cause by referring to
open when the engine coolant temperature rises Diagnostic aid.
(4H: 85 C, 6H: 82 C), and the engine coolant 5. If the Engine coolant temperature sensor displays
temperature is stabilized. more than the specified value when the ECT sensor
To make sure the correct performance of the ECT connector is removed, the circuit beyond the sensor is
sensor, check with various temperatures using the normal including ECM.
reckoner table between temperature and
may be affected.

1 system check, and
2
Check the value for ECT sensor using scan
tool.
3 0.1V
3. Check the value for Engine coolant
Is the Engine coolant temperature sensor Go to Diagnostic
less than the specified value? Go to Step 4. aid.

Check for installation condition of the ECT
4 connection.
as required.
2. Disconnect the ECT sensor connector.
5 4. Check the value for Engine coolant 4.8V
Is the Engine coolant temperature sensor
more than the specified value? Go to Step 7. Go to Step 6.
between ECM and ECT sensor using
breaker box or DMM.
procedure.
Short circuit to ECT sensor ground
circuit
6 Short circuit to ground
2. Measure the resistance of ECT sensor,
and check if the measured value is within
the normal range.
as required.
Replace the ECT sensor.
7
necessary.
9 Note:


Replace the ECM.
Note:
10

2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
12 Go to each DTC
2. Check the display of the engine coolant
temperature.
Display of engine coolant temperature is 214 C
13 214 C due to back-up mode after fault (Displayed
judgment. error value)
Does the display of Engine coolant

temperature show error value? Go to Step 11. Go to Step 14.
14 connection.
as required.

breaker box or DMM.
procedure.
Short circuit to ECT sensor ground
circuit
2. Measure the resistance of ECT sensor,
and check if the measured value is within
the normal range.
as required.
About ECT sensor Characteristics of ECT sensor

The output voltage of ECT sensor changes according to
the engine coolant temperature. The scan tool with CAN
  communication displays a fixed value when the value
exceeds the threshold voltage. Therefore, judge as it is
more than the threshold value if the value of 40 C or
120 C is not changed.

   display both voltage and physical value.



Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)

 



Name
1. Breaker box
2. DMM

Key switch OFF

 machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
 

Engine coolant temperature sensor input is high (open circuit and short to power supply).
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 


The engine coolant temperature (ECT) sensor detects Noise deteriorates.
the engine coolant temperature. The ECT sensor is White smoke emitted at low temperatures.
installed near the thermostat housing. The ECT sensor Rough idling
is the thermistor type and the value of resistance inside
the sensor changes according to the temperature. If the Preconditions when DTC is set
temperature is high, the resistance becomes low; if the
temperature is low, the resistance becomes high. The Key switch input voltage is 18V or more.
engine control module (ECM) is connected to the ECT DTC P1630 or P1633 is not detected.
sensor via signal circuit and ground circuit, and 3 minutes or more has elapsed after starting
energizes +5 V power supply to the signal circuit. ECM engine.
recognizes the applied voltage, which varies with
change in the resistance of ECT sensor according to DTC set condition
temperature (If the temperature is high, the voltage ECT sensor voltage is 4.85V or more for 4 seconds
becomes low; if the temperature is low, the voltage or more.
becomes high), as an input signal.
Action taken when DTC is set If the intermittent trouble is suspected, followings may
Fault indication* is displayed on the monitor of the be the cause.
machine or diagnosis lamp comes on. (* Nothing is Improper connection of harness connector
displayed depending on the machine Defective harness routing
manufacturer) Worn harness cladding
Coolant temperature default setting causes.
(at starting: 20 C, at driving: 80 C) Improper connection of harness connector and
EGR stopped ECM connector
Diagnostic aid
3. In case of current trouble, the Engine coolant
After starting the engine, the thermostat begins to temperature sensor displays more than the specified
open when the engine coolant temperature rises value. In this case, identify the cause by referring to
(4H: 85 C, 6H: 82 C), and the engine coolant Diagnostic aid.
temperature is stabilized. 5. If the Engine coolant temperature sensor displays
To make sure the correct performance of the ECT less than the specified value when terminals between
sensor, check with various temperatures using the the ECT sensor connector are shorted, the circuit
reckoner table between temperature and beyond the sensor is normal including ECM.
may be affected.

1 system check, and
2
Check the value for ECT sensor using scan
tool.
3 4.85V
Is the Engine coolant temperature sensor Go to Diagnostic
more than the specified value? Go to Step 4. aid.
4 connection.
as required.

3. Short the ECT sensor connector signal
cable.
less than the specified value? Go to Step 9. Go to Step 6.
ECT sensor for short circuit to the power
procedure.
6 Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.

required.
breaker box or DMM.
procedure.
7 Open circuit
High resistance
as required.
breaker box or DMM.
procedure.
8 Open circuit
High resistance
as required.
9

necessary.
11 Note:

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC
2. Check the display of the Engine coolant
15 temperature. 40 C
Is the Engine coolant temperature more than Go to Diagnostic
16 connection.
as required.

ECT sensor for short circuit to the power
procedure.
17 Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.

required.
breaker box or DMM.
procedure.
18 Open circuit
High resistance
as required.
breaker box or DMM.
procedure.
19 Open circuit
High resistance
as required.
About ECT sensor
 


  


Name Breaker box inspection procedure

1. Sensor GND (for engine control)
2. Sensor signal (for engine control) Perform the inspection in the following procedure if
3. Sensor signal (for meter) there is such an instruction to use breaker box in the
Characteristics of ECT sensor

The output voltage of ECT sensor changes according to
the engine coolant temperature. The scan tool with CAN
communication displays a fixed value when the value
120 C is displayed.


Name
1. Breaker box
2. DMM

 


Key switch ON
Key switch OFF
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Fuel temperature sensor fault (low voltage fault, ground short)
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 


The fuel temperature (FT) sensor is the thermistor type Key switch input voltage is 18V or more.
and the value of resistance changes according to the DTC P1630 or P1633 is not detected.
temperature. The fuel temperature (FT) sensor is
installed near the fuel inlet duct in the supply pump. The DTC set condition
FT sensor voltage is 0.1V or less for 4 seconds or
is high when the temperature is low. The ECM
more.
energizes 5 V to the FT sensor through the pull up
resistance, and calculates the fuel temperature from
the change in voltage, to utilize for supply control etc. If
the resistance is low (temperature is high), the voltage Fault indication* is displayed on the monitor of the
becomes low; if the resistance is high (temperature is machine or diagnosis lamp comes on. (* Nothing is
low), the voltage becomes high. displayed depending on the machine
manufacturer)
Operationality is affected.
Back-up mode Wire disconnection inside harness cladding
Fuel temperature default setting Following inspections are necessary to detect these
(at starting: 20 C, at running: 70 C) causes.
failure. Damage of connector lock
The conditions to clear the MIL/DTC Damaged harness
The current trouble turns to past trouble (history) Visually check the harness for damage.
when the condition is out of the range from DTC Check the relevant items on the scan tool data
set condition (recovery from failure). display while moving the connector and the
Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.
Diagnostic aid Test description

When the engine cold (before starting engine), Numbers below indicate step numbers in the chart.
check if the temperatures of the FT sensor and IAT 3. In the case of current trouble, the Fuel temperature
sensor are close. sensor displays more than the specified value. In this
If the intermittent trouble is suspected, followings may case, identify the cause by referring to Diagnostic aid.
be the cause. 5. If the Fuel temperature sensor displays more than
Improper connection of harness connector the specified value when the FT sensor connector is
Defective harness routing removed, the circuit beyond the sensor is normal
Worn harness cladding including ECM.

1 system check, and
2
Check the value for FT sensor using scan tool.
3 3. Check the value for Fuel temperature 0.1V
Is the Fuel temperature sensor less than the Go to Diagnostic
Check for installation condition of the FT
4 connection.
as required.
2. Disconnect the FT sensor connector.
Is the Fuel temperature sensor more than the

between ECM and FT sensor using
breaker box or DMM.
procedure.
6 Short circuit to FT sensor ground circuit
as required.
Replace the supply pump (FT sensor).
7
necessary.
Note:
9

Replace the ECM.
Note:
10

2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
12 Go to each DTC

2. Check the display of Fuel temperature. 214 C
13 (Displayed
Does the display of Fuel temperature show error value) Go to Diagnostic
error value? Go to Step 14. aid.
14 connection.
as required.
breaker box or DMM.
procedure.
15 Short circuit to FT sensor ground circuit
as required.
About FT sensor Characteristics of FT sensor

The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN
120 C is not changed.


Name
1. GND
2. Signal

 





               

Name
1. Breaker box
2. DMM

Key switch OFF
On-board check of sensors 2. Machine harness

3. Sensor connector
 4. Engine harness

open circuit.
 

Name
machine
Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply
circuit)
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 


The fuel temperature (FT) sensor is the thermistor type Key switch input voltage is 18V or more.
and the value of resistance changes according to the DTC P1630 or P1633 is not detected.
temperature. The fuel temperature (FT) sensor is 3 minutes or more has elapsed after starting
installed near the fuel inlet duct in the supply pump. The engine.
is high when the temperature is low. The ECM DTC set condition
energizes 5 V to the FT sensor through the pull up
resistance, and calculates the fuel temperature from FT sensor voltage is 4.85V or more for 4 seconds
the change in voltage, to utilize for supply control etc. If or more.
the resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is Action taken when DTC is set
low), the voltage becomes high. Fault indication* is displayed on the monitor of the
Not in particular manufacturer)
Fuel temperature default setting Following inspections are necessary to detect these
(at starting: 20 C, at running: 70 C) causes.
Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.
Diagnostic aid Test description

When the engine cold (before starting engine), Numbers below indicate step numbers in the chart.
check if the temperatures of the FT sensor and IAT 3. In the case of current trouble, the Fuel temperature
sensor are close. sensor displays more than the specified value. In this
If the intermittent trouble is suspected, followings may case, identify the cause by referring to Diagnostic aid.
be the cause. 5. If the Fuel temperature sensor displays less than
Improper connection of harness connector the specified value when terminals between the FT
Defective harness routing sensor connector are shorted, the circuit beyond the
Worn harness cladding sensor is normal including ECM.

1 system check, and
2
Check the value for FT sensor using scan tool.
Is the Fuel temperature sensor more than the Go to Diagnostic
4 connection.
as required.

2. Disconnect the FT sensor connector.
3. Short the FT sensor connector signal
cable.
5. Check the value for Fuel temperature
Is the Fuel temperature sensor less than the
FT sensor for short circuit to the power
procedure.
6 Important:
If the FT sensor circuit is shorted to the power

required.
breaker box or DMM.
procedure.
7 Open circuit
High resistance
as required.
breaker box or DMM.
procedure.
8 Open circuit
High resistance
as required.
Replace the supply pump (FT sensor).
9

necessary.
11 Note:

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC
2. Check the display of Fuel temperature.
15 30 C
Is the Fuel temperature more than the Go to Diagnostic
16 connection.
as required.

FT sensor for short circuit to the power
procedure.
17 Important:
If the FT sensor circuit is shorted to the power

required.
breaker box or DMM.
procedure.
18 Open circuit
High resistance
as required.
breaker box or DMM.
procedure.
19 Open circuit
High resistance
as required.
About FT sensor Name

1. GND
2. Signal
Characteristics of FT sensor Breaker box inspection procedure
The output voltage of FT sensor changes according to Perform the inspection in the following procedure if
the fuel temperature. The scan tool with CAN there is such an instruction to use breaker box in the
communication displays a fixed value when the value step. After inspection, return to the diagnostic step.
exceeds the threshold voltage.


Name
1. Breaker box

2. DMM
 





               


Key switch ON
Key switch OFF
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Common rail pressure sensor fault (low voltage fault)


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 


The common rail pressure sensor detects the common Engine blow up
rail internal pressure. The common rail pressure sensor
is installed to the common rail. As the common rail Preconditions when DTC is set
internal pressure changes depending on engine Key switch input voltage is 18V or more.
sensor will change (if the common rail internal fuel
DTC set condition
pressure is high, the output voltage becomes high as
well). The engine control module (ECM) reads this Common rail pressure sensor voltage becomes
output voltage change, converting it into common rail 0.7V or less.
internal pressure, to utilize for control. Dedicated
communication circuits are used for the sensor power Action taken when DTC is set
supply (5V), SIG, and ground in the common rail Fault indication* is displayed on the monitor of the
pressure sensor, which are connected to the ECM. machine or diagnosis lamp comes on. (* Nothing is
Also, the sensor circuit is shielded to avoid electrical displayed depending on the machine
noise etc. manufacturer)
Specified back-up value (depending on the Following inspections are necessary to detect these
machine manufacturer) causes.
The diagnosis lamp will go off after the code turns harness which are related to the sensor. The
to history code and the key switch is turned OFF variation of the display indicates the faulty part.
then ON again.
Using the scan tool, or memory clear switch and Test description
diagnostic switch operation enables to clear DTCs. Numbers below indicate step numbers in the chart.
3. In the case of current trouble, the Common rail
Diagnostic aid pressure sensor displays more than the specified
If the intermittent trouble is suspected, followings may value. If more than the specified value, identify the
be the cause. cause by referring to Diagnostic aid.
Improper connection of harness connector 5. If the Common rail pressure sensor displays more
Defective harness routing than the specified value when the common rail
beyond the sensor is normal including ECM.

1 system check, and
2
Check the value for common rail pressure
2. Start the engine. 0.7V
3
3. Check the value for Common rail (at idle)
pressure sensor using scan tool.
Is the Common rail pressure sensor output Go to Diagnostic
voltage less than the specified value? Go to Step 4. aid.
Check for installation condition of the common
rail pressure sensor, ECM and coupling
connector.
4 connection.
as required.

sensor connector.
5 0V
4. Check the value for Common rail
Is the Common rail pressure sensor output
voltage specified value? Go to Step 8. Go to Step 6.
circuit between ECM and common rail
DMM.
procedure.
6
Open circuit
High resistance
as required.
between ECM and common rail pressure
procedure.
7 Short circuit to common rail pressure
as required.
pressure sensor).
Note:
8

necessary.
Note:
10


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
connector.
14 connection.
as required.
sensor connector.
15 0V
4. Connect the DMM between the common
rail pressure sensor signal terminal and
the ground.
Does the DMM indicate the specified value? Go to Step 8. Go to Step 6.
About common rail pressure sensor Breaker box inspection procedure
  

Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
About common rail pressure sensor 2. DMM


  


Key switch OFF
ground circuit/ measureme sensor 90 - 101 more less
ground nt connector. 82 - Ground
Key switch OFF 90 - Ground

Key switch OFF 90 - Sensor
connector signal
terminal
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Common rail pressure sensor fault (high voltage fault)


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 


rail internal pressure. The common rail pressure sensor Engine stall possible
is installed to the common rail. As the common rail
internal pressure changes depending on engine Preconditions when DTC is set
sensor will change (if the common rail internal fuel
pressure is low, output voltage becomes low, if the DTC P1630 or P1635 is not detected.
pressure is high, the output voltage becomes high as
well). The engine control module (ECM) reads this DTC set condition
output voltage change, converting it into common rail Common rail pressure sensor voltage becomes
internal pressure, to utilize for control. Dedicated 4.5V or more.
communication circuits are used for the sensor power
supply (5V), SIG, and ground in the common rail Action taken when DTC is set
pressure sensor, which are connected to the ECM. Fault indication* is displayed on the monitor of the
Also, the sensor circuit is shielded to avoid electrical machine or diagnosis lamp comes on. (* Nothing is
noise etc. displayed depending on the machine
manufacturer)
Specified back-up value (depending on the Following inspections are necessary to detect these
machine manufacturer) causes.
then ON again.
3. In the case of current trouble, the Common rail
Diagnostic aid pressure sensor displays more than the specified
If the intermittent trouble is suspected, followings may value. If more than the specified value, identify the
be the cause. cause by referring to Diagnostic aid.
Improper connection of harness connector 5. If the Common rail pressure sensor displays less
Defective harness routing than the specified value when terminals between the
common rail pressure sensor connector are shorted,
the circuit beyond the sensor is normal including ECM.

1 system check, and
2
Check the value for common rail pressure
3 4.5V
Is the Common rail pressure sensor more Go to Diagnostic
than the specified value? Go to Step 4. aid.
connector.
4 connection.
as required.

sensor connector.
3. Short the common rail pressure sensor
connector power supply terminal and the
5 signal terminal using jump cable. 4.8V
Is the Common rail pressure sensor less than
common rail pressure sensor for short
box or DMM.
procedure.
6 Important:
If the common rail pressure sensor circuit is
may be broken.

required.
procedure.
7 Open circuit
High resistance
as required.
procedure.
8 Open circuit
High resistance
as required.

pressure sensor).
Note:
9

necessary.
Note:
11

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC

connector.
15 connection.
as required.
sensor connector.
16 4. Connect the DMM between the common 4.8V
rail pressure sensor power supply terminal
and the signal terminal.
Is the DMM indication less than the specified
About common rail pressure sensor About common rail pressure sensor


   
  
 
Name
1. GND
2. Signal
3. Power supply
Name
1. Breaker box
2. DMM

power supply measureme sensor 90 - Ground more
Key switch ON
connector signal
terminal
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Open circuit in injection nozzle #1 drive system
4HK1
       
   
   

   
 
     
               
               
       

       
           
            

   
   

 

6HK1
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 


The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and
energizes the pressurized voltage (more than 100 V) to
the injector. For injector operation, the voltage applied
to the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
 7. Cylinder block
 8. Engine front
Fuel injection is performed to each cylinder in the order

 of 1 5 3 6 2 4.
  Main trouble symptom

 Rough idling
Output lowering
Engine blow up fault
Preconditions when DTC is set

Main relay power supply voltage is 18V or more.

Name 70 rpm or more

1. Cylinder No. 1 DTC P0611, P1261, or P0201 is not detected.
2. Cylinder No. 2
3. Cylinder No. 3 DTC set condition
4. Cylinder No. 4
Open/short circuit is detected in No. 1 cylinder
5. Cylinder block
injector drive circuit.
6. Engine front
No. 1 cylinder injector monitor input signal does not
Fuel injection order is 1 3 4 2. exist for 3 seconds or more.
6HK1

 displayed depending on the machine
manufacturer)
Back-up mode

Injection for cylinder #1 stopped, EGR stopped



 Refer to List of diagnostic trouble code and About

failure.



 set condition (recovery from failure).
then ON again.
Diagnostic aid Poor connection of terminal from connector
If the intermittent trouble is suspected, followings may Unmatched terminals are fitted.
be the cause. Damage of connector lock
Improper connection of harness connector Poor contact between terminal and wire
Defective harness routing Damaged harness
Worn harness cladding Visually check the harness for damage.
Wire disconnection inside harness cladding Check the relevant items on the scan tool data
Following inspections are necessary to detect these display while moving the connector and the
causes. harness which are related to the sensor. The
Improper connection of harness connector and variation of the display indicates the faulty part.
ECM connector

1 system check, and
Check the DTC.
10 seconds.
2 2. Start the engine.
3. Check the DTC.
Go to Diagnostic
Is DTC detected? Go to Step 3. aid.
2. Remove the coupling connector (H 94)
from the cylinder head cover case.
3. Measure the resistance between the 0.45 0.1
3 coupling connector terminals (power (20 C)
supply terminal No. 1 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
ECM and coupling connector (H 94) using
breaker box or DMM.
procedure.
4 Open circuit
High resistance
required.
Check for installation condition of the injector
terminal nut.
2. Check the injector terminal nut for
5 looseness etc.
required.

Check for installation condition of the coupling
connector.
6 connection.
required.
injector terminal and coupling connector.
Open circuit
7 High resistance
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
connector.
2. Remove the ECM.
8 3. Check for play or looseness in the
connection.
required.
1. Replace the No. 1 cylinder injector.
Note:

necessary.
Note:
11


Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC

Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Remove the 119 - Coupling 100 or 10M or
high measureme coupling connector terminal less more
resistance nt connector. (H 94)
Key switch OFF (4H: No. 5,
6H: No. 2)
4HK1
       
   
   

   
 
     
               
               
       

       
           
            

   
   

 

6HK1
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 


2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
 8. Engine front

 of 1 5 3 6 2 4.

 Rough idling
Output lowering


Name 70 rpm or more

2. Cylinder No. 2
4. Cylinder No. 4
5. Cylinder block
6. Engine front
6HK1

manufacturer)
Back-up mode





failure.



then ON again.
ECM connector

1 system check, and
Check the DTC.
10 seconds.
3. Check the DTC.
Go to Diagnostic
breaker box or DMM.
procedure.
4 Open circuit
High resistance
required.
terminal nut.
5 looseness etc.
required.

connector.
6 connection.
required.
Open circuit
7 High resistance
as required.
connector.
2. Remove the ECM.
connection.
required.
Note:

necessary.
Note:
11


Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC

Name
1. Breaker box
2. DMM

high measureme coupling connector (H 94) less more
Key switch OFF (4H: No.7, 6H: No.7)
4HK1
       
   
   

   
 
     
               
               
       

       
           
            

   
   

 

6HK1
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 


2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
 8. Engine front

 of 1 5 3 6 2 4.

 Rough idling
Output lowering


Name 70 rpm or more

2. Cylinder No. 2
4. Cylinder No. 4
5. Cylinder block
6. Engine front
6HK1

manufacturer)
Back-up mode





failure.



then ON again.
ECM connector

1 system check, and
Check the DTC.
10 seconds.
3. Check the DTC.
Go to Diagnostic
breaker box or DMM.
procedure.
4 Open circuit
High resistance
required.
terminal nut.
5 looseness etc.
required.

connector.
6 connection.
required.
Open circuit
7 High resistance
as required.
connector.
2. Remove the ECM.
connection.
required.
Note:

necessary.
Note:
11


Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC

Name
1. Breaker box
2. DMM

Key switch OFF (4H: No. 6, 6H: No.
6)
4HK1
       
   
   

   
 
     
               
               
       

       
           
            

   
   

 

6HK1
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 


Cylinder No. and injection order 6HK1
4HK1






 

 Name
Name 1. Cylinder No. 1
1. Cylinder No. 1 2. Cylinder No. 2
5. Cylinder block 6. Cylinder No. 6
6. Engine front 7. Cylinder block
8. Engine front
Fuel injection order is 1 3 4 2.
of 1 5 3 6 2 4.

Rough idling
Output lowering

70 rpm or more
DTC P0612, P1262, or P0204 is not detected.
DTC set condition

exist for 3 seconds or more.

manufacturer)
Back-up mode Improper connection of harness connector
Injection for cylinder #4 stopped, EGR stopped Defective harness routing
Recovery from failure Wire disconnection inside harness cladding
Refer to List of diagnostic trouble code and About Following inspections are necessary to detect these
recovery from failure in this section for recovery from causes.
failure. Improper connection of harness connector and
ECM connector
The conditions to clear the MIL/DTC Poor connection of terminal from connector
The current trouble turns to past trouble (history) Unmatched terminals are fitted.
when the condition is out of the range from DTC Damage of connector lock
set condition (recovery from failure). Poor contact between terminal and wire
The diagnosis lamp will go off after the code turns Damaged harness
then ON again.
Diagnostic aid
be the cause.

1 system check, and
Check the DTC.
10 seconds.
3. Check the DTC.
Go to Diagnostic
2. Remove the coupling connector (4H: H
94, 6H: H 95) from the cylinder head
cover case.
3
coupling connector terminals (power (20 C)
ECM and coupling connector (4H: H 94,
6H: H 94) using breaker box or DMM.
procedure.
4 Open circuit
High resistance
required.

terminal nut.
5 looseness etc.
required.
connector.
6 connection.
required.
Open circuit
7 High resistance
as required.
connector.
2. Remove the ECM.
connection.
required.
Note:


necessary.
11 Note:

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC
Name
1. Breaker box
2. DMM

high measureme coupling connector terminal less more
resistance nt connector. (4H: H 94 No. 8,
Key switch OFF 6H: H 95 No. 2)
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 


Cylinder No. and injection order Back-up mode
 Recovery from failure


 failure.




 to history code and the key switch is turned OFF
then ON again.
 Using the scan tool, or memory clear switch and
 Diagnostic aid

Name If the intermittent trouble is suspected, followings may
1. Cylinder No. 1 be the cause.
2. Cylinder No. 2 Improper connection of harness connector
3. Cylinder No. 3 Defective harness routing
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6 Wire disconnection inside harness cladding
7. Cylinder block Following inspections are necessary to detect these
8. Engine front causes.
Fuel injection is performed to each cylinder in the order ECM connector
of 1 5 3 6 2 4. Poor connection of terminal from connector
Rough idling
Damaged harness
Output lowering
Main relay power supply voltage is 18V or more. variation of the display indicates the faulty part.
70 rpm or more
DTC set condition


manufacturer)

1 system check, and
Check the DTC.
10 seconds.
3. Check the DTC.
Go to Diagnostic
breaker box or DMM.
procedure.
4 Open circuit
High resistance
required.
terminal nut.
5 looseness etc.
required.
connector.
6 connection.
required.
Open circuit
7 High resistance
as required.

connector.
2. Remove the ECM.
connection.
required.
Note:

necessary.
Note:
11

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.

14 Go to each DTC

Name
1. Breaker box
2. DMM

resistance nt connector. No. 7 terminal
Key switch OFF
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 


Cylinder No. and injection order Back-up mode
 Recovery from failure


 failure.




 to history code and the key switch is turned OFF
then ON again.
 Using the scan tool, or memory clear switch and
 Diagnostic aid

Name If the intermittent trouble is suspected, followings may
1. Cylinder No. 1 be the cause.
2. Cylinder No. 2 Improper connection of harness connector
3. Cylinder No. 3 Defective harness routing
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6 Wire disconnection inside harness cladding
7. Cylinder block Following inspections are necessary to detect these
8. Engine front causes.
Fuel injection is performed to each cylinder in the order ECM connector
of 1 5 3 6 2 4. Poor connection of terminal from connector
Rough idling
Damaged harness
Output lowering
Main relay power supply voltage is 18V or more. variation of the display indicates the faulty part.
70 rpm or more
DTC set condition


manufacturer)

1 system check, and
Check the DTC.
10 seconds.
3. Check the DTC.
Go to Diagnostic
breaker box or DMM.
procedure.
4 Open circuit
High resistance
required.
terminal nut.
5 looseness etc.
required.
connector.
6 connection.
required.
Open circuit
7 High resistance
as required.

connector.
2. Remove the ECM.
connection.
required.
Note:

necessary.
Note:
11

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.

14 Go to each DTC

Name
1. Breaker box
2. DMM

resistance nt connector. No. 6 terminal
Key switch OFF
Overrun


 
 

 
 
 
                   
                 

  

 
  
 
   
   
   

          
 

Description of circuit Action taken when DTC is set

The engine control module (ECM) detects the engine Fault indication* is displayed on the monitor of the
speed based on the crankshaft position (CKP) sensor machine or diagnosis lamp comes on. (* Nothing is
signal. The ECM stops the fuel injection to lower the displayed depending on the machine
engine speed when the engine speed exceeds the manufacturer)
specified value.
Back-up mode
Main trouble symptom Limited injection amount 1
Output lowering Limitation is lifted if the speed decreases
Preconditions when DTC is set Recovery from failure

Key switch input voltage is 18V or more. Refer to List of diagnostic trouble code and About
DTC set condition failure.
The engine speed exceeds setting value* for 1
second or more (* depending on the machine
manufacturer)
The conditions to clear the MIL/DTC Diagnostic aid
The current trouble turns to past trouble (history) Load (fluid pressure pump etc.) is light.
when the condition is out of the range from DTC Crankshaft position (CKP) sensor, camshaft
set condition (recovery from failure). position (CMP) sensor fault (signal fault etc.)
The diagnosis lamp will go off after the code turns Engine body fault (supply pump, injector, body,
to history code and the key switch is turned OFF etc.)
then ON again. ECM internal trouble
Using the scan tool, or memory clear switch and Check the connector for poor contact, the harness
diagnostic switch operation enables to clear DTCs. for fault such as wear or bend, and the wire inside
the harness for loosened wire causing short circuit
to other circuits. Also, perform the function
diagnosis to check the operation and control of
each part. Repair if faulty.
When this DTC is detected, check the engine body
for trouble such as seizure and breakage.

1 Go to OBD
Confirm the driving status (improper operation
of the vehicle due to engine over speed).
2 (Interview the operator for driving status in the
past.)
Has the vehicle been operated improperly? Go to Step 3. Go to Step 4.
Tell the operator that it is the over speed
caused by improper operation, and give a
3 driving instruction.

Check for adverse effect (fault in the engine
body) caused by the engine over speed.
4 Repair or replace if fault is found.

1. Clear the DTC.
DTCs.
5 2. Turn the key switch to OFF for more than
10 seconds.
DTC is set.
4. Check the DTC.
Go to each DTC
Is DTC detected? diagnosis. Verify repair.
Boost sensor pressure fault (low voltage fault, open circuit)

 

 




       
       
    

    
         



Description of circuit The ECM provides 5 V to the boost pressure sensor

The boost pressure sensor is installed to the intake through 5-V power supply circuit, and grounds to the
manifold. The boost pressure sensor outputs the inside of the ECM through ground circuit. Also, the
voltage corresponding to the internal pressure of the boost pressure sensor outputs the signal voltage to the
intake manifold, and the ECM detects the boost by this ECM through boost pressure sensor signal circuit. The
signal. The boost pressure sensor includes following ECM detects a low boost condition (the engine load is
circuits. low) when the signal voltage from the boost pressure
sensor is low, and a high boost condition (the engine
5-V power supply circuit
load is high) when the signal voltage from the boost
Ground circuit pressure sensor is high.
Boost pressure sensor signal circuit The ECM sets the DTC when the signal voltage from
the boost pressure sensor is less than the normal
range.
Main trouble symptom Using the scan tool, or memory clear switch and
Operationality is affected. diagnostic switch operation enables to clear DTCs.
Preconditions when DTC is set Diagnostic aid
Key switch input voltage is 18V or more. If the intermittent trouble is suspected, followings may
be the cause.
DTC set condition Defective harness routing
Boost pressure sensor voltage is 0.1V or less for 3 Worn harness cladding
seconds or more. Wire disconnection inside harness cladding
Action taken when DTC is set causes.
Fault indication* is displayed on the monitor of the Improper connection of harness connector and
machine or diagnosis lamp comes on. (* Nothing is ECM connector
displayed depending on the machine Poor connection of terminal from connector
manufacturer) Unmatched terminals are fitted.
Back-up mode Poor contact between terminal and wire
Specified back-up value (depending on the Damaged harness
machine manufacturer) (4HK1) Visually check the harness for damage.
Boost pressure default setting (150kPa) (6HK1) Check the relevant items on the scan tool data
Boost pressure correction/EGR stopped (6HK1) display while moving the connector and the
Recovery from failure variation of the display indicates the faulty part.
recovery from failure in this section for recovery from Test description
failure. Numbers below indicate step numbers in the chart.
3. In the case of current trouble, the MAP (manifold
The conditions to clear the MIL/DTC absolute pressure) sensor displays less than the
The current trouble turns to past trouble (history) specified value. If more than the specified value,
when the condition is out of the range from DTC identify the cause by referring to Diagnostic aid.
set condition (recovery from failure). 5. If MAP (manifold absolute pressure) sensor
The diagnosis lamp will go off after the code turns displays more than the specified value when terminals
to history code and the key switch is turned OFF between the boost pressure sensor connector are
then ON again. shorted, the circuit beyond the sensor is normal
including ECM.

1 Go to OBD
2
2. Check for MAP (manifold absolute
pressure) sensor on the data display
3 using scan tool. 0.18V
Is the MAP (manifold absolute pressure) Go to Diagnostic

sensor less than the specified value? Go to Step 4. aid.

Check for installation condition of the boost
pressure sensor connector, ECM connector
and coupling connector.
4 connection.
required.
2. Disconnect the boost pressure sensor
connector.
3. Short between the boost pressure sensor
connector power supply terminal and the
signal terminal using jump cable.
5 4. Turn the key switch to ON. 4.8V
using scan tool.
Is the MAP (manifold absolute pressure)
sensor more than the specified value? Go to Step 8. Go to Step 9.
circuit between ECM and boost pressure
procedure.
6 Open circuit
High resistance
required.
between ECM and boost pressure sensor
using breaker box or DMM.
procedure.
Short circuit to boost pressure sensor
ground circuit
7
Open circuit
High resistance
required.
Replace the boost pressure sensor.
8

necessary.
10 Note:

Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
2. Check the display of boost pressure 508kPa
14 sensor. (Displayed
Does the display of Boost pressure sensor error value) Go to Diagnostic
15 connection.
required.

circuit between ECM and boost pressure
procedure.
16 Open circuit
High resistance
required.
procedure.
Short circuit to boost pressure sensor
ground circuit
17
Open circuit
High resistance
required.
About boost pressure sensor
  

Name
1. Sensor ground
2. Sensor signal
Characteristics of boost pressure sensor Breaker box inspection procedure
The output voltage of boost pressure sensor changes Perform the inspection in the following procedure if
according to the boost pressure. The scan tool with CAN there is such an instruction to use breaker box in the
communication displays a fixed value when the value step. After inspection, return to the diagnostic step.
more than the threshold value if the value of 40MPa or
350MPa is not changed.
When error occurs, error value (508MPa) is displayed.


Name
1. Breaker box
2. DMM

  


Key switch OFF
Key switch OFF
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Boost pressure sensor fault (high voltage fault, short to power supply circuit, open
ground circuit)

 

 




       
       
    

    
         



Description of circuit The ECM provides 5 V to the boost pressure sensor

The boost pressure sensor is installed to the intake through 5-V power supply circuit, and grounds to the
manifold. The boost pressure sensor outputs the inside of the ECM through ground circuit. Also, the
voltage corresponding to the internal pressure of the boost pressure sensor outputs the signal voltage to the
intake manifold, and the ECM detects the boost by this ECM through boost pressure sensor signal circuit. The
signal. The boost pressure sensor includes following ECM detects a low boost condition (the engine load is
circuits. low) when the signal voltage from the boost pressure
sensor is low, and a high boost condition (the engine
load is high) when the signal voltage from the boost
Ground circuit pressure sensor is high.
Boost pressure sensor signal circuit The ECM sets the DTC when the signal voltage from
the boost pressure sensor is more than the normal
range.

Black smoke emitted
Preconditions when DTC is set Diagnostic aid
Key switch input voltage is 18V or more. If the intermittent trouble is suspected, followings may
DTC P1630 or P1634 is not detected. be the cause.
DTC set condition Defective harness routing
Boost pressure sensor voltage is 4.9V or more for Worn harness cladding
3 seconds or more. Wire disconnection inside harness cladding
Action taken when DTC is set causes.
Fault indication* is displayed on the monitor of the Improper connection of harness connector and
machine or diagnosis lamp comes on. (* Nothing is ECM connector
displayed depending on the machine Poor connection of terminal from connector
manufacturer) Unmatched terminals are fitted.
Back-up mode
Specified back-up value (depending on the
Damaged harness
machine manufacturer) (4HK1)
Boost pressure default setting (150kPa) (6HK1)
Boost pressure correction/EGR stopped (6HK1)
recovery from failure in this section for recovery from Test description
failure.
3. In the case of current trouble, the MAP (manifold
absolute pressure) sensor displays more than the
The current trouble turns to past trouble (history) specified value. If less than the specified value, identify
when the condition is out of the range from DTC the cause by referring to Diagnostic aid.
set condition (recovery from failure). 5. If MAP (manifold absolute pressure) sensor
The diagnosis lamp turns off when the trouble code displays less than the specified value when the boost
turns to the past trouble. pressure sensor connector is removed, the circuit
Using the scan tool, or memory clear switch and beyond the sensor is normal including ECM.
diagnostic switch operation enables to clear past
trouble (history).

1 Go to OBD
2
3 using scan tool. 4.9V
Is the MAP (manifold absolute pressure) Go to Diagnostic

sensor more than the specified value? Go to Step 4. aid.
4 connection.
required.

connector.
5 4. Check for MAP (manifold absolute 0.1V
using scan tool.
Is the MAP (manifold absolute pressure)
sensor less than the specified value? Go to Step 8. Go to Step 6.
boost pressure sensor for short circuit to
the power supply circuit or ignition power
supply circuit using breaker box or DMM.
procedure.
6 Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.

required.
procedure.
7 Open circuit
High resistance
required.
Replace the boost pressure sensor.
8
necessary.
Note:
10


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
2. Check the display of boost pressure 508kPa
14 sensor. (Displayed
Does the display of Boost pressure sensor error value) Go to Diagnostic
15 connection.
required.
boost pressure sensor for short circuit to
the power supply circuit or ignition power
procedure.
16 Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.

required.

procedure.
17 Open circuit
High resistance
required.
About boost pressure sensor Characteristics of boost pressure sensor

The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with CAN
more than the threshold value if the value of 40MPa or
350MPa is not changed.
When error occurs, error value (508MPa) is displayed.
   Tech2 and scan tools with KW communication can



Name
1. Sensor ground
2. Sensor signal

  

Name
1. Breaker box
2. DMM

Key switch ON
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Crank sensor fault (no signal)


 
 

 
 
 
                   
                 

  

 
  
 
   
   
   

          
 


The crankshaft position (CKP) sensor detects the Cam pulse is normal.
engine speed. When the sensing hole installed in the DTC P0335, P0336, P0340, P0341, or P1345 is
flywheel passes the tip of the CKP sensor, a voltage is not detected.
generated and turned into a pulse signal. The engine Engine under operation
control module (ECM) reads this pulse signal, and
obtains the engine speed and injection timing based on DTC set condition
the signal.
Cam signal exists but no crank signal.
Output lowering
White smoke emitted
Intense engine vibration possible displayed depending on the machine
Engine stall possible (restart is possible when manufacturer)
camshaft position sensor is normal.)
Back-up mode
Control based on cam when cam sensor is normal
Recovery from failure Diagnostic aid
Refer to List of diagnostic trouble code and About If the intermittent trouble is suspected, followings may
recovery from failure in this section for recovery from be the cause.
failure. Improper connection of harness connector
The current trouble turns to past trouble (history) Wire disconnection inside harness cladding
when the condition is out of the range from DTC Following inspections are necessary to detect these
set condition (recovery from failure). causes.
The diagnosis lamp will go off after the code turns Improper connection of harness connector and
to history code and the key switch is turned OFF ECM connector
then ON again.
Damaged harness

1 Go to OBD
crankshaft position (CKP) sensor.
2. Visually check the sensor for installation
2 condition such as play or looseness.
required.
Check for installation condition of the CKP
3 connection.
as required.
1. Clear the DTC.
DTCs.
10 seconds.
4. Check the DTC.
Is DTC detected? Go to Step 5. Go to Step 12.

Check the CKP sensor body. Between
1. Turn the key switch to OFF. terminals:
2. Remove the harness from the CKP 108.5
sensor. 142.5 ; Each
5
terminal
3. Measure the resistance between the
ground: (at
sensor connector terminals.
normal
Is the resistance within the specified value? temperature) Go to Step 6. Go to Step 7.
ECM and CKP sensor using breaker box
or DMM.
procedure.
Open circuit
High resistance
Short circuit between terminals
Short circuit to power supply circuit or
as required.
Replace the CKP sensor.
7
necessary.
Note:
9

Replace the ECM.
Note:
10


2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
12 Go to each DTC
About CKP sensor 4HK1
 
Name
1. GND
2. Power supply
6HK1 6HK1
 
About CKP sensor and CMP sensor signals Name

1. CKP signal
4HK1 2. CMP signal


Name
1. Breaker box
2. DMM

high measureme sensor connector (-) less more
connector (+)
terminal
ground measureme sensor 107 - Ground more less
nt connector.
Key switch OFF
Short circuit Resistance Disconnect the 106 - 107 10M or 100 or
between measureme sensor more less
terminals nt connector.
Key switch OFF
power supply measureme sensor 107 - Ground more
Key switch ON
On-board check of sensors If both steps 1 and 2 are faulty, repair the
 If only step 1 is faulty, replace the sensor.
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Crank sensor fault (signal fault)


 
 

 
 
 
                   
                 

  

 
  
 
   
   
   

          
 


The crankshaft position (CKP) sensor detects the Cam pulse is normal.
engine speed. When the sensing hole installed in the DTC P0335, P0336, P0340, P0341, or P1345 is
flywheel housing passes the tip of the CKP sensor, a not detected.
voltage is generated and turned into a pulse signal. The Engine under operation
engine control module (ECM) reads this pulse signal,
and obtains the engine speed and injection timing DTC set condition
based on the signal.
Number of pulse for crank signal is mismatched.
Output lowering
White smoke emitted
Intense engine vibration possible displayed depending on the machine
Engine stall possible (restart is possible when manufacturer)
camshaft position sensor is normal.)
Back-up mode
Control based on cam when cam sensor is normal
Recovery from failure Diagnostic aid
Refer to List of diagnostic trouble code and About If the intermittent trouble is suspected, followings may
recovery from failure in this section for recovery from be the cause.
failure. Improper connection of harness connector
The current trouble turns to past trouble (history) Wire disconnection inside harness cladding
when the condition is out of the range from DTC Following inspections are necessary to detect these
set condition (recovery from failure). causes.
The diagnosis lamp will go off after the code turns Improper connection of harness connector and
to history code and the key switch is turned OFF ECM connector
then ON again.
Damaged harness

1 Go to OBD
crankshaft position (CKP) sensor.
required.
Check for installation condition of the CKP
3 connection.
as required.
1. Clear the DTC.
DTCs.
10 seconds.
4. Check the DTC.

1. Check the CKP sensor circuit for short
circuit to other signal circuit using breaker
box or DMM.
5 procedure.
as required.
Check the CKP sensor body.
1. Turn the key switch to OFF. Between
2. Remove the harness from the CKP terminals:
sensor. 108.5
3. Measure the resistance between the 142.5 ; Each
6
sensor connector terminals. terminal
ground: (at
4. Remove the CKP sensor, and check the
normal
sensor tip for scratch or damage.
temperature)
Is the CKP sensor normal? Go to Step 8. Go to Step 7.
Replace the CKP sensor.
7
1. Visually check the flywheel for chipped
tooth.
8 2. If the trouble is detected, replace it.

necessary.
10 Note:

Replace the ECM.
Note:
11


2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
 
Name
1. GND
2. Power supply
6HK1 6HK1
 
About CKP sensor and CMP sensor signals Name

1. CKP signal
4HK1 2. CMP signal


Name
1. Breaker box
2. DMM

5 Short circuit to Voltage Disconnect the 106 - Ground 0V 1V or more
Key switch ON
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Cam sensor fault (no signal)


 
 

 
 
 
                   
                 

  

 
  
 
   
   
   

          
 

Description of circuit Engine under operation

The camshaft position (CMP) sensor detects the
camshaft rotation and identifies the cylinder. When the DTC set condition
pulsar installed in the camshaft passes the tip of the Crank signal exists but no cam signal.
camshaft position (CMP) sensor, a voltage is generated
and turned into a pulse signal. The engine control Action taken when DTC is set
module (ECM) reads this pulse signal, and identifies Fault indication* is displayed on the monitor of the
the cylinder based on the signal. machine or diagnosis lamp comes on. (* Nothing is
Engine does not start (restart).
Behavior does not change during engine running. Back-up mode
Engine running based on crank when it is normal
Preconditions when DTC is set After engine stops: Unable to identify cylinder
Crank pulse is normal. (unable to restart)
DTC P0335, P0336, P0340, P0341, P1345, or
P1635 is not detected.
Recovery from failure Improper connection of harness connector
Refer to List of diagnostic trouble code and About Defective harness routing
recovery from failure in this section for recovery from Worn harness cladding
failure. Wire disconnection inside harness cladding
The conditions to clear the MIL/DTC causes.
The current trouble turns to past trouble (history) Improper connection of harness connector and
when the condition is out of the range from DTC ECM connector
set condition (recovery from failure). Poor connection of terminal from connector
The diagnosis lamp will go off after the code turns Unmatched terminals are fitted.
to history code and the key switch is turned OFF Damage of connector lock
then ON again.
Damaged harness
be the cause.

1 Go to OBD
Check for installation condition of the CMP
sensor.
required.
3 connection.
as required.
1. Clear the DTC.
DTCs.
10 seconds.
4. Check the DTC.
Remove the CMP sensor, and check the
5 sensor tip for scratch or damage.
Is the CMP sensor normal? Go to Step 6. Go to Step 9.

circuit between ECM and CMP sensor
procedure.
Open circuit
6
High resistance
as required.
between ECM and CMP sensor using
breaker box or DMM.
procedure.
Open circuit
7 High resistance
as required.
1. Check for followings in the shield circuit
between ECM and CMP sensor using
breaker box or DMM.
procedure.
Open circuit
8 High resistance
as required.
Replace the CMP sensor.
9
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing
gear.
10 3. If the trouble is detected, repair or replace
it.
Note:


necessary.
13 Note:

Replace the ECM.
Note:
14

2. Clear the DTC.
15 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
16 Go to each DTC
About camshaft position (CMP) sensor 6HK1


Name Name
1. Shield 1. CMP sensor
2.
3. +
About CKP sensor and CMP sensor signals
4HK1 4HK1





6HK1 Breaker box inspection procedure

Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM

Key switch OFF
ground measureme sensor more less
nt connector.
Key switch OFF
Key switch OFF
Key switch ON
high measureme sensor connector shield less more
Key switch OFF
Key switch ON
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Cam sensor fault (signal fault)


 
 

 
 
 
                   
                 

  

 
  
 
   
   
   

          
 

Description of circuit Engine under operation

The camshaft position (CMP) sensor detects the
camshaft rotation and identifies the cylinder. When the DTC set condition
pulsar installed in the camshaft passes the tip of the When unnecessary G sensor pulse is detected, or
CMP sensor, a voltage is generated and turned into a when shortage of G sensor pulse is detected.
pulse signal. The engine control module (ECM) reads
this pulse signal, and identifies the cylinder based on Action taken when DTC is set
the signal. Fault indication* is displayed on the monitor of the
Engine does not start (restart). manufacturer)
Behavior does not change during engine running.
Back-up mode
Preconditions when DTC is set Engine running based on crank when it is normal
Crank pulse is normal. After engine stops: Unable to identify cylinder
DTC P0335, P0336, P0340, P0341, P1345, or (unable to restart)
P1635 is not detected.
Recovery from failure Improper connection of harness connector
Refer to List of diagnostic trouble code and About Defective harness routing
recovery from failure in this section for recovery from Worn harness cladding
failure. Wire disconnection inside harness cladding
then ON again.
Damaged harness
be the cause.

1 Go to OBD
sensor.
required.
3 connection.
as required.
1. Clear the DTC.
DTCs.
10 seconds.
4. Check the DTC.
Remove the CMP sensor, and check the
5 sensor tip for scratch or damage.
Is the CMP sensor normal? Go to Step 6. Go to Step 8.

2. Remove the harness from the CMP
sensor.
3. Connect the breaker box or DMM between
6 the CMP sensor terminals. 0V
procedure.
Is the DMM indication specified value? Go to Step 8. Go to Step 7.
1. Check the CMP sensor circuit for short
circuit to other signal circuit using breaker
box or DMM.
7 procedure.
as required.
Replace the CMP sensor.
8
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing
gear.
9 3. If the trouble is detected, repair or replace
it.
Note:

necessary.
12 Note:


Replace the ECM.
Note:
13

2. Clear the DTC.
14 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
15 Go to each DTC
About CMP sensor 4HK1


Name
1. Shield
2.
3. +
6HK1 6HK1



 
Name Name
1. CMP sensor 1. CKP signal
2. CMP signal

4HK1 Breaker box inspection procedure

Name
1. Breaker box
2. DMM

other signal measureme sensor
Key switch ON
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Glow relay circuit fault



 



  

   

 


 
      
   
 
 
 
 
    
  

  





Note: Preconditions when DTC is set

The QOS circuit is the same for both the starter Key switch input power supply voltage is 16 V or
ECM control specifications and the safety relay more and 32 V or less.
specifications.
DTC set condition
Glow relay drive indication signal is unmatched
The glow relay cuts off the power supply voltage (24 V) with glow relay monitor signal.
to the glow plug, and turns ON when the signal from
ECM is input. The ECM recognizes the starter switch Action taken when DTC is set
ON signal, and outputs the ON signal to the glow
relay. Fault indication* is displayed on the monitor of the
manufacturer)
Startability deteriorates at low temperatures.
Back-up mode
No back-up operation (4HK1)
Specified back-up value (depending on the Wire disconnection inside harness cladding
machine manufacturer) (6HK1) Following inspections are necessary to detect these
causes.
Refer to List of diagnostic trouble code and About ECM connector
The diagnosis lamp turns off when the trouble code
turns to the past trouble.
Using the scan tool, or accelerator pedal operation variation of the display indicates the faulty part.
enables to clear past trouble (history).
Test description
Diagnostic aid
If the intermittent trouble is suspected, followings may 6. If the Glow relay displays ON when terminals
be the cause. between the glow relay are shorted, the circuit beyond
Improper connection of harness connector the relay is normal including ECM.
Defective harness routing 9. If the Glow relay displays OFF when the glow
Worn harness cladding relay is removed, the circuit beyond the relay is normal
including ECM.

1 Go to OBD
1. Turn the key switch to ON position.
2. Check for Glow relay on the data display
3 using scan tool.
Is the Glow relay displayed ON? Go to Step 4. Go to Step 5.

1. Turn the key switch to ON position.
2. Hold it for more than 10 seconds.
4 3. Check for Glow relay on the data display
using scan tool.
Go to Diagnostic
Is the Glow relay displayed OFF? aid. Go to Step 9.
Check for installation condition of the glow
relay, ECM connector and coupling connector.
5 connection.
required.

2. Remove the glow relay.
3. Short between the terminals 2 - 4 in the
glow relay installing portion using jump
6 cable.
using scan tool.
Is the Glow relay displayed ON? Go to Step 11. Go to Step 7.
the fuse and the glow relay.
Open circuit
Short circuit to ground circuit
7 High resistance
required.
glow relay and ECM using breaker box or
DMM.
procedure.
Open circuit
8
High resistance
required.
2. Remove the glow relay.
9
using scan tool.
Is the Glow relay displayed OFF? Go to Step 11. Go to Step 10.
1. Check the circuit between glow relay and
ECM for short circuit to the power supply
circuit or ignition power supply circuit
10 Refer to Breaker box inspection
procedure.
required.
Replace the glow relay.
11

necessary.
13 Note:

Replace the ECM.
Note:
14

2. Clear the DTC.
15 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
16 Go to each DTC
Check for installation condition of the glow
17 connection.
required.
Name
1. Breaker box
2. DMM

8 Open circuit/ Resistance Disconnect the 10 - FL 12 10M or 10M or
high measureme relay. connector terminal less more
resistance nt Key switch OFF No. 1
Short circuit to Resistance Disconnect the 10 - Ground 10M or 10M or

ground measureme relay. more less
nt Key switch OFF
power supply measureme relay. more
circuit nt Key switch ON
Glow plug lamp circuit fault

 



   
  
   
 
 
 

 
 

             




   
   

 

Description of circuit DTC set condition

The QOS indicator lamp is installed in the meter. The Glow lamp indication signal is unmatched with
engine control module (ECM) turns the QOS indicator glow lamp monitor signal.
lamp on to tell the glow plug operation when the key
switch is turned ON. The ECM detects the glow plug Action taken when DTC is set
operating condition, and turns the lamp off upon Fault indication* is displayed on the monitor of the
completion of preheat. machine or diagnosis lamp comes on. (* Nothing is
Operationality is not affected.
Back-up mode
Preconditions when DTC is set Back-up: No back-up action
DTC P0381 is not detected.
Damaged harness
The diagnosis lamp will go off after the code turns variation of the display indicates the faulty part.
then ON again. Test description
Using the scan tool, or memory clear switch and Numbers below indicate step numbers in the chart.
diagnostic switch operation enables to clear DTCs. 2. If the lamp does not come on with the key switch
ON, open circuit, short circuit to the ground circuit,
Diagnostic aid blown light bulb, or ECM fault is suspected.
If the intermittent trouble is suspected, followings may 2. If the lamp does not go OFF, short circuit to the
be the cause. ground circuit, meter circuit fault, or ECM fault is
Blown lamp bulb suspected.
Improper connection of harness connector 4. If the lamp goes off when the ECM connector is
removed, the circuit beyond the ECM is normal
including meter.
Worn harness cladding 7. If the lamp comes on when the lamp control terminal
Wire disconnection inside harness cladding is shorted to the ground, the circuit beyond the ECM is
Following inspections are necessary to detect these normal including meter.
causes.
ECM connector

1 system check, and
2 2. Check if the QOS indicator lamp is ON.
Turn the key switch ON and wait for 10
3 seconds. Does the QOS indicator lamp go Go to Diagnostic
OFF? aid. Go to Step 4.
2. Remove the connector from the ECM.
4 3. Turn the key switch to ON.
4. Check if the QOS indicator lamp is ON.
Does the QOS indicator lamp go OFF? Go to Step 12. Go to Step 5.
Check for installation condition of the meter,
ECM connector and coupling connector.
5 connection.
required.

1. Check the circuit between QOS indicator
lamp and ECM for ground short circuit
6 procedure.
required.
3. Short between the QOS indicator lamp
control terminal of the ECM and the
ground using breaker box.
procedure.
5. Check if the QOS indicator lamp is ON.
8 connection.
required.
the fuse and the QOS indicator lamp.
Open circuit
9 High resistance
required.
QOS indicator lamp and ECM using
breaker box or DMM.
procedure.
10 Open circuit
High resistance
required.
Replace the meter.
11
Replace the QOS indicator lamp bulb.
12

necessary.
14 Note:

Replace the ECM.
Note:
15

Check if DTC is not detected again.
2. Clear the DTC.
16 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Check if DTC is detected. (DTC for entire
engine control) Go to the related
17 Inspection method
Is DTC detected? by DTC. Verify repair.
Name
1. Breaker box
2. DMM

6 Short circuit to Resistance Remove the 11 - Ground 10M or 10M or
ground measureme meter connector. more less
nt Key switch OFF
10 Open circuit/ Resistance Remove the 11 - Meter 10M or 10M or
high measureme meter connector. connector QOS less more
resistance nt Key switch OFF indicator lamp
terminal
EGR position sensor fault


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 

Description of circuit The ECM provides 5 V to the EGR position sensors U,

The EGR position sensor is installed inside the EGR V, and W through 5-V power supply circuit, and grounds
valve. The EGR position sensor is the hall IC type to the inside of the ECM through ground circuit. Also,
sensor and is installed to 3 locations. It detects the the EGR position sensor outputs polarity (ON/OFF) of
motor phase based on each polarity output (ON/OFF). any one of the EGR position sensors U, V, and W
The EGR position sensor includes following circuits. through respective signal circuit, to the ECM. The ECM
detects the EGR valve position by counting the number
of change in polarity.
Ground circuit The ECM sets the DTC when all of the EGR position
EGR position sensor U signal circuit sensors U, V, and W output ON or OFF
EGR position sensor V signal circuit simultaneously.
EGR position sensor W signal circuit

Main relay input voltage is 18 V or more.
DTC set condition Diagnostic aid
Input signals from EGR position sensors U, V, and If the intermittent trouble is suspected, followings may
W are all ON or all OFF for 3 seconds or more. be the cause.
Action taken when DTC is set Defective harness routing
Fault indication* is displayed on the monitor of the Worn harness cladding
machine or diagnosis lamp comes on. (* Nothing is Wire disconnection inside harness cladding
displayed depending on the machine Following inspections are necessary to detect these
manufacturer) causes.
Back-up mode
ECM connector
Instruction to fully close EGR valve Poor connection of terminal from connector
The conditions to clear the MIL/DTC Check the relevant items on the scan tool data
Test description
then ON again. Numbers below indicate step numbers in the chart.
Using the scan tool, or memory clear switch and 3. Check all the signal circuits of the EGR position
diagnostic switch operation enables to clear DTCs. sensors U, V, and W.

1 Go to OBD
Check for installation condition of the EGR
valve connector, ECM connector and coupling
connector.
2 connection.
required.
ECM and EGR position sensor using
breaker box or DMM.
procedure.
Short circuit to EGR position sensor
ground circuit
3
Open circuit
High resistance
required.

2. Clear the DTC.
4 DTCs.
10 seconds, and then start the engine.
coolant temperature exceeds 80 C.
5. Check the DTC.
Go to Diagnostic
Is DTC P0487 detected? Go to Step 5. aid.
Replace the EGR valve (EGR position sensor).
Note:

2. Clear the DTC.
6 DTCs.
5. Check the DTC.
necessary.
Note:
8


Replace the ECM.
Note:
9

2. Clear the DTC.
10 DTCs.
10 seconds.
5. Check the DTC.
11 Go to each DTC
About EGR position sensor Breaker box inspection procedure


Name
1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V Name
4. Position sensor signal U 1. Breaker box
5. Position sensor ground 2. DMM
6. Motor drive W
7. Motor drive V
8. Motor drive U

3 Open circuit/ Resistance Disconnect the 87 - EGR valve 100 or 10M or
high measureme EGR valve connector sensor less more
resistance nt connector. power supply
Key switch OFF terminal

ground circuit/ measureme EGR valve 93 - 101 more less
ground nt connector. 94 - 101
Key switch OFF 92 - Ground
93 - Ground
94 - Ground
Open circuit/ Resistance Disconnect the 92 - EGR valve 100 or 10M or
high measureme EGR valve connector position less more
resistance nt connector. sensor signal W
93 - EGR valve
connector position
sensor signal V
terminal
94 - EGR valve
connector position
sensor signal U
terminal
On-board check of sensors 3. Check the harness from coupling connector for
open circuit.
 If both steps 1 and 2 are faulty, repair the
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

EGR valve control fault


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 


The EGR motor is installed inside the EGR valve. The Operationality is not affected.
EGR motor is the brushless DC motor, and is driven by
three phases. The EGR position sensor includes Preconditions when DTC is set
following circuits. DTC P1630, P1635, P0487, P0488, or P1635 is
EGR motor drive circuit U not detected.
EGR motor drive circuit V Main relay input power supply voltage is higher
EGR motor drive circuit W than 20 V but lower than 32 V.
The ECM drives the EGR motor through the EGR Difference between target EGR opening angle and
motor drive circuits U, V, and W. The ECM outputs drive actual one is 20% or less.
signals by the switching inside the ECM, and the motor
rotates with the combination of three-phase signals. DTC set condition
Also, the valve opening angle is controlled by duty.
Difference between target valve lift and actual
The ECM sets the DTC when the EGR motor drive duty
position is more than 20% for 10 seconds or more.
is high and the difference between the target EGR
position and actual EGR position is large.
Back-up mode
Instruction to fully close EGR valve Following inspections are necessary to detect these
causes.
failure.
set condition (recovery from failure). Visually check the harness for damage.
The diagnosis lamp will go off after the code turns Check the relevant items on the scan tool data
to history code and the key switch is turned OFF display while moving the connector and the
then ON again. harness which are related to the sensor. The
Test description
5. Check all the EGR motor drive circuits U, V, and W.

1 Go to OBD
2
1. Perform EGR control test using scan
tool.
3 2. Press the Up Down soft key. 3%
3. Check the value for EGR position.
Is EGR position within the specified value? Go to Step 4. Go to Step 5.
1. Clear the DTC.
DTCs.
4. Check the DTC.
Go to Diagnostic

1. Check for followings in the motor drive
circuit between ECM and EGR motor
procedure.
Open circuit
High resistance
required.
Note:

2. Clear the DTC.
7 DTCs.
5. Check the DTC.
necessary.
Note:
9


Replace the ECM.
Note:
10

2. Clear the DTC.
11 DTCs.
10 seconds.
5. Check the DTC.
12 Go to each DTC
2. Check the EGR valve for anchoring,
clogging, etc.
required.
About EGR valve Name

1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V
4. Position sensor signal U
5. Position sensor ground
6. Motor drive W
7. Motor drive V
8. Motor drive U

EGR valve check Breaker box inspection procedure


Name
1. Breaker box
2. DMM

power supply measureme EGR valve 103 - Ground more
circuit nt connector. 110 - Ground
Key switch ON
ground measureme EGR valve 103 - Ground more less
nt connector. 110 - Ground
Key switch OFF
Open circuit/ Resistance Disconnect the 111 - EGR valve 100 or 10M or
high measureme EGR valve connector motor less more
resistance nt connector. drive U terminal
Key switch OFF 103 - EGR valve
connector motor
drive V terminal
110 - EGR valve
connector motor
drive W terminal
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 


The engine oil pressure sensor detects the engine oil Operationality is not affected.
pressure. The engine oil pressure sensor is installed
near the starter motor of the cylinder block. The Preconditions when DTC is set
resistance value in the engine oil pressure sensor Key switch input voltage is 18V or more.
changes according to the pressure. If the pressure is
high, the resistance becomes low; if the pressure is low,
the resistance becomes high.
DTC set condition
The engine control module (ECM) is connected to the
engine pressure sensor via power supply circuit, signal Engine oil pressure sensor voltage is 0.1V or less
circuit and ground circuit, and energizes +5 V power for 4 seconds or more.
supply to the power supply circuit. The ECM detects the
signal voltage change in response to the change in Action taken when DTC is set
resistance according to the engine pressure sensor Fault indication* is displayed on the monitor of the
pressure (If the pressure is high, the voltage becomes machine or diagnosis lamp comes on. (* Nothing is
high; if the pressure is low, the voltage becomes low) as displayed depending on the machine
a signal. manufacturer)
Back-up mode Improper connection of harness connector and
Back-up: No back-up action ECM connector
Diagnostic aid 3. In the case of current trouble, the Engine oil
If the intermittent trouble is suspected, followings may pressure sensor displays more than the specified
be the cause. value. In this case, identify the cause by referring to
Improper connection of harness connector Diagnostic aid.
Defective harness routing 5. If the Engine oil pressure sensor displays more
than the specified value when the ECT sensor
connector is removed, the circuit beyond the sensor is
Wire disconnection inside harness cladding normal including ECM.
causes.

1 system check, and
2
Check the value for engine oil pressure sensor
using scan tool.
3 0.1V
3. Check the value for Engine oil pressure
Is the Engine oil pressure sensor less than Go to Diagnostic
Check for installation condition of the engine oil
pressure sensor, ECM and coupling connector.
4 connection.
as required.

2. Disconnect the engine oil pressure sensor
connector.
5 0V
Is the Engine oil pressure sensor more than
between ECM and engine oil pressure
procedure.
6 Short circuit to engine oil pressure
as required.
Replace the engine oil pressure sensor.
7
necessary.
Note:
9

Replace the ECM.
Note:
10


2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
2. Check the display of engine oil pressure. 1016kPa
12 (Displayed
Does the display of engine oil pressure show error value) Go to Diagnostic
13 connection.
as required.
procedure.
14 Short circuit to engine oil pressure
as required.
About engine oil pressure sensor Breaker box inspection procedure
  

Name
1. Sensor ground
2. Sensor signal
1. Breaker box
Characteristics of engine oil pressure sensor 2. DMM
The output voltage of engine oil pressure sensor

changes according to the engine oil pressure. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage.
the value of 0kPa or 1088.5kPa is not changed.
display both physical value and voltage.



  


ground circuit/ measureme sensor 67 - GND more less
ground nt connector. 80 - 79
Key switch OFF 80 - GND
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Engine oil pressure sensor fault (high voltage fault, short to power supply, open ground
circuit)
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 

Description of circuit The engine control module (ECM) is connected to the

The engine oil pressure sensor detects the engine oil engine pressure sensor via power supply circuit, signal
pressure. The engine oil pressure sensor is installed circuit and ground circuit, and energizes +5 V power
near the starter motor of the cylinder block. The supply to the power supply circuit. The ECM detects the
resistance value in the engine oil pressure sensor signal voltage change in response to the change in
changes according to the pressure. If the pressure is resistance according to the engine pressure sensor
high, the resistance becomes low; if the pressure is low, pressure (If the pressure is high, the voltage becomes
the resistance becomes high. high; if the pressure is low, the voltage becomes low) as
a signal.


DTC P1633 is not detected. Improper connection of harness connector
DTC set condition Worn harness cladding
Engine oil pressure sensor voltage is 4.85V or Wire disconnection inside harness cladding
more for 4 seconds or more. Following inspections are necessary to detect these
causes.
Action taken when DTC is set Improper connection of harness connector and
Fault indication* is displayed on the monitor of the ECM connector
machine or diagnosis lamp comes on. (* Nothing is Poor connection of terminal from connector
displayed depending on the machine Unmatched terminals are fitted.
manufacturer)
Back-up mode Poor contact between terminal and wire
Damaged harness
Back-up: No back-up action
Recovery from failure Check the relevant items on the scan tool data
failure.
Test description
3. In the case of current trouble, the Engine oil
pressure sensor displays more than the specified
value. In this case, identify the cause by referring to
Using the scan tool, or memory clear switch and Diagnostic aid.
diagnostic switch operation enables to clear DTCs. 5. If the Engine oil pressure sensor displays less than
the specified value when terminals between the engine
Diagnostic aid oil pressure sensor connector are shorted, the circuit
If the intermittent trouble is suspected, followings may beyond the sensor is normal including ECM.
be the cause.

1 system check, and
2
Check the value for engine oil pressure sensor
using scan tool.
3 4.85V
Is the Engine oil pressure sensor more than Go to Diagnostic
4 connection.
as required.

connector.
3. Short the engine oil pressure sensor
connector signal terminal to the ground
5 terminal using jump cable. 0V
Is the Engine oil pressure sensor less than
engine oil pressure sensor for short circuit
to the power supply circuit or ignition
power supply circuit, using breaker box or
DMM.
procedure.
6 Important:
If the engine oil pressure sensor circuit is
may be broken.

required.
procedure.
7 Open circuit
High resistance
as required.
sensor, using breaker box or DMM.
procedure.
8 Open circuit
High resistance
as required.
Replace the engine oil pressure sensor.
9

necessary.
11 Note:

Replace the ECM.
Note:
12

2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
14 Go to each DTC
2. Check the display of engine oil pressure. 1016 kPa
15 (Displayed
Does the display of engine oil pressure show error value) Go to Diagnostic

engine oil pressure sensor for short circuit
DMM.
procedure.
16 Important:
If the engine oil pressure sensor circuit is
may be broken.

required.
procedure.
17 Open circuit
High resistance
as required.
procedure.
18 Open circuit
High resistance
as required.
About engine oil pressure sensor Breaker box inspection procedure
  

Name
1. Sensor GND
2. Sensor signal
1. Breaker box
Characteristics of engine oil pressure sensor 2. DMM
The output voltage of engine oil pressure sensor

changes according to the engine oil pressure. The scan
the value of 0kPa or 1088.5kPa is not changed.



  


6 Short circuit to Voltage Disconnect the 67 - GND 0V 18V or
Key switch ON
Key switch OFF
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
ROM fault
Description of circuit Back-up mode

The internal part of the ECM consists of ROM, Engine stopped
EEPROM, CPU, and Sub-CPU, which perform data
storage, data clear and various controls. Recovery from failure
The ECM sets the DTC when the ROM fault inside the Refer to List of diagnostic trouble code and About
ECM is detected. recovery from failure in this section for recovery from
failure.
Engine stopped The conditions to clear the MIL/DTC
DTC set condition when the condition is out of the range from DTC
ROM fault is detected. set condition (recovery from failure).
Action taken when DTC is set to history code and the key switch is turned OFF
Fault indication* is displayed on the monitor of the then ON again.
machine or diagnosis lamp comes on. (* Nothing is Using the scan tool, or memory clear switch and
displayed depending on the machine diagnostic switch operation enables to clear DTCs.
manufacturer)

1 Go to OBD
1. Clear the DTC.
DTCs.
10 seconds.
DTC is set.
4. Check the DTC.
Go to Diagnostic
necessary.
4 Note:


Replace the ECM.
Note:
5

6 Go to each DTC
EEPROM fault

The internal part of the ECM consists of ROM, Back-up: No back-up action
EEPROM, CPU, and Sub-CPU, which perform data
storage, data clear and various controls. Recovery from failure
The ECM sets the DTC when the EEPROM fault inside Refer to List of diagnostic trouble code and About
the ECM is detected. recovery from failure in this section for recovery from
failure.
Operationality is not affected. The conditions to clear the MIL/DTC
EEPROM fault is detected. set condition (recovery from failure).
Action taken when DTC is set to history code and the key switch is turned OFF
Fault indication* is displayed on the monitor of the then ON again.
machine or diagnosis lamp comes on. (* Nothing is Using the scan tool, or memory clear switch and
displayed depending on the machine diagnostic switch operation enables to clear DTCs.
manufacturer)

1 Go to OBD
1. Clear the DTC.
DTCs.
10 seconds.
DTC is set.
4. Check the DTC.
Go to Diagnostic
necessary.
4 Note:


Replace the ECM.
Note:
5

6 Go to each DTC
DTC: P0606 (Flash code 51/52)
CPU fault
Description of circuit Action taken when DTC is set

The internal part of the ECM consists of ROM, Fault indication* is displayed on the monitor of the
EEPROM, CPU, and Sub-CPU, which perform data machine or diagnosis lamp comes on. (* Nothing is
storage, data clear and various controls. displayed depending on the machine
The ECM sets the DTC when the CPU fault or Sub- manufacturer)
CPU fault inside the ECM is detected.
Back-up mode
Main trouble symptom Limited injection amount 2 (multi-injection stopped)
Output lowering SUB-CPU stops CPU.
Unable to start Limited injection amount 1

480 msec or more has elapsed after key switch Refer to List of diagnostic trouble code and About
ON. recovery from failure in this section for recovery from
Key switch input power supply voltage is higher failure.
than 16 V.
DTC set condition The current trouble turns to past trouble (history)
Sub-CPU detects main CPU fault in 100 msec after when the condition is out of the range from DTC
key switch ON. set condition (recovery from failure).
RUN-SUB pulse does not change for 20 msec or The diagnosis lamp will go off after the code turns
more. to history code and the key switch is turned OFF
then ON again.

1 Go to OBD
1. Clear the DTC.
DTCs.
10 seconds.
DTC is set.
4. Check the DTC.
Go to Diagnostic

necessary.
4 Note:

Replace the ECM.
Note:
5

6 Go to each DTC
Charge circuit fault (bank 1)


 

                   
   
 

   
 


The charge circuit inside the ECM is the voltage Main relay power supply voltage is 18V or more.
pressurizing circuit to apply voltage to the injector, and
is divided in to two systems (4H: 2 cylinders each, 6H: 3 DTC set condition
cylinders each). The charge circuit 1 supplies the power When charge circuit bank 1 voltage inside ECU is
supply voltage to the injectors (4H: No. 1, 2 cylinders, low for 1.5 seconds or more.
6H: No. 1, 2, 3 cylinders). The ECM sets the DTC when
the voltage in the charge circuit 1 is excessively high or Action taken when DTC is set
excessively low.
Main trouble symptom machine or diagnosis lamp comes on. (* Nothing is
Intense engine vibration manufacturer)
Rough idling
Output lowering Back-up mode
Engine blow up fault Common 1 stop (#1, #4 cylinders stopped), EGR
Engine stall possible stopped (4HK1)
Common 1 stop (#1, #2, #3 cylinders stopped), The conditions to clear the MIL/DTC
EGR stopped (6HK1) The current trouble turns to past trouble (history)
Recovery from failure set condition (recovery from failure).
Refer to List of diagnostic trouble code and About The diagnosis lamp will go off after the code turns
recovery from failure in this section for recovery from to history code and the key switch is turned OFF
failure. then ON again.

1 Go to OBD
1. Make sure all the communication between
ECU and scan tool is normal.
2. Make sure the system which require
3 programming operates normally.
3. Check the DTC.
between ECM terminals (1, 3, 4, 43, 62,
81) and ECM ground terminal (E2) using
breaker box or DMM.
4 Open circuit
High resistance
required.
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
5 intermittent trouble or poor contact.
required.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
6 81) for intermittent trouble or poor contact.
required.

necessary.
8 Note:

Replace the ECM.
Note:
9

2. Clear the DTC.
10 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
11 Go to each DTC
12 Is DTC P0611 detected? Go to Step 4. Go to Step 10.
Charge circuit fault (bank 2)


 

                   
   
 

   
 


The charge circuit inside the ECM is the voltage Main relay power supply voltage is 18V or more.
pressurizing circuit to apply voltage to the injector, and
is divided in to two systems (4H: 2 cylinders each, 6H: 3 DTC set condition
cylinders each). The charge circuit 2 supplies the power When ECU charge circuit bank 2 voltage is low for
supply voltage to the injectors (4H: No. 3, 4 cylinders, 1.5 seconds or more.
6H: No. 4, 5, 6 cylinders). The ECM sets the DTC when
the voltage in the charge circuit 2 is excessively high or Action taken when DTC is set
excessively low.
ECM turns the diagnosis lamp ON.
Back-up mode
Common 2 stop (#2, #3 cylinders stopped), EGR
Rough idling
stopped (4HK1)
Output lowering
Common 2 stop (#4, #5, #6 cylinders stopped),
Engine blow up fault EGR stopped (6HK1)
Engine stall possible
Recovery from failure The diagnosis lamp will go off after the code turns
Refer to List of diagnostic trouble code and About to history code and the key switch is turned OFF
recovery from failure in this section for recovery from then ON again.
failure. Using the scan tool, or memory clear switch and

1 Go to OBD
1. Make sure all the communication between
ECU and scan tool is normal.
2. Make sure the system which require
3 programming operates normally.
3. Check the DTC.
between ECM terminals (1, 3, 4, 43, 62,
81) and ECM ground terminal (E2) using
breaker box or DMM.
4 Open circuit
High resistance
required.
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
5 intermittent trouble or poor contact.
required.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
6 81) for intermittent trouble or poor contact.
required.

necessary.
8 Note:

Replace the ECM.
Note:
9

2. Clear the DTC.
10 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
11 Go to each DTC
12 Is DTC P0612 detected? Go to Step 4. Go to Step 10.
Check engine lamp circuit fault

 



   
  
   
 
 
 

 
 

             




   
   

 


The power supply voltage is supplied to the diagnosis Key switch input voltage is 18V or more.
lamp via key switch, and the signal from ECM will turn DTC P0650 is not detected.
the lamp on. The ECM turns the diagnosis lamp on
during lamp check with the key switch ON and when DTC set condition
DTC is detected. Also when the diagnosis connector is
No diagnosis lamp monitor signal exists for 1.5
connected, it blinks the diagnosis lamp according to the
seconds or more.
Back-up mode
The ECM sets the DTC when the output to the
diagnosis lamp does not match with the check engine Back-up: No back-up action
lamp operation.
Main trouble symptom Refer to List of diagnostic trouble code and About
Operationality is not affected. recovery from failure in this section for recovery from
failure.
The current trouble turns to past trouble (history) Poor contact between terminal and wire
set condition (recovery from failure). Visually check the harness for damage.
The diagnosis lamp will go off after the code turns Check the relevant items on the scan tool data
to history code and the key switch is turned OFF display while moving the connector and the
then ON again. harness which are related to the sensor. The
Test description
If the intermittent trouble is suspected, followings may 2. If the lamp does not come on with the key switch
be the cause. ON, open circuit, short circuit to the ground circuit,
Improper connection of harness connector blown light bulb, or ECM fault is suspected.
Defective harness routing 2. If the lamp does not go OFF, short circuit to the
ground circuit, meter circuit fault, or ECM fault is
suspected.
Wire disconnection inside harness cladding 4. If the lamp goes off when the ECM connector is
Following inspections are necessary to detect these removed, the circuit beyond the ECM is normal
causes. including meter.
Improper connection of harness connector and 7. If the lamp comes on when the lamp control terminal
ECM connector is shorted to the ground, the circuit beyond the ECM is
Poor connection of terminal from connector normal including meter.

1 system check, and
2 2. Check if the diagnosis lamp is ON.
Does the diagnosis lamp come on? Go to Step 3. Go to Step 7.
Turn the key switch ON and wait for 30 Go to Diagnostic
3
seconds. Does the diagnosis lamp go OFF? aid. Go to Step 4.
4 3. Turn the key switch to ON.
4. Check if the diagnosis lamp is ON.
Does the diagnosis lamp go OFF? Go to Step 12. Go to Step 5.
5 connection.
required.
1. Check the circuit between diagnosis lamp
and ECM for ground short circuit using
breaker box or DMM.
6 procedure.
required.

3. Short between the diagnosis lamp control
terminal of the ECM and the ground using
breaker box or DMM.
procedure.
5. Check if the diagnosis lamp is ON.
Does the diagnosis lamp come on? Go to Step 13. Go to Step 8.
8 connection.
required.
the fuse and the diagnosis lamp.
Open circuit
9 High resistance
required.
diagnosis lamp and ECM using breaker
box or DMM.
procedure.
10 Open circuit
High resistance
required.
Replace the meter.
11
Replace the diagnosis lamp bulb.
12

necessary.
14 Note:

Replace the ECM.
Note:
15

2. Clear the DTC.
16 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Check if DTC is detected. (DTC for entire
engine control) Go to the related
17 Inspection method
Is DTC detected? by DTC. Verify repair.
Name
1. Breaker box
2. DMM

6 Short circuit to Resistance Remove the 6 - Ground 10M or 100 or
ground measureme meter connector. more less
nt Key switch OFF
10 Open circuit/ Resistance Remove the 6 - Meter connector 100 or 10M or
high measureme meter connector. diagnosis lamp less more
resistance nt Key switch OFF terminal
No pump pressure feed (2nd stage)
 




 

Name
3. Electromagnetic pump 7. Injector
4. Pre-filter


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 


The supply pump sucks fuel from the fuel tank using the Intense engine vibration
trochoid-type feed pump located inside of the supply Rough idling
pump. The sucked fuel is sent through the SCV to the Output lowering
two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The SCV
opening angle controls the fuel flow; if the SCV drive Black smoke emitted
duty is large, the SCV opening angle becomes small Engine stall
resulting in less fuel flow. The ECM drives the SCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the SCV drive duty, or the
target fuel flow and target common rail pressure exceed
certain amount.
Fuel system filter
 
 











Name Fault indication* is displayed on the monitor of the
1. Fuel pump strainer machine or diagnosis lamp comes on. (* Nothing is
2. Pre-fuel filter displayed depending on the machine
3. Electromagnetic pump filter manufacturer)
4. Main fuel filter
5. Gauze filter Back-up mode
Filter clogging in the fuel system may establish the DTC Limited injection amount 3 (multi-injection stopped)
set condition. Check as required. Target RP upper limit (80MPa)

Key switch input voltage is 18V or more. Refer to List of diagnostic trouble code and About
DTC P0192, P0193, P1093, P0090, P1291, recovery from failure in this section for recovery from
P1292, or P1635 is not detected. failure.
Coolant temperature is 60 C or more, and 375 rpm
or more. The conditions to clear the MIL/DTC
Duty to SCV is 33% or less. set condition (recovery from failure).
Differential pressure feed is 28000mm3/sec or The diagnosis lamp will go off after the code turns
more. to history code and the key switch is turned OFF
Either of the above conditions and the following then ON again.
condition Using the scan tool, or memory clear switch and
At 1200rpm or more, actual rail pressure is 50MPa diagnostic switch operation enables to clear DTCs.
or more higher than target rail pressure for 5
seconds or more. Diagnostic aid
Followings are suspected as the cause.
Injector internal trouble
Supply pump internal trouble
Fuel system pipe fault (fuel leakage, clogging,
crush, etc.)
Fuel filter fault (clogging)
Fuel tank fault (clogging)
Pressure limiter trouble (operation under specified
pressure, degradation of sealability)
ECM trouble
Common rail pressure sensor trouble
Test description
5. When rise of fuel level or diesel fuel odor is
confirmed, fuel leakage in the injector portion may be
the cause of the DTC detection.
9. If the Common rail pressure sensor displays more
than the specified value when the common rail
1 Go to OBD
procedure.
clogging.
Check the clogging in the following
procedure.
Fuel filter (main fuel filter, pre-fuel filter,
2 gauze filter)
Fuel tank (pump strainer)
Fuel system pipe
2. Check the fuel pipe, fuel filter, and inside
cold temperature)
Check the electromagnetic pump.
1. Inspect the electromagnetic pump by
referring to the Electromagnetic pump
3 inspection procedure.
2. Repair or replace the faulty part.
Check for rise of fuel level in the oil level gauge
4 or light oil odor.
Check the connection of the fuel pipe in each
injector, and replace the injector if oil leakage is
confirmed.
5 Note:

6

Check the injector.
1. Clear the DTC.
DTCs.
7 3. Select the Actuator test from the menu.
1. Replace the injector in the cylinder of
which engine sound did not change when
it is stopped in step 9.
8 Note:

2. Check for Common rail pressure on the
3. Start the engine and run it at idle. At engine
4. Check for Common rail pressure on the stopping:
9 data display using scan tool. -30 MPa; At
5. Race it quickly for about 5 times. idling, racing:
6. Check for Common rail pressure on the 5 MPa
Is each value of Common rail pressure (at
engine stopped, idling and racing) around
sensor connector.
10 4.8V
Is the Common rail pressure sensor more

procedure.
required.
necessary.
Note:
13

Replace the ECM.
Note:
14

pressure sensor).
Note:
15

1. Clear the DTC.
DTCs.
16 3. Select the Actuator test from the menu. 5MPa
Common rail system.
of Common rail pressure.
Is Common rail pressure within the specified

Note:

2. Clear the DTC.
18 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
19 Go to each DTC
Check the injector using injector checker.
Refer to How to use injector checker in this
20 section for how to use injector checker.
About common rail pressure sensor Electromagnetic pump inspection procedure

1. Turn the key switch to ON, and check for pulsation
in the fuel hose.
It is normal if pulsation exists.
2. Disconnect the electromagnetic pump connector,
and connect 24V power supply to the
electromagnetic pump side to check if the pump
operates.
If it operates properly, there may be open
circuit, short circuit or poor contact in the
machine-side harness. Repair the faulty part,
and check again from Step 1.
  
If the electromagnetic pump does not operate,
replace the pump.

Name
1. Sensor ground
2. Sensor signal
4. Install the removed parts, and check again from
Step 1.




Name
1. Electromagnetic Pump
2. + terminal
3. terminal
3. Blow air into the inlet of the electromagnetic pump

with your mouth.
The internal seal may be stuck. Blow air to
eliminate sticking. Name
1. Breaker box
2. DMM

Name
1. Fuel inlet port
2. Fuel outlet port

Key switch ON
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Pressure limiter open
 




 

Name
4. Pre-filter


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 


The supply pump sucks fuel from the fuel tank using the Output lowering
trochoid-type feed pump located inside of the supply Hunting
pump. The sucked fuel is sent through the SCV to the
two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The SCV
opening angle controls the fuel flow; if the SCV drive
duty is large, the SCV opening angle becomes small
resulting in less fuel flow. The ECM drives the SCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the common rail pressure
increases to certain level then lowers sharply, as it
recognizes that the pressure limiter is activated.
Fuel system filter DTC set condition
When pressure limiter is opened.
 When the common rail pressure is more than
 200MPa for 1 second or more.
DTC set condition in the case of high common rail
pressure is described below.
Only P1095 is detected if the fuel pressure
 overshoots due to entry of air.









Name
1. Fuel pump strainer 
2. Pre-fuel filter 
3. Electromagnetic pump filter

4. Main fuel filter
5. Gauze filter

Filter clogging in the fuel system may establish the DTC
set condition. Check as required. Action taken when DTC is set
Preconditions when DTC is set Turns the diagnosis lamp ON.
Key switch input voltage is 18V or more. Back-up mode

DTC P1095, P0192, P0193, P1630, or P1635 is
Limited injection amount 1
not detected.
Output goes down to about 50% since fuel flow is
50 rpm or more
limited.

failure.

then ON again.
Diagnostic aid
Followings are suspected as the cause.
Air mixed in the high-pressure fuel pipe.
Injector internal trouble
Supply pump internal trouble
Fuel system pipe fault (clogging etc.)
Fuel filter fault (temporary clogging due to waxing Test description
at low temperatures, improper tightening of filter Numbers below indicate step numbers in the chart.
cartridge, etc.) 7. When rise of fuel level or diesel fuel odor is
Fuel tank fault (temporary clogging, air mixed due confirmed, fuel leakage in the injector portion may be
to fuel shortage, air mixed due to modified fuel pipe the cause of the DTC detection.
for additional tank etc.) 11. If the Common rail pressure sensor displays more
Pressure limiter trouble (operation under specified than the specified value when the common rail
pressure, degradation of sealability) pressure sensor connector is removed, the circuit
ECM trouble beyond the sensor is normal including ECM.
Common rail pressure sensor trouble
Running out of fuel

1 Go to OBD
1. Check and record the DTC.
2. Clear the DTC.
DTCs.
3. Check the fuel amount, and add fuel as
required. If fuel is low, P1095 may be
detected due to entry of air.
2 Note:
Bleeding air from fuel must be
performed correctly, following the
procedure.
4. Bleed air from the fuel.

5. Race it quickly for about 5 times.
Refer to
6. Check the DTC.
Diagnostic aid
Is DTC P1095 detected? Go to Step 3. and Go to Step 4.
Narrow down the cause.
1. Clear the DTC.
DTCs.
3 2. Connect another pipe to the supply pump
inlet duct, and test run while supplying
fuel. (At this time, replace the fuel hose
with a transparent hose to visually check
for air mixture in the fuel.)
3. Check the DTC.

procedure.
clogging.
procedure.
4 gauze filter)
Fuel system pipe
cold temperature)
5
6
2. Check for Differential fuel rail pressure
3. Start the engine and run it at idle. At engine
4. Check for Differential fuel rail pressure stopping:
7 on the data display using scan tool. -30 MPa, At
5. Race it quickly for about 5 times. idling, racing:
6. Check for Differential fuel rail pressure 5 MPa
Is each value of Fuel rail pressure (at engine
stopped, idling and racing) around the
sensor connector.
8 0V
Is the Common rail pressure sensor specified

procedure.
required.
necessary.
Note:
11

Replace the ECM.
Note:
12

pressure sensor).
Note:
13

1. Restore the machine.
3. Clear the DTC.
14 diagnosis in this section for how to clear
DTCs.
DTC is set.
5. Check the DTC.

1. Replace the common rail.
Note:

3. Clear the DTC.
15 Refer to How to clear diagnosis trouble
DTCs.
DTC is set.
5. Check the DTC.
1. Clear the DTC.
DTCs.
If Tech2 is available, go to step 3.
If Tech2 is not available, go to step 17.
16 5MPa
3. Select the Actuator test from the menu.
Common rail system.
of Differential fuel pressure.
Is Differential fuel rail pressure within the
Note:
Bleed air completely after the parts are
replaced. If air bleeding is not
17 sufficient, P1095 may be detected due
to overshoot of fuel pressure.

2. Clear the DTC.
18 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
19 Go to each DTC
sensor connector.
rail pressure sensor connector signal
terminal and the ground.
20 0V
Is the DMM indication specified value?
Note:
If the display of DMM is not specified value,
ECM side wiring, wrap-around in ECM or
short circuit may be the cause.
If it is specified value, ECM side wiring is
normal. Go to Step 13. Go to Step 9.
About common rail pressure sensor 3. Sensor power supply


  

  
Name
1. Sensor ground 
2. Sensor signal
Name
1. Breaker box
2. DMM

Key switch ON


machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.



Boost temperature sensor fault (low voltage fault, ground short)

 

 




       
       
    

    
         




The boost temperature sensor is installed to the intake Key switch input voltage is 18V or more.
manifold. The resistance value of boost temperature DTC P1634 is not detected.
sensor changes according to the temperature in intake
manifold. DTC set condition
The resistance is low when the intake air temperature is
Boost temperature sensor voltage is 0.1V or less
high, and is high when the temperature is low. The
for 4 seconds or more.
ECM energizes 5 V to the boost temperature sensor
through the pull up resistance, and calculates the boost
temperature from the change in voltage, to utilize
various control such as fuel injection control. If the Turns the diagnosis lamp ON.
becomes low; if the resistance is high (temperature is Back-up mode
low), the voltage becomes high. Back-up: No back-up action

failure.
The conditions to clear the MIL/DTC Poor connection of terminal from connector
when the condition is out of the range from DTC Damage of connector lock
set condition (recovery from failure). Poor contact between terminal and wire
The diagnosis lamp will go off after the code turns Damaged harness
to history code and the key switch is turned OFF Visually check the harness for damage.
then ON again.
Diagnostic aid
If the intermittent trouble is suspected, followings may Test description
be the cause. Numbers below indicate step numbers in the chart.
Improper connection of harness connector 3. In the case of current trouble, the Boost temperature
Defective harness routing sensor displays less than the specified value. If more
Worn harness cladding than the specified value, identify the cause by referring
Wire disconnection inside harness cladding to Diagnostic aid.
Following inspections are necessary to detect these 5. If the Boost temperature sensor displays more than
causes. the specified value when terminals between the boost
temperature sensor connector are shorted, the circuit
ECM connector

1 Go to OBD
2
2. Check for Boost temperature sensor on
3 the data display using scan tool. 0.1V
Is the Boost temperature sensor less than the Go to Diagnostic
temperature sensor connector, ECM connector
4 connection.
required.
2. Disconnect the boost temperature sensor
connector.
3. Short between the boost temperature
sensor connector ground terminal and the
5 signal terminal using jump cable. 4.8V
5. Check for Boost temperature on the data
display using scan tool.
Is the Boost temperature more than the

circuit between ECM and boost
temperature sensor, using breaker box or
DMM.
procedure.
6
Open circuit
High resistance
required.
between ECM and boost temperature
procedure.
Short circuit to boost temperature
7
Open circuit
High resistance
required.
Replace the boost temperature sensor.
8
necessary.
Note:
10

Replace the ECM.
Note:
11


2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
2. Check the display of boost temperature. 214 C
14 (Displayed
Does the display of Boost temperature show error value) Go to Diagnostic
15 connection.
required.
circuit between ECM and boost
temperature sensor, using breaker box or
DMM.
procedure.
16
Open circuit
High resistance
required.

procedure.
Short circuit to boost temperature
17
Open circuit
High resistance
required.
About boost temperature sensor The following illustration shows the correlation between



Name
1. Signal  
2. GND 
Characteristics of boost temperature sensor

The output voltage of boost temperature sensor
changes according to the boost temperature. The scan






                   



Name
1. Breaker box
2. DMM

Key switch OFF

ground circuit/ measureme sensor 74 - GND more less
Key switch OFF
Key switch OFF
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Boost temperature sensor fault (high voltage fault)

 

 




       
       
    

    
         




The boost temperature sensor is installed to the intake Key switch input voltage is 18V or more.
manifold. The resistance value of boost temperature DTC P1634 is not detected.
sensor changes according to the temperature in intake Coolant temperature is 50 C or more.
manifold.
3 (or 5) minutes have passed after engine starting
The resistance is low when the intake air temperature is
(depending on the machine manufacturer)
high, and is high when the temperature is low. The
ECM energizes 5 V to the boost temperature sensor
DTC set condition
through the pull up resistance, and calculates the boost
temperature from the change in voltage, to utilize Boost temperature sensor voltage is 4.95V or more
various control such as fuel injection control. If the for 4 seconds or more.
becomes low; if the resistance is high (temperature is Action taken when DTC is set
low), the voltage becomes high. Turns the diagnosis lamp ON.
Main trouble symptom Back-up mode

Operationality is not affected. Back-up: No back-up action
Recovery from failure Following inspections are necessary to detect these
Refer to List of diagnostic trouble code and About causes.
recovery from failure in this section for recovery from Improper connection of harness connector and
failure. ECM connector
The conditions to clear the MIL/DTC Unmatched terminals are fitted.
The current trouble turns to past trouble (history) Damage of connector lock
when the condition is out of the range from DTC Poor contact between terminal and wire
set condition (recovery from failure). Damaged harness
The diagnosis lamp turns off when the trouble code Visually check the harness for damage.
turns to the past trouble.
Diagnostic aid
If the intermittent trouble is suspected, followings may Test description
be the cause. Numbers below indicate step numbers in the chart.
Improper connection of harness connector 3. In the case of current trouble, the Boost temperature
Defective harness routing sensor displays more than the specified value. If less
Worn harness cladding than the specified value, identify the cause by referring
Wire disconnection inside harness cladding to Diagnostic aid.

1 Go to OBD
2
2. Check for Boost temperature sensor on
3 the data display using scan tool. 4.95V
Is the Boost temperature sensor more than Go to Diagnostic
4 connection.
required.

boost temperature sensor for short circuit
DMM.
procedure.
5 Important:
If the boost temperature sensor circuit is
may be broken.

required.
procedure.
6 Open circuit
High resistance
required.
Replace the boost temperature sensor.
7
necessary.
9 Note:

Replace the ECM.
Note:
10


2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
12 Go to each DTC
2. Check the display of boost temperature. 214 C
13 (Displayed
Does the display of Boost temperature show error value) Go to Diagnostic
14 connection.
required.
procedure.
15 Open circuit
High resistance
required.
About boost temperature sensor
Name
1. Signal
2. GND
Characteristics of boost temperature sensor
The output voltage of boost temperature sensor
changes according to the boost temperature. The scan 
tool with CAN communication displays a fixed value 

 







                   


Name
1. Breaker box
2. DMM

5 Short circuit to Voltage Disconnect the 74 - GND 0V 18V or
Key switch ON
Key switch OFF
Overheat
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 

The engine coolant temperature (ECT) sensor is
installed in the thermostat housing. The ETC sensor is
the thermistor-type sensor, and the value of resistance
and output voltage change according to the engine
coolant temperature. As the engine coolant
temperature increases, the resistance becomes small,
and the voltage lowers. The ECM detects the engine
coolant temperature based on the signal from the ECT
sensor to perform various controls.
The ECM sets the DTC when it judges that the engine
coolant temperature exceed certain level based on the
signal from the ECT sensor.
Main trouble symptom The conditions to clear the MIL/DTC
Output lowering The current trouble turns to past trouble (history)
Fuel flow is regulated during overheat when the when the condition is out of the range from DTC
temperature exceeds 108 C. set condition (recovery from failure).
then ON again.
Diagnostic aid

be the cause.


causes.

ECM connector

Preconditions when DTC is set Unmatched terminals are fitted.

DTC P1630, P1633, P0117, or P0118 is not
detected. Damaged harness
Engine under operation Visually check the harness for damage.
DTC set condition display while moving the connector and the
Engine coolant temperature is more than 120 C for
5 seconds or more.
Test description
Turns the diagnosis lamp ON.
4. If the Engine coolant temperature sensor displays
less than the specified value when the ECT sensor
Back-up mode
connector is removed, the sensor is faulty.
Back-up: No back-up action 9. If no DTC is detected, intermittent trouble is
suspected. Identify the cause by referring to
Recovery from failure Diagnostic aid.
failure.

1 Go to OBD
2 2. Check the DTC. Go to the relevant
Is DTC P0088, or P1093 detected? DTC detected. Go to Step 3.

4. Check for Engine coolant temperature
4 4.9V/ 40 C
sensor on the data display using scan
tool.
more than the specified value? Go to Step 6. Go to Step 5.
1. Check the signal circuit between ECT
sensor and ECM for short circuit to signal
circuits of other sensors using breaker box
or DMM.
procedure.
required.
1. Check the engine coolant amount.
2. If insufficient, add engine coolant.
3. Clear the DTC.
DTCs.
10 seconds.
5. Start the engine, and check the DTC.
1. Check for following mechanical defects.
(Refer to Cooling system of Engine
section in the service manual.)
Clogging of radiator
Defective radiator cap
Loose fan belt
7 Defective thermostat
Defective water pump
Defective cylinder head gasket
2. If the trouble is detected, adjust or replace
as required.
8

1. Clear the DTC.
DTCs.
10 seconds.
DTC is set.
4. Check the DTC.
Go to Diagnostic
necessary.
Note:
11

Replace the ECM.
Note:
12

13 Go to each DTC
14 4. Check the display of the Engine coolant 40 C
temperature.
Is the Engine coolant temperature more than
About ECT sensor The following illustration shows the correlation between
  Tech2 and scan tools with KW communication can



  


Name
 
1. Sensor GND (for engine control)
2. Sensor signal (for engine control) 
3. Sensor signal (for meter)
Characteristics of ECT sensor Perform the inspection in the following procedure if
The output voltage of ECT sensor changes according there is such an instruction to use breaker box in the
to the engine coolant temperature. The scan tool with step. After inspection, return to the diagnostic step.
CAN communication displays a constant value when
the value exceeds the threshold voltage. Therefore,
judge as it is more than the threshold value if shown as
40 C or 120 C.
Name
1. Breaker box
2. DMM

other signal measureme sensor
Key switch ON
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Idle UP/DOWN switch fault


    


    


           


     

     


The idling control switch is provided to adjust idle speed Key switch input voltage is 18V or more.
during warming-up, and is available for use when the
idling control selector switch is in Manual. The power DTC set condition
supply voltage is supplied to the idling control switch When both of idling control up signal and idling
through the key switch. By pressing the Up or Down, control down signal are ON.
each ground circuit is completed and the signal is input
to the ECM. Action taken when DTC is set
The ECM sets the DTC when the signal inputs are
detected for idling control switch Up side and Down Turns the diagnosis lamp ON.
side at the same time.
Back-up mode
Main trouble symptom Unable to change the speed in mode driving
Using the scan tool, or memory clear switch and Visually check the harness for damage.
Diagnostic aid
If the intermittent trouble is suspected, followings may variation of the display indicates the faulty part.
be the cause.
Fault in switch body Test description
Improper adjustment of switch Numbers below indicate step numbers in the chart.
Improper connection of harness connector 3. If the Idle up switch and Idle down switch display
Defective harness routing OFF when the idling control switch connector is
Worn harness cladding removed, the circuit is shorted between idle up circuit
and idle down circuit, or the switch is faulty.

1 Go to OBD
2. Disconnect the idling control switch
connector.
3 4. Check for Idle up switch and Idle down
switch on the data display using scan
tool.
Are the Idle up switch and Idle down switch
displayed OFF? Go to Step 6. Go to Step 4.
1. Check the idle up-side circuit between
idling control switch and ECM for short
box or DMM.
procedure.
required.

1. Check the idle down-side circuit between
idling control switch and ECM for short
box or DMM.
procedure.
required.
Replace the idling control switch.
6
necessary.
Note:
8

Replace the ECM.
Note:
9

2. Clear the DTC.
DTCs.
4. Check the DTC.
11 Go to each DTC
About idling control switch
Note:
Refer to the machines manual for installing
position of the idling control switch.

Name
1. Breaker box
2. DMM

power supply measureme switch connector. more
power supply measureme switch connector. more
Injection nozzle common 1 drive system fault
4HK1
       
   
   

   
 
     
               
               
       

       
           
            

   
   

 

6HK1
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 



The COMMON circuit is provided to supply the power Main relay power supply voltage is 18V or more.
supply voltage pressurized in the charge circuit inside 70 rpm or more
the ECM to the injector, and is divided in to two systems None of the following DTC sets are detected; DTC
(4H: 2 cylinders each, 6H: 3 cylinders each). The P0611 and P1261 and P201; DTC P0611 and
COMMON 1 circuit supplies the power supply voltage P1261 and P0202; DTC P0611 and P1261 and
to the injectors (4H: No. 1, No. 2 cylinders, 6H: No. 1, P0203.
No. 2, No. 3 cylinders). The ECM sets the DTC when
faults are detected simultaneously for all the injector DTC set condition
drive circuits of COMMON 1 system.
None of injector monitor input signal for COMMON
Main trouble symptom 1 system exists for 3 seconds or more.
Intense engine vibration Action taken when DTC is set

Rough idling
Output lowering
Engine blow up fault Back-up mode
Engine stall possible Common 1 stop (#1, #4 cylinders stopped), EGR
stopped (4HK1)
Common 1 stop (#1, #2, #3 cylinders stopped), EGR Improper connection of harness connector
stopped (6HK1) Defective harness routing
ECM connector
to history code and the key switch is turned OFF Damaged harness
then ON again. Visually check the harness for damage.
Using the scan tool, or memory clear switch and Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs. display while moving the connector and the
Diagnostic aid variation of the display indicates the faulty part.
be the cause.

1 Go to OBD
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Connect the DMM between the injector
power supply 1 circuit and the ground.
2 7.0V
4H: H94 female-side No. 1
3. Measure the resistance between the
3 injector harness connector terminals. 1.0
4H: H94 male-side No. 1 and No. 4
harness connector, ECM connector and
coupling connector.
4 connection.
required.

1. Check for followings in the injector power
supply 1 circuit using breaker box or DMM.
procedure.
Open circuit
5 High resistance
required.
3. Measure the resistance between the No. 1
cylinder injector drive circuit and the
6 ground. 10M
4H: H94 male-side No. 5
Is the resistance more than the specified
cylinder (4H: No. 4 cylinder) injector drive
7 circuit and the ground. 10M
Is the resistance more than the specified 4H: Go to Step 12.
value? 6H: Go to Step 8. Go to Step 10.
8 cylinder injector drive circuit and the 10M
ground.
1. Check the No. 1 cylinder injector drive
circuit between ECM and coupling
connector (H-94) for ground short circuit
procedure.
required.

1. Check the No. 2 cylinder (4H: No. 4
cylinder) injector drive circuit between
ECM and coupling connector (H-94) for
ground short circuit, using breaker box or
DMM.
procedure.
required.
procedure.
required.
2. Check for installation condition of the
injector harness.
required.
1. Remove the injector harness from the
injector.
4H: No. 1 cylinder, No. 4 cylinder
6H: No. 1 cylinder, No. 2 cylinder, No. 3
13 cylinder 10M
2. Measure the resistance between each
injector terminal and the ground.
2. Remove the injector-side harness
connector from the coupling connector (H-
94).
3. Connect the DMM between the No. 1
14 cylinder injector drive circuit and the 0V
ground.

94).
15 circuit and the ground. 0V
Is the DMM indication more than the specified 4H: Go to Step 17.
value? Go to Step 19. 6H: Go to Step 16.
94).
ground.
94).
17 power supply 1 circuit and the ground. 7.0V
connector (H-94) for short circuit to the
power supply circuit or ignition power
procedure.
required.

ECM and coupling connector (H-94) for
short circuit to the power supply circuit or
ignition power supply circuit, using breaker
19 box or DMM.
procedure.
required.
supply circuit, using breaker box or DMM.
procedure.
required.
1. Check the injector power supply 1 circuit
between ECM and coupling connector (H-
94) for short circuit to the power supply
procedure.
required.
Replace the injector harness.
22
Replace the injector.
Note:


necessary.
25 Note:

Replace the ECM.
Note:
26

2. Clear the DTC.
27 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
28 Go to each DTC
Name
1. Breaker box
2. DMM

5 Open circuit/ Resistance Remove the 121 - Female-side 100 or 10M or
high measureme ECM-side terminal less more
resistance nt harness (4H: No. 1, 6H: No.
connector from 3)
the coupling
connector.
Key switch OFF
Short circuit to Resistance Remove the 121 - Ground 10M or 100 or
ground measureme ECM-side more less
nt harness
connector from
the coupling
connector.
Key switch OFF
nt harness
connector from
the coupling
connector.
Key switch OFF

nt harness
connector from
the coupling
connector.
Key switch OFF
nt harness
connector from
the coupling
connector.
Key switch OFF
18 Short circuit to Voltage Remove the 119 - Ground 0V 18V or
power supply measureme ECM-side more
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
Injection nozzle common 2 drive system fault
4HK1
       
   
   

   
 
     
               
               
       

       
           
            

   
   

 

6HK1
     

     
           
     
  
        
                   
                   
         
         
               
               
     

     
     

 



The COMMON circuit is provided to supply the power Main relay power supply voltage is 18V or more.
supply voltage pressurized in the charge circuit inside 70 rpm or more
the ECM to the injector, and is divided in to two systems None of the following DTC sets are detected;
(4H: 2 cylinders each, 6H: 3 cylinders each). The P0612, P1262 and P0204; P0612, P1262 and
COMMON 2 circuit supplies the power supply voltage P0205; P0612, P1262 and P0206.
to the injectors (4H: No. 3, No. 4 cylinders, 6H: No. 4,
No. 5, No. 6 cylinders). The ECM sets the DTC when DTC set condition
faults are detected simultaneously for all the injector
drive circuits of COMMON 2 system. None of injector monitor input signal for COMMON
2 system exists for 3 seconds or more.
Rough idling
Output lowering Back-up mode
Common 2 stop (#2, #3 cylinders stopped), EGR
Engine stall possible stopped (4HK1)
Common 2 stop (#4, #5, #6 cylinders stopped), EGR Improper connection of harness connector
stopped (6HK1) Defective harness routing
ECM connector
to history code and the key switch is turned OFF Damaged harness
then ON again. Visually check the harness for damage.
Using the scan tool, or memory clear switch and Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs. display while moving the connector and the
Diagnostic aid variation of the display indicates the faulty part.
be the cause.

1 Go to OBD
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
(4H: H-94, 6H: H-95).
3 3. Measure the resistance between the 1.0
injector harness connector terminals.
harness connector, ECM connector and
coupling connector.
4 connection.
required.

1. Check for followings in the injector power
supply 2 circuit using breaker box or DMM.
procedure.
Open circuit
5 High resistance
required.
(4H: H-94, 6H: H-95).
6 cylinder (4H: No. 2 cylinder) injector drive 10M
circuit and the ground.
(4H: H-94, 6H: H-95).
7 cylinder (4H: No. 3 cylinder) injector drive 10M
Is the resistance more than the specified 4H: Go to Step 12.
value? 6H: Go to Step 8. Go to Step 10.
8 cylinder injector drive circuit and the 10M
ground.
ECM and coupling connector (4H: H-94,
6H: H-95) for ground short circuit using
breaker box or DMM.
procedure.
required.

6H: H-95) for ground short circuit using
breaker box or DMM.
procedure.
required.
procedure.
required.
2. Check for installation condition of the
injector harness.
required.
1. Remove the injector harness from the
injector.
4H: No. 2 cylinder, No. 3 cylinder
6H: No. 4 cylinder, No. 5 cylinder, No. 6
13 cylinder 10M
2. Measure the resistance between each
injector terminal and the ground.
(4H: H-94, 6H: H-95).
14 cylinder (4H: No. 2 cylinder) injector drive 0V

(4H: H-94, 6H: H-95).
15 circuit and the ground. 0V
Is the DMM indication more than the specified 4H: Go to Step 17.
value? Go to Step 19. 6H: Go to Step 16.
95).
ground.
(4H: H-94, 6H: H-95).
6H: H-95) for short circuit to the power
18 circuit, using breaker box or DMM.
procedure.
required.

6H: H-95) for short circuit to the power
19 circuit, using breaker box or DMM.
procedure.
required.
procedure.
required.
1. Check the injector power supply 2 circuit
between ECM and coupling connector
(4H: H-94, 6H: H-95) for short circuit to the
procedure.
required.
Replace the injector harness.
22
Replace the injector.
Note:


necessary.
25 Note:

Replace the ECM.
Note:
26

2. Clear the DTC.
27 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
28 Go to each DTC
Name
1. Breaker box
2. DMM

5 Open circuit/ Resistance Remove the 116 - Female-side 100 or 10M or
high measureme ECM-side terminal less more
resistance nt harness (4H: H94 No.3, 6H:
connector from H95 No.3)
the coupling
connector.
Key switch OFF
Short circuit to Resistance Remove the 116 - Ground 10M or 100 or
nt harness
connector from
the coupling
connector.
Key switch OFF
nt harness
connector from
the coupling
connector.
Key switch OFF

nt harness
connector from
the coupling
connector.
Key switch OFF
nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
circuit nt harness
connector from
the coupling
connector.
Key switch OFF
Accelerator sensor 1-2 comparison fault
  

 
   
   
 
 

   
                 


 
     
                     
  

 

Description of circuit The ECM provides 5 V to the AP sensor through 5-V

The accelerator position (AP) sensor is installed to the power supply circuit, and grounds to the inside of the
accelerator pedal. The AP sensor is the potentiometer- ECM through ground circuit. Also, the AP sensor
type sensor, and the value of output voltage changes outputs the signal voltage to the ECM through AP
according to the accelerator opening angle. Two AP sensor signal circuit. When the accelerator opening
sensors are installed, each of which includes following angle is large, the AP sensor 1 outputs high voltage,
circuits. whereas the AP sensor 2 outputs low voltage.
The ECM sets the DTC when the difference in the
accelerator opening angle is large between which is
Ground circuit detected based on the AP sensor 1 signal, and which is
AP sensor signal circuit detected based on the AP sensor 2 signal.

1 system fault: No backup
2 systems fault: Accelerator opening angle is controlled
to 0%.
Preconditions when DTC is set The diagnosis lamp will go off after the code turns
Key switch input voltage is 18V or more. to history code and the key switch is turned OFF
then ON again.
DTC P1630, P1631, P1271, P1277, P1278,
P1282, or P1283 is not detected. Using the scan tool, or memory clear switch and
DTC set condition
Diagnostic aid
Difference in opening angle between accelerator
sensors 1 and 2 is 45% or more for 3 seconds or more. If the intermittent trouble is suspected, followings may
be the cause.
[Accelerator sensor 1 voltage + Accelerator sensor
2 voltage] is higher than 6.4 V. Improper connection of harness connector
[Accelerator sensor 1 voltage + Accelerator sensor Defective harness routing
2 voltage] is lower than 3.6 V. Worn harness cladding
Action taken when DTC is set Following inspections are necessary to detect these
The diagnosis lamp does not come on. causes.
Back-up mode ECM connector
1 system fault...No back-up Poor connection of terminal from connector
2 system fault...Accelerator opening angle is Unmatched terminals are fitted.
controlled to 0%. Damage of connector lock
Recovery from failure Damaged harness
Refer to List of diagnostic trouble code and About Visually check the harness for damage.
recovery from failure in this section for recovery from Check the relevant items on the scan tool data
failure. display while moving the connector and the
The conditions to clear the MIL/DTC variation of the display indicates the faulty part.
when the condition is out of the range from DTC Test description
set condition (recovery from failure). Numbers below indicate step numbers in the chart.
3. Measure at the harness connector-side.

1 Go to OBD
10 seconds.
3. Check the DTC.
Go to Diagnostic
2. Disconnect the AP sensor connector.
3. Connect the DMM between the sensor
power supply terminal of the AP sensor
3 connector and the ground. 4.7V

3. Short between the sensor power supply
terminal of the AP sensor connector and
the signal terminal using jump cable.
5 4. Turn the key switch to ON. 4.7V
5. Check for Accelerator sensor 1 on the
Is the Accelerator sensor 1 more than the
1. Check for high resistance in the power
supply circuit between ECM and AP
6 procedure.
required.
1. Check for high resistance in the signal
circuit between ECM and AP sensor using
breaker box or DMM.
7 procedure.
required.
1. Check for high resistance in the ground
breaker box or DMM.
8 procedure.
required.
1. Check for high resistance in the signal
breaker box or DMM.
9 procedure.
required.
3. Check the AP sensor connector terminal
10 for intermittent trouble or poor contact.
required.

2. Remove the ECM.
3. Check the ECM terminals (41, 63, 42, 60,
64, 61) for intermittent trouble or poor
11 contact.
required.
Replace the AP sensor.
12
necessary.
Note:
14

Replace the ECM.
Note:
15

2. Clear the DTC.
16 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
17 Go to each DTC

4. Connect the DMM between the sensor
18 4.7V
power supply terminal of the AP sensor
connector and the signal circuit.
About AP sensor Breaker box inspection procedure

Refer to the machines manual for installing position of Perform the inspection in the following procedure if
the AP sensor. there is such an instruction to use breaker box in the
Characteristics of AP sensor

  

Name
1. Breaker box
2. DMM

high measureme sensor connector sensor less more
resistance nt connector. ground terminal
Key switch OFF
resistance nt connector. signal terminal
Key switch OFF

Key switch OFF
Accelerator sensor 1 fault (low voltage fault)
  

 
   
   
 
 

   
                 


 
     
                     
  

 


The accelerator position (AP) sensor is installed to the 1 system fault: No backup
accelerator pedal. The AP sensor is the potentiometer- 2 systems fault: Accelerator opening angle is controlled
type sensor, and the value of output voltage changes to 0%.
according to the accelerator opening angle. The AP
sensor includes following circuits. Preconditions when DTC is set
5-V power supply circuit Key switch input voltage is 18V or more.
Ground circuit DTC P1630, P1277, or P1631 is not detected.
AP sensor signal circuit
The ECM provides 5 V to the AP sensor through 5-V DTC set condition
power supply circuit, and grounds to the inside of the AP sensor 1 voltage is 0.2V or less for 1 second or
ECM through ground circuit. Also, the AP sensor more.
outputs the signal voltage to the ECM through AP
sensor signal circuit. The AP sensor 1 outputs high Action taken when DTC is set
voltage when the accelerator opening angle is large.
The ECM sets the DTC when the signal voltage from The diagnosis lamp does not come on.
the AP sensor 1 is less than the normal range.
1 system fault...No back-up Worn harness cladding
2 system fault...Accelerator opening angle is Wire disconnection inside harness cladding
controlled to 0%. Following inspections are necessary to detect these
causes.
Diagnostic aid
3. In the case of current trouble, the Accelerator
When the DTC P1282 is detected at the same time, the sensor 1 displays less than the specified value. If more
accelerator pedal position sensor and the accelerator than the specified value, identify the cause by referring
pedal position sensor signal circuit (before the to Diagnostic aid.
bifurcation point) may be faulty. 5. If the Accelerator sensor 1 displays more than the
If the intermittent trouble is suspected, followings may specified value when terminals between the AP sensor
be the cause. connector are shorted, the circuit beyond the sensor is
Improper connection of harness connector normal including ECM.

1 Go to OBD
3 data display using scan tool. 0.2V
Is the Accelerator sensor 1 less than the Go to Diagnostic
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
4 connection.
required.

the sensor 1 signal terminal using jump
5 cable. 4.8V
breaker box or DMM.
procedure.
6 Open circuit
High resistance
required.
between ECM and AP sensor using
breaker box or DMM.
procedure.
Short circuit to AP sensor ground circuit
Open circuit
High resistance
required.
8
necessary.
10 Note:


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
14 data display. 0.2V
coupling connector.
15 connection.
required.
16 cable. 4.8V
data display.

  

Name
1. Breaker box
2. DMM

high measureme sensor connector sensor 1 less more

Key switch OFF
Key switch OFF
Accelerator sensor 1 fault (high voltage fault)
  

 
   
   
 
 

   
                 


 
     
                     
  

 


power supply circuit, and grounds to the inside of the AP sensor 1 voltage is 4.9V or more for 1 second
ECM through ground circuit. Also, the AP sensor or more.
the AP sensor 1 is more than the normal range.
causes.
Diagnostic aid
When the DTC P1283 is detected at the same time, the sensor 1 displays more than the specified value. If less
accelerator pedal position sensor and accelerator pedal than the specified value, identify the cause by referring
position sensor signal circuit (before the bifurcation to Diagnostic aid.
point) may be faulty. 5. If the Accelerator sensor 1 displays less than the
If the intermittent trouble is suspected, followings may specified value when the AP sensor connector is
be the cause. removed, the circuit beyond the sensor is normal
Improper connection of harness connector including ECM.

1 Go to OBD
Is the Accelerator sensor 1 more than the Go to Diagnostic
coupling connector.
4 connection.
required.
5 4. Check for Accelerator sensor 1 on the 0.1V
Is the Accelerator sensor 1 less than the

AP sensor 1 for short circuit to the power
procedure.
6 Important:
If the AP sensor circuit is shorted to the power

required.
breaker box or DMM.
procedure.
7 Open circuit
High resistance
required.
8
necessary.
10 Note:

Replace the ECM.
Note:
11


2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
coupling connector.
15 connection.
required.
data display.
About AP sensor
Refer to the machines manual for installing position of
the AP sensor.
Characteristics of AP sensor Breaker box inspection procedure
 step. After inspection, return to the diagnostic step.
  

Name
1. Breaker box
2. DMM

Key switch ON
Key switch OFF
Accelerator sensor 2 fault (low voltage fault)
  

 
   
   
 
 

   
                 


 
     
                     
  

 


Ground circuit DTC P1630, P1282, P1631 is not detected.
power supply circuit, and grounds to the inside of the AP sensor 2 voltage is 0.2V or less for 1 second or
ECM through ground circuit. Also, the AP sensor more.
the AP sensor 2 is less than the normal range.
causes.
Diagnostic aid
When the DTC P1277 is detected at the same time, the sensor 2 displays less than the specified value. If more
point) may be faulty. 5. If the Accelerator sensor 2 displays more than the
If the intermittent trouble is suspected, followings may specified value when terminals between the AP sensor
be the cause. connector are shorted, the circuit beyond the sensor is
Improper connection of harness connector normal including ECM.

1 Go to OBD
coupling connector.
4 connection.
required.

5 cable. 4.8V
circuit between ECM and AP sensor 1
procedure.
6 Open circuit
High resistance
required.
between ECM and AP sensor 1 using
breaker box or DMM.
procedure.
Short circuit to AP sensor 1 ground
circuit
7
Open circuit
High resistance
required.
8
necessary.
10 Note:


Replace the ECM.
Note:
11

2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
coupling connector.
15 connection.
required.
16 cable. 4.8V
data display.

  

Name
1. Breaker box
2. DMM


Key switch OFF
Key switch OFF
Accelerator sensor 2 fault (high voltage fault)
  

 
   
   
 
 

   
                 


 
     
                     
  

 


power supply circuit, and grounds to the inside of the AP sensor 2 voltage is 4.9V or more for 1 second
ECM through ground circuit. Also, the AP sensor or more.
the AP sensor 2 is more than the normal range.
causes.
Diagnostic aid
When the DTC P1278 is detected at the same time, the sensor 2 displays more than the specified value. If less
point) may be faulty. 5. If the Accelerator sensor 2 displays less than the
If the intermittent trouble is suspected, followings may specified value when the AP sensor connector is
be the cause. removed, the circuit beyond the sensor is normal
Improper connection of harness connector including ECM.

1 Go to OBD
coupling connector.
4 connection.
required.

AP sensor 1 for short circuit to the power
procedure.
6 Important:
If the AP sensor circuit is shorted to the power

required.
breaker box or DMM.
procedure.
7 Open circuit
High resistance
required.
8
necessary.
10 Note:

Replace the ECM.
Note:
11


2. Clear the DTC.
12 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
13 Go to each DTC
coupling connector.
15 connection.
required.
data display.
About AP sensor
Refer to the machines manual for installing position of
the AP sensor.
Characteristics of AP sensor Breaker box inspection procedure
 step. After inspection, return to the diagnostic step.
  

Name
1. Breaker box
2. DMM

Key switch ON
Key switch OFF
Cam sensor out of phase


 
 

 
 
 
                   
                 

  

 
  
 
   
   
   

          
 

Description of circuit DTC P0335, P0336, P0340, P0341, P1345, or

The crankshaft position (CKP) sensor generates pulse P1635 is not detected.
when the tooth of the flywheel passes the sensor. Also, Cam pulse is normal.
the camshaft position (CMP) sensor, the same as CKP Crank pulse is normal.
sensor, generates pulse when the sensing hole for
signal detection installed in the supply pump camshaft DTC set condition
gear passes the sensor. Correct CMP sensor pulse does not exist in crank
The ECM sets the DTC when the number of pulses for gap position.
CKP sensor and CMP sensor are normal but mutual
pulses do not synchronize. Action taken when DTC is set
Main trouble symptom Turns the diagnosis lamp ON.

Behavior does not change during engine running. Back-up mode
After engine stalls, engine will not start.
Specified back-up value (depending on the machine
manufacturer)
Recovery from failure Defective harness routing
Refer to List of diagnostic trouble code and About Worn harness cladding
recovery from failure in this section for recovery from Wire disconnection inside harness cladding
failure. Excessive air mixed in the fuel.
then ON again.
Damaged harness
be the cause.

1 Go to OBD
1. Check the CMP sensor condition.
Improper connection of harness
connector
2 Loose installation and rattling of sensor
required.
1. Check for the condition of the CKP sensor.
Improper connection of harness
connector
3 Loose installation and rattling of sensor
required.
1. Clear the DTC.
DTCs.
10 seconds.
DTC is set.
4. Check the DTC.

1. Check that the camshaft gear is installed
properly.
required.
1. Check that the flywheel is installed
properly.
required.
1. Clear the DTC.
DTCs.
15 seconds.
DTC is set.
4. Check the DTC.
8 Go to each DTC
 
Name
1. GND
2. Power supply
6HK1 4HK1

 
About CMP sensor 6HK1


Name Name
1. Signal 1. CMP sensor
2. GND
3. Power supply
4HK1

6HK1

Name
1. CKP signal
2. CMP signal
Main relay fault
 
 
       
 




The main relay is installed near the blower motor inside Key switch input voltage is 18V or more.
the instrument panel. The ECM turns the main relay DTC P1630 is not detected.
ON when the key switch inputs ON signal, and turns 3 seconds or more has elapsed after key switch
the main relay OFF when the key switch is OFF. The ON.
battery voltage is supplied to the main relay via fuse,
Main relay drive indication ON
and turning the main relay ON will supply the power
supply voltage to the ECM. DTC P1625, or P0606 is not detected.
The ECM sets the DTC when the output to/input from
the main relay do not match. DTC set condition
Main relay input power supply voltage is 1 V or less
Main trouble symptom for 2 seconds or more.
Engine does not start or power supply cannot be shut Relay does not cut off for 5 seconds or more even
off. after the main relay coil OFF command is sent.

Back-up: No back-up action causes.
then ON again.
3. If the main relay is stuck closed, it is possible to
Diagnostic aid communicate with ECM using scan tool even with the
If the intermittent trouble is suspected, followings may key switch OFF.
be the cause. 5. If it is still possible to communicate with ECM using
Fault in switch body scan tool and the DTC is detected when the main relay
Improper adjustment of switch is removed, the circuit beyond the relay or ECM is
faulty.
8. If the Main relay voltage displays more than the
Defective harness routing specified value when terminals between the main relay
Worn harness cladding installing portion are shorted, the circuit beyond the
Wire disconnection inside harness cladding relay is normal including ECM.

1 Go to OBD
2
2. Check for Main relay voltage on the data
3 display using scan tool. 1V
Is the Main relay voltage more than the
4 2. Check the DTC. Go to Diagnostic
1. Remove the main relay.
2. Check the DTC.
Note:
5 Refer to the machines manual for installing
position and installation/removal
procedures of the main relay.


1. Check the circuit (contact point side)
between main relay and ECM for short
box or DMM.
procedure.
required.
Check for installation condition of the main
7 connection.
required.
3. Short between the terminals 1 - 2 and 3 - 5
in the main relay installing portion
respectively using jump cable.
5. Check for Main relay voltage on the data
display using scan tool.
Is the Main relay voltage more than the
slow-blow fuse and main relay.
Open circuit
9 High resistance
required.
main relay and ECM using breaker box or
DMM.
procedure.
Open circuit
10
High resistance
required.
Replace the main relay.
11

necessary.
13 Note:

Replace the ECM.
Note:
14

2. Clear the DTC.
15 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
16 Go to each DTC
4. Connect the DMM between the main relay
17 1V
connector coil-side terminal and the
ground.
18 2. Check the DTC. Go to Diagnostic

2. Check the DTC.
Note:
19 Refer to the machines manual for installing
position and installation/removal
procedures of the main relay.

1. Check the circuit (contact point side)
between main relay and ECM for short
box or DMM.
procedure.
required.
Check for installation condition of the main
21 connection.
required.
22 4. Connect the DMM between the main relay 24V
connector terminal (contact point side) and
the ground.
Name
1. Breaker box
2. DMM

power supply measureme relay. 5 - Ground more
10 Open circuit/ Resistance Disconnect the 2 - Relay installing 100 or 10M or
high measureme relay. terminal No. 2 less more
resistance nt Key switch OFF 5 - Relay installing
terminal No. 2
21 - Relay installing
terminal No. 5
40 - Relay installing
terminal No. 5
ground measureme relay. 5 - Ground more less
nt Key switch OFF 21 - Ground
40 - Ground
 

Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
A/D conversion fault

The ECM processes the analog signals (voltage signal Analog sensor system default processing
etc.) which are input from each sensor into digital Limited injection amount 3 (multi-injection stopped)
signals, to perform various controls and calculations. Target RP upper limit (80MPa)
The ECM sets the DTC when the fault is detected for
the analog-digital conversion. Recovery from failure
Main trouble symptom Refer to List of diagnostic trouble code and About
Output lowering failure.
Black smoke emitted
DTC set condition
Analog/digital conversion failure when the condition is out of the range from DTC
Action taken when DTC is set The diagnosis lamp will go off after the code turns
Turns the diagnosis lamp ON. to history code and the key switch is turned OFF
then ON again.

1 Go to OBD
1. Clear the DTC.
DTCs.
10 seconds.
DTC is set.
4. Check the DTC.
Go to Diagnostic
necessary.
Note:
4


Replace the ECM.
Note:
5

6 Go to each DTC
Voltage fault in 5-V power supply 1
  

 
   
   
 
 

   
                 


 
     
                     
  

 


The 5-V power supply circuit is provided to the ECM for Key switch power supply voltage is 5.5 V or more,
5 systems. The 5-V power supply circuit 1 supplies or 4.5 V or less for 0.5 seconds or more.
power to the accelerator position (AP) sensor.
The ECM sets the DTC when the voltage in the 5-V Action taken when DTC is set
power supply circuit 1 is higher or lower than the normal Turns the diagnosis lamp ON.
range.
Back-up mode
Same to accelerator sensor fault
Accelerator opening angle is controlled to 0%.
DTC P1630 is not detected. recovery from failure in this section for recovery from
Key switch input power supply voltage is higher failure.
than 16 V but lower than 32 V.
The conditions to clear the MIL/DTC Using the scan tool, or memory clear switch and
The current trouble turns to past trouble (history) diagnostic switch operation enables to clear DTCs.
set condition (recovery from failure). Test description
The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history code and the key switch is turned OFF 2. Measure at the harness connector-side.
then ON again. 3. Measure at the harness connector-side.

1 Go to OBD
3. Connect the DMM between the AP sensor
2 power supply terminal and the ground. 5.5V
3. Connect the DMM between the AP sensor
3 power supply terminal and the ground. 4.5V
1. Check the power supply circuit between
AP sensor 1 and ECM for short circuit to
the battery power supply circuit or ignition
power supply circuit using breaker box or
DMM.
procedure.
required.
AP sensor 1 and ECM for ground short
5 procedure.
required.

necessary.
7 Note:

Replace the ECM.
Note:
8

2. Clear the DTC.
9 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
10 Go to each DTC
  

 
   
   
 
 

   
                 


 
     
                     
  

 


power to the barometric pressure sensor.
power supply circuit 5 and 5 is higher or lower than the Turns the diagnosis lamp ON.
normal range.
Back-up mode
Same to barometric pressure and intake air
Due to back-up equivalent to 2500m temperature sensor fault
Output shortage at low altitude Recovery from failure
Preconditions when DTC is set recovery from failure in this section for recovery from
DTC P1630 is not detected. failure.
Key switch input power supply voltage is higher
than 16 V but lower than 32 V.

1 Go to OBD
sensor connector.
3. Connect the DMM between the barometric
2 pressure sensor power supply terminal 5.5V
and the ground.
sensor connector.
3. Connect the DMM between the barometric
and the ground.
Is the DMM indication less than the specified Go to Diagnostic
value? Go to Step 5. aid.
barometric pressure sensor and ECM for
short circuit to the battery power supply
procedure.
required.
barometric pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
procedure.
required.

necessary.
7 Note:

Replace the ECM.
Note:
8

2. Clear the DTC.
9 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
10 Go to each DTC
 
   

  

 
  
   
                 
 
       
        

  

   

    
 
  
             
   



  




     


   
 

 
 


 


 
 

Description of circuit Key switch input power supply voltage is higher

The 5-V power supply circuit is provided to the ECM for than 16 V but lower than 32 V.
5 systems. The 5-V power supply circuit 3 supplies
power to the engine oil pressure sensor. DTC set condition
The ECM sets the DTC when the voltage in the 5-V Key switch power supply voltage is 5.5 V or more,
power supply circuit 3 is higher or lower than the normal or 4.5 V or less for 0.5 seconds or more.
range.
Main trouble symptom Turns the diagnosis lamp ON.
Startability deteriorates at low temperatures.
Black smoke emission possible Back-up mode
Operationality is affected. Same to coolant temperature, fuel temperature,
and oil pressure sensor fault
Test description
when the condition is out of the range from DTC Numbers below indicate step numbers in the chart.
set condition (recovery from failure). 2. Measure at the harness connector-side.

1 Go to OBD
connector.
3. Connect the DMM between the engine oil
and the ground.
connector.
3. Connect the DMM between the engine oil
and the ground.
engine oil pressure sensor and ECM for
procedure.
required.
engine oil pressure sensor and ECM for
DMM.
procedure.
required.

necessary.
7 Note:

Replace the ECM.
Note:
8

2. Clear the DTC.
9 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
10 Go to each DTC

 

 




       
       
    

    
         




power to the boost pressure sensor.
power supply circuit 4 and 3 is higher or lower than the Turns the diagnosis lamp ON.
normal range.
Back-up mode
Same to boost pressure and boost temperature
Operationality is affected. sensor fault
DTC P1630 is not detected. Refer to List of diagnostic trouble code and About
Key switch input power supply voltage is higher recovery from failure in this section for recovery from
than 16 V but lower than 32 V. failure.

1 Go to OBD
connector.
3. Connect the DMM between the boost
and the ground.
connector.
3. Connect the DMM between the boost
and the ground.
boost pressure sensor and ECM for short
circuit to the battery power supply circuit or
box or DMM.
procedure.
required.
boost pressure sensor and ECM for
DMM.
procedure.
required.

necessary.
7 Note:

Replace the ECM.
Note:
8

2. Clear the DTC.
9 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
10 Go to each DTC


    

    

  
                         
           
           
  

          
       
               

   
   
           
 


 


The 5-V power supply circuit is provided to the ECM for DTC P1630 is not detected.
5 systems. The 5-V power supply circuit 5 supplies Key switch input power supply voltage is higher
power to the common rail pressure sensor and the than 16 V but lower than 32 V.
EGR position sensor.
The ECM sets the DTC when the voltage in the 5-V DTC set condition
power supply circuit 5 and 2 is higher or lower than the
Key switch power supply voltage is 5.5 V or more,
normal range.
or 4.5 V or less for 0.5 seconds or more.
Engine blow up
Output lowering
Black smoke emitted Back-up mode
Engine stall possible Same to rail pressure sensor fault and EGR
position sensor fault
Test description
when the condition is out of the range from DTC Numbers below indicate step numbers in the chart.
set condition (recovery from failure). 2. Measure at the harness connector-side.

1 Go to OBD
sensor connector.
and the ground.
sensor connector.
and the ground.
common rail pressure sensor and ECM for
procedure.
required.
common rail pressure sensor and ECM for
DMM.
procedure.
required.

necessary.
7 Note:

Replace the ECM.
Note:
8

2. Clear the DTC.
9 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
10 Go to each DTC
DTC: U2104 (Flash code 84)
CAN Bus fault


 

                   
   
 

   
 


The ECM communicates with the machine control unit Key switch input voltage is 12V or more.
(ECU) through CAN communication circuit. The ECM
data outputs through the CAN-High circuit, and other Action taken when DTC is set
ECU data inputs through the CAN-Low circuit. The Turns the diagnosis lamp ON.
CAN communication performs at a constant speed
without interruption, and the number of data outputs Back-up mode
and inputs must always be the same.
The ECM sets the DTC when the fault is detected for Specified back-up value (depending on the
the CAN communication. machine manufacturer)
Main trouble symptom Recovery from failure

Vary depending on setting. Refer to List of diagnostic trouble code and About
DTC set condition failure.
Revolution command message of CAN

communication is disrupted for 1 second or more.
The conditions to clear the MIL/DTC Test description
The current trouble turns to past trouble (history) Numbers below indicate step numbers in the chart.
when the condition is out of the range from DTC 2. If no DTC is detected, intermittent trouble is
set condition (recovery from failure). suspected. Identify the cause by referring to
Using the scan tool, or memory clear switch and Diagnostic aid.
diagnostic switch operation enables to clear DTCs. 5. Measure at the harness connector-side.
6. Measure at the TCM harness connector-side.

Perform the OBD check.
1 Go to OBD
10 seconds.
3. Check the DTC.
Go to Diagnostic
Is DTC U2104 detected? Go to Step 3. aid.
3 Is DTC U2106 detected? Go to DTC U2106. Go to Step 4.
4 Is the breaker box available? Go to Step 5. Go to Step 15.
2. Remove the ECM.
3. Connect the breaker box to the ECM.
4. Connect the breaker box with the ECM
harness.
5 5. Measure the resistance between the CAN- 50 70
High-side terminal and CAN-Low-side
terminal using breaker box.
procedure.
Is the resistance within the specified value? Go to Step 13. Go to Step 6.
1. Remove the ECM from the breaker box.
2. Measure the resistance between the CAN-
High-side terminal and CAN-Low-side
6 terminal using breaker box. Approx. 120
procedure.
1. Connect the ECM to the breaker box.
2. Remove the machine control unit and the
harness.
7 High-side terminal and CAN-Low-side Approx. 120
terminal using breaker box.
procedure.

1. Check the CAN-Low circuit and CAN-High
circuit between ECM and machine control
unit for short circuit to the power supply
procedure.
2. If the trouble is detected, replace the
harness.
1. Check for followings in the CAN-Low
circuit and CAN-High circuit between ECM
and machine control unit using breaker
box or DMM.
procedure.
9 Open circuit
High resistance
Replace the
required.
machine control
Is the trouble detected? Go to Step 2. unit.
necessary.
11 Note:

Replace the ECM.
Note:
12


2. Clear the DTC.
13 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Is DTC U2104 detected? Go to Step 2. Go to Step 14.
14 Go to each DTC
Remove the ECM, and measure the resistance
between the CAN-High-side terminal and
15 CAN-Low-side terminal of the ECM connector. Approx. 120
1. Install the ECM, and remove the machine
control unit.
16 High-side terminal and CAN-Low-side Approx. 120
terminal of the machine control unit
connector.

Name
1. Breaker box
2. DMM

8 Short circuit to Voltage Remove all the 18 - Ground 0V 18V or
power supply measureme relevant ECU 37 - Ground more
circuit nt connectors.
Key switch ON
9 Open circuit/ Resistance Remove all the 37 - Machine control 100 or 10M or
high measureme relevant ECU unit less more
resistance nt connectors. 18 - Machine control
Key switch OFF unit
Short circuit to Resistance Remove all the 18 - Ground 10M or 100 or

ground measureme relevant ECU 37 - Ground more less
nt connectors.
Key switch OFF
DTC: U2106 (Flash code 85)
CAN timeout fault


 

                   
   
 

   
 


The ECM communicates with the machine control unit Instruction message on CAN communication to run
(ECU) through CAN communication circuit. The ECM is disrupted for 1 second or more.
data outputs through the CAN-High circuit, and other
ECU data inputs through the CAN-Low circuit. The Preconditions when DTC is set
CAN communication performs at a constant speed DTC U2104 is not detected.
without interruption, and the number of data outputs
Key switch input voltage is 20 V or more.
and inputs must always be the same.
The ECM sets the DTC when the CAN communication
is disrupted with the machine control unit (ECU).
Back-up mode
Vary depending on setting.
It cannot be controlled from the machine side since Specified back-up value (depending on the
CAN communication is disabled. The engine machine manufacturer)
speed becomes back-up speed specified by each
machine manufacturer.
Using the scan tool, or memory clear switch and Visually check the harness for damage.
Diagnostic aid
If the intermittent trouble is suspected, followings may variation of the display indicates the faulty part.
be the cause.
Improper connection of harness connector Test description
Defective harness routing Numbers below indicate step numbers in the chart.
Worn harness cladding 2. If no DTC is detected, intermittent trouble is
Wire disconnection inside harness cladding suspected. Identify the cause by referring to
Diagnostic aid.

1 Go to OBD
10 seconds.
3. Check the DTC.
Go to Diagnostic
and machine control unit (ECU) using
breaker box or DMM.
procedure.
3
Open circuit
High resistance
required.
and machine control unit (ECU) using
breaker box or DMM.
procedure.
4 Short circuit to ground circuit
required.

2. Clear the DTC.
5 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Go to Diagnostic
6 Is DTC U2104 detected at the same time? Go to Step 8. Go to Step 7.
Replace the machine control unit.
7
necessary.
Note:
9

Replace the ECM.
Note:
10


2. Clear the DTC.
11 DTCs.
10 seconds.
DTC is set.
5. Check the DTC.
Is DTC U2106 detected? Go to Step 2. Go to Step 12.
12 Go to each DTC

Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Remove the 18 - Machine control 100 or 10M or
high measureme machine control unit (ECU) less more
resistance nt unit (ECU) connector terminal
connector. 37 - Machine control
Key switch OFF unit (ECU)
connector terminal

ground measureme machine control 37 - Ground more less
nt unit (ECU)
connector.
Key switch OFF
Short circuit to Voltage Remove the 18 - Ground 0V 18V or
power supply measureme machine control 37 - Ground more
circuit nt unit (ECU)
connector.
Key switch ON
List of trouble symptom
Symptom Description
Engine start failure Crank speed is slow.
Crank speed is normal but engine does not start (no first
combustion).
Engine starts (first combustion exists) but cannot maintain
stable engine speed, or no blow up.
Engine stall Engine cranks but take long time before start. It operates
eventually, or starts but stops immediately.
Engine hunting, rough idling Engine idle speed is rough, or idle speed changes. In a more
severe case, engine or machine vibrates. In any serious
situations, the engine stalls.
Engine output shortage, lag down Engine output is lower than expected, and output does not
change with the accelerator lever (throttle lever) released,
engine response deteriorates.
Exhaust gas contains a lot of white smoke. A lot of white smoke emitted while running.
Exhaust gas contains a lot of black smoke. A lot of black smoke emitted while running.
Noise Abnormal sound occurs from the engine.
Fuel consumption deteriorates. Fuel consumption is remarkably more than that indicated in
the machines manual. The situation shown here is that the
problem is not found on the machine side and the engine
needs to be checked.
Oil consumption deteriorates. Oil consumption is remarkably lower than that indicated in the
machines manual. The situation shown here is that the
problem is not found on the machine side and the engine
needs to be checked.
Engine start failure
Pre-inspection Fuel system is free from oil leakage, and pipe is
Before using this paragraph, perform the OBD system not damaged or dent.
check and check all the following items. Intake system parts for fault.
Check if excessive load is applied to the machine Exhaust system parts for fault.
side.
ECM and diagnosis lamp operate properly. Diagnostic aid
Check the DTC. If the crank sensor is faulty, crank more than 60rpm
Scan tool data shows normal operating range. for 14 seconds or more since it is not judged on
cranking for less than 14 seconds.
Check the condition of the machine to identify the
applicable symptom from List of trouble Fuel system fault (run out of fuel, frozen fuel, air
symptom. Perform the procedure described in the mixed in fuel pipe, faulty filter [clog in main filter,
symptom chart. gauze filter], pipe fault, fuel quality, fuel tank
[foreign matter, fuel suction fault])
Check with the customer if correct engine oil and
fuel are used. Intake system fault (clogging in filter, intake pipe
fault, etc.)
Visual check Supply pump fault (no fuel pressure feed)
Careful visual check is required for some symptom Common rail fault (flow damper or pressure limiter
procedures. By this inspection, the problem can be is activated, degradation of sealability)
corrected without performing further inspection, and Injector fault (no fuel injection)
time can be saved. System down due to trouble
This inspection includes the following items. Engine body fault
This inspection includes the following items. (seizure, compression pressure shortage, other
There is no dirt or clogging in fuel filter. mechanical trouble)
There is no poor contact in connector (it must be ACG trouble
connected with click sound). Especially for CKP Machine side related equipment trouble
sensor and CMP sensor. (oil pressure pump etc.)
The terminal voltage of battery is not low. Effect of commercial electrical equipment (radio,
Wire is connected, tightened or cut properly. lamp, etc.)
Commercial accessory power supply is not ECM trouble
bifurcated from ECM power supply. (body, power supply, ground, etc.)
ECM ground is not contaminated and installed to Check the connector for poor contact, the harness
the proper position securely. for fault such as wear or bend, and the wire inside
Pipes and hoses relevant to fuel, air and oil are the harness for loosened wire causing short circuit
free of crack or twist, and are properly connected. to other circuits. Also, perform the function
Thoroughly check for any oil leakage and clogging. diagnosis to check the operation and control of

1 OFF, and Go to
2 Go to OBD
Check if following DTCs are detected.
3 DTC: P0335, P0336, P0340, P0341, P0601, Go to the related
P1261, P1262
Inspection method
Is DTC detected? by DTC. Go to Step 4.
Check the crank speed.
Check if the crank speed is more than the
4 necessary speed for ECM to identify engine 60 rpm
rotation.
Is the crank speed more than specified value? Go to Step 5. Go to Step 6.

Check the crank speed.
Check if the crank speed is more than the
5 necessary speed to start the engine (first 80 rpm
combustion).
Is the crank speed more than specified value? Go to Step 7. Go to Step 6.
Check the starting system.
6 Go to Starting
procedure.
clogging.
procedure.
gauze filter)
7 Fuel system pipe
cold temperature)
If opaque frosty object is found in the
filter part of the main filter, waxing may
occurs. Replace fuel.
Check the injector.
1. Clear the DTC.
DTCs.
3. Select the Actuator test from the scan
tool menu.
When the scan tool is not available, use
8 the injector checker. Refer to How to use
injector checker in this section for how to
use injector checker.

stopped.
9 Note:

Check the ACG.
Check if the charge warning lamp turns on
while engine is running.
10 Note:
Refer to the machines manual for charge
warning.
Does the charge warning operate? Go to Step 17. Go to Step 11.

Replace the ACG. Also, check the charge
11 warning system, and repair or replace if faulty.
Check the condition of commercial electrical
equipment such as radio and lights.
12
Does the engine start when the commercial
electrical equipment is powered OFF? Go to Step 13. Go to Step 14.
Correct the installation condition of the
electrical equipment, or remove the electrical
13 equipment.

Check the mechanical part of the engine, and
repair if faulty.
Compression pressure
Valve system
Injector
Timing gear
14 Related part of piston/crank
Note:


necessary.
16 Note:

Replace the ECM.
Note:
17

Engine stall
Check if excessive load is applied to the machine Exhaust system parts for fault.
side.
ECM and diagnosis lamp operate properly. Diagnostic aid
Check the DTC. Fuel system fault (run out of fuel, frozen fuel, air
To detect crank sensor fault, crank more than mixed in fuel pipe, faulty filter [clog in main filter,
60rpm for 14 seconds or more since it is not judged gauze filter], pipe fault, fuel quality, fuel tank
on cranking for less than 14 seconds. [foreign matter, fuel suction fault])
Scan tool data shows normal operating range. Intake system fault (clogging in filter, intake pipe
fault, etc.)
applicable symptom from List of trouble Supply pump fault (no fuel pressure feed)
symptom. Perform the procedure described in the Common rail fault (flow damper or pressure limiter
symptom chart. is activated, degradation of sealability)
Check with the customer if correct engine oil and Injector fault (no fuel injection)
fuel are used. System down due to trouble
Engine body fault
Visual check (seizure, compression pressure shortage, other
Careful visual check is required for some symptom mechanical trouble)
procedures. By this inspection, the problem can be ACG trouble
corrected without performing further inspection, and Machine side related equipment trouble
time can be saved. (oil pressure pump etc.)
This inspection includes the following items.
Effect of commercial electrical equipment (radio,
There is no poor contact in connector (it must be lamp, etc.)
connected with click sound). Especially for CKP
ECM trouble
sensor and G sensor.
(body, power supply, ground, etc.)
Wire is connected, tightened or cut properly.
Check the connector for poor contact, the harness
Commercial accessory power supply is not for fault such as wear or bend, and the wire inside
bifurcated from ECM power supply. the harness for loosened wire causing short circuit
ECM ground is not contaminated and installed to to other circuits. Also, perform the function
the proper position securely. diagnosis to check the operation and control of
Pipes and hoses relevant to fuel, air and oil are each part. Repair if faulty.
free of crack or twist, and are properly connected.
Thoroughly check for any oil leakage and clogging.

1 Go to OBD
Check if excessive load is applied to the
machine side.
2 Note:
Refer to the machines manual for check
and repair.


Check the electrical system.
1. To detect crank sensor fault, crank more
than 60rpm for 14 seconds or more and
check the DTC since it is not judged on
cranking for less than 14 seconds.
2. Check the connectors of the ECM, fuel
pump, ACG and electronic governor for
poor contact or play.
3 Note:
Poor contact in the connector, especially
CKP sensor and CMP sensor, causes
engine stall. It must be connected with click
sound.
3. Check the harness for open or short

circuit.
Check the ACG.
Check if the charge warning lamp turns on
while engine is running.
4 Note:
Refer to the machines manual for charge
warning.
Does the charge warning operate? Go to Step 6. Go to Step 5.

Replace the ACG. Also, check the charge
5 warning system, and repair or replace if faulty.
6
Does the engine stall when the commercial
electrical equipment is powered OFF? Go to Step 7. Go to Step 8.
7 equipment.


procedure.
clogging.
procedure.
gauze filter)
8
Fuel system pipe
cold temperature)
Check the intake system.
9 Go to Intake
Check the exhaust system.
10 Go to Exhaust
repair if faulty.
Valve system
11 Injector
Timing gear
Related part of piston/crank
necessary.
Note:
13


Replace the ECM.
Note:
14

Engine hunting, rough idling
ECM and diagnosis lamp operate properly. Exhaust system parts for fault.
Check the DTC.
Diagnostic aid
Scan tool data shows normal operating range.
Check the condition of the machine to identify the Fuel system fault (run out of fuel, frozen fuel, air
applicable symptom from List of trouble mixed in fuel pipe, faulty filter [clog in main filter,
symptom. Perform the procedure described in the gauze filter], pipe fault, fuel quality, fuel tank
symptom chart. [foreign matter, fuel suction fault])
Check with the customer if correct engine oil and Intake system fault (clogging in filter, intake pipe
fuel are used. fault, etc.)
Supply pump (including feed pump) fault (no fuel
Visual check pressure feed)
Careful visual check is required for some symptom Switch input circuit system fault
procedures. By this inspection, the problem can be Sensor input circuit system fault (accelerator
corrected without performing further inspection, and position (AP) sensor, harness, engine coolant
time can be saved. temperature (ECT) sensor, etc.)
This inspection includes the following items. AP sensor system fault (sensor, harness, etc.)
There is no poor contact in connector (it must be Engine body fault (seizure, compression pressure
connected with click sound). shortage, other mechanical trouble)
The terminal voltage of battery is not low. Machine side related equipment trouble (oil
Wire is connected, tightened or cut properly. pressure pump etc.)
Commercial accessory power supply is not Effect of commercial electrical equipment (radio,
bifurcated from ECM power supply. lamp, etc.)
ECM ground is not contaminated and installed to Check the connector for poor contact, the harness
the proper position securely. for fault such as wear or bend, and the wire inside
Pipes and hoses relevant to fuel, air and oil are the harness for loosened wire causing short circuit
free of crack or twist, and are properly connected. to other circuits. Also, perform the function
Thoroughly check for any oil leakage and clogging. diagnosis to check the operation and control of

1 Go to OBD
machine side.
2 Note:
and repair.

Check the fuel.
1. Supply fuel from a container other than the
fuel tank.
3 2. Start the engine, operate the machine, and
check for trouble symptom.
3. Replace the fuel in the fuel tank and pipe.
Is the engine symptom corrected? Go to Step 24. Go to Step 4.

Bleed air from fuel, and check for trouble
symptom again.
Note:
4

5 Go to Intake
Check the fuel system.
6 Go to Fuel system
Is the procedure completed? Go to Step 7. check.
Check the injector.
1. Clear the DTC.
DTCs.
tool menu.
stopped.
8 Note:

Check for the engine symptom again.
9
10 Does the engine symptom change when the
commercial electrical equipment is powered
11 equipment.


crankshaft position (CKP) sensor and camshaft
position (CMP) sensor.
12 Check the CKP sensor and CMP sensor for
improper installation such as play.
Is it properly installed? Go to Step 14. Go to Step 13.
Correct the installation conditions of the CKP
13 sensor and CMP sensor.
Check the signal conditions of CKP sensor and
CMP sensor using scan tool.
15 2. Crank the engine.
3. Correct the data list on the scan tool.
Is the speed displayed? Go to Step 18. Go to Step 16.
Check for signal detection condition of the CKP
sensor.
2. Remove the harness from the CMP
16 sensor.
(The DTC is detected when this procedure
is performed. Be sure to clear the DTC
after repairing the machine.)
Is the idle condition normal? Go to Step 23. Go to Step 17.
Check for signal detection condition of the
CMP sensor.
2. Remove the harness from the CKP
17 sensor.
(The DTC is detected when this procedure
is performed. Be sure to clear the DTC
after repairing the machine.)
Is the idle condition normal? Go to Step 23. Go to Step 18.
18
necessary.
20 Note:


Replace the ECM.
Note:
21

Restore the ECM to its original condition of
before replacement.
Note:
22 after replacing or rewriting the ECM.

repair if faulty.
ompression pressure
Valve system
23 Flywheel
Camshaft gear
Timing gear
Repair the machine, and check the repair.
24
Engine output shortage
Pre-inspection Sensor input circuit system fault (accelerator
Before using this paragraph, perform the OBD system position (AP) sensor, harness, etc.)
check and check all the following items. Switch input circuit system fault
ECM and diagnosis lamp operate properly. Engine body fault (compression pressure, valve
Check the DTC. clearance, turbocharger, supply pump, injector,
common rail and other mechanical trouble, etc.)
Machine side related equipment trouble (oil
pressure pump etc.)
applicable symptom from List of trouble
symptom. Perform the procedure described in the Effect of commercial electrical equipment (radio,
symptom chart. lamp, etc.)
Check with the customer if correct engine oil and Check the connector for poor contact, the harness
fuel are used. for fault such as wear or bend, and the wire inside
Various kinds of causes are assumed for output the harness for loosened wire causing short circuit
shortage, therefore thoroughly investigate the relation to other circuits. Also, perform the function
between engine body and machine. diagnosis to check the operation and control of
Check what operation triggers the output shortage.
If hesitations or lag down is included in the symptom of Output lowering due to regulated fuel flow during
the output shortage, the fault is related to the machine- overheat
side control. Contact with the machine manufacturer. Control during overheat
If Tech2 is available, checking the boost of Q enables to In overheating, ECM begins to limit fuel flow when the
check the engine output at rated point as a simplified engine coolant temperature exceeds 108 C, for engine
method. protection. It limits fuel flow further as the engine
coolant temperature goes up. Fuel flow is limited to a
Visual check certain level at around 120 C*. (* Setting varies
Careful visual check is required for some symptom depending on the machine manufacturer)
procedures. By this inspection, the problem can be The system raises an alarm from 105 C for some
corrected without performing further inspection, and machines. In addition to alarm, by reducing the load to
time can be saved. the machine, it enables to avoid such conditions that
This inspection includes the following items. the fuel flow is limited.
There is no dirt or clogging in air cleaner element.
Wire is connected, tightened or cut properly.
Commercial accessory power supply is not
bifurcated from ECM power supply.
ECM ground is not contaminated and installed to
the proper position securely.
Pipes and hoses relevant to fuel, air and oil are 


Fuel system is free from oil leakage, and pipe is

not damaged or dent.
Increase in resistance due to dirt or clogging in
intake system parts (especially air cleaner
element) and crushed intake pipes
Exhaust system parts for fault.

Diagnostic aid

Fuel system fault (run out of fuel, frozen fuel, air
mixed in fuel pipe, faulty filter [clog in main filter,
gauze filter], pipe fault, fuel quality, fuel tank
Intake system fault (clogging in filter, intake pipe
fault, etc.)
Exhaust system fault (exhaust brake, exhaust pipe
fault, etc.)
About high-altitude correction
ECM calculates the current altitude based on the
barometric pressure sensor signal.
It regulates the opening/closing period of PCV or
electric conduction of injector according to the altitude
etc. at this time, to correct the optimum fuel flow.






1 Go to OBD
1. Make sure that the engine coolant
temperature does not exceed 108 C.
2. Examine and repair the cause of overheat.
2 3. Lower the engine coolant temperature to
make sure that the output lowering has
corrected.
Check driving environment.
Contact the
Fuel flow may be limited by correction when
3 machine
driving at high altitude.
manufacturer for
Did you drive at high altitude? countermeasure. Go to Step 4.
machine side.
4 Note:
and repair.

Check the fuel.
1. Replace the fuel in the fuel tank and pipe.
5 2. Start the engine, operate the machine, and
Bleed air from fuel, and check for trouble
symptom again.
Note:
6


7 Go to Fuel system
8 Go to Intake
9 Go to Exhaust
10
11 Does the engine symptom change when the
commercial electrical equipment is powered
12 equipment.

13
Check the injector.
1. Clear the DTC.
DTCs.
tool menu.
stopped.
15 Note:


necessary.
17 Note:

Replace the ECM.
Note:
18

before replacement.
Note:
19 after replacing or rewriting the ECM.

repair if faulty.
Valve system
20 Injector
Timing gear
Check the machine-side equipment (trouble of
21 oil pressure pump etc.), and repair if faulty.
22
Exhaust gas contains a lot of white smoke.
Pre-inspection Commercial accessory power supply is not
Before using this paragraph, perform the OBD system bifurcated from ECM power supply.
check and check all the following items. ECM ground is not contaminated and installed to
ECM and diagnosis lamp operate properly. the proper position securely.
Check the DTC. Pipes and hoses relevant to fuel, air and oil are
symptom. Perform the procedure described in the
symptom chart. Intake system parts for fault.
Check with the customer if correct engine oil and Exhaust system parts for fault.
fuel are used.
Diagnostic aid
Visual check Fuel quality (use of fuel other than specified)
Careful visual check is required for some symptom Long-term idling
procedures. By this inspection, the problem can be Trouble of engine coolant temperature (ECT)
corrected without performing further inspection, and sensor, fuel temperature (FT) sensor, intake air
time can be saved. temperature (IAT) sensor, boost pressure sensor,
This inspection includes the following items. or barometric pressure sensor.
There is no poor contact in injector connector (it Engine body trouble (compression pressure
must be connected with click sound). shortage, related to piston, turbocharger, rise/
Wire is connected, tightened or cut properly. decline of oil, etc.)
ECM trouble (body, power supply, ground, etc.)

1 Go to OBD
Check the fuel.
1. Replace the fuel tank and the fuel in the
pipe, or supply the specified oil suitable for
current environment from the fuel
2 container.
2. Start the engine, operate the machine, and
3 Go to Fuel system
Check if oil is mixed in the intake air.
1. Is the blow-by emitted excessively?
Excessive engine oil
Clogged or deformed oil return pipe
4 Clogged or crushed breather hose
2. Wear of turbocharger seal ring

Check the injector.
1. Clear the DTC.
DTCs.
6 tool menu.
Perform the pre-injection stop test.
Select the Stop pre-injection from the scan
7 tool menu to perform the test.
stopped.
9 Note:

Check the coupling of the supply pump for
damage.
10 If the trouble is detected, repair as required.

11

necessary.
13 Note:

Replace the ECM.
Note:
14

15 before replacement.
repair if faulty.
Valve system
16 Injector
Timing gear
17
Exhaust gas contains a lot of black smoke.
Pre-inspection ECM ground is not contaminated and installed to
Before using this paragraph, perform the OBD system the proper position securely.
check and check all the following items. Pipes and hoses relevant to fuel, air and oil are
ECM and diagnosis lamp operate properly. free of crack or twist, and are properly connected.
Check the DTC.
Intake system parts for fault.
symptom. Perform the procedure described in the Exhaust system parts for fault.
symptom chart.
Diagnostic aid
fuel are used. Fuel quality (use of fuel other than specified)
Intake system fault (clogging in filter, intake pipe
Visual check fault, etc.)
Careful visual check is required for some symptom EGR control system fault
procedures. By this inspection, the problem can be Exhaust system fault (exhaust pipe fault etc.)
corrected without performing further inspection, and Engine coolant temperature (ECT) sensor fault
time can be saved. Boost pressure sensor fault (sensor, pipe, etc.)
This inspection includes the following items.
Engine body trouble (compression pressure
There is no dirt or clogging in air cleaner element. shortage, related to the piston, turbocharger, rise of
Wire is connected, tightened or cut properly. oil)
Commercial accessory power supply is not
bifurcated from ECM power supply.

1 Go to OBD
2 Go to Intake
Check the EGR control system.
3 Go to EGR control
Check the reed valve of the EGR.
4 If the trouble is detected, repair as required.
5 Go to Fuel system
6 Go to Exhaust
7
repair if faulty.
8 Valve system (valve clearance)

9

necessary.
11 Note:

Replace the ECM.
Note:
12

13
repair if faulty.
Valve system
14 Injector
Timing gear
15
EGR valve check


Noise
Pre-inspection Pipes and hoses relevant to fuel, air and oil are
Before using this paragraph, perform the OBD system free of crack or twist, and are properly connected.
check and check all the following items. Thoroughly check for any oil leakage and clogging.
Check for noise by referring to the machines Fuel system is free from oil leakage, and pipe is
manual. not damaged or dent.
ECM and diagnosis lamp operate properly. Intake system parts for fault.
Check the DTC. Exhaust system parts for fault.
Diagnostic aid
applicable symptom from the table of contents. Fuel system fault (run out of fuel, frozen fuel, air
Perform the procedure described in the symptom mixed in fuel pipe, faulty filter [clog in main filter,
chart. gauze filter], pipe fault, fuel quality, fuel tank
fuel are used. Intake system fault (EGR valve fault)
Injector fault (no fuel injection)
Visual check Engine body fault (seizure, compression pressure
Careful visual check is required for some symptom shortage, other mechanical trouble)
procedures. By this inspection, the problem can be Machine side related equipment trouble (oil
corrected without performing further inspection, and pressure pump etc.)
time can be saved. This inspection includes the ECM trouble (body, power supply, ground, etc.)
following items. Check the connector for poor contact, the harness
Wire is connected, tightened or cut properly. for fault such as wear or bend, and the wire inside
ECM ground is not contaminated and installed to the harness for loosened wire causing short circuit
the proper position securely. to other circuits. Also, perform the function
diagnosis to check the operation and control of

Identify the source of the noise and confirm the
1 noise. Repair or replace
Is the noise metallic noise? the faulty parts. Go to Step 2.
Perform the pre-injection stop test.
Select the Stop pre-injection from the scan
3 tool menu to perform the test.
Perform Injection Stop for Each Injector.
tool menu.
4

stopped.
5 Note:

Check the EGR valve.
Fault in reed valve
6 Fault in EGR valve body
Refer to Engine section in the service manual
to check the engine trouble.
7 Repair or replace the faulty part.

Fuel consumption deteriorates.
Pre-inspection Wire is connected, tightened or cut properly.
Before using this paragraph, perform the OBD system ECM ground is not contaminated and installed to
check and check all the following items. the proper position securely.
Fuel consumption varies depending on handling of Pipes and hoses relevant to fuel, air and oil are
each machine. Check the machine manufacturers free of crack or twist, and are properly connected.
measure of fuel consumption (A). Thoroughly check for any oil leakage and clogging.
Measure of fuel consumption (/hour) Fuel system is free from oil leakage, and pipe is
Check the actual fuel consumption (B). not damaged or dent.
Actual fuel consumption (/hour) Intake system parts for fault.
If B is bigger than A, check the machines setting Exhaust system parts for fault.
by referring to the machines manual.
Check if excessive load is applied to the machine. Diagnostic aid
Refer to the list of inspection and maintenance Fuel system fault (run out of fuel, frozen fuel, air
items of the operation manual for proper inspection mixed in fuel pipe, faulty filter [clog in main filter,
depending on the operation time. gauze filter], pipe fault, fuel quality, fuel tank
If the operation time exceeds 3000 hours, inspect [foreign matter, fuel suction fault])
by referring to the machines manual. Intake system fault (EGR valve fault)
ECM and diagnosis lamp operate properly. Injector fault (excessive fuel injection etc.)
Check the DTC. Engine body fault (seizure, compression pressure
Check the condition of the machine to identify the shortage, other mechanical trouble)
applicable symptom from List of trouble Machine side related equipment trouble (oil
symptom. Perform the procedure described in the pressure pump etc.)
symptom chart. ECM trouble (body, power supply, ground, etc.)
Check with the customer if correct engine oil and Check the connector for poor contact, the harness
fuel are used. for fault such as wear or bend, and the wire inside
Check if periodic maintenance has been performed the harness for loosened wire causing short circuit
for engine oil replacement, air cleaner filter, fuel to other circuits. Also, perform the function
filter, etc. diagnosis to check the operation and control of
Visual check
Careful visual check is required for some symptom
procedures. By this inspection, the problem can be
corrected without performing further inspection, and
time can be saved. This inspection includes the
following items.

1. Compare the measure of fuel consumption
with the actual fuel consumption.
A: Measure of fuel consumption (/hour)
B: Actual fuel consumption (/hour)
2. If B is bigger than A, check the machines
1 setting or if excessive load is applied to
the machine by referring to the machines
manual.
Check for fuel leakage.

Check if periodic maintenance has been
performed for engine oil replacement, air
3 Perform
cleaner filter, fuel filter, etc.
maintenance for
Is the procedure completed? the machine. Go to Step 4.
Check the intake system and intercooler for
4 water accumulation. Go to Intake
Check the exhaust system for crush, bent or
5 clogging. Go to Exhaust
Check for output shortage. Go to Output
6 shortage, lag
Go to Step 7. down.
1. Check the coupling of the supply pump for
damage.
2. Check the coupling of the supply pump for
7 worn out of alignment mark.
Check if the engine oil of viscosity mentioned
in the operation manual is used. Replace with the
8 appropriate oil, and
Is the appropriate oil used? Go to Step 9. Go to Step 1.
Check the cooling fan for fault.
10
Perform Injection Stop for Each Injector.
tool menu.
11
stopped.
12 Note:

Check the engine compression pressure.

Check the valve clearance.
Has the engine operated for more than 3000
hours?
If more than 3000 hours, check or repair the
15 engine friction by referring to Engine section
in the service manual.
Check the injector using injector checker. Refer
to How to use injector checker in this section
16 for how to use injector checker.
Inspection location of engine intake/exhaust

system
 
    

Name
1. Exhaust pipe 6. Secondary EGR cooler
2. To intercooler 7. From intercooler
3. From air cleaner 8. EGR valve
4. EGR duct 9. EGR duct
5. Primary EGR cooler 10. EGR duct
Check the above intake/exhaust system for fault such as clogging, crush or breakage.
Besides the inspection location of engine body, check the air cleaner, intercooler and muffler.
Oil consumption deteriorates.
Pre-inspection Visual check
Before using this paragraph, perform the OBD system Careful visual check is required for some symptom
check and check all the following items. procedures. By this inspection, the problem can be
Oil consumption varies depending on handling of corrected without performing further inspection, and
each machine. Check the machine manufacturers time can be saved. This inspection includes the
measure of oil consumption (A). following items.
Measure of oil consumption/hour If bluish-white smoke is emitted continuously while
Measure of oil consumption for engine alone: engine running.
4/100 hours If blow-by gas is emitted.
Check the actual oil consumption (B). If oil is mixed in the coolant.
Actual oil consumption /hour Pipes and hoses relevant to oil are free of crack or
Refer to the list of inspection and maintenance twist, and are properly connected. Thoroughly
items of the operation manual for proper inspection check for any oil leakage and clogging.
depending on the operation time. Lubrication system is free from oil leakage, and
If the operation time exceeds 3000 hours, inspect pipe is not damaged or dent.
by referring to the machines manual. Intake system parts for fault (turbocharger check).
ECM and diagnosis lamp operate properly.
Check the DTC. Diagnostic aid
Check the condition of the machine to identify the Intake system fault (rise/decline of oil, excessive
applicable symptom from the table of contents. blow-by gas)
Perform the procedure described in the symptom Engine body fault (oil combustion, excessive blow-
chart. by gas)
Check with the customer if correct engine oil and Also, perform the function diagnosis to check the
fuel are used. operation and control of each part. Repair if faulty.

Check the following for trouble occurrence:
Engine speed
Operational pattern (continuous/intermittent)
Operating load (mode in use)
Oil consumption /hour
If more than 100 hours has elapsed since
initial operation.
1 Compare with the specified value of oil
consumption by referring to the machines
manual.
Note:
Use the operation mode mentioned in the
machines manual to make comparison.
Explain this to the
Is the oil consumption within specified value? customer. Go to Step 2.
Check for oil leakage. Repair or replace the
2 faulty part.
Check if bluish-white smoke is emitted while
engine running.
3 If it is emitted only at the starting, go to
Exhaust gas contains a lot of white smoke.
Is bluish-white smoke emitted? Go to Step 4. Go to Step 6.
Check the blow-by gas quantity.
4
Is it more than the specified value? Go to Step 7. Go to Step 5.

Check for oil leakage from the turbocharger.
Check if oil is mixed in the coolant.
6
Is oil mixed in the coolant? Go to Step 10. Go to Step 11.
Check the engine compression pressure.
Check the engine for wear around the piston or
wear of the cylinder liner.
Note:

Check for oil decline from the valve stem or oil
seal.
Note:

Overhaul the water pump.
Note:

Check for oil leakage from the engine external/
internal.
11 Note:

Special tool
Tool No. Tool No.
Illustration Illustration
Tool name Tool name
5-8840-2691-0
Injector checker
Digital multimeter

Tech2
Scan tool
5-8840-0632-0
Terminal remover
5-8840-0388-0
Weather pack terminal
remover
5-8840-0385-0
Breaker box

Engine module
programming system

Difference by each machine manufacturer
JCB
List of DTC JCB ISUZU DTC description Fault

JCB ISUZU DTC description Fault P Code P Code indicati
P Code P Code indicati on on
on on monitor
monitor P1630 P1630 Analog/digital signal
P0340 P0340 Camshaft position conversion fault
sensor circuit fault P0234 P0234 High boost fault
P0341 P0341 Camshaft position P0487 P0487 EGR valve BLDC

sensor fault position circuit fault
P0335 P0335 Crankshaft position P0488 P0488 EGR valve fault
sensor circuit fault
P0606 P0606 ECM internal trouble
P0336 P0336 Crankshaft position (CPU fault)

sensor fault
P1631 P1631 5V #1 circuit fault
P1345 P1345 Injection pump
Camshaft positional P1632 P1632 5V #2 circuit fault
correlation fault P1633 P1633 5V #3 circuit fault
P0113 P0113 Intake air temperature P1634 P1634 5V #4 circuit fault
sensor circuit high input
P1635 P1635 5V #5 circuit fault
P0112 P0112 Intake air temperature
sensor circuit low input P1636 P1636 12V circuit fault
P0118 P0118 Engine coolant P0236 P0236 Low boost fault

temperature sensor input P0380 P0380 Glow relay circuit fault
is high.
P0381 P0381 Glow plug lamp circuit
P0117 P0117 Engine coolant
fault
temperature sensor low
input P0108 P0108 Barometric pressure
P1277 P1277 Accelerator sensor 1 low
P0107 P0107 Barometric pressure
input
sensor circuit low input
P1283 P1283 Accelerator sensor 2
P0650 P0650 Check engine control
high input
circuit fault
P2104 U2104 CAN communication
input
fault
P2106 U2106 Communication fault
input
with TCM (Transmission
P1271 P1271 Accelerator sensor 1 control module)
2 positional correlation
fault P0088 P0088 Common rail pressure
abnormally high (1st or
P0238 P0238 Turbocharger boost 2nd stage)
P0089 P0089 Common rail pressure
P0237 P0237 Turbocharger boost fault (Excessive
sensor circuit low input pressure feed in supply
P0611 P0611 EDU charge circuit 1 low pump)
voltage P1261 P1261 COMMON1 (Harness or
P0612 P0612 EDU charge circuit 2 low injector harness)
voltage
JCB ISUZU DTC description Fault JCB ISUZU DTC description Fault
P Code P Code indicati P Code P Code indicati
on on on on
monitor monitor
P1262 P1262 COMMON2 (Harness or P1113 P1113 Boost temperature

injector harness) circuit sensor open circuit
fault
P1112 P1112 Boost temperature

P0183 P0183 Fuel temperature sensor sensor short circuit

circuit high input
P0219 P0219 Overrun
P0182 P0182 Fuel temperature sensor
P1173 P1173 Overheat
circuit low input
P0603 P0603 EEPROM fault
P1095 P1095 Pressure limiter is
operated. P0601 P0601 ROM fault
P1094 P1094 Fuel leakage (small P0606 P0606 CPU monitoring IC fault
amount) or (supply pump

or injection system)
control malfunction
P1093 P1093 Fuel leakage (large
amount)
low pressure fault (No
pressure feed in supply
pump)
sensor circuit low input
control adjusting valve
circuit fault
P0201 P0201 No. 1 injector injector
circuit fault
circuit fault
circuit fault
circuit fault
circuit fault
circuit fault
P1625 P1625 Main relay circuit stuck
open or stuck closed
P0522 P0522 Oil pressure circuit open
circuit
P0523 P0523 Oil pressure circuit short
circuit
List of DTC that vary depending on the machine manufacturer
4HK1
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagnos
DTC DTC set condition from
code description detected DTC is set Time trouble occurs is lamp
failure
sensor fault harness more. voltage is less ous to Rail pressure
(low voltage DTC P1630 or than 0.7 V. fault feedback control
fault) P1635 is not occurrenc stopped
detected. e Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
fault) harness P1635 is not occurrenc Rail pressure
detected. e feedback control
stopped
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
P0219 543 Overrun Engine Key switch input When engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed is more sec. Back-up:
abnormally more. than 210 rpm. Limited injection
high amount 1
Limitation is lifted if
the speed
decreases
(low voltage sensor or DTC P1630 or Boost pressure
detected. (150 kPa)
Boost pressure
correction/
EGR stopped
(high voltage DTC P1630 or Boost pressure
detected. (150 kPa)
Boost pressure
correction/
EGR stopped
P1113 295 Boost Short circuit Key switch input Boost Approx. 4 Operationality is ON *2
50 C or more.
5 minutes or more
has elapsed after
starting engine.
DTC P1634 is not
detected.
Recovery
failure
damage in detected. Engine running
gear. CMP sensor pulse based on crank
is normal. when it is normal
Crank pulse is After engine stops:
normal. Unable to identify
cylinder (unable to
restart)
rpm.
on fault Key switch input not complete at a sly Running at 1500
voltage is 20V or set time. rpm.
more.
*1, *2, *3: Refer to About failure restoration in List of diagnostic trouble code.
6HK1
Recovery
failure
sensor fault harness more. sensor voltage is Intake air
(low voltage DTC P1630 or less than 0.1 V. temperature default
fault) P1632 is not setting
at running: 25 C)
EGR stopped
lowering depending
on conditions.
Back-up:
Coolant
temperature default
setting
(at starting: 20 C,
at running: 80 C)
EGR stopped
(low voltage DTC P1630 or less than 0.1 V. Fuel temperature
at running: 70 C)
Recovery
failure
sensor fault harness more. voltage is less ous to Rail pressure
(low voltage DTC P1630 or than 0.7 V. fault feedback control
fault) P1635 is not occurrenc stopped
detected. e Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
fault) harness P1635 is not occurrenc Rail pressure
detected. e feedback control
stopped
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
P0219 543 Overrun Engine Key switch input When engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed is more sec. Back-up:
abnormally more. than 2300 rpm. Limited injection
high amount 1
Limitation is lifted if
the speed
decreases
P0380 66 Glow relay Open/short Key switch input No glow relay When Operationality is ON *1
fault circuit/ power supply monitor signal trouble not affected.
relay or than 16 V but lower glow relay drive out of 30 Back-up: No back-
harness than 32 V. indication. samples. up action
P1113 295 Boost Short circuit Key switch input Boost Approx. 4 Operationality is ON *2
50 C or more, or 3
minutes or more
has elapsed after
starting engine.
DTC P1634 is not
detected.
damage in detected. Engine running
gear. CMP sensor pulse based on crank
is normal. when it is normal
Crank pulse is After engine stops:
normal. Unable to identify
cylinder (unable to
restart)
Recovery
failure
rpm.
on fault Key switch input not complete at a sly Running at 1350
voltage is 20V or set time. rpm.
more.
*1, *2, *3: Refer to About failure restoration in List of diagnostic trouble code.
About wiring diagrams
There are some sensors which are not connected to the ECM depending on the machine.
Check the specifications of the machine, since some sensors input/output to ECM via CAN communication.
The areas with screening indicate that are not connected to the ECM.
4HK1




 
 
 

 


 
 



  



  
 


  

  

 


 




 
  
 



  

 
 
 


 





 



  
  





  

 
 





   
 

 
  
 
 
 

  

 
   
  
 
 
 


  
  
 
  


 

6HK1

  
 

 



 
  
 




 



  

 
 







 

 
  


  
  
 


 
 






 



  
 





 
 

 



 

  
  

  
 
 
  

 


  
 
  
 
  

 
 


  
  
 
  


 


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

ENGINE MECHANICAL (4HK1, 6HK1) 1A-1

ISUZU DIESEL ENGINE (4HK1, 6HK1)

Explanations on functions and operation Cylinder liner

Function check Caution:

Adjustment table (6HK1)

 If the No. 1 cylinder is the compression TDC,

 Attach the harness ASM to the fuel injector.

Tightening torque: 2 N m (17 lb ft)

Compression gauge: 5-8840-2675-0 (J-26999-12)

 Measure each cylinder one by one.

Item Engine model 4HK1

Item Engine model 4HK1

Item Engine model 6HK1

Item Engine model 6HK1

Illustration Tool Number/Description

Cylinder Head Cover

4. Install the gasket on the head cover.

4. Remove the inlet cover.

Tightening torque: 24 N m (17 lb ft)

* 4HK1 is shown for illustration.

 Install within seven minutes after applying liquid

Tightening torque: 22 N m (16 lb ft)

3. Install the gasket on the inlet pipe and tighten up

Turbocharger and Exhaust Manifold

Manifold installation plane surface mm (in)

* 4HK1 is shown for illustration.

Wheel shaft axial play

Tightening torque: 34 N m (25 lb ft)

Tightening torque: 55 N m (40 lb ft)

2. Install the gasket and turbocharger to the exhaust

Tightening torque: 52 N m (38 lb ft)

4. Install the water feed pipe to the turbocharger.

Tightening torque: 41 N m (30 lb ft)

Tightening torque: 24 N m (17 lb ft)

Tightening torque: 24 N m (17 lb ft)

Tightening torque (Cylinder block):

5. Install the water return pipe. Tighten the joint bolts

Tightening torque: 41 N m (30 lb ft)

Tightening torque: 24 N m (17 lb ft)

* 4HK1 is shown for illustration.

9. Install the air intake duct and tighten the bolts to

Tightening torque: 10 N m (87 lb in)

12. Add cooling water to the radiator. (4HK1 only)

Tightening torque: 24 N m (17 lb ft)

  

* 4HK1 is shown for illustration.

Timing Gear Train

7. Remove the flywheel.

 Loosen the fastening bolts of the flywheel little by

 After loosening all the bolts, remove the stopper to

8. Remove the rear oil seal.

* 4HK1 is shown for illustration.

10. Remove the oil pan.

* 4HK1 is shown for illustration.

 If the measurement exceeds the limit, replace the

Backlash of the timing gear mm (in)

 Measure backlash of the idle gear before removing

3. Outside diameter of idle gear shaft

 If the measurement exceeds the limit, replace the

If the No. 1 cylinder is the compression TDC,

Attach the harness ASM to the fuel injector.

Measure each cylinder one by one.

Install within seven minutes after applying liquid

Loosen the fastening bolts of the flywheel little by

After loosening all the bolts, remove the stopper to

If the measurement exceeds the limit, replace the

Measure backlash of the idle gear before removing

If the measurement exceeds the limit, replace the

Measure an end clearance of the idle gear before

As the figure shows, apply the liquid gasket

4HK1 Install the oil pan within 7 minutes after applying

With the flywheel housing, the front cover and the

After pressing in the slinger, make sure that the

After pressing the oil seal, make sure that the

Check if it is bent by rotating the shaft with a dial

As a result of measurement, if its bend is slight,

If the measurement exceeds the limit, replace the

If the measurement falls is the limit or less, replace

Apply engine oil on a screw of the bolts and nuts.

Tighten up the tightening bolts of the rocker arm

If the measurement exceeds the limit, replace the

Rotate the camshaft slowly to measure how much

Use snap ring pliers to assemble the snap ring and

Apply engine oil over the screw part and tighten up