4HK1 FT4 EngineManual

PART NO.
ETDC150-EN-01
4HK1
TIER 4 COMPATIBLE
Engine Manual
Technical Manual
ENGINE MANUAL TECHNICAL MANUAL

4HK1
Tier 4 Compatible
URL:http://www.hitachi-c-m.com
ETDC150-EN-01
Service Manual consists of the following sections.

Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
PRINTED IN JAPAN (K) 2016, 02 Engine Manual
IDE-2720_前書_4405172 2014.7.9 4:21 PM ページ 1
FOREWORD
This manual describes the service procedures for the 4HK1 diesel engine (Tier 4/Stage 4 compatible).
The contents of this manual are current at the date of issue, but may differ slightly from your engine due to specification changes
or other modifications made thereafter.
This manual consists of the following sub-sections.

Publication No. Publication Name Sub-sections
IDE-2720 ENGINE 0 Introduction
14A Service Information Guide
15B Maintenance Information
15C Functional Inspection
15D Symptom
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1J Electrical
38B Maintenance Information (Urea SCR System)
38C Functional Inspection (Urea SCR System)
38D Symptom (Urea SCR System)
38E DTC Information (Urea SCR System)
10M Emission Control (Urea SCR System)
– Wiring Diagram
IDE-2720_前書_4405172 2014.7.9 4:21 PM ページ 2
Introduction (All models) 0-1
Introduction
Introduction
(All models)
Table of Contents
Introduction........................................................................0-2
safety information..........................................................0-2
0-2 Introduction (All models)
Introduction
safety information 9. Be sure to check that there is no fuel leaks when

performing maintenance on fuel systems.
1. Repair work safety information
1. Use an engine stand when demounting the engine
from the equipment.
Be sure not to place the engine directly on the
ground or allow the oil pan to come into contact with
the ground.
2. When performing a procedure with two or more
people, make sure to ensure each other's safety.
3. Do not disconnect the battery cable for 3 minutes
after turning OFF the ignition switch.
4. When repairing the electrical system, make sure to
disconnect the cable from the negative (-) battery
terminal before working. Keep fire away when
removing the battery cover.
10. When handling volatile materials, be extremely

careful to not let them catch fire.
Also make sure to wipe away any oil that sticks to
rubber parts, as it can cause deterioration.
2. Replacement parts and parts number safety
information
1. Whenever disassembly is performed, make sure to
replace the packing, oil seals, O-rings, crimping lock
nuts, bending lock plate, and split pins, etc., with
new ones.
2. Since the part numbers indicated in this manual may
differ from the supply system and are subject to
change, make sure to check the supply system and
part numbers in the parts catalog.
5. Do not leave the engine running for an extended
period of time or perform painting in a poorly
ventilated working environment.
6. Make sure to use only the special tools if the
procedure requires them for the work. Performing
the procedure using other tools may cause damage to
parts or personal injury.
7. Inspect the tools, instruments, and special tools
regularly, and prepare them before working. Do not
use tools such as a wrench that has lost its edges, a
hammer with frayed edges, or a chipped chisel.
8. When performing work using a device such as a
grinder, crane or welder, make sure to pay sufficient
attention to the handling precautions.
Wear work clothes and safety equipments in the
other operations as well.
Service Information Guide (All models) 14A-1
Description General Information

Service Information Guide
(All models)
Table of Contents
Contents included in service information.....................14A-2
Plastic gauge..................................................................14A-4
Recommended liquid gasket.........................................14A-6
Thread locking adhesive agent......................................14A-8
Term..............................................................................14A-9
Abbreviations .............................................................14A-10
Standard bolts..............................................................14A-14
14A-2 Service Information Guide (All models)
Contents included in service information

1. Contents included in service information Includes the maintenance precautions specific to each
item.
Removal
Includes the removal procedure for repairing parts and Disconnection
devices, etc. Includes the disconnection procedures of wiring, piping,
etc.
Installation
Includes the installation procedure for repairing parts and Connection
devices, etc. Includes the connection procedures for wiring, piping,
etc.
Disassembly
Includes the disassembly procedure for performing an Setting
overhaul of a unit or assembly part, etc. Includes the setting procedure necessary after replacing
the ECM, etc.
Assembly
Includes the assembly procedure for performing an Replacement
overhaul of a unit or assembly part, etc. Includes the replacement procedure for parts and oils, etc.
Inspection Prioritized DTC
Includes the inspection items for the parts that Includes DTCs that need to be diagnosed and resolved
particularly require inspection to ensure continued before the relevant DTC when multiple DTCs are
performance of parts and devices. detected.
The standard values, set values, and limits for use of parts
Diagnosis
are included if they have these specifications set.
Includes the diagnosis procedure for troubleshooting
Cleaning symptoms.
Includes the cleaning procedure for parts and devices, etc. DTCs are listed in the descending order of priority.
Preparation Confirmation of problem resolution
Includes the preparatory procedure necessary before Includes procedures to clear the DTC and any necessary
removing parts and devices, etc. confirmation steps using numeric values, etc.
Adjustment Functional description
Includes the adjustment procedure when parts have to be Includes detailed functional description related to
adjusted to set values or standard values when performing functional inspection.
assembly or installation.
Symptom description
Measurement Includes detailed symptom descriptions related to
Includes the measurement procedure to judge if parts are diagnosis by symptom.
installed correctly, etc.
DTC description
Drain Includes circuit description related to DTCs.
Includes the draining procedure of oil, etc.
Setting conditions
Refill Includes the preconditions and judgment conditions
Includes the refilling procedure of oil, etc. required for the ECU to detect a DTC.
Air removal Action upon setting
Includes the air removal procedure when air removal is Includes information related to control actions taken by
necessary after replacing oil, etc. the ECU when DTCs are set.
Writing Items related to ETM
Includes the writing procedure necessary after replacing Items related to the ETM are included in "Using the
the ECM or supply pump. Wiring Diagram".
Precaution 2. Arrows and symbols
1. Vehicle front 9. Gas or warm air

2. Upper 10. Mixing of outside air and gas, or cold air and
3. Operating section or operating direction warm air
4. Detail on a section 11. Rotation direction
5. Detailed view from the direction of A 12. Oil feeding
6. Arrow indicates measurement 13. Lubrication
7. Arrow indicates cross-section 14. Application area of liquid gasket
8. Outside air or cold air
Plastic gauge
1. Using the plasti-gauge
Type Measurable range
： 0.025 to 0.076 mm { 0.00098
PG-1 (Green)
to 0.00299 in }
： 0.051 to 0.152 mm { 0.00201
PR-1 (Red)
to 0.00598 in }
： 0.102 to 0.229 mm { 0.00402
PB-1 (Blue)
to 0.00902 in }
Method for measuring the gap between the connecting
rod bearing and crank pin
Clean the connecting rod and bearing, and assemble them
on the connecting rod. Cut the plasti-gauge to the width
of the crank pin and lay it parallel avoiding the crank pin
oil hole. Align the markings on the connecting rod and on
the cap to assemble it on the crank pin. Apply
molybdenum disulfide to the threaded portion and seat
surface of the tightening bolts. Alternately tighten them Method for measuring the gap between the crank bearing
so that the cap is at the specified torque. and crank journal
Caution： Clean the installation surfaces of the cylinder block and
crankcase bearing, and assemble them on the cylinder
・ Never move the connecting rod when the block and crankcase. Gently place the crankshaft on the
plasti-gauge is in use. cylinder block, and lock it into place by turning it
Gently remove the cap and connecting rod and use a scale approximately 30 degrees. Cut the plasti-gauge to the
printed on the packaging of the plasti-gauge to measure width of the crank journal and lay it parallel avoiding the
the flattened plasti-gauge. journal oil hole. Gently place the crankcase on the
cylinder block, and apply molybdenum disulfide to the
threaded portion and seat surface of the tightening bolts.
Tighten in the specified order at the specified torques.
Caution：
・ Never move the connecting rod when the
plasti-gauge is in use.
Gently remove the crankcase and use a scale printed on
the packaging of the plasti-gauge to measure the flattened
plastic gauge.
Recommended liquid gasket

1. Using the thread liquid gasket
Manufacturer
Type Product name Area used (reference)
name
Silicon type ThreeBond 1207B ThreeBond Engine oil seal retainer
(room temperature ThreeBond 1207C ThreeBond engine oil pan
vulcanization ThreeBond 1215 ThreeBond timing gear case
process) ThreeBond 1216 ThreeBond cylinder head cover
Water–soluble ThreeBond 1141 ThreeBond fuel pump
ThreeBond 1104 ThreeBond water pump
Solvent type etc.
ThreeBond 1194 ThreeBond
Loctite 515 Loctite
Engine oil seal retainer
Loctite 518 Loctite
water pump
Anaerobic FMD127 Loctite
plug
(Loctite 5127) Loctite
etc.
Loctite 271 Loctite
Caution： Caution：
・ Make sure to use a liquid gasket with the ・ Be careful to apply a proper amount of the
above product name or equivalent. liquid gasket to avoid an excess or lack in
・ Use an appropriate amount of liquid gasket. application.
・ Follow the handling precautions for the ・ Be sure to overlap the beginning and ending of
product. the liquid gasket application.
・ Do not use Loctite 515/518 or FMD 127 ・ Be careful not to misalign the applied part with
(Loctite 5127), as they are anaerobic, and do the mating part when assembling.
not provide sufficient effect when there is a Note：
gap larger than 0.25 mm {0.0098 in} between
・ When there is a misalignment, apply again.
the contact surfaces of metals.
・ Use the same size studs as a guide when
Whenever disassembling, completely remove old liquid using with a section which has no positioning
gasket using a scraper, and clean by removing any oil, such as a knock pin.
moisture, filth, etc. from the locations of parts and the
mating parts where liquid gasket was used by using a rag, Caution：
etc. After cleaning, apply the specified liquid gasket to ・ After applying the liquid gasket, assemble
each location and assemble them. within 15 minutes.
Note： Note：
・ It is better to start the removal operation ・ When more than 15 minutes have passed after
approximately 10 minutes after applying when applying liquid gasket, remove the liquid
using gasket remover to make the operation gasket and apply it again.
easier while cleaning.
Caution：
Caution：・ Wait at least 30 minutes before starting the
・ Do not apply gasket remover to plastic parts engine after assembling each part.
and painted parts.
Apply liquid gasket of the specified bead width to one
side of the contact surface thoroughly.
Caution：
・ If the workshop manual specifies an
application method, follow that method.
Thread locking adhesive agent

1. Using the thread locking adhesive agent
Type Color
Loctite 242 Blue
Loctite 262 Red
Loctite 271 Red
Caution：
・ Remove grime, fluid, oil, and grease off
thoroughly from the bolts, bolt holes, and
screw thread section of nuts to which thread
locking adhesive agent will be applied.
Note：
・ Check if the cleaned sections are dry.
Caution：
・ After tightening, do not apply excessive torque
or vibrations for at least an hour until the
thread locking adhesive agent hardens.
Apply thread locking adhesive agent to the end 1/3 of the
screw and tighten at the specified torque.
Term
1. Term
Nominal dimensions
Refers to standard values for production.
Specified value
Refers to specified values for inspection, adjustment,
assembly, and installation.
Limit
Refers to a maximum or minimum value that should not
be exceeded during maintenance. If this value is
exceeded, replacement or repair must be made.
Warning Refers to something which may cause serious
injuries if it is not performed properly.
CAUTION
Refers to something which may cause physical loss or
damage if it is not performed properly.
NOTE
Instruction, guidance, and usage conditions regarding
usage, operation, and repair in the additional information.
Abbreviations
1. Abbreviations
Abbreviation Description
A/D Analog/Digital
ABDC After bottom dead center
AC Alternating current
ACC Accessory
ACG Alternating current generator
ACT Actuator
API American Petroleum Industry
ASM Assembly
ATDC After top dead center
ATF Automatic transmission fluid
B+ Battery + terminal
BAT Battery
BBDC Before bottom dead center
BKT Bracket
BRG Bearing
BTDC Before the top dead center
C/B Circuit breaker
C/U Control unit
CAN A control unit communication method (Control area network)
CKP Crankshaft position
CMP Camshaft position
CO Carbon monoxide
CPU CPU (Central processing unit)
DC Direct current
DI Direct injection type
DLC Data link connector
DPD Diesel particulate diffuser
DTC Self-diagnosis code
DMM Digital multi–meter
ECM Engine control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable/programmable ROM
EGR EGR (Exhaust gas recirculation)
EMI Electromagnetic interference
EVRV Electric vacuum regulating valve
EXH Exhaust
F/B Feedback
F/C Fuel cut
F/L Fusible link
FLW Fusible link wire
FRT Front
FT Fuel temperature
FWD Front
GEN Generator
GND Ground
HC Hydrocarbon
HO2S Superheat O2 sensor
IAC Idle air control
IAT Intake air temperature
IC Integrated circuit
ID Plate ID plate (Name plate)
IDSS ISUZU Diagnostic Service System
IMT Intake manifold temperature
INL Intake
INJ Injection
ISO International Organization for Standardization
ISP Intake shutter position
ITP Intake throttle position
J/C Joint connector
JIS Japan Industrial Standard
KW A communication method (Keyword)
LH Left side
LLC Long life coolant
M/V Electromagnetic valve
MAF Mass air flow
MAP Manifold air pressure
Max Maximum
MIL Warning light (Diagnostic light)
Min Minimum
MPU Micro processing unit
NC Normally closed
NC Normally closed
NO Normally open
NOx Nitrogen oxide
N–TDC Top dead center revolution speed
O2S O2 sensor
OBD On–board diagnosis
OEM Original equipment manufacturer
OPT Option
OT Oil temperature
P/L Pilot light
PCV Pump control valve/Positive crankcase ventilation
P–I Proportion–integration
PM Particle material
PTO Power take–off
PWM Pulse width modulation wave
QOS QOS (Quick on start system)
QWS QWS (Quick warming up system)
RH Right side
R/L Relay
RAM RAM (Random access memory)
REF Reference
ROM ROM (Read only memory)
RP Rail pressure
Rr Rear
Rr Rear
RWD Rear
SAE Society of Automotive Engineers
SBF Slow blow fuse
SCV Suction control valve
SIG Signal
SLD Shield
ST Starter/start
STD Standards
SW Switch
TDC Top dead center
TEMP Temperature
TP Throttle position
VB Battery voltage
VGS Turbo Variable geometry system turbo, VGS turbo
W/H Wire/harness
W/L Warning light (Warning light)
W/S Weld splice
WOT Wide open throttle
Standard bolts
1. List of standard bolt and nut tightening torques Note：
・ The tightening torque values in the following
table apply to locations where tightening
torques are not specified.
Strength 4.8
7T
category 4T
Bolt head
Hex bolt Flange bolt Hex bolt Flange bolt
shape
： 3.9 to 7.8 N・m { 0.4 to ： 4.6 to 8.5 N・m { 0.5 to ： 4.9 to 9.8 N・m { 0.5 to ： 5.7 to 10.6 N・m { 0.6
M6 x 1 0.8 kgf・m / 35 to 69 lb・ 0.9 kgf・m / 41 to 75 lb・ 1.0 kgf・m / 43 to 87 lb・ to 1.1 kgf・m / 50 to 94
in } in } in } lb・in }
： 7.8 to 17.7 N・m { 0.8 ： 10.5 to 19.6 N・m { 1.1 ： 11.8 to 22.6 N・m { 1.2 ： 13.5 to 25.0 N・m { 1.4
M8 x 1.25 to 1.8 kgf・m / 69 to 157 to 2.0 kgf・m / 93 to 173 to 2.3 kgf・m / 9 to 17 lb・ to 2.5 kgf・m / 10 to 18
lb・in } lb・in } ft } lb・ft }
M10 x 1.25 to 3.5 kgf・m / 15 to 25 to 3.9 kgf・m / 17 to 28 to 4.7 kgf・m / 20 to 34 to 5.3 kgf・m / 23 to 38
lb・ft } lb・ft } lb・ft } lb・ft }
*M10 x 1.5 to 3.4 kgf・m / 14 to 25 to 3.8 kgf・m / 16 to 27 to 4.6 kgf・m / 20 to 33 to 5.1 kgf・m / 22 to 37
： 49.0 to 73.5 N・m { 5.0 ： 54.9 to 82.3 N・m { 5.6 ： 60.8 to 91.2 N・m { 6.2 ： 68.1 to 102.1 N・m
M12 x 1.25 to 7.5 kgf・m / 36 to 54 to 8.4 kgf・m / 40 to 61 to 9.3 kgf・m / 45 to 67 { 6.9 to 10.4 kgf・m / 50
lb・ft } lb・ft } lb・ft } to 75 lb・ft }
： 76.5 to 114.7 N・m ： 83.0 to 124.5 N・m ： 93.2 to 139.3 N・m ： 100.8 to 151.1 N・m
M14 x 1.5 { 7.8 to 11.7 kgf・m / 56 { 8.5 to 12.7 kgf・m / 61 { 9.5 to 14.2 kgf・m / 69 { 10.3 to 15.4 kgf・m / 74
to 85 lb・ft } to 92 lb・ft } to 103 lb・ft } to 111 lb・ft }
*M14 x 2 { 7.3 to 10.9 kgf・m / 53 { 7.9 to 11.8 kgf・m / 57 { 9.0 to 13.4 kgf・m / 65 { 9.7 to 14.5 kgf・m / 70
M16 x 1.5 { 10.6 to 16.0 kgf・m / 77 { 11.8 to 17.7 kgf・m / 85 { 13.8 to 20.8 kgf・m / { 15.3 to 23.0 kgf・m /
to 116 lb・ft } to 128 lb・ft } 100 to 150 lb・ft } 111 to 166 lb・ft }
*M16 x 2 { 10.2 to 15.2 kgf・m / 74 { 11.2 to 16.7 kgf・m / 81 { 13.2 to 19.8 kgf・m / 95 { 14.5 to 21.8 kgf・m /
to 110 lb・ft } to 121 lb・ft } to 143 lb・ft } 105 to 158 lb・ft }
： 151.0 to 225.6 N・m ： 195.2 to 293.2 N・m
M18 x 1.5 { 15.4 to 23.0 kgf・m / - { 19.9 to 29.9 kgf・m / -
111 to 166 lb・ft } 144 to 216 lb・ft }
： 151.0 to 225.6 N・m ： 196.1 to 294.2 N・m
*M18 x 2.5 { 15.4 to 23.0 kgf・m / - { 20.0 to 30.0 kgf・m / -
111 to 166 lb・ft } 145 to 217 lb・ft }
： 206.0 to 310.0 N・m ： 269.7 to 405.0 N・m
M20 x 1.5 { 21.0 to 31.6 kgf・m / - { 27.5 to 41.3 kgf・m / -
152 to 229 lb・ft } 199 to 299 lb・ft }
： 190.2 to 286.4 N・m ： 249.1 to 374.6 N・m
*M20 x 2.5 { 19.4 to 29.2 kgf・m / - { 25.4 to 38.2 kgf・m / -
140 to 211 lb・ft } 184 to 276 lb・ft }
： 251.1 to 413.8 N・m ： 362.8 to 544.3 N・m
M22 x 1.5 { 25.6 to 42.2 kgf・m / - { 37.0 to 55.5 kgf・m / -
185 to 305 lb・ft } 268 to 401 lb・ft }
： 217.7 to 327.5 N・m ： 338.3 to 507.0 N・m
*M22 x 2.5 { 22.2 to 33.4 kgf・m / - { 34.5 to 51.7 kgf・m / -
161 to 242 lb・ft } 250 to 374 lb・ft }
： 358.9 to 539.4 N・m ： 430.5 to 711.0 N・m

M24 x 2 { 36.6 to 55.0 kgf・m / - { 43.9 to 72.5 kgf・m / -
265 to 398 lb・ft } 318 to 524 lb・ft }
： 338.3 to 507.0 N・m ： 406.0 to 608.0 N・m
*M24 x 3 { 34.5 to 51.7 kgf・m / - { 41.4 to 62.0 kgf・m / -
250 to 374 lb・ft } 299 to 448 lb・ft }
Strength 9.8
8.8
category 9T
Bolt head
Hex bolt Flange bolt Hex bolt Flange bolt
shape
： 5.6 to 11.2 N・m { 0.6 ： 6.6 to 12.2 N・m { 0.7
M6 x 1 to 1.1 kgf・m / 50 to 99 to 1.2 kgf・m / 58 to 108 - -
lb・in } lb・in }
： 64.8 to 96.1 N・m { 6.6 ： 71.4 to 107.2 N・m ： 71.6 to 106.9 N・m ： 79.5 to 119.2 N・m
*M12 x 1.75 to 9.8 kgf・m / 48 to 71 { 7.3 to 10.9 kgf・m / 53 { 7.3 to 10.9 kgf・m / 53 { 8.1 to 12.2 kgf・m / 59
lb・ft } to 79 lb・ft } to 79 lb・ft } to 88 lb・ft }
*M14 x 2 { 10.3 to 15.3 kgf・m / 74 { 11.0 to 16.5 kgf・m / 80 { 10.9 to 16.3 kgf・m / 79 { 11.8 to 17.7 kgf・m / 85
M16 x 1.5 { 15.7 to 23.7 kgf・m / { 17.4 to 26.2 kgf・m / { 16.3 to 24.5 kgf・m / { 18.0 to 27.1 kgf・m /
114 to 171 lb・ft } 126 to 189 lb・ft } 118 to 177 lb・ft } 130 to 196 lb・ft }
*M16 x 2 { 15.1 to 22.6 kgf・m / { 16.6 to 24.9 kgf・m / { 15.6 to 23.4 kgf・m / { 17.2 to 25.8 kgf・m /
109 to 163 lb・ft } 120 to 180 lb・ft } 113 to 169 lb・ft } 124 to 186 lb・ft }
： 222.5 to 334.3 N・m ： 229.5 to 345.2 N・m
M18 x 1.5 { 22.7 to 34.1 kgf・m / - { 23.4 to 35.2 kgf・m / -
164 to 247 lb・ft } 169 to 255 lb・ft }
： 223.6 to 335.4 N・m ： 230.5 to 346.2 N・m
*M18 x 2.5 { 22.8 to 34.2 kgf・m / - { 23.5 to 35.3 kgf・m / -
165 to 247 lb・ft } 170 to 255 lb・ft }
： 307.4 to 461.7 N・m ： 293.2 to 440.3 N・m
M20 x 1.5 { 31.3 to 47.1 kgf・m / - { 29.9 to 44.9 kgf・m / -
227 to 341 lb・ft } 216 to 325 lb・ft }
： 284.0 to 472.1 N・m ： 293.2 to 440.3 N・m
*M20 x 2.5 { 29.0 to 48.1 kgf・m / - { 29.9 to 44.9 kgf・m / -
209 to 348 lb・ft } 216 to 325 lb・ft }
： 413.6 to 620.5 N・m ： 424.6 to 636.5 N・m
M22 x 1.5 { 42.2 to 63.3 kgf・m / - { 43.3 to 64.9 kgf・m / -
305 to 458 lb・ft } 313 to 469 lb・ft }
： 385.7 to 578.0 N・m ： 394.2 to 592.3 N・m
*M22 x 2.5 { 39.3 to 58.9 kgf・m / - { 40.2 to 60.4 kgf・m / -
284 to 426 lb・ft } 291 to 437 lb・ft }
： 490.8 to 810.5 N・m ： 554.1 to 830.6 N・m

M24 x 2 { 50.0 to 82.6 kgf・m / - { 56.5 to 84.7 kgf・m / -
362 to 598 lb・ft } 409 to 613 lb・ft }
： 462.8 to 693.1 N・m ： 520.7 to 781.6 N・m
*M24 x 3 { 47.2 to 70.7 kgf・m / - { 53.1 to 79.7 kgf・m / -
341 to 511 lb・ft } 384 to 576 lb・ft }
Note：・ Refer to the following diagram regarding the
・ Those indicated with an asterisk ( * ) are used marking on the top of standard bolts.
for the female threaded portion of soft
materials such as castings.
1. Hex bolt, 4.8, 4 T 10. Hex bolt, non-thermal refining 8.8

2. Hex bolt, 4.8, 4 T 11. Flange bolt 8.8
3. Flange bolt, 4.8, 4 T 12. Flange bolt 8.8
4. Flange bolt, 4.8, 4 T 13. Hex bolt, 9.8, 9 T
5. Hex bolt, 7 T 14. Hex bolt, 9.8, 9 T
6. Flange bolt, 7 T 15. Flange bolt, 9.8, 9 T
7. Hex bolt, thermal refining 8.8 16. Flange bolt, 9.8, 9 T
8. Hex bolt, thermal refining 8.8
9. Hex bolt, non-thermal refining 8.8
Tightening torque for large/medium sizeFlare nut width across flat

Pipe diameter
vehicles Previous New
： 12.8 to 18.6 N・m { 1.3 to 1.9 kgf・： 14 mm ： 14 mm
： 4.6 mm { 0.181 in }
m / 9 to 14 lb・ft } { 0.55 in } { 0.55 in }
： 23.5 to 49.0 N・m { 2.4 to 5.0 kgf・： 17 mm ： 17 mm
： 6.35 mm { 0.25 in }
m / 17 to 36 lb・ft } { 0.67 in } { 0.67 in }
： 23.5 to 49.0 N・m { 2.4 to 5.0 kgf・： 19 mm ： 17 mm
Tightening torque of ： 8.0 mm { 0.31 in } m / 17 to 36 lb・ft } { 0.75 in } { 0.67 in }
the flare nut
Service standard value ： 10.0 mm { 0.39 in } ： 44.1 to 93.2 N・m { 4.5 to 9.5 kgf・： 22 mm ： 19 mm
m / 33 to 69 lb・ft } { 0.87 in } { 0.75 in }
： 58.8 to 137.3 N・m { 6.0 to 14.0 kgf・： 27 mm ： 24 mm
： 12.0 mm { 0.47 in }
m / 43 to 101 lb・ft } { 1.06 in } { 0.94 in }
： 78.5 to 156.9 N・m { 8.0 to 16.0 kgf・： 30 mm ： 30 mm
： 15.0 mm { 0.59 in }
m / 58 to 116 lb・ft } { 1.18 in } { 1.18 in }
Tapered thread for connectors and brass products

Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12
- { 0.20 to 1.50 kgf・m / { 0.5 to 1.6 kgf・m / 43 { 1.0 to 1.7 kgf・m / 87 { 1.0 to 1.8 kgf・m / 87
18 to 130 lb・in } to 139 lb・in } to 148 lb・in } to 157 lb・in }
Tapered thread for products other than connectors and brass products
Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/2 PT (R) 3/4
： 58.8 to 98.0 N・
： 5.9 to 11.8 N・m ： 14.7 to 29.4 N・： 29.4 to 39.2 N・： 29.4 to 58.8 N・
m { 6.0 to 10.0
- { 0.6 to 1.2 kgf・m / m { 1.5 to 3.0 kgf・ m { 3.0 to 4.0 kgf・ m { 3.0 to 6.0 kgf・
kgf・m / 43 to 72
52 to 104 lb・in } m / 11 to 22 lb・ft } m / 22 to 29 lb・ft } m / 22 to 43 lb・ft }
lb・ft }
Note： Note：
・ The tightening torque of the tapered thread for ・ For the elbow-type connector, tighten it with
products other than connectors and brass the minimum torque shown above and then
products is only applied when the opposite tighten it further until the angle matches.
side is not made of aluminum. ・ Apply Loctite 575 to the threaded portion and
tighten. Completely dry then let air in after
tightening.
・ Do not use seal tape, etc.
Maintenance Information (4HK1) 15B-1
Description Engine
Maintenance Information
(4HK1)
Table of Contents
Maintenance precautions...............................................15B-2
Primary specifications...................................................15B-5
Function, Structure, Operation......................................15B-8
Introduction to the trouble diagnosis...........................15B-60
15B-2 Maintenance Information (4HK1)
Maintenance precautions
1. Maintenance precautions Important precautions for handling this engine
The holes and gaps in the fuel system including inside the
1. Precautions on maintenance
injector where the fuel passes through are manufactured
To prevent the engine from being damaged and to ensure with high precision. Therefore, these are extremely
the reliability of engine performance, be careful of the sensitive to any foreign matter, and may be severely
following points when performing maintenance works. damaged due to foreign matter accidentally intruded. For
When placing the engine on the ground, make sure that this reason, extreme care must be taken to prevent any
the bearing surface of the oil pan does not directly contact foreign matter from entering.
the ground. When performing maintenance on the fuel system, take
Use an appropriate wood frame, etc. to support the engine extreme care to prevent any foreign matter from entering
at the engine foot portion and the flywheel housing the system.
portion.
・Before starting maintenance, clean the fuel line and its
There is only a small gap between the oil pan and oil
surroundings.
pump strainer, so be careful not to damage the oil pan and
oil strainer. ・Be sure to wash your hands before starting
maintenance. Do not put on cotton work gloves.
・While the air duct or air cleaner is removed, cover the
open section of the intake to prevent foreign matters from ・When the fuel hose or fuel pipe is removed, cover the
entering the cylinder. opening with a plastic bag and fix it with a piece of tape.
If a foreign matter enters the cylinder, it may seriously
・When the high-pressure piping of the fuel system is
damage the cylinder when the engine starts.
removed, be sure to replace it with a new one. If it is
・When maintaining the engine, be sure to disconnect the reused, the sealing surface may be damaged to cause fuel
negative battery cable. Failure to do this may cause the leakage.
harness or electrical components to be damaged.
・When replacing the fuel hose and/or fuel pipe, do not
If energizing is required for inspection, be careful not to
unpack new components before starting installation.
cause a short.
・When the fuel pipe, injection pipe, fuel injector, fuel
・Before assembly, apply the engine oil to the slide
supply pump, and/or common rail are removed, seal each
contact surface of the engine.
opening immediately.
This work ensures appropriate lubrication when first
starting the engine. ・Store the eyebolt and gasket in a clean parts box with a
cover so that foreign matter does not attach to them.
・When the valve train component, piston, piston ring,
connecting rod, connecting rod bearing, and/or crankshaft ・Fuel leakage may cause a fire. Therefore, be sure to
journal bearing are removed, line them up in the correct wipe spilled fuel after completing the maintenance work
order so that their original positions are clear. and confirm that there is no fuel leakage before starting
the engine.
・When installing, install it in the same position as when
it was removed. 2. Urea fluid precautions
・When assembling the engine, replace the gasket, oil Urea fluid is a colorless, odorless, and harmless aqueous
seal, and O-ring with new ones. solution.
Although there are no problems associated with it coming
・For a component with the liquid gasket applied,
in contact with skin, in rare instances such contact may
carefully remove the old liquid gasket and clean the
result in irritation. Please take the following precautions.
component so that no oil, water, and/or dust remain.
Wash off with water when contact is made with skin.
Thereafter, apply the specified liquid gasket to each
If accidentally swallowed, drink 1 to 2 cups of water or
component before assembly.
milk and immediately seek the advice of a doctor.
・Assemble components with the liquid gasket applied If contact is made with eyes, immediately wash out with
within 5 minutes of applying the liquid gasket. large amounts of water for 15 minutes or more and seek
If 5 minutes have passed, remove the old liquid gasket the advice of a doctor.
and apply liquid gasket again.
When using urea fluid, avoid the following. Failure to
・When assembling or installing a component, make sure avoid the following may result in damage or breakage of
to tighten them at the specified torque to ensure secure the urea SCR system.
installation. Do not dilute with water.
Do not add any substance to the system other than urea is required for a person to be able to detect electrostatic
fluid, such as gasoline or diesel oil. discharge.
Do not add any urea fluid other than that specified. There are various ways a person can build up an
electrostatic charge. The most common way to build up
3. Cautions on electronic system
an electrostatic charge is through methods based on
Using circuit test tools friction or induction.
Unless specifically instructed in the diagnostic procedure, An example of when a person builds an electrostatic
do not use a test light when diagnosing the powertrain charge by friction is when he/she slides across the seat of
electronic system. When a probe connector is required in the machine.
the diagnostic procedure, use the connector test adapter A person wearing insulated shoes can build an
kit. electrostatic charge by induction if he/she momentarily
touches the ground while standing near a highly charged
object. A charge of the same polarity flows out, and with
a highly opposing polarity, that person becomes charged.
As static electricity causes damage, be cautious when
handling or testing electronic components.
Caution：
・ To prevent damage due to electrostatic
SST: 5-8840-2835-0 - connector test adapter kit discharge, do not touch the connector pins of
the ECM or the electronic components
Commercial electronic equipment soldered onto the circuit board of the ECM.
Commercial electronic equipment refers to commercially
available electronic equipment attached to the machine ・ To prevent damage due to electrostatic
after it has been shipped from the factory. Be careful, as discharge, do not open the packaging of a
such accessories are not taken into particular replacement part until installation preparation
consideration at the machine design stage. for the replacement part is completed.
Commercial electronic equipment may cause ・ To prevent damage due to electrostatic
malfunctions in the electronic control system, even if the discharge, connect the part packaging to a
equipment is properly attached. This includes equipment properly working ground connection of the
not connected to the electronic system of the machine, machine before removing the part from its
such as mobile telephones and radios. Therefore, when packaging.
diagnosing power train problems, confirm whether such ・ To prevent damage due to electrostatic
commercial electronic equipment is attached first and discharge, when handling a part while sliding
then remove them from the machine if such equipment is across the seat, sitting down from a standing
attached. If the problem has not been resolved after position, or walking a certain distance, touch a
removing the equipment, perform the diagnosis using the properly working ground connection before
regular procedure. attaching the part.
Caution： Fuel injection system
・ Make sure that commercial electronic Fuel piping
equipment is connected to a circuit that is not The high pressure pipe and injector pipe in the fuel
involved with the circuits of the electronic system should not be reused. When it is once removed,
control system for both power and ground. make sure to replace it with new one.
The pressure limiter or fuel pressure sensor should not be
Welding operation for the machine replaced individually. When a failure is found, the
When performing welding to the machine, make sure to common rail assembly and all fuel pipes should be
disconnect the battery in prior to the operation. replaced.
Current that occurred during welding may lead to failure
and/or damage to the electronic control system.
Damage caused by electrostatic discharge
As the electronic components used in the electronic
control system are designed to operate at extremely low
voltages, they can be easily damaged by electrostatic
discharge, and some types of electronic components can
be damaged by static electricity of 100 V or less, which
cannot be felt by a person. Note that a voltage of 4000 V
1. Injector pipe
2. Fuel pressure sensor
3. Pressure limiter
4. Common rail
4. Programming
Programming guideline
When the ECM or injector has been replaced, use the
trouble diagnosis scan tool to write each data into the
ECM.
As for the programming method, refer to the instruction
manual of the trouble diagnosis scan tool.
About items to check before programming
When performing programming, check the following
items as necessary.
・ECM part No.
・Engine model
・Engine No.
・Injector ID Code
About items which require programming
・When the ECM has been replaced, perform
programming.
・When the engine has been replaced, perform
programming.
・When the injector has been replaced, perform
programming.
Primary specifications
1. Primary specifications Engine main specifications
Item Engine model 4HK1

Type Diesel/4-cycle/water-cooled, inline 4-cylinder OHC
Combustion chamber shape Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm {4.53 in} x 125 mm {4.92 in}
Displacement 5.193 L {316.88 cu⋅in}
Compression ratio 16.5
Compression pressure ： 3.23 MPa { 32.9 kgf/cm2 / 468 psi } 200 r/min
Idling speed 800 r/min
Intake ： 0.4 mm { 0.016 in } When cold
Valve clearance
Exhaust ： 0.4 mm { 0.016 in } When cold
Ignition method Compression ignition
Injection order 1, 3, 4, 2
Lubrication system
Lubrication type Compression type
Oil pump type Gear type
Lubrication oil amount ： 19.5 to 27.0 L { 5.2 to 7.1 US gal }
Oil filter type Full-flow/partial flow integrated filter (Cartridge type)
Oil cooling type Built-in type, water-cooled
Cooling system
Cooling type Water-cooled
Radiator type Corrugated fin (Pressure type)
Water pump type Centrifugal type, belt type
Thermostat type 2-wax type unit
： 76.5 ℃ { 170 °F } With jiggle valve
Type 1 ： 82.0 ℃ { 180 °F } Without jiggle valve
Thermostat valve open temperature
： 85.0 ℃ { 185 °F } With jiggle valve
Type 2
： 82.0 ℃ { 180 °F } Without jiggle valve
Coolant capacity ： 14.5 L { 3.8 US gal }
Fuel system
Injection pump type Electronic control common rail (fuel rail) type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
8 holes, inner diameter φ 0.14 mm {0.0055 in}
Charging system
Generator type AC type
： 24 V / 50 A
Output
： 12 V / 110 A
Regulator type IC
Starter system
Starter type Reduction type
： 24 V / 5.0 kW
Output
： 12 V / 2.5 kW
Preheat system type Glow plug
： 23 V / 3.8 A
Glow plug standard voltage/current
： 11 V / 4.8 A
Cooling system main specifications
Item Specifications
Water pump Centrifugal impeller method
Pulley ratio 0.85
Thermostat Wax pellet type
： 90 ℃ { 194 °F } With jiggle valve
Type 1
： 95 ℃ { 203 °F } Without jiggle valve
Full open temperature
： 100 ℃ { 212 °F } With jiggle valve
Type 2
： 95 ℃ { 203 °F } Without jiggle valve
Electrical system main specifications
Generator
Item Specifications
Isuzu part number 8980921161 8980762602
Nominal output ： 24 V / 50 A ： 12 V / 110 A
Rated speed ： 5000 r/min ： 5000 r/min
Regulator type IC type IC type
Regulated voltage ： 28 to 29 V ： 14.1 to 14.7 V
Weight ： 9.5 kg { 20.9 lb } ： 6.0 kg { 13.2 lb }
Starter
Model (Manufacturer) Nikko
Rating Voltage ： 24 V ： 12 V
Output ： 5.0 kW ： 2.5 kW
Time 30 seconds 30 seconds
Number of pinion teeth 13 13
Rotational direction (To the pinion) Right Right
Weight (Approx.) ： 8.0 kg { 17.6 lb } ： 8.0 kg { 17.6 lb }
Current/voltage ： less than 85 A / 24 V ： less than 150 A / 12 V
No-load characteristics
Speed ： more than 3300 r/min ： more than 2600 r/min
Current/voltage ： 400 A / 18.5 V ： 400 A / 9.0 V
： more than 14.7 N・m { more than
Load characteristics Torque 28.4 N⋅m {2.9 kgf⋅m} or more
1.5 kgf・m }
Speed 1250 r/min or more ： more than 900 r/min
Current/voltage ： less than 1400 A / 9 V ： less than 1400 A / 5.2 A
Locking characteristics ： more than 44.1 N・m { more than
Torque 88.2 N⋅m {9.0 kgf⋅m} or more
4.5 kgf・m }
Glow plug
Item Model
Preheat device model Glow plug
Glow plug rated voltage/current ： 23 V / 3.8 A
： 11 V / 4.8 A
Function, Structure, Operation

1. Engine number
1. Engine number stamping
2. Function, Structure, Operation 1. Engine structural diagram

2. Description of functions and operations Crankshaft

The crankshaft uses tufftrided steel, and each of the
Engine electronic control
journal diameter grades are marked on the No. 1 balance
The control provided by the control unit applies to the
weight.
range from injection to air intake and exhaust, including
fuel injection quantity, injection timing, air intake EGR system
restriction, EGR, and idling speed. The EGR system is controlled by the engine control
module (ECM) according to various data, including the
Cylinder block
water temperature, engine speed, and engine load, to
The cylinder block is made of cast iron, and it has an
recirculate the exhaust gas for purification.
equal center distance for each bore and a high rigidity,
The primary components are the EGR valve, EGR cooler,
and the center of the crankshaft matches the center of the
and various sensors.
block. The bearing cap is tightened using the plastic
region rotational angle tightening method with the ladder Connecting rod cap bolt
frame structure. The angle tightening method has been adopted for the
connecting rod cap bolt to further improve its reliability
Cylinder liner
and durability.
A cylinder liner that matches with the cylinder block bore
inner diameter is selected, and the identification number Common rail (fuel rail) type electronic control injection
is stamped on the left side of the cylinder. system
The common rail (fuel rail) type electronic control
Piston
injection system consists of the fuel supply pump that
The piston is a strut cast auto-thermatic piston made of
sets the target pressure of the high-pressure fuel to supply
aluminum alloy, and the combustion chamber is the
the fuel, the common rail (fuel rail) that measures the
round re-entrant type.
high-pressure fuel, and the fuel injector that injects the
Cylinder head fuel in the form of a fine mist. Each of these is controlled
The cylinder head is made of cast iron and has four by the ECM based on various signals that control the
valves per cylinder. The angle tightening method has injection timing and injection quantity in accordance with
been adopted for the cylinder head bolt to further improve driving conditions.
its reliability and durability.
Fuel injector
The fuel injector has adopted the 7-hole nozzle, and Preheat system
adjusts the fuel injection quantity and injection timing by The preheat system consists of the ECM, glow relay,
opening or closing the electromagnetic valve on the glow plug, and glow indicator light The preheat system is
injector head portion. activated when the engine coolant temperature is low so
The ECM corrects variations in the fuel injection quantity as to help engine start.
between fuel injectors in accordance with the ID code
Lubrication system
data in the memory. When adjusting the fuel injector, the
An oil filter with a full-flow bypass is used, and the
ID code data must be recorded in the ECM.
pistons are cooled down using the water-cooled oil cooler
Fuel filter with sedimenter and the oil jet.
The fuel filter with sedimenter removes water by using
3. Fuel system
the difference in the specific gravity of diesel oil and
water, and notifies the operator through the indicator Fuel system diagram (Type 1)
when it becomes full of water.
1. Electromagnetic pump 6. Fuel tank

2. Fuel filter 7. Fuel return pipe
3. Common rail 8. Pre-fuel filter
4. Fuel injector
5. Supply pump
Fuel system diagram (Type 2)

1. Electromagnetic pump 5. Supply pump

2. Fuel filter 6. Fuel tank
3. Common rail (Fuel rail) 7. Pre-fuel filter
4. Fuel injector
Caution： Common rail

・ Since the high-precision fuel system has been
adopted, take care to prevent any foreign
matter from entering the fuel system.
1. Pressure sensor 3. Common rail (Fuel rail)

2. Pressure limiter
Fuel supply pump (Type 1)

1. Fuel temperature sensor 5. Camshaft nut

2. Suction control valve 6. Union
3. High pressure pipe 7. Joint bolt
4. Camshaft key
Fuel supply pump (Type 2)

1. Camshaft key 4. FRP regulator

2. Fuel temperature sensor
3. High pressure pipe
Caution：
・ There is a gauze filter assembled inside the
union of the fuel supply pump, but the union
should not be removed to prevent any foreign
matter from entering.
5. Gasket
6. O-ring
7. Leak-off pipe installation section
Fuel filter (Element replacement type specification)
1. Union
2. Gauze filter
3. Supply pump
4. Strainer
5. Joint bolt
Injector
1. Priming pump
2. Air bleeding plug
3. Case
4. Drain plug
Fuel filter (Cartridge type specification)
1. ID plate
2. Terminal stud
3. Injector drive section
4. Injector assembly
1. Air bleeding plug The coolant system is the forced-circulation system, and
2. Cartridge type element its main components are the water pump, thermostat and
radiator.
4. Cooling system
1. Water jacket 10. Radiator reserve tank

2. Drain plug 11. Air removal plug
3. Oil cooler 12. Water outlet pipe
4. Water pump 13. Thermostat, 2 units
5. Drain cock 14. Water temperature sensor
6. Radiator 15. Bypass route
7. Cooling fan 16. Turbocharger
8. Radiator cap 17. EGR cooler
9. Heater core
Water pump The water pump is a centrifugal-impeller-type pump and

is driven by the engine fan belt.
1. Fan guide 4. Seal unit

2. Bearing
3. Impeller
Thermostat housing unit and allow for specific temperature

The thermostat is a wax pellet type, and consists of 2 adjustments.
units. One is a bottom bypass type while the other is an
inline type. They are installed inside the thermostat
1. Jiggle valve 4. Gasket

2. Stamp mark (initial open valve temperature) 5. Piston
3. Valve
5. Lubrication system A full-flow bypass integrated filter element, water

cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.
Oil pump structural diagram

1. Driven gear 6. Drive gear

2. Oil pump body 7. Driven gear
3. Drive gear 8. Oil pump drive gear
4. Oil pump drive gear
5. Oil pump body
6. Induction system Turbocharger structural diagram

1. Connector 6. Coolant inlet

2. Rod 7. Coolant outlet
3. Oil inlet 8. Oil outlet
4. Turbine housing 9. Compressor housing
5. Exhaust adapter
7. Exhaust system cleans exhaust gases by purifying NOx in the exhaust

gases treated with the catalyst though a reaction with urea
The exhaust throttle valve adjusts the exhaust pressure to
fluid.
perform engine QWS.
The urea SCR system is installed to the rear of the
oxidation catalyst. The urea SCR system is a system that
1. Front chamber 7. NOx sensor 1

2. EGT sensor 3 8. Oxidation catalyst 2
3. SCR catalyst 9. EGT sensor 1
4. NOx sensor 2 10. EGT sensor 2
5. Exhaust silencer 11. Oxidation catalyst 1
6. Mixer chamber
SCR is short for Selective Catalytic Reduction. The EGR is activated when the specified conditions of
engine speed, engine coolant temperature, intake air
8. Emission control device
temperature, and barometric pressure are met. Then, the
EGR valve opening position is calculated based on engine
The EGR system recirculates part of the exhaust gas back speed and the desired fuel injection quantity. The motor
into the intake manifold, which results in reduced drive duty is determined from this valve opening
nitrogen oxide emissions. Higher operability and position, and the valve is driven according to the motor
emission reduction are both realized by controlling the drive duty. The intake throttle valve closes when the EGR
EGR system. A control current from the ECM operates a is activated in order to maintain an appropriate pressure
solenoid to control the lift amount of the EGR valve. In in the intake manifold.
addition, the EGR position sensor is used for detection of
the actual valve lift amount and for precision control of
the EGR amount.
1. EGR position sensor 9. IMT sensor

2. EGR valve 10. Intake throttle valve
3. Intake throttle position sensor 11. Boost pressure sensor/boost temperature sensor
4. EGR gas temperature sensor 2 12. MAF/IAT sensor
5. Coolant outlet 13. Engine speed
6. Coolant inlet 14. Engine load
7. EGR cooler
8. EGR gas temperature sensor 1
9. Electrical system The main components include the rotor, stator, rectifier
assembly, front bracket, rear bracket, IC regulator,
Charging system
bearing, and pulley.
The main components of the charging system are the
The moving parts are the rotor and pulley. The field coil
battery, the generator, and the battery discharge indicator
is fixed to the rear bracket.
light circuit. The generator is the self-rectifier type with a
6 main diodes and 2 additional diodes are used to change
regulator built in.
the three-phase alternating current generated in the stator
Generator (24 V/50 A) coil to a direct current.
The generator is the brushless type. 3 out of the 6 main diodes are referred to as positive
diodes, and the rest are referred to as negative diodes.
In addition, 3 small diodes that are referred to as trio- Also, it functions as an output terminal. (Current capacity
diode are used to supply the field current. is 1 A.) When the L terminal voltage reaches the battery
This generator has 3 terminals: the B terminal (direct voltage, the charge light turns OFF.
current output terminal), L terminal, and R terminal. Since the both bearings are sealed, periodic lubrication is
Since the L terminal is connected to the field coil, it not required.
works as an input terminal of the initial excitation current The IC regulator cannot be disassembled, so it should be
together with the R terminal until the generator starts handled as an assembly.
generating power.
1. Rectifier 7. Rotor
2. Field coil 8. Rear bracket
3. Stator 9. Regulator
4. Bearing 10. Bearing
5. Pulley
6. Front bracket
Generator (12 V/110 A) voltage is not required. There are 8 diodes in the rectifier
The charging system uses an IC integral regulator connected to the stator coil. They convert AC voltage into
charging method. The regulator is an integrated solid- DC voltage. The DC voltage is connected to the generator
state type regulator. It is built into the generator, and output terminal.
installed onto the rear end cover together with the brush
holder. Generator maintenance such as adjusting the
1. Pulley 6. Rectifier
2. Bearing 7. Regulator
3. Front bracket 8. Bearing
4. Stator 9. Rear bracket
5. Rotor
Starter system When the ignition switch is turned ON, the plunger is
The starter is 24 V/5.0 kW or 12 V/2.5 kW and is a drawn in, the contact point of the magnetic switch closes
reduction type. and the armature rotates. At the same time, the pinion is
The gear housing and armature end bearing housing are pushed to the front via the shift lever to mesh with the
made of aluminum. Brush assembly is the replaceable ring gear. When the ring gear rotates, the crankshaft is
type. turned to start the engine. After the engine starts and the
The starter circuit is started using the battery. ignition switch is turned OFF, the plunger returns, the
The battery cable is connected to a large terminal on the pinion separates from the ring gear, and the armature
starter. stops rotating . When the engine speed becomes faster
The wiring is connected from the terminal to the engine than the pinion, the pinion attempts to turn in reverse, but
control switch and starter relay. it just idles due to the one-way clutch function, so the
armature is not driven.
Starter
The starter is a magnetic-shift-type, inner gearing mesh
method reduction starter.
1. Lever assembly 6. Internal gear

2. Magnetic switch assembly 7. Clutch
3. Yoke 8. Pinion
4. Armature
5. Brush holder
Preheat system Also, besides controlling the engine, the engine control
The preheat system adopts the glow plug type QOS system has a QOS system, engine speed signal output,
system. Also, energization is controlled by the ECM. self-diagnosing functionality, and CAN communication
SAE J1939/21 and SAE J1939/11 system control
10. Engine control system
functions.
Engine control system overview and implementation
System control schematic
The engine control system is an electronic control system
The specifications vary depending on the machine, so
that controls the engine so as to always be in the optimal
refer to the manual of the machine.
combustion state according to the driving condition, and
consists of the electronic control fuel injection system,
the EGR, and the idling control.
Fuel injection correction

The ECM calculates the basic injection quantity based on
the signals from the accelerator position sensor, boost
sensor, CKP sensor, CMP sensor, etc. Then, the open/
close timing of the SCV and the energizing time of the
injector are controlled based on conditions such as the
common rail (fuel rail) pressure and engine coolant
temperature, which allows for optimal corrections to the
injection timing and the injection quantity.
About the initial fuel delivery rate
The ECM implements the initial fuel delivery rate when
the initial fuel delivery rate is less than the specified
engine speed when the engine is started. Also, when the
engine speed is lower than the system can recognize, the
ECM cannot implement the initial fuel delivery rate and
cannot start the engine because it does not recognize the
engine speed.
About high altitude correction
The ECM calculates the current altitude using signals the corresponding function is added to the calibration of
from the barometric pressure sensor. the ECM.
According to conditions such as the current altitude, the
Input from the engine stop switch
fuel flow rate is optimally calibrated.
The engine stops when battery voltage is applied to ECM
terminal No. B50.
Control during overheat

A fuel flow rate is restricted to protect the engine when
Decrease in engine oil pressure
the engine coolant temperature excessively increases. If
When the engine oil pressure excessively decreases, an
the engine coolant temperature continues to increase, fuel
alarm for the engine oil pressure decrease is issued and
flow will be further restricted according to the
the engine is stopped.
temperature increase.
The system to issue an alarm is employed together with Increase in engine coolant temperature
the fuel flow restriction depending on the machine. When the engine coolant temperature excessively
increases, an alarm for the engine coolant temperature
Engine emergency stop function
increase is issued and the engine is stopped.
The ECM is designed to make an emergency engine stop
when there is input from the engine stop switch, when Overrun
there is a decrease in the engine oil pressure, when there When the engine speed reaches a specified value or more,
is an increase in the engine coolant temperature, or when an overrun alarm is issued and the engine is stopped.
an overrun occurs. Varies depending on the machine manufacturer.
For an emergency stop made due to a decrease in the I/O Table
engine oil pressure, an increase in the engine coolant
temperature, or an overrun, the control is performed when
Electronic control fuel injection system Injection quantity control

This is the system in which the ECM obtains information To optimize the injection quantity, the fuel injection
such as engine speed and engine load, and sends quantity is controlled by regulating the injector based
electrical signals based on this information to the supply mainly on the signals from the engine speed and the
pump, injectors, etc., to properly control the fuel injection accelerator opening position or the instructed rotation
quantity and the injection timing for each cylinder. from the control unit in the machine.
Injection pressure control second injection is performed when ignition is made.

The injection pressure is controlled by regulating the fuel This control of the injection timing and injection quantity
pressure inside the common rail (fuel rail). The proper is performed by regulating the injector.
pressure inside the common rail (fuel rail) is controlled
Maximum fuel injection quantity
based on calculations of the engine speed, the fuel
The maximum fuel injection quantity is the quantity of
injection quantity, etc., and the appropriate amount of
fuel injection calculated by adjustment of the initial
fuel is discharged and force-fed to the common rail (fuel
injection quantity under a certain water temperature, the
rail) via regulation of the supply pump.
limitation of the maximum injection quantity for the
Injection timing control boost pressure, and the control of the injection quantity
This control is performed by calculating the proper fuel for high altitudes according to barometric pressure.
injection timing mainly from the engine speed or the
Inter-cylinder correction
injection quantity in substitution of the timer function to
It is not used for this engine.
regulate the injector.
System schematic
Injection rate control
To improve combustion inside the cylinder, only a small
amount of fuel is injected first to be ignited, and then the
Fuel system fuel amount to be supplied to the common rail (fuel rail)
The fuel is supplied to the supply pump from the fuel is controlled by regulating the FRP regulator based on the
tank, and then it is boosted by the pump before being signal from the ECM.
supplied to the common rail (fuel rail). At this time, the
1. Electromagnetic pump 6. Fuel tank

2. Fuel filter 7. Fuel return pipe
3. Common rail 8. Pre-fuel filter
4. Fuel injector
5. Supply pump
Removing air from the fuel system Wait for approx. 1 minute, and then loosen the plug to
Place an appropriate pan under the air removal plug. remove the air in the fuel filter. This should be repeated
Turn the ignition switch ON, and activate the at least 3 times until no air comes out from the plug.
electromagnetic pump. Securely tighten each plug, and wipe up any fuel spilled
Loosen the air removal plug of the fuel filter sufficiently, in the vicinity. Operate the priming pump 10 - 15 times
and operate the priming pump 20 times or more until the until the fuel permeates and is fed to the engine.
fuel comes out from near the plug.
Tighten the plug, and operate the priming pump 10 times
or more until the fuel permeates.
EGR The ECM controls the EGR valve lift amount by

The EGR system recirculates part of the exhaust gas to operating the motor according to the engine status,
the intake manifold, and by mixing in inert gas with the determined by the engine speed and engine load, etc. The
intake air, combustion temperature is lowered and the valve lift amount is detected by the EGR position sensor.
generation of nitrogen oxide is suppressed. The darker portions of the diagram represent large valve
The EGR amount is controlled by opening and closing lift amounts, and the darkest portion represents a lift
the EGR valve installed between the exhaust manifold amount of nearly 100%.
and intake manifold. The EGR amount is determined
from the engine speed and engine load ratio, and the EGR
valve is operated to control the EGR amount.
By providing the EGR cooler on the path of the EGR gas,
high-temperature EGR gas is cooled by the EGR cooler
and then mixed with air to further lower the combustion
temperature in order to reduce the NOx amount.
Further, the EGR system is also equipped with a check
valve to prevent the EGR from flowing in the opposite
direction to increase the EGR amount.
EGR control
EGR system schematic diagram
1. EGR position sensor 2. EGR valve

3. Intake throttle position sensor 10. Intake throttle valve
4. EGR gas temperature sensor 2 11. Boost pressure sensor/boost temperature sensor
5. Coolant outlet 12. MAF/IAT sensor
6. Coolant inlet 13. Engine speed
7. EGR cooler 14. Engine load
8. EGR gas temperature sensor 1
9. IMT sensor
EGR and turbine noise control unit via CAN communication in order to properly
Depending on the engine, high frequency sounds may be control the boost pressure in accordance with the engine
generated based on the turbine speed. The high-frequency load requirements. The turbo control unit drives the turbo
sounds can be muted by installing an appropriate silencer. actuator based on the information received from the ECM
Depending on the OEM, if use in residential areas is not and controls the nozzle vane via the control rod.
expected, the silencer high-frequency sound The position sensor is installed to the turbo actuator. The
countermeasure specification may not be included and turbo control unit performs feedback control based on
some high-frequency sounds may remain audible. The information from the position sensor, etc. It is at this time
high-frequency sounds tend to lessen in intensity during the actual nozzle opening position is determined, and the
EGR control and return to their original sound levels nozzle vane opening position is adjusted to an optimal
when control stops. level via the nozzle control rod.
Turbocharger control 1. Turbine wheel

The turbocharger is a system which efficiently uses boost 2. Nozzle
pressure to enable a turbocharger effect even when turbo 3. Turbo actuator
is weakest (when engine speed and exhaust energy are 4. Exhaust gas inlet
low). The turbocharger optimizes turbine speed by 5. Control rod
varying the opening position of the nozzle inside the 6. Exhaust gas outlet
turbine housing, adjusting the inlet area of the turbo
based on engine speed and load to control boost pressure.
The ECM sends the desired nozzle opening position
based on information from each sensor to the turbo
Turbo actuator operation nozzle vane operates the nozzle control rod movement
The actuator is activated based on signals from the turbo via an operating plate.
control unit, and the nozzle control rod is moved. The
Engine operation control

There are the following 4 types of operation control
instructions, and the selection varies depending on each
specification.
・Voltage input by APS {1 to 4 V}
・CAN communication control
Accelerator opening position instructions {0 to 100%}
and speed instructions
・Mode map switch control
Change instructions given by the APS and speed
instructions
・Increase and decrease instructions for each rotation
given by the idle switch
Accelerator position switch {APS}
By operating the accelerator position switch, the output
voltage changes between 1 V and 4 V.
If the voltage is between 0.2 V and 1.05 V, it is
recognized as 1 V. If below 0.2 V or above 1.05 V, an
Accelerator position switch {APS learning control}
error is detected.
If APS learning control is available, when the ignition
If ECM terminal numbers B30 and B27 do not have the
cycle ends with the accelerator position at 2 V, for
same potential, DTC P2138 is set.
example (1), the accelerator position learning causes the 2
V status to be recognized as the opening position 0%, and
the control range changes from 2 V to 4 V (2).
CAN communication Mode map switch

There are 7 speed control mode types: S1, S2, S3, L1, L2,
When CAN controller does not exist on the machine side
L3, and L4 via combinations of the 3 switches.
L1, L2, L3, and L4 are the maximum speed restriction
control modes and allow the speed to be changed by the
APS.
S1, S2, and S3 are the speed-fixed modes and do not
allow the speed to be changed by the APS.
The set engine speeds are determined by calibration of
the ECM.
Mode map switch control
When CAN controller exists on the machine side

Outer switch
Operation mode Control
MAP0 MAP1 MAP2
- OFF OFF OFF -
S1 ON OFF OFF Constant rotation operation #1
S2 ON ON OFF Constant rotation operation #2
S3 ON ON ON Constant rotation operation #3
L1 OFF ON OFF Maximum speed control #1
L2 OFF ON ON Maximum speed control #2
L3 OFF OFF ON Maximum speed control #3
L4 ON OFF ON Maximum speed control #4
Regulation mode switch Idling control
When the regulation mode switch input is present in By operating the idling control change switch during the
addition to the mode map switch, the following 2 types of warm-up operation, the minimum idling speed can be
control methods are available. adjusted. In addition, by operating the idling control
change switch, the minimum idling speed can be
automatically set to the optimum value in accordance
with the engine coolant temperature.
Note：
・ The specifications vary depending on the
machine, so availability of functions also
differs.
Idling control change switch
By operating the idling control change switch, the idling
control functions can be switched.
Idling control switch
By operating the idling control switch, the idling speed
can be adjusted.
Note：
・ For the installation positions of the idling
control change switch and the idling control
1. Directed speed switch, refer to the manual of the machine.
The engine speed upper limit varies depending
on the engine type, the machine specifications,
and the engine warm-up condition.
Up
While the Up side of the switch is pressed, the engine
speed is increased and the idling speed can be raised.
Down
While the Down side of the switch is pressed, the engine
speed is decreased and the idling speed can be lowered.
However, the engine speed cannot be lowered to below
the minimum idling speed.
Control during ignition switch OFF state
There are 2 types of controls provided when the ignition
switch is turned OFF after the idling control switch is
operated, and either one of them is performed depending
on the specification.
The engine speed adjusted by the idling control switch is
recorded in the ECM, and the next time the vehicle is
1. Directed speed
operated, the engine speed is set to the speed it was at For verification and questions regarding the
when the ignition switch was turned OFF. specifications, contact an Isuzu service representative.
The engine speed adjusted by the idling control switch is
Idle manual control
not recorded in the ECM, and the next time the vehicle is
operated, the engine speed is set to the default speed.
Engine speed output to tachometer displays the engine speed based on the engine speed pulse
The ECM outputs the engine speed pulse to the sent from the ECM.
tachometer as a tachometer output. The tachometer
Preheat control switch is turned ON, the ECM detects the temperature of
QOS system the engine coolant based on the signal sent from the
The ECM determines the glow time according to the engine coolant temperature sensor to change the glow
engine coolant temperature, and activates the glow relay time, so the engine can always be started under optimum
and the QOC indicator light. The QOS system is a system conditions. Also, the after-glow function can stabilize the
to facilitate engine starting in low temperatures as well as idling immediately after the engine is started.
to reduce the amount of white smoke and noise generated
immediately after the engine is started. When the ignition
1. Engine 2. MAF/IAT sensor

3. Air cleaner 8. Oxidation catalyst 2
4. Various sensors 9. Oxidation catalyst 1
5. ECM 10. EGT sensor
6. Silencer
7. SCR catalyst
ECM accurate voltage reading can be obtained by using a

About ECM functions digital multimeter (for example, 5-8840-2691-0) with an
The ECM constantly monitors the information sent from input impedance of 10 MΩ.
various sensors, and controls the various systems of the
powertrain. The ECM performs the diagnostic functions
of the system, detects operational problems with the
system, warns the operator via the diagnostic light, and
stores DTCs. The DTC identifies the areas where
problems have occurred to assist the repair operation
performed by the technician.
The ECM outputs voltages (e.g. 5 V) to supply power to
various sensors and switches. The ECM controls the SST: 5-8840-2691-0 - digital multi-meter
output circuit by controlling the ground or power supply
Electrically erasable programmable read only memory,
circuit via one of the devices.
EEPROM
Note：
EEPROM contains various programs and calibration
・ As for the ECM installation position, refer to information necessary for the ECM to control the
the manual of the machine. powertrain operations.
If a malfunction is found with the EEPROM, replace the
ECM.
The program and calibration information for the ECM
powertrain control includes the engine type, engine
number, ECM part number, DTC, inter-cylinder
correction learning value, QR, Q adjustment, and EGR
correction learning value.
Notes on ECM maintenance
The ECM has been designed to withstand the regular
current consumption associated with machine operation.
Make sure that the circuit does not overload. When
testing for an open circuit or short circuit, do not ground
or apply voltage to any of the ECM circuits unless
instructed to do so. When performing these circuit tests,
make sure to use digital multimeter 5-8840-2691-0.
Note：
・ Use the ECM with the part No. corresponding
ECM and components to the machine.
The ECM is designed to maintain regulation levels of When performing welding work on the
exhaust gases while obtaining excellent performance and machine, start the work after disconnecting the
fuel efficiency. The ECM monitors various engine negative terminal of the battery.
functions via sensors such as the CKP sensor.
ECM voltage
The ECM applies the specified voltage to various
switches and sensors. The ECM is able to apply voltage
in such a way because the ECM resistance is very high,
and the voltage that is actually applied to the circuit is
low. Therefore, the test lamp may not illuminate even if it
is connected to the circuit. The voltmeter that is normally
SST: 5-8840-2691-0 - digital multi-meter
used at maintenance factories may not display a correct
reading because its input impedance is too low. An About turning OFF the ECM
In approximately 1 minute after turning the ignition Engine components location diagram
switch OFF, the internal power of the ECM is not turned The locations, shapes, and existence or nonexistence of
OFF. When it is necessary to turn OFF the ECM power, components vary depending on the specifications of the
e.g., when clearing the memory, it is necessary to wait 1 machine.
minute or more after turning the ignition switch OFF.
1. Overheat switch 9. Fuel temperature sensor

2. Engine coolant temperature sensor 10. Oil pressure sensor
3. Injector 11. EGR valve
4. Glow plug 12. CMP sensor
5. IMT sensor 13. Oil level switch
6. Boost pressure sensor/boost temperature sensor 14. CKP sensor
7. FRP sensor
8. FRP regulator
Supply pump
The supply pump highly pressurizes the fuel using the
engine torque, and force-feeds the fuel to the common
rail (fuel rail). The FRP regulator and fuel temperature
sensor are also installed to the supply pump.
resistance is lower, and it becomes higher when the
resistance is higher.
1. Suction control valve

FRP regulator 1. FRP regulator

The FRP regulator is installed on the supply pump and 2. Fuel temperature sensor
controls the fuel force fed to the common rail (fuel rail).
Note：
The ECM controls the fuel discharge amount by
regulating the energizing time for the FRP regulator. ・ Do not replace the fuel temperature sensor.
When a malfunction is found, replace the
supply pump assembly.
Common rail (fuel rail)
The common rail (fuel rail) receives the fuel from the
supply pump, retains the fuel pressure, and distributes the
fuel to each cylinder. The FRP sensor and the pressure
limiter are installed on the common rail (fuel rail).
1. FRP regulator
Fuel temperature sensor

The fuel temperature sensor is installed on the supply
pump, and the thermistor changes the resistance
according to the temperature change. The resistance
becomes lower when the fuel temperature is high, and
1. Pressure limiter
higher when the fuel temperature is low. The ECM
applies 5 V to the fuel temperature sensor through the
3. Common rail
pull-up resistor, and calculates the fuel temperature from
changes in the voltage, which is used to control the Pressure limiter
supply pump, etc. The voltage becomes lower when the
The pressure limiter is activated when the pressure in the injectors and applies this voltage to the injectors. Then,
common rail (fuel rail) becomes unusually high so as to by controlling the period of time in which the injectors
release the pressure inside the common rail (fuel rail). are energized, the ECM performs fuel injection quantity
control, as well as control of the fuel injection period.
1. Pressure limiter
Engine coolant temperature sensor
FRP sensor The engine coolant temperature sensor is installed on the
The FRP sensor, installed on the common rail (fuel rail), cylinder head, and the thermistor resistance changes
detects the fuel pressure inside the common rail (fuel according to the temperature change. The resistance
rail), converts pressure into a voltage signal, and sends it becomes lower when the engine coolant temperature is
to the ECM. The voltage becomes higher when the high, and higher when the engine coolant temperature is
pressure is higher, and it becomes lower when the low. The ECM applies 5 V to the engine coolant
pressure is lower. The ECM calculates the actual fuel temperature sensor through the pull-up resistor, and
pressure from the voltage signal sent from the sensor, and calculates the engine coolant temperature from changes in
uses it to control fuel injection, etc. the voltage. This value is used in various control
mechanisms, such as fuel injection control. The voltage
becomes lower when the resistance is lower, and it
becomes higher when the resistance is higher.
Injector
The injector is installed on the cylinder head portion, and
Overheat switch
is controlled by the ECM to perform fuel injection. The
ECM internally increases the voltage for driving the
The overheat switch is installed to the water outlet pipe uses the information for the fuel injection control and the
and turns ON if the engine coolant temperature exceeds calculation of the engine speed. While these controls are
105°C {221°F}. usually performed using the CKP signal, the CMP signal
is used instead when the CKP sensor is faulty.
CKP sensor
The CKP sensor is installed on the flywheel housing and 1. Camshaft gear
generates a CKP signal when the sensing hole on the 2. Rotational direction
flywheel passes by the sensor. The ECM determines the 3. CMP sensor
cylinder and specifies the crank angle using the CKP
signal input from the CKP sensor, and uses the Oil pressure sensor
information for the fuel injection control and the The oil pressure sensor is installed near the starter motor
calculation of the engine speed. on the cylinder block, and it detects the pressure of the
While these controls are usually performed using the engine oil, converts it into a voltage signal, and sends it
CKP signal, the CMP signal is used instead when the to the ECM.
CKP sensor is faulty. The voltage becomes higher when the pressure is higher,
and it becomes lower when the pressure is lower.
CMP sensor
The CMP sensor is installed on the rear part of the Accelerator position sensor
cylinder head and generates a CMP signal when the cam The accelerator position sensor is installed on the console
section of the camshaft passes by the sensor. The ECM panel of the machine and supplies to the ECM a voltage
determines the cylinder and specifies the crank angle signal that varies in accordance with the accelerator
using the CMP signal input from the CMP sensor, and volume angle. The ECM calculates the accelerator
position from the voltage signal, and uses it for fuel
injection control and many other controls.
Note：
・ As for the installation position of the
accelerator position sensor, refer to the
manual of the machine.
Barometric pressure sensor
The barometric pressure sensor is installed in the ECM,
and it converts the barometric pressure to a voltage
signal. The ECM uses this voltage signal to calibrate the
injection quantity and injection timing for altitude
compensation.
Boost pressure sensor/boost temperature sensor

Boost pressure sensor
The boost pressure sensor detects the boost pressure of
the intake pipe and converts the pressure into a voltage
signal to send to the ECM. The voltage becomes higher
when the pressure is higher, and it becomes lower when
the pressure is lower. The ECM calculates the boost
pressure from the voltage signal sent from the sensor and
uses it to control the fuel injection, etc.
Boost temperature sensor
The boost temperature sensor measures the temperature
of air entering the intake pipe. When the sensor is cold,
the sensor resistance is high. As the air temperature rises,
the sensor resistance decreases. The ECM detects a high
EGR position sensor voltage in the signal circuit when the sensor resistance is
This sensor is installed inside the EGR valve to detect the high. The ECM detects a low voltage in the signal circuit
EGR valve lift amount. when the sensor resistance is low.
Note：
・ Do not disassemble the EGR position sensor.
When an abnormality is found, replace the
EGR valve assembly.
MAF sensor and IAT sensor

MAF sensor
The MAF sensor measures the amount of air entering the
engine, and is installed to the duct between the air cleaner
and turbocharger. The MAF sensor consists of an MAF
sensor and IAT sensor, and measures a portion of the air
that passes through the measurement duct. When the
amount of air entering the engine is small, it indicates
deceleration or idling speed. When the amount of air is
large, it indicates acceleration or a high load state.
IAT sensor
The IAT sensor is installed to the duct between the air
cleaner and the turbocharger. The IAT sensor is a
variable resistor located inside the MAF sensor and
measures the temperature of the air flowing into the
engine. When the IAT sensor is cold, the sensor
resistance is high. As the air temperature rises, the sensor
resistance decreases. The ECM detects a high voltage in
the signal circuit when the sensor resistance is high. The
ECM detects a low voltage in the signal circuit when the
sensor resistance is low. EGT sensor
The EGT sensors are variable resistors installed in front
of oxidation catalyst 1 and oxidation catalyst 2. EGT
sensor 1 measures the temperature of the exhaust gas in
front of oxidation catalyst 2, while EGT sensor 2
measures the temperature of the exhaust gas in front of
oxidation catalyst 1. When the EGT sensor is cold, the
sensor resistance is high. As the exhaust temperature
rises, the sensor resistance decreases. The ECM detects a
high voltage in the signal circuit when the sensor
resistance is high. Also, the ECM detects a low voltage in
the signal circuit when the sensor resistance is low.
Intake throttle valve

The intake throttle valve is installed on the inlet of the
inlet manifold. The ECM controls the opening position of
the intake throttle valve based on the operating conditions
of the engine. The motor inside the intake throttle valve is
controlled according to duty ratio signals sent from the
ECM. The opening position of the intake throttle valve is
changed in the appropriate increments from a duty ratio
of 0%. The valve closes with increases in duty signals
and opens as duty signals decrease. The opening position
of the intake throttle valve is detected by the position
sensor. The position sensor outputs signals related to the IMT sensor
opening position of the intake throttle valve. The IMT sensor is a variable resistor that is installed to
The ECM detects a low signal voltage when the valve the intake manifold and measures the intake air
opening is small or closed. Also, the ECM detects a high temperature of the intake manifold. Sensor resistance is
signal voltage when the valve opening is large. high when the sensor is cool and lowers as the intake air
temperature increases. The ECM detects a low voltage in
the signal circuit when the sensor resistance is low.
when the sensor resistance is high. The ECM detects a
low voltage in the signal circuit when the sensor
resistance is low.
Charge air cooler temperature sensor 1

Charge air cooler temperature sensor 1 is installed to the
upstream side of the intercooler. Charge air cooler
temperature sensor 1 is a variable resistor. Charge air
EGR gas temperature sensor 2
cooler temperature sensor 1 measures the temperature of
EGR gas temperature sensor 2 is installed to the EGR
the air flowing into the intercooler.
cooler duct. EGR gas temperature sensor 2 is a variable
When the intercooler temperature sensor is cold, the
resistor and measures the exhaust gas temperature of the
sensor resistance is high. As the air temperature
EGR cooler outlet. The EGR gas temperature sensor 2
increases, the sensor resistance decreases. The ECM
resistance is high at low temperatures. As the exhaust gas
detects a high voltage in the signal circuit when the
temperature rises, the sensor resistance decreases. The
sensor resistance is high. The ECM detects a low voltage
ECM detects a high voltage in the signal circuit when the
in the signal circuit when the sensor resistance is low.
in the signal circuit when the sensor resistance is low.

Turbo actuator
The turbo actuator is installed to the turbocharger. The
resistor and measures the temperature of the exhaust gas
ECM communicates with the turbo control unit based on
at the EGR cooler inlet. The EGR gas temperature sensor
the engine load, etc., and the turbo control unit controls
1 resistance is high at low temperatures. As the exhaust
the turbo actuator.
gas temperature rises, the sensor resistance decreases.
Turbocharger nozzle control is performed by operating
The ECM detects a high voltage in the signal circuit
the motor built into the turbo actuator, which controls the
variable nozzle. The ECM adjusts the opening position of Exhaust throttle solenoid valve (12 V generator
the variable nozzle to control changes in boost pressure specifications)
according to the load requirements of the engine. The exhaust throttle solenoid valve is energized by
signals from the ECM to apply vacuum pressure to the
diaphragm chamber of the exhaust throttle valve.
1. Turbine wheel
2. Nozzle
3. Turbo actuator 1. Vacuum inlet
4. Exhaust gas inlet 2. Vacuum outlet
5. Control rod 3. Vacuum exhaust
6. Exhaust gas outlet 4. Solenoid valve
Turbo control unit Exhaust throttle valve (12 V generator specifications)

The turbo control unit is installed to the machine. The Vacuum pressure is applied to the diaphragm via the
ECM communicates with the turbo control unit based on exhaust throttle solenoid valve, and the exhaust throttle
the engine load, etc., and the turbo control unit performs valve activates by a linking mechanism of the diaphragm.
control by operating the motor built into the turbo
actuator. The turbo control unit also receives signals from
the position sensor built into the turbo actuator, and
provides feedback to the ECM concerning the amount of
turbocharger operation via communication with the ECM.
1. Exhaust throttle valve
Diagnostic light
By turning ON the diagnostic switch, the DTC is
indicated by flashing.
Note： The operation can be performed at the engine speed
・ As for the installation position of the diagnostic specified for each mode by switching the mode change
light, refer to the manual of the machine. switch.
DLC Note：
The DLC is the connector for communication and ・ As for the installation position of the mode
connection between the trouble diagnosis scanning tool change switch, refer to the manual of the
and various controllers. machine.
Note：
・ As for the DLC installation position, refer to the
manual of the machine.
1. Water temperature gauge

2. Oil temperature gauge
3. Hour meter
4. Ignition switch
Diagnostic switch 5. Engine stop switch
The diagnostic switch shorts DLC terminal No. 12 and 6. Fuel meter
No. 4 or No.5 and flashes the diagnostic light to indicate 7. Mode switch
the DTC.
ECM wiring diagram
Note：
Some sensors may not be connected to the ECM
・ As for the installation position and shape of the depending on the specifications of the machine.
diagnostic switch, refer to the manual of the Since some sensors may perform input/output with the
machine. ECM depending on CAN communication, check the
Mode change switch (0, 1, 2) specifications of the machine.
ECM pin assignment

105 pin (A connector)

Pin No. Terminal name Connection

1 - -
2 OS-INJ3 No. 4 cylinder injector control
5 SP-5V6 CKP sensor power source
6 - -
7 - -
8 - -
9 - -
10 IA-IDMPOS Intake throttle position sensor signal
11 IA-MAP Boost pressure sensor signal
12 IA-THTCO Boost temperature sensor signal
13 - -
14 IA-EGRTI1 EGR gas temperature sensor 1 signal
15 IA-EGRTO1 EGR gas temperature sensor 2 signal
16 IA-PFUEL1 FRP sensor signal
17 IA-OILPRESS Oil pressure sensor signal
18 IA-IMT IMT sensor signal
19 - -
20 IA-THL Fuel temperature sensor signal
21 - -
22 - -
23 OP-COM1A Injector power source 1 (No. 1 cylinder)
24 OP-COM1B Injector power source 1 (No. 4 cylinder)
25 - -
26 SP-5V9 EGR position sensor, oil pressure sensor power source
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 IA-THW Engine coolant temperature sensor signal
40 - -
41 - -
42 IA-SCVLO SCV-LO drive
44 OP-COM2A Injector power source 2 (No. 3 cylinder)
45 OP-COM2B Injector power source 2 (No. 2 cylinder)

46 - -
47 - -
48 SG-5VRT6 CKP sensor GND
49 SG-5VRT7 CMP sensor, FRP sensor GND
Boost pressure sensor, intake throttle position sensor, engine coolant temperature
50 SG-5VRT8 sensor, IMT sensor, EGR gas temperature sensor 1, EGR gas temperature sensor
2, boost temperature sensor GND
51 - -
52 - -
53 IS-EBMPOS1 EGR position sensor signal U
54 IS-EBMPOS2 EGR position sensor signal V
55 IS-EBMPOS3 EGR position sensor signal W
56 - -
57 - -
58 - -
59 SG-5VRT9 EGR position sensor, oil pressure sensor, fuel temperature sensor GND
60 - -
61 - -
62 - -
63 IA-SCVLO SCV-LO drive
64 - -
65 - -
66 - -
67 - -
68 SP-5V8 Boost pressure sensor, intake throttle position sensor power source
69 SP-5V7 CMP sensor, FRP sensor power source
70 - -
71 SG-SLD6 CMP sensor shield
72 - -
73 SG-SLD7 FRP sensor shield
74 SG-SLD4 CKP sensor shield
75 OS-ADBIL Abnormal urea fluid injection warning light
76 OS-ADBFUL Urea fluid refill warning light
77 - -
78 IF-CRANK CKP sensor signal
79 - -
80 OS-CEMMIL Exhaust system warning light
81 - -
82 - -
83 - -
84 OP-SCVHI SCV-HI drive
85 - -
86 - -
87 - -
88 - -
89 OM-IDM2 Intake throttle motor drive Low

90 OM-IDM1 Intake throttle motor drive High
91 OM-EBM3 EGR valve DC servo motor drive W
92 OM-EBM2 EGR valve DC servo motor drive V
93 OM-EBM1 EGR valve DC servo motor drive U
94 OS-IADBL Abnormal urea fluid quality warning light
95 - -
96 - -
97 - -
98 - -
99 IF-CAM CMP sensor signal
100 - -
101 - -
102 - -
103 - -
104 - -
105 OP-SCVHI SCV-HI drive
91 pin (B connector)
Pin No. Terminal name Connection

1 PS-+B Battery power source
2 PG-POWER ECM power source GND
7 CC-KW2000 Data link connector
8 - -
9 SG-5VRT1 Accelerator position sensor GND
10 - -
11 SG-5VRT3 IAT sensor, charge air cooler temperature sensor 1, EGT sensor 1 GND
12 - -
13 - -
14 - -
15 SP-5V1 Accelerator position sensor power source
16 SP-5V5 Fuel filter pressure sensor power source
17 IA-FIPRESS Fuel filter pressure sensor signal
18 IA-THCSFI EGT sensor 1 signal
19 IA-THDOCI EGT sensor 2 signal
20 - -
21 IA-THCAI Charge air cooler temperature sensor 1 signal
22 - -
23 OF-TACHO Tachometer
24 - -
25 - -
26 - -
27 IA-ACCEL2 Accelerator position sensor 2 signal
28 - -
29 IA-IAT IAT sensor signal
30 IA-ACCEL1 Accelerator position sensor 1 signal
31 - -
32 - -
33 - -
34 - -
35 SG-5VRT5 Fuel filter pressure sensor, EGT sensor 2 GND
36 SG-12VRT MAF sensor GND
37 SP-12V MAF sensor power source
38 OS-OVRL Engine overrun light
39 OS-DIAGL Diagnostic light
40 OS-MAINR ECM main relay control
41 PG-SIGN Signal GND
42 PG-SIGN Signal GND
43 - -
44 IS-DIAG Diagnostic switch signal
45 - -
46 IS-AC Air cleaner switch signal
47 IS-IDLDWN Idling control switch Down signal
48 - -
49 - -
50 IS-ENGSTP Engine stop switch signal
51 - -
52 IS-DIAG Diagnostic switch signal
53 - -
54 OS-TRQRL Output restricted warning light
55 OS-OILPL Engine oil pressure light
56 - -
57 OS-MAINR ECM main relay control
58 SG-SLD1 Accelerator position sensor shield
59 - -
60 CC-CAN-H CAN-High
61 IA-MDMAP2 Mode map switch 2 signal
62 - -
63 - -
64 CC-ISOCAN-H1 ISO CAN-High
65 IS-MDMAP0 Mode map switch 0 signal
66 - -
67 - -
68 IS-REG Regulation mode switch signal
69 - -
70 IS-MDMAP1 Mode map switch 1 signal
71 IS-IDLUP Idling control switch Up signal
72 OS-HOUR Hour meter relay
73 OS-EXTH Exhaust throttle valve signal (12 V generator specifications)
74 OS-STARTR Starter cut relay
75 PG-CASE ECM case GND
76 IS-IGKEY Ignition switch ON signal
77 CC-CAN-L CAN-Low
78 - -
79 - -
80 - -
81 CC-ISOCAN-L1 ISO CAN-Low
82 IS-START Ignition switch start signal
83 - -
84 - -
85 - -
86 IS-LOAD Load advance switch signal
87 IS-IDLMNL Idling control change switch signal
88 IA-MAF MAF sensor signal
89 OS-GLOWL Glow light
90 OS-OVHL Overheat light

91 OS-GLOWR Glow relay
Introduction to the trouble diagnosis

1. Introduction to the trouble diagnosis The customer complaint is clear, but the failure
conditions are unclear.
1. About trouble diagnosis
Therefore, the person performing the diagnosis can
The following trouble diagnosis procedure is
reproduce the failure by understanding the machine
extremely important to resolve problems of all
conditions.
electric/electronic systems.
Intermittent failures, intermittent
Neglecting to implement these steps may result in
requiring unnecessary repairs. Read and understand Stage where failure is realistic
the procedure carefully and proceed with the trouble The occurrence of the failure is set, and the customer
diagnosis. complaint is real and clear.
Also, use available functions and the trouble Therefore, the person performing the diagnosis can
diagnosis scan tool to perform the trouble diagnosis reproduce the failure. However, there may sometimes be
and system check. more than 2 causes for the failure.
Current malfunction, Current failures
2. Trouble diagnosis procedure
Checking complaints from customer 3. Diagnosis
・Use the check sheet to organize the trouble Fully understand the description given by the
situation. customer using the Engine Control System Check
Sheet.
Performing preliminary inspection
・Perform overall visual inspection. Note：
・Check the past maintenance history. ・ When questioning, do not ask randomly but
・Detect any abnormality such as abnormal noise, smell, focus on the system that is inferred to be
etc. defective based on the malfunction
・Collect the failure trouble DTC information to provide phenomenon.
effective repair.
・Inspect for an abnormality by comparing to the standard Determine failure information accurately.
value. Have concrete understanding based on 5W1H.
Low air temperature, at start or on a steady basis, near the
Inspect the service information engine parts, metallic sound, etc.
・Check the service bulletin.
Check points
Perform inspection for the displayed code. ・Failure symptoms
・Inspect the item shown by DTC. ・Month and Date, Time, Frequency of occurrence
Perform an inspection for problems according to ・Road conditions
symptoms ・Driving conditions, Operation conditions, Weather
・Check the item that is not displayed in the DTC. ・Feeling of symptom
NOTE Engine control system check sheet

System trouble diagnosis type When receiving the machine from the customer at the
The system diagnosis method is a standardized method service factory, the failure symptoms and the data on
applied for repairing all electric/electronic systems. occurrence of failure must be confirmed with the
Failures in electric/electronic systems often occur in the customer based on the engine control check sheet.
following steps unlike common machine failures. ・Failure symptoms may not be able to be reproduced at
Initial stage of failure the service factory.
The failure occurs sporadically and for a short time, often ・The customer's complaint may not always be a
times the driver does not notice it. At this stage, the malfunction.
customer's complaint is unclear, and the malfunction ・Notification of incorrect malfunction conditions to the
cannot be reproduced. However, the ECM may have person in charge of repairs may result in unnecessary
recorded the failure. man-hours for repairs.
Past malfunction, past failures ・The check sheet assists machine diagnosis, repair, and
repair confirmation at the vehicle servicing station.
Middle stage of failure
The failure occurs sporadically and for a short time, but
may occur repeatedly at intervals, and occurs under
specific conditions.
1. Failure symptoms
2. Failure frequency・failure conditions
4. Preparatory check When implementing the diagnostic procedures,

Visual inspection of engine room carefully make a visual inspection of the engine
room. This inspection can often lead to solving a understanding of hand tools, such as the
problem without taking extra steps. trouble diagnosis scan tools, is required to
・Visually inspect all air hoses for punched holes, cuts, utilize the service manual effectively.
disconnections, and appropriate piping. About the diagnostic test performed on the machine
・Visually inspect the hoses that are difficult to see Past failures
behind other components. ・The diagnostic tests of the previous ignition cycle have
・For every harness in the engine room, visually inspect been completed.
that all harnesses are properly connected. Inspect that ・The diagnostic tests of the current ignition cycle have
there are no burned or worn areas, that the harnesses are passed.
properly fastened and that they are not in contact with ・Problems identified in the diagnostic tests currently do
sharp edges or the hot exhaust manifold or pipes. not exist.
Checking the machine maintenance status Current failures
If the machine is not maintained properly, the diagnostic ・The diagnostic tests of the previous ignition cycle have
light is turned on. been completed.
Restricted oil filters, fuel filters, and crankcase deposits ・Problems identified in the diagnostic tests currently
due to lack of oil changes or improper oil viscosity can exist.
trigger machine failure that were not previously ・Problems exist in the current ignition cycle.
monitored prior to OBD.
Poor vehicle maintenance cannot be classified as a non- Glossary
machine failure, but since the sensitivity of OBD system DTC
checks is high, the machine maintenance schedules must Every time the ignition switch is turned ON, the ECM
be further closely followed. performs the self-test on most of the wiring and
components, records any detected system failure in the
Non-OEM parts memory of the ECM, and performs the backup control,
All the OBD system checks are adjusted to operate with depending on the DTC.
the genuine parts. Therefore, when a commercially sold Also, as for an abnormality that can affect driving, the
sensor or switch, etc. is installed, a wrong diagnosis is diagnostic light is turned on to inform the operator.
made, and the diagnostic light comes on.
Commercial electronics, such as mobile phones, stereos, Ignition cycle
and anti-theft devices, may emit EMI into the control Because the machine activates with a method to satisfy a
system when they are improperly installed. As the result, predetermined diagnosis standard, an ignition cycle is
false sensor information is generated causing the defined as turning the ignition switch ON, running, then
diagnostic light to come on. When conducting a trouble turning the ignition switch OFF.
diagnoses, either turn OFF the power for all Diagnostic light
commercially sold parts or remove them, and then check Basically, the diagnostic light is turned on when a DTC is
the failure again. detected due to a failure occurred in the electronic control
NOTE system such as ECM.
Related system failure DLC
Many OBD system checks go into the backup operation The equipment for communicating with the control unit is
mode based on the instruction from the ECM which is the Data Link Connector (DLC). The DLC is also
given when the ECM detects a failure in the related provided to establish a connection with the scan tool.
systems or components. When the backup operation Identification of recorded
mode is activated, the output is reduced to protect the DTC reading the serial data
machine.
Note：
5. Trouble diagnosis
・ The installation position of the DLC and
Basic knowledge of tools required
existence or nonexistence of the DLC vary
Note： depending on the machine, so refer to the
・ When performing the diagnostic procedure, manual of the machine.
lack of basic knowledge regarding this ECM OFF
powertrain could result in an incorrect When approximately 1 minute or more has passed since
diagnosis or damage to the powertrain the ignition switch has turned OFF, the ECM power is
components. Do not attempt to diagnose a completely down, turning to the ECM OFF status.
problem related to the powertrain without
having the basic knowledge. A basic General diagnostic operations of the components monitor
To run the engine normally, a general diagnosis of the ・Turn the ignition switch ON, but the engine OFF.
components is required. ・Connect the diagnostic switch. For a machine with
no diagnostic switch, short No. 12and No. 4 or No. 5
Input components
of the DLC.
Inspect the input components to see whether an open in
・Read the flashing count of the diagnostic light.
the circuit or outside range value exists.
・The DTC determines the failure contents from the
CKP sensor
Diagnostic trouble code list.
CMP sensor
If the trouble diagnosis scan tool is connected, the
diagnostic codes can be read by operating the trouble
Boost sensor
diagnosis scan tool.
Fuel pressure sensor
Accelerator position sensor Note：
Output components ・ As for the installation position of the diagnostic
The output components are inspected to diagnose whether light, refer to the manual of the machine.
responses to commands from the control unit are Display code when no DTC is recorded
appropriate. Inspect whether the circuits have Code 1 (indicating the start of code display) continues to
disconnections and whether their values are within the be displayed.
range.
Suction control valve Display when a DTC is recorded
Light, Relay control The recorded trouble codes are displayed 3 times. If more
Magnetic valve than 2 or more trouble codes have been recorded, the
Diagnostic light DTCs will be output in ascending order with each DTC
being displayed three times. After displaying all codes,
6. Procedure for reading the DTC the codes will be displayed again starting with the
Reading the DTC with a diagnostic light smallest code number. This display continues while the
Current and past DTCs recorded in the ECM can be diagnosis connector is connected.
displayed by connecting the diagnostic switch and
flashing the diagnostic light.
・Turn the ignition switch ON and check that the
diagnostic light illuminates.
DTC indicated by diagnostic light blinking display Using the scan tool to read the DTC
The current and past DTCs are both displayed while the The DTC can be read using the trouble diagnosis scan
engine is being stopped. tool.
While the engine is in operation, the light is turned on
Note：
only when a current DTC exists.
・ For the work procedure, refer to the manual of
Using the trouble display monitor to read the DTC the trouble diagnosis scan tool.
When a DTC occurs, the DTC can be displayed on the
trouble display monitor of the machine. When the DTC is recorded
Perform repairs accurately according to the specified that the symptom has been corrected. This includes the
DTC chart. confirmation test performed on the machine or other
methods to confirm that the complaint has been resolved.
If no DTC is available
Confirm by testing under the conditions given by the
Select the symptom from "Diagnosis By Symptom".
customer.
Complete the repair according to the diagnostic
When a DTC is diagnosed, confirm that the failure has
procedure. It is also possible to perform the inspection by
been repaired by reproducing the condition that appeared
referring to the functional diagnosis.
when the DTC was set while checking the scan tool data.
When the appropriate symptom is not found
7. Check after repair
Investigate the complaint in detail.
Check repair on machine
Create a diagnosis plan.
When a repair has been performed for the electronic
Utilize the schematics and operation principles.
control system, it is necessary to check that the repair
When repair history for similar cases are available,
is accurate after repairing the machine. If this check
request technical assistance. Combine technical
is not adequate, the diagnostic light may light again
knowledge and effective utilization of available service
while returning the machine to the customer, or
information.
drivability problems may occur. Especially for an
Intermittent intermittent failure, it is necessary to perform the
A failure condition that does not necessarily always check by reproducing the conditions of the customer
appear is referred to as intermittent. complaint.
Check the DTC information and the data display.
About confirmation of the machine repairs
Verify the symptoms and conditions reported by the
It is effective to use the OBD system check for
customer.
confirming machine repairs.
Use a check sheet or other method to check the circuit or
After the repair is completed, the person who has
electronic system components.
performed the machine diagnosis shall review either the
When no trouble is detected DTC that was diagnosed or scan tool data, or both, and
This status indicates that the machine is determined as record it.
operating properly. The condition reported by the Clear the DTC.
customer may be normal. Check the customer complaint Run the machine based on the scan tool data.
by comparing to other machine that is operating properly. Check the DTC status information of the specified DTC
However, depending on the condition, it may be an that was diagnosed until the diagnosis test related to that
intermittent. Before returning the machine, check the DTC is implemented by the control unit.
complaint under the conditions given by the customer. The implementation of these steps is extremely important
Investigate the complaint again. when checking the repair status with the OBD system
If the complaint cannot be adequately detected or check. Neglecting to implement these steps may result in
confirmed, it is necessary to perform the diagnosis again unnecessary repairs.
to verify the complaint. As stated above in "Intermittent",
8. Final check item list
the complaint may be an intermittent or normal condition.
Repair and confirm.
Perform the repair when the cause has been confirmed.
Confirm that the operation is performed properly, and
Item Item Objective Method

Clear the previous DTCs. Keep the engine idling
Confirm the DTC display after to warm up, then perform a racing run to
1 DTC check
the repair increase the engine rpm to No Load Max to
secure the test conditions.
Check whether the idling rotation speed is
constant under the no load condition after
Idling speed check after To check whether the idling
2 engine is warmed up. If a problem is detected,
warming up the engine control is operating normally.
refer to Idling Unstable in Diagnosis by
Symptom.
Check the engine control,
Monitor the scan tool data list, and check the
Confirm the scan tool communication status error and
3 values using a typical value sheet. Confirm the
data list abnormality under the standard
typical values of the scan tool data list.
condition.
After warming up the engine, confirm that the
To check whether the starting cranking time is 5 seconds or less when
4 Re-startability check
control is normal. restarting the vehicle, and that the engine
revolution is stable after starting.
Check whether turning the electromagnetic
When electromagnetic
transmitter such as a transceiver ON and OFF
Check powerful transmitters such as a transceiver
causes the idling engine rpm to change. If a
5 electromagnetic have been added to the vehicle,
problem is found, let the customer know that the
transmitters confirm that no interfering waves
installation position and output of the
are being emitted.
electromagnetic transmitter need to be changed.
Supplementary information regarding the check for Clearing the DTC
powerful electromagnetic transmitters If an error occurs in the system and the DTC is
If you discover a problem in this item, convey it to the recorded in the ECM, that DTC is not cleared from
customer as necessary. the memory even when the malfunctioning part is
・Install the antenna to the a place distant from the repaired, so use the clear function of the trouble
electronic control system of the machine such as the diagnosis scan tool to execute a forced deletion.
control units and sensors.
Erasure by ECM
・Install the antenna cord at least 20 cm away from the
A DTC recorded in the ECM is erased if the same DTC
electronic systems of the machine, such as the control
has not been satisfied for 40 consecutive ignition cycles.
units and sensors.
・Do not wire other cables together with antenna. About trouble diagnosis scan tool
Also, locate the antenna cord as far away from other This tool is effective for diagnosing electrical failures in
wiring as possible. engine control units and performing system checks.
・Make sure to attach retrofitted equipment in accordance If you connect the SAE 16/19 adapter to the DLC
with their respective installation manuals. installed in the unit, it performs communication with the
・Do not install high-output mobile communication control units of the machine, and enables various
devices. diagnoses and tests to be performed.
Caution： Functions of the trouble diagnosis scan tool.
・ Follow the steps when performing the OBD Data display
system checks to confirm the repair. Failure to
follow these steps may result in performing Snapshot
unnecessary repair works. Programming
・ Review the scan tool data relating to the DTC Actuator test
that was diagnosed and make a record.
・ Clear the DTC. Caution：
・ Operate the machine while checking the ・ When conditions such as the running state of
related scan tool data. the machine or the engine, water temperature,
switches and gear position are not met, or
9. Method for clearing the DTC
when a DTC has been detected, each test Actuator test

may possibly not operate. The injector test, fuel injection test, rail pressure test,
glow plug test, and EGR control test are performed to
ECM reflash inspect the operation and function of each target
The ECM can be updated by overwriting its control component.
program using the most recent control data issued every 3
months. Caution：
Normal reflash ・ When conditions such as the running state of
The ECM is reflashed by automatically searching for the the machine or the engine, water temperature,
ECM part number compatible with the part number switches and gear position are not met, or
currently reflashed. when a DTC has been detected, each test
Forced reflash may possibly not operate.
The ECM is reflashed by specifying an arbitrary ECM
Links with the HTML manual display
part number.
DTC to display the manual along with the failure
In this case, a password dedicated for forced reflash is
diagnosis procedure.
necessary.
Campaign reflash Reading saved data
The ECM is reflashed by selecting the part number Read in the saved snapshot data to display reproduction.
during a campaign carried out by the manufacturer.
Caution：
Rewriting injector QR code ・ When using the trouble diagnosis scan tool,
The injector QR code that is required when replacing the refer to the separate instruction manual for the
injector can be rewritten. This allows fuel compensation trouble diagnosis scan tool.
to be performed on each injector to optimize the engine
condition. 10. Data list
Engine replacement mode The list is the items registered on the scan tool data
This should be used when changing back to the old ECM display.
part number which requires hardware changes such as Confirm that each item in the list is normal (the condition
addition of machine wiring is performed along with before it is sold, etc.), and record that status so that it can
engine replacement, etc. serve as reference data when performing a trouble
diagnosis.
ECM replacement This data is used in trouble diagnosis by comparing each
When replacing the ECM within the same model, the data machine's data with the reference values, and checking
can be updated from the current ECM to a trouble whether the machine data is temporarily or always
diagnosis scan tool and then downloaded from the trouble different from the reference values.
diagnosis scan tool to a new ECM after replacement. This display menu is subject to change without notice.
Factory shipment settings
Based on the engine serial number, data such as ECM
injector QR code can be downloaded to ECM.
Data Display Items Unit Reference value

Battery voltage V
Desired engine speed RPM
Engine speed RPM
Accelerator pedal position sensor 1 （APP1） V
Accelerator pedal position sensor 2 （APP2） V
Accelerator pedal position （APP）％
Fuel rail pressure difference
MPa
(Actual - desired)
Fuel rail pressure sensor V
Fuel rail pressure feedback
Engine coolant temperature sensor V
Coolant temperature °C
Intake air temperature sensor V
Intake air temperature °C
Fuel temperature sensor V
Fuel temperature °C
Barometric pressure sensor V
Barometric pressure kPa
Boost temperature sensor voltage V
Boost pressure sensor kPa
No. 1 cylinder fuel correction amount mm3/st
Engine mode
EGR valve 1 drive duty ％
EGR position 1 ON/OFF
Ignition switch ON/OFF
Ignition switch ON/OFF
Glow relay ON/OFF
Fuel delivery rate data 1
Functional Inspection (4HK1) 15C-1
Description Engine
Functional Inspection
(4HK1)
Table of Contents
Engine compression pressure inspection.......................15C-2
Fuel system check.........................................................15C-4
Lubrication system check..............................................15C-5
Air intake system check................................................15C-6
Exhaust system check....................................................15C-7
EGR control system check............................................15C-8
Starting system check....................................................15C-9
Glow control system check.........................................15C-10
OBD system check......................................................15C-12
Inspection of the diagnostic light warning light illumination
circuit system...............................................................15C-13
Inspection of the diagnostic light warning light blinking
circuit system...............................................................15C-14
Inspection of the starter circuit system........................15C-15
15C-2 Functional Inspection (4HK1)
Engine compression pressure inspection

1. Engine compression pressure inspection inspection SST: 5-8840-2675-0 (5-8531-7002-0) - compression
gauge
Note：
・ Warm-up the engine.
1. Remove the glow plug from the cylinder head
assembly.
Note：
・ Remove all glow plugs.
2. Remove the injector harness connector from the
lower cover.
1. Injector harness connector 1. Compression gauge

2. Compression gauge adapter
3. Install the special tool to the cylinder head assembly.
Note：
Note：
・ Measure the compression pressure.
・ Insert the compression gauge adapter into the
installation hole of the glow plug to install the ・ Rotate the starter, and read the indication of
compression gauge. the compression pressure when the
compression gauge needle stabilizes at
approximately 200 r/min.
・ Measure the compression pressure of all
cylinders.
specified value： 2840.0 to 3240.0 kPa { 28.96 to 33.04
kgf/cm2 / 412 to 470 psi }
limit： 1960.0 kPa { 19.99 kgf/cm2 / 284 psi }
SST: 5-8840-2815-0 - compression gauge adapter
difference between each cylinder： 294.0 kPa { 3.00 kgf/
cm2 / 43 psi }
Caution：
・ Note that air will burst out through the glow
plug hole during rotation.
Note：
・ When the ignition switch is turned to ON with
the injector harness connector removed, the
ECM determines a malfunction and records a
DTC, so make sure the DTC has been cleared
after the inspection is completed.
Fuel system check

1. Fuel system check description of function
The fuel system is composed of the fuel filter, supply
pump, common rail, and injector, and each of them
connects with the fuel pipe.
2. Fuel system check inspection
Inspection when there is a possibility that there is an
abnormality in the fuel system
1. Inspect the quality of fuel.
Appropriate fuel should be used.
2. Check the amount of fuel.
Sufficient amount should be supplied.
3. Perform the fuel discharge inspection for the supply
pump.
The fuel discharge should be normal and no air should be
mixed.
4. Confirm that the genuine fuel filter, pre filter, and
filters other than for the electromagnetic pump are
added to the fuel piping of the machine.
Note：
・ An additional filter increases the fuel
resistance and may cause DTC P1093 or
other malfunctions to be detected.
5. Remove it if the filter is added.
6. Inspect the main fuel filter, pre-fuel filter, and
electromagnetic pump filter.
･ No excessive contamination or clogging should be
found.
･ No air should be mixed in.
7. If a problem is found, clean or replace it.
8. Inspect the fuel pipe.
No damage, clogging, or poor connections should be
found.
9. If a problem is found, repair or replace it.
10. Inspect the fuel tank.
･ No dust should be mixed in.
･ The fuel supply pipe should have no misalignment or
damage.
･ The tank should have no collapsing or damage.
･ The fuel pipe should not be arranged incorrectly.
･ The fuel filler should have no clogging.
･ No water should be mixed into the tank.
11. If a problem is found, repair or replace the fuel tank.
12. Remove air.
Lubrication system check

1. Lubrication system check inspection
Note：
・ Oil pressure inspection
1. Inspect whether the engine oil is dirty, or contains
water, etc.
Note：
・ If oil is dirty or contains water, change the oil
after investigating the causes and taking
appropriate measures.
2. Inspect the engine oil level.
Note：
・ When the oil level is low, replenish it.
3. Remove the oil pressure switch.
4. Install the oil pressure gauge.
SST: 5-8840-2843-0 - oil pressure gauge

5. Start the engine.
Note：
・ Warm-up the engine.
6. Measure and confirm that the oil pressure is 550 kPa
(5.6 kg/cm2 / 80 psi) or higher at 2000 r/min.
7. Turn OFF the ignition switch.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
Note：
・ Check for oil leakage.
・ Check for engine oil leakage
Inspect for oil leaks from the cylinder head cover and oil
pan, etc. while the vehicle is lifted up.
Air intake system check

1. Air intake system check description of function
Caution：
・ If the air intake system part is installed by the
machine manufacturer, refer to the manual of
the machine.
The air intake system is comprised of the air cleaner, air
intake piping, turbocharger, etc. The intake air is supplied
to the engine through the air cleaner and intake manifold.
2. Air intake system check inspection
abnormality in the air intake system
1. Inspect the air cleaner.
･ No excessive contamination or clogging should be
found.
2. If a problem is found, clean or replace it.
3. Inspect the air intake piping.
･ No collapsing, damage, or air leakage should be found.
･ There are no distorted or improper piping arrangements
which may lead to an increase in the air intake resistance.
･ The lead valve should have no damage.
5. Inspect the turbocharger.
･ The turbine axis should have no abnormal looseness. ･
There are no oil leaks.
Exhaust system check

1. Exhaust system check description of function
The exhaust system is comprised of the exhaust pipe, tail
pipe, etc.
2. Exhaust system check inspection
abnormality in the exhaust system
1. Inspect the exhaust pipe and tail pipe.
･ No collapsing, damage, or exhaust leakage should be
found.
3. Repair the machine.
EGR control system check

1. EGR control system check description of function
The ECM controls the EGR valve based on the engine
speed, engine coolant temperature, intake air temperature,
fuel injection amount, and barometric pressure. The EGR
valve is driven by the EGR motor, and the EGR valve
opening is detected by the EGR position sensor.
2. EGR control system check inspection
abnormality in the locations relating to the EGR.
1. Check the DTC.
Note：
・ If the DTC is detected, inspect the
corresponding DTC.
2. Start the engine and warm it up until the coolant
temperature exceeds the specified value.
specified value： 70 ℃ { 158 °F }
3. Check the EGR position display using a trouble
values： (-3) - 3 %
4. Perform the actuator test EGR control using a trouble
diagnosis scan tool if the EGR position display is
outside the specified value.
5. Execute an Up and Down command to the EGR
valve and check the EGR position display.
values： (-3) - 3 %
6. Inspect the EGR piping if the EGR position display
is outside the specified value.
No damage or gas leaks should be found.
temperature exceeds the specified value.
specified value： 70 ℃ { 158 °F }
9. Check the EGR position display using a trouble
values： (-3) - 3 %
10. Replace the EGR valve if the EGR position display
is outside the specified value.
Refer to "1.Engine 1H.Aux. Emission Control
Devices(4HK1) EGR valve removal".
Devices(4HK1) EGR valve installation".
11. When replacing the EGR valve, perform EGR
learning to the ECM.
Starting system check

1. Starting system check description of function Note：
This diagnosis chart is an organized approach to ・ If the engine starts, perform DTC P0092
identifying a condition that causes the status for when an diagnosis.
engine does not start. The appropriate system diagnosis 9. Inspect the fuel system if the engine does not start.
can be performed with this diagnostic chart.
10. Inspect the engine coolant temperature sensor.
･ The battery should be fully charged when performing
this diagnosis. 11. Inspect the fuel pressure sensor.
･ The battery cable should be securely connected when 12. Inspect the EGR position sensor.
performing this diagnosis.
･ The rotation speed during cranking should be normal 13. Inspect the injector.
when performing this diagnosis. 14. Inspect the engine mechanical timing.
･ The appropriate fuel should be sufficiently supplied
when performing this diagnosis. 15. Inspect the installation status of the flywheel.
･ No fuel leaks should be found when performing this 16. Inspect the air intake system.
diagnosis.
17. Inspect the exhaust piping for collapsing, damage,
･ No air should be mixed into the fuel when performing
and exhaust leakage.
this diagnosis.
･ The air cleaner element should be clean when 18. Repair or replace the part found to have a problem.
performing this diagnosis.
･ The fuel filter should be clean when performing this
diagnosis.
2. Starting system check inspection
Inspection when the starter operates and cranks but the
engine does not start
1. Turn the emergency stop switch to OFF.
Note：
・ If the actual unit does not have an emergency
stop switch setting, do not perform this
operation.
2. Inspect the overheat switch circuit.
Note：
・ If the actual unit does not have a overheat
switch setting, do not perform this operation.
3. If a problem is found, repair the circuit.
4. Check the DTC.
Note：
・ If the DTC is detected, inspect the
corresponding DTC.
5. Observe the rail pressure regulator feedback current
display on a trouble diagnosis scan tool while
cranking the engine.
standard： 900 mA
6. If the reading is less than or equal to the specified
value, repair the SCVLO drive circuit.
7. Remove the harness connector from the SCV.
8. Crank the engine.
Glow control system check

1. Glow control system check description of function 10. Measure the resistance between the glow plug
terminal and GND using the DMM.
Caution：
・ The starter ECM control specification and values： 6 Ω At room temperature
safety relay specification are the same for the Note：
QOS circuit.
・ If the reading is outside the specified range,
The QOS system is comprised of the ECM, glow relay, inspect the corresponding glow plug.
glow plug, and QOS indicator light. When the ignition
11. If a problem is found, replace the glow plug.
switch is turned to ON under low engine coolant
temperature, the ECM determines the glow time 12. Connect the DMM to the glow plug connector and
according to the engine coolant temperature, and starts GND.
the glow relay and QOS indicator light. The ECM will
13. Turn ON the ignition switch.
turn to OFF the glow relay and QOS indicator light after
a certain period of time. 14. Perform the actuator test glow plug relay using a
trouble diagnosis scan tool.
2. Glow control system check inspection
Note：
abnormality in the locations relating to the QOS system ・ Turn the command to OFF and check the
control voltage value of the DMM.
1. Perform the OBD system check. standard： 0 V
2. Check the DTC. 15. If the reading is outside the specified range, inspect
the circuit.
Note：
Note：
・ If DTCs P0117 or P0118 are set, inspect the
applicable DTC. ・ No short circuit to battery or ignition power
supply should be found between the glow relay
3. Turn ON the ignition switch. and glow plug.
4. Check the operation of the QOS indicator light. 16. If a problem is found, repair or replace the circuit.
Note： 17. Perform the actuator test glow plug relay using a
・ If the QOS does not operate, the QOS trouble diagnosis scan tool.
indicator light will illuminate when the ignition
Note：
switch is turned to ON by the light check
function. ・ Turn the command to ON and check the
voltage value of the DMM.
・ The QOS indicator light turns off within 10
seconds. standard： 18 V
5. Inspect the circuit if the QOS indicator light does not 18. If the reading is less than or equal to the specified
illuminate or turn off. value, inspect the circuit.
･ No fuse should be blown. ･ No fuse should be blown.
･ No open circuit should be found between the fuse and ･ No open circuit should be found between the fuse and
QOS indicator light. glow relay.
･ No open circuit or short circuit should be found ･ No open circuit should be found between the glow relay
between the QOS indicator light and ECM. and glow plug.
･ The QOS indicator light should not have a burned-out ･ No open circuit should be found between the glow relay
bulb. and ECM.
6. If a problem is found, repair or replace the circuit. 19. If a problem is found, repair or replace the circuit.
7. Inspect the glow relay. 20. Replace the ECM.
8. If a problem is found, replace the relay. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
9. Remove all glow plugs.
Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
21. Set the Injector ID Code, fuel delivery rate, and
engine No. for the ECM.
OBD system check

1. OBD system check description of function ・ If the diagnostic light is not blinking, inspect
The OBD system check is a systematic method for the diagnostic light blinking circuit system.
checking problems caused by functional failures in the 5. Use the trouble diagnosis scan tool to confirm the
engine control system, and is also the starting point for all DTCs of the ECU that has communication
diagnoses for driveability complaints. By correctly using established.
this diagnostic step, it is possible to reduce the time for Loss of communication with the trouble diagnosis
diagnosis and prevent the replacement of parts that are scan tool occurs due to the abnormalities in the
not defective. communication circuit of ECM and the trouble
Note： diagnosis scan tool.
・ Points to remember regarding the OBD system 6. Start the engine.
check
Note：
･ If there are no complaints on driveability, do not ・ If the starter does not operate, inspect the
perform these diagnostic steps unless otherwise instructed starter circuit system.
in other sections.
・ If the engine does not start, check the DTC.
･ Check the service technical report before starting the
diagnosis. ・ If the DTC is detected, inspect the
･ Do not delete the DTCs unless it is instructed in a corresponding DTC.
diagnostic step. ・ If no DTC has been detected, inspect the
･ If a malfunction is found in the engine starting system, starting system.
inspect the starting system.
7. Check the engine stalling for problems.
･ The battery should be fully charged.
･ The battery cable should be normal and securely 8. Check the engine hunching and rough idling for
connected. problems.
･ The GND of the ECM should be securely connected in 9. Check if there are problems with insufficient engine
the correct position. output, blowup failure, or engine hesitation.
･ The harness connector of the ECM should be clean and
correctly connected. 10. Check for problems with sudden stopping.
2. OBD system check inspection 11. Check for problems with sudden change.
Inspection for determining the failure location in the 12. Check for problems with insufficient output or
OBD system blowup failure.
1. Turn ON the ignition switch. 13. Check for problems with engine hesitation or
acceleration failure.
2. Check if the diagnostic light is illuminated.
14. Check for problems with dark smoke.
Note：
・ If the machine does not have a diagnostic light 15. Check for problems with white smoke.
setting, do not perform this operation. 16. Check for problems with the idling revolution speed
・ If the diagnostic light is not illuminated, inspect maladjustment.
the diagnostic light illumination circuit system. 17. Check for problems with the idling revolution speed
3. Short the DTC. not decreasing.
Note：
・ Short the No.4 terminal and No.12 terminal.
・ If the machine does not have a diagnostic light
setting, do not perform this operation.
4. Check if the diagnostic light is blinking.
Note：
・ If the machine does not have a diagnostic light
setting, do not perform this operation.
Inspection of the diagnostic light warning light illumination circuit system

1. Inspection of the diagnostic light warning light
illumination circuit system description of function
The diagnostic light supplies power voltage via the
ignition switch and is lit by a signal from the ECM. The
ECM lights the diagnostic light at the light check and at
the time the DTC is set when the ignition switch is turned
to ON. It also blinks the diagnostic light depending on the
detected DTC when the body ground terminal and
diagnostic switch terminal of the DLC are shorted. A
monitor circuit is incorporated inside the ECM and
monitors operation of the light.
Note：
machine, so refer to the manual for the
machine.
2. Inspection of the diagnostic light warning light
illumination circuit system inspection
Inspection when the diagnostic light is not illuminated
when the ignition switch is turned to ON
1. Perform the OBD system check.
2. Inspect the diagnostic light bulb.
3. If a problem is found, replace the valve.
4. Inspect the diagnostic light circuit.
･ No open circuit or high resistance should be found
between the fuse and diagnostic light.
･ No open circuit or high resistance should be found
between the diagnostic light and ECM.
6. Replace the ECM.
ECM removal".
ECM installation".
Inspection of the diagnostic light warning light blinking circuit system

1. Inspection of the diagnostic light warning light Note：
blinking circuit system description of function ・ If it does not blink, inspect the diagnostic light
The diagnostic light supplies power voltage via the blinking circuit system.
ignition switch and is lit by a signal from the ECM. The 13. Replace the ECM.
ECM lights the diagnostic light at the light check and at
the time the DTC is set when the ignition switch is turned Refer to "1.Engine 1J.Electrical(4HK1)
to ON. It also blinks the diagnostic light depending on the ECM removal".
detected DTC when the body ground terminal and Refer to "1.Engine 1J.Electrical(4HK1)
diagnostic switch terminal of the DLC are shorted. A ECM installation".
monitor circuit is incorporated inside the ECM and
monitors operation of the warning light. 14. Set the Injector ID Code, fuel delivery rate, and
Note：
machine, so refer to the manual for the 16. Short the body ground terminal and diagnostic
machine. switch terminal of the DLC.
2. Inspection of the diagnostic light warning light 17. Check if the diagnostic light is blinking.
blinking circuit system inspection 18. Perform the OBD system check.
Inspection when the diagnostic light does not blink but
continues to light when the diagnostic switch is turned to
ON
1. Perform the OBD system check.
3. Connect the DMM between the DLC diagnostic
switch terminal and GND.
5. Confirm that the voltage displayed on the DMM
exceeds the specified value.
standard： 18 V
6. Inspect the diagnostic switch circuit between the
ECM and DLC using the DMM if it is under the
specified value.
･ No open circuit or high resistance should be found.
values: 100Ω or less
･ No short circuit with GND should be found.
values: 10MΩ or more
7. If a problem is found, repair it.
9. Confirm that there is continuity between the DLC
body ground and GND.
11. Short the DTC.
Note：
・ Short the No.4 terminal and No.12 terminal.
12. Check if the diagnostic light is blinking.
Inspection of the starter circuit system

1. Inspection of the starter circuit system description of ･ No open circuit should be found between the starter
function relay and starter.
The starter relay on the ECM is turned to ON when the 13. If a problem is found, repair the circuit.
ignition switch moves to the START position. When the
14. Inspect the starter.
starter relay is turned to ON, the starter operates to start
the engine. Inspection of the starter
2. Inspection of the starter circuit system inspection 15. If a problem is found, replace the starter.
Inspection when the starter does not operate 16. Replace the ECM.
1. Turn the emergency stop switch to OFF. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
Note：
・ If the machine does not have an emergency Refer to "1.Engine 1J.Electrical(4HK1)
stop switch setting, do not perform this ECM installation".
operation. 17. Set the Injector ID Code, fuel delivery rate, and
2. Check the DTC. engine No. for the ECM.
Note：
・ If a DTC is set, inspect the applicable DTC.
4. Remove the starter cut relay.
5. Inspect the starter cut relay.
･ Check the continuity between the switch side terminals.
6. If a problem is found, replace the relay.
7. Remove the starter relay.
8. Inspect the starter relay.
･ Connect the battery between the coil side terminals and
check the continuity between the switch side terminals.
9. If a problem is found, replace the relay.
10. Inspect the ignition switch start signal circuit.
･ No open circuits or high resistance should be found
between the ignition switch and ECM.
･ No short circuits with the GND should be found
between the ignition switch and ECM.
values: 10MΩ or more
12. Inspect the starter circuit.
･ No open circuit should be found between the ignition
switch and starter cut relay.
･ No open circuit should be found between the starter cut
relay and starter relay.
･ No open circuit should be found between the starter
relay and GND.
Symptom (4HK1) 15D-1
Description Engine
Symptom
(4HK1)
Table of Contents
Engine start failure........................................................15D-2
Engine stalling...............................................................15D-4
Engine hunching, rough idling......................................15D-6
Excessive white smoke in the exhaust gas....................15D-7
Excessive black smoke in the exhaust gas....................15D-8
Abnormal noise.............................................................15D-9
Large fuel consumption...............................................15D-10
Large oil consumption.................................................15D-12
Insufficient engine output...........................................15D-13
15D-2 Symptom (4HK1)
Engine start failure

1. Engine start failure description of symptom
The cranking speed is low.
The cranking speed is normal, but the engine does not
start.
The engine starts but cannot maintain its speed stably or
does not reach normal speed.
2. Engine start failure diagnostics
･ Preliminary inspection
Before using this section, perform the functional
inspection and OBD system check to check all of the
following.
Check whether the machine has a significant load.
The ECM and diagnostic light are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the machine, and locate the
appropriate symptom. ･ Diagnostic aids
Check with the customers whether they are using the
Fuel system abnormalities such as fuel running out, fuel
specified engine oil and fuel.
freezing, mixture of air into the fuel piping, filter
･ Visual inspection abnormalities, piping abnormalities, fuel quality, fuel
Careful visual inspection is required for several symptom tank, etc.
procedures. This can lead to fixing a problem without Air intake system abnormalities such as filter clogging,
further inspections, and can save valuable time. air intake piping abnormalities, etc.
The inspection includes the following. Use of low-viscosity fuel such as kerosene causes worn
Whether there is grime or clogging of the fuel filter. on the supply pump plunger and may result in the
Whether there is an improper connection of connectors. discharge abnormalities and cause start failure. In such
Particularly for the CKP sensor and CMP sensor. cases, replacement of the supply pump is required.
Whether the battery terminal voltage has dropped. When a start failure has occurred, check with the
Proper wiring connections, tightening, and disconnection customer about the fuel used. If low-viscosity fuel such
Whether the power of any commercial accessories is as kerosene has been used, instruct the customer not to
being taken divergingly from the ECM power. use low-viscosity fuel because the malfunction recurs
Whether the ECM ground is free of dirt, etc. and securely even after replacing the supply pump.
installed in the correct location. A mixed oil biofuel containing long-term storage fuel and
Proper connections, cracks, and twists in the pipes and organic substances is easily oxidizable. An oxidized fuel
hoses related to fuel, air, and oil. Extensively check for causes worn on the camshaft related parts in the supply
any leaks or blockage. pump and may result in start failure due to discharge
Whether the layout of the fuel filter, pre-filter, and abnormalities. In such cases, replacement of the supply
electromagnetic pump has a structure in which air pump is required.
accumulates easily. Since the replacement of the supply pump due to the use
of mixed oil biofuel containing long-term storage fuel
Check whether they are arranged to prevent air and organic substances is at the customer’s expense,
accumulation as Isuzu genuine pre-filters do not have any instruct the customer not to use mixed oil biofuel
plugs for air removal. containing long-term storage fuel and organic substances.
Also check whether the inlet and outlet of the solenoid When using fuel with high water content, add the larger
pump have an appropriate layout. Fix layouts which have sedimenter to the pre-fuel filter to prevent water from
the solenoid pump inlet on the upper side or have an entering into the fuel system.
outlet toward the motion direction of the machine. Abnormalities of the supply pump, non-pressure fuel
Whether there are any fuel leaks, pipe damage, or dents supply
in the fuel system. The ECM determination of the supply pump non-pressure
Abnormalities of the air intake system parts fuel supply DTC will not be detected unless a condition
Abnormalities of the exhaust system parts continues for 3 seconds or more in which the engine
speed is 900 r/min and the absolute pressure is below 15
MPa{153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine
does not start with non-pressure fuel supply due to the
supply pump abnormalities.
Note：
・ Since the CKP sensor abnormalities will not be
diagnosed unless cranking is performed 14
revolutions or more, crank for more than 14
seconds at 60 r/min or more.
For CKP sensor errors at low engine speed,
the DTC of CKP sensor may not be detected.
For intermittent failure, increase the engine
speed to No Load Max and check if the CKP
sensor related DTC is detected.
Abnormalities of the common rail such as the flow
damper, operation of the pressure limiter, or inside
sealing degradation
Abnormalities of the injector, no fuel injection
System down due to failure
Engine body abnormalities such as seizure, insufficient
compression pressure, and other mechanical failures, etc.
ACG failure
Failure related to the machine equipment such as the oil
pressure pump, etc.
Effect of the post-installed accessories such as wireless
devices and lights, etc.
ECM failure
Inspect the connector for connection failures and the
harness for abnormalities such as abrasions, bending, etc.
Inspect to see if the wires inside the harness are separate
and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm
the operation, control of each part, etc. Repair if
abnormalities are found.
Engine stalling
1. Engine stalling description of symptom the solenoid pump inlet on the upper side or have an
outlet toward the motion direction of the machine.
Engine cranks but takes a long time to start. The engine
Abnormalities of the air intake system parts
ultimately operates, or starts but stops soon.
Abnormalities of the exhaust system parts
2. Engine stalling diagnostics
following.
Check whether the machine has a significant load.
Since the CKP sensor abnormalities will not be diagnosed
with cranking less than 14 revolutions, crank for more
than 14 seconds at 60 r/min or more.
DTC check.
For CKP sensor errors at low engine speed, the CKP
sensor DTC may not be detected.
For intermittent failure, increase the engine speed to No
Load Max and check if the CKP sensor related DTC is
detected.
･ Diagnostic aids
appropriate symptom.
Check with the customers whether they are using the Fuel system abnormalities such as fuel running out, fuel
specified engine oil and fuel. freezing, mixture of air into the fuel piping, filter
Check whether fuel is contained. abnormalities, piping abnormalities, fuel quality, fuel
tank, etc.
･ Visual inspection
Air intake system abnormalities such as filter clogging
Careful visual inspection is required for several symptom and air intake piping abnormalities, etc.
procedures. This can lead to fixing a problem without Abnormalities of the supply pump, non-pressure fuel
further inspections, and can save valuable time. supply
The inspection includes the following. The ECM determination of the supply pump non-pressure
Whether there is an improper connection of connectors. fuel supply DTC will not be detected unless a condition
Particularly for the CKP sensor and CMP sensor. continues for 3 seconds or more in which the engine
Proper wiring connections, tightening, and disconnection revolution speed is 900 r/min and the absolute pressure is
Whether the power of any commercial accessories is below 15 MPa {153 kgf/cm2 / 2175 psi}.
being taken divergingly from the ECM power. Therefore, the DTC will not be detected when the engine
Whether the ECM ground is free of dirt, etc. and securely does not start with non-pressure fuel supply due to supply
installed in the correct location. pump abnormalities.
Proper connections, cracks, and twists in the pipes and
Abnormalities of the common rail such as the flow
hoses related to fuel, air, and oil. Extensively check for
damper, operation of the pressure limiter, or inside
any leaks or blockage.
sealing degradation
Whether there are any fuel leaks, pipe damage, or dents
in the fuel system.
System down due to failure
Whether the layout of the fuel filter, pre-filter, and
electromagnetic pump has a structure in which air
accumulates easily.
ACG failure
Check whether they are arranged to prevent air Failure related to the machine equipment such as the oil
accumulation as Isuzu genuine pre-filters do not have any pressure pump, etc.
plugs for air removal. Effect of the post-installed accessories such as wireless
Also check whether the inlet and outlet of the solenoid devices and lights, etc.
pump have an appropriate layout. Fix layouts which have ECM failure
Inspect to see if the wires inside the harness are separate
and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm
the operation, control of each part, etc. Repair if
Engine hunching, rough idling

1. Engine hunching, rough idling description of symptom
The engine has variable engine idling, or has change in
idling speed. In a severe case, the engine or the machine
may vibrate. In either case, the engine stall may occur if
the symptom gets worse.
2. Engine hunching, rough idling diagnostics
following.
DTC check.
specified engine oil and fuel. ･ Diagnostic aids
･ Visual inspection Fuel system abnormalities such as fuel running out, fuel
Careful visual inspection is required for several symptom freezing, mixture of air into the fuel piping, filter
procedures. This can lead to fixing a problem without abnormalities, piping abnormalities, fuel quality, fuel
further inspections, and can save valuable time. tank, etc.
The inspection includes the following. Air intake system abnormalities such as filter clogging,
Whether there is an improper connection of connectors. air intake piping abnormalities, etc.
Whether the battery terminal voltage has dropped. Abnormalities of the supply pump, non-pressure fuel
Proper wiring connections, tightening, and disconnection supply
Whether the power of any commercial accessories is Switch input circuit system abnormalities
being taken divergingly from the ECM power. Abnormalities of the sensor input circuit system such as
Whether the ECM ground is free of dirt, etc. and securely the accelerator position sensor, harness, and engine
installed in the correct location. coolant temperature sensor
Proper connections, cracks, and twists in the pipes and Accelerator position sensor system abnormalities
hoses related to fuel, air, and oil. Extensively check for Engine body abnormalities such as seizure, insufficient
any leaks or blockage. compression pressure, and other mechanical failures, etc.
Whether there are any fuel leaks, pipe damage, or dents Failure related to the machine equipment such as the oil
in the fuel system. pressure pump, etc.
Whether the layout of the fuel filter, pre-filter, and Effect of the post-installed accessories such as wireless
electromagnetic pump has a structure in which air devices and lights, etc.
accumulates easily. Inspect the connector for connection failures and the
Check whether they are arranged to prevent air Inspect that the wires inside the harness are separate and
accumulation as Isuzu genuine pre-filters do not have any have not caused a short circuit with other circuits.
plugs for air removal. Perform inspections for functional diagnosis, and confirm
Also check whether the inlet and outlet of the solenoid the operation, control of each part, etc. Repair if
pump have an appropriate layout. Fix layouts which have abnormalities are found.
the solenoid pump inlet on the upper side or have an
outlet toward the motion direction of the machine.
in the fuel system.
Excessive white smoke in the exhaust gas

1. Excessive white smoke in the exhaust gas description Engine body failure such as insufficient compression
of symptom pressure, piston related failure, turbocharger failure, and
raised oil or sucked down oil, etc.
Excessive white smoke when driving.
ECM failure
2. Excessive white smoke in the exhaust gas diagnostics
following.
DTC check.
Careful visual inspection is required for several symptom
procedures. This can lead to fixing a problem without
further inspections, and can save valuable time.
The inspection includes the following.
Whether there is an improper connection of injector
connectors.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is
being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely
installed in the correct location.
in the fuel system.
･ Diagnostic aids
Fuel quality when using a product with a low cetane
number or a product other than those specified
Use of low-viscosity fuel such as kerosene may result in
abnormal worn on the seat area of the injector and cause
abnormal spray and white smoke. In such cases,
replacement of the injector is required.
Since the replacement of the injector due to the use of
low-viscosity fuel such as kerosene is at the customer's
expense, instruct the customer not to use low-viscosity
fuel such as kerosene.
Idling for a long time
Failure of the engine coolant temperature sensor, fuel
temperature sensor, IAT sensor, boost sensor failure, or
barometric pressure sensor
Excessive black smoke in the exhaust gas

1. Excessive black smoke in the exhaust gas description
of symptom
Excessive black smoke when driving.
2. Excessive black smoke in the exhaust gas diagnostics
Note：
・ Preliminary inspection
following.
DTC check.
Note：
・ Visual inspection
Whether there is grime or clogging in the air cleaner
element.
Whether the power of any commercial accessories is
being taken divergingly from the ECM power.
in the fuel system.
Note：
・ Diagnostic aids
Fuel quality when using a product other than those
specified, etc.
Air intake system abnormalities such as filter clogging,
air intake piping abnormalities, etc.
Abnormalities of the EGR control system
Abnormalities of the exhaust system such as exhaust pipe
abnormalities, etc.
Engine coolant temperature sensor malfunction
Boost sensor failure
Engine body failure such as insufficient compression
pressure, piston related failure, turbocharger failure, and
raised oil, etc.
Abnormal noise
1. Abnormal noise description of symptom the operation, control of each part, etc. Repair if
Engine combustion noise is abnormal.
2. Abnormal noise diagnostics
following.
Refer to the machine manual and inspect the abnormal
noise.
DTC check.
in the fuel system.
･ Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel
freezing, mixture of air into the fuel piping, filter
abnormalities, piping abnormalities, fuel quality, fuel
tank, etc.
Air intake system abnormalities such as EGR valve
abnormalities, etc.
Failure related to the machine equipment such as the oil
pressure pump, etc.
ECM failure
Inspect that the wires inside the harness are separate and
have not caused a short circuit with other circuits. Also
perform inspections for functional diagnosis, and confirm
Large fuel consumption

1. Large fuel consumption description of symptom Proper wiring connections, tightening, and disconnection
Fuel consumption is significantly larger than indicated in
the machine manual.
2. Large fuel consumption diagnostics hoses related to fuel, air, and oil. Extensively check for
Before using this section, perform the functional in the fuel system.
inspection and OBD system check to check all of the Abnormalities of the air intake system parts
following. Abnormalities of the exhaust system parts
Since the fuel consumption varies widely depending on
･ Diagnostic aids
the handling of the machine, check the reference fuel
consumption (A) of the machine manufacturer. Reference Fuel system abnormalities such as fuel running out, fuel
fuel consumption (L {qts}/hour) freezing, mixture of air into the fuel piping, filter
Check the actual fuel consumption (B). Actual fuel abnormalities, piping abnormalities, fuel quality, fuel
consumption (L {qts}/hour) tank, etc.
If B is greater than A, refer to the machine manual and Air intake system abnormalities such as EGR valve
check the setting of the unit. abnormalities, etc.
Check whether the actual unit does not have a significant Abnormalities of the injector such as excessive fuel
load. injection
Refer to the inspections and maintenance list in the Engine body abnormalities such as seizure, insufficient
operation manual and perform the inspection based on the compression pressure, and other mechanical failures, etc.
operation time of the machine. Failure related to the actual unit equipment such as the oil
Refer to the machine manual to inspect a machine whose pressure pump, etc.
operation time exceeds 3,000 hours. ECM failure
The ECM and diagnostic light are operating correctly. Inspect the connector for connection failures and the
DTC check. harness for abnormalities such as abrasions, bending, etc.
Check the condition of the machine, and locate the Inspect that the wires inside the harness are separate and
appropriate symptom. have not caused a short circuit with other circuits.
Check with the customers whether they are using the Perform inspections for functional diagnosis, and confirm
specified engine oil and fuel. the operation, control of each part, etc. Repair if
Check whether engine oil change or periodical abnormalities are found.
maintenance for the air cleaner filter or fuel filter, etc. has
For the inspection locations of the engine air intake and
been performed.
exhaust system
･ Visual inspection Inspect the air intake and exhaust system for
abnormalities such as clogging, collapsing and damage.
Other than the inspection locations of the engine body,
inspect the air cleaner, intercooler, and muffler.
1. EGR valve 5. Exhaust pipe

2. From the intercooler 6. EGR cooler
3. From the air cleaner
4. To the intercooler
Large oil consumption

1. Large oil consumption description of symptom
The oil consumption amount described in the manual of
the machine is significantly exceeded.
2. Large oil consumption diagnostics
following.
Since the oil consumption varies widely by handling of
the machine, check the reference oil consumption (A) of
the machine manufacturer. Reference oil consumption/
hour Reference oil consumption per engine: 4L {4.2 qts}/
100 hours
Check the actual oil consumption (B). Actual oil
consumption/hour
Refer to the inspections and maintenance list in the
operation manual and perform the inspection based on the
operation time of the machine.
Refer to the machine manual to inspect a machine whose
operation time exceeds 3,000 hours.
DTC check.
Whether bluish white smoke continuously comes out
when the engine is running.
Whether blow-by gas comes out excessively.
Whether oil is mixed into the coolant.
hoses related to oil. Extensively check for any leaks or
blockage.
Whether there is any fuel leak, pipe damage, or dents in
the lubricant system.
Abnormalities of the air intake system parts such as the
turbocharger inspection
･ Diagnostic aids
Air intake system abnormalities such as sucked down oil
or raised oil and excessive blow-by gas
Engine body abnormalities such as oil combustion and
excessive blow-by gas Perform inspections for functional
diagnosis, and confirm the operation, control of each part,
etc. Repair if abnormalities are found.
Insufficient engine output

1. Insufficient engine output description of symptom Fuel system abnormalities such as running out of fuel,
fuel freezing, air intrusion in the fuel pipe, filter
The engine output is lower than expected, the output does
abnormality, pipe abnormality, fuel quality, and fuel tank
not change when the accelerator lever (throttle lever) is
Air intake system abnormalities such as filter clogging
lifted up, the operation is not effective.
and air intake pipe abnormality
2. Insufficient engine output diagnostics Exhaust system abnormalities such as exhaust pipe
abnormality
Abnormalities of the sensor input circuit system
Before using this section, perform the functional including the accelerator position sensor and the harness
inspection, OBD system check to confirm the following Abnormalities of the switch input circuit system
all items. Engine unit abnormalities including other mechanical
The ECM and the diagnostic light are operating properly. failures such as compression pressure, valve clearance,
DTC check. turbocharger, supply pump, injector, and common rail
The scan tool data is within the normal operating range. Failures related to the machine side equipment such as
Check the machine condition, and locate the hydraulic pump
corresponding symptom. Influence of the post-mounted electrical components such
Check with the customer if the customer is using the as wireless devices and lights
specified engine oil and fuel. Inspect for connector improper connections, harness
For insufficient output, various causes can be suspected, abnormalities such as abrasions and bends, and short
so thoroughly investigate the relationship between the circuits with other circuits due to wire split inside
engine and the machine side. harness. Also, perform inspections for functional
Check what kind of operations cause insufficient output. diagnosis, and check the operation and control of each
If hesitation or lug-down is included in the symptoms of part. Make repairs if any abnormality is found.
insufficient output, it is related to the control on the Output reduction due to fuel flow restriction imposed
machine side, so contact the manufacturer of the upon overheat
machine. Insufficient output due to fuel flow restriction during
If a trouble diagnosis scan tool is available, the engine operation at high altitude
output at the rated point can be easily verified by
･ Control when overheating
checking the boost at the rated point.
To protect the engine, restriction on fuel flow is started
when the engine coolant temperature exceeds 100º C
Careful visual inspection is required for several symptom (212º F). When the engine coolant temperature increases
procedures. This can lead to fixing a problem without further, the fuel flow is also restricted further. When the
further inspections, and can save valuable time. temperature is near 120º C (248º F), the fuel flow is
The inspection includes the following. restricted to a certain level. The setting varies depending
Whether there is grime or clogging in the air cleaner on the machine manufacturer.
element. The machine is designed to issue an alarm from 105º C
Proper wiring connections, tightening, and disconnection (221º F). By reducing the load applied to the machine
Whether the power of any commercial accessories is upon alarm issuance, it is possible to avoid the operation
being taken divergingly from the ECM power. condition with fuel flow restriction.
in the fuel system.
Increased resistance due to grime, clogging, or air intake
piping collapsing particularly in the air cleaner element
among the air intake system parts
･ Diagnostic aids
･ High altitude correction

The ECM calculates the current altitude in accordance
with the signal from the barometric pressure sensor.
Depending on the conditions of altitude, etc. at this time,
the SCV opening and closing timing and injector
energizing time are controlled and the fuel flow is
corrected to be optimum.
DTC Information (4HK1 (Generator 12V)) 15E-1
Description Engine
DTC Information
(4HK1 (Generator 12V))
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor
Position Correlation Error.............................................15E-4 Circuit High.................................................................15E-25
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0201 (Flash Code 271) Injector Circuit Open -
VNT Error......................................................................15E-5 Cylinder 1....................................................................15E-26
DTC P0079 (Flash Code 38) Exhaust Valve Control DTC P0202 (Flash Code 272) Injector Circuit Open -
Solenoid Circuit Low.....................................................15E-6 Cylinder 2....................................................................15E-27
Solenoid Circuit High....................................................15E-7 Cylinder 3....................................................................15E-28
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit Open -
Too Low........................................................................15E-8 Cylinder 4....................................................................15E-29
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0217 (Flash Code 542) Engine Coolant Over
Performance...................................................................15E-9 Temperature Condition................................................15E-30
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Control Circuit Low.....................................................15E-10 .....................................................................................15E-31
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit High....................................................15E-11 Condition.....................................................................15E-32
DTC P0097 (Flash Code 214) Intake Air Temperature (IAT) DTC P0237 (Flash Code 32) Turbocharger Boost Sensor
Sensor 2 Circuit Low Voltage.....................................15E-12 Circuit Low..................................................................15E-33
Sensor 2 Circuit High Voltage.....................................15E-13 Circuit High.................................................................15E-34
DTC P0102 (Flash Code 91) Mass Air Flow Sensor Circuit DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Low Input....................................................................15E-14 Circuit..........................................................................15E-35
High Input....................................................................15E-15 Circuit Range/Performance.........................................15E-36
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit Low..................................................................15E-16 Circuit..........................................................................15E-37
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0380 (Flash Code 66) Glow Relay Circuit Error
Circuit High.................................................................15E-17 .....................................................................................15E-38
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0404 (Flash Code 45) EGR Control Circuit Range/
Sensor Circuit Low......................................................15E-18 Performance.................................................................15E-39
DTC P0118 (Flash Code 23) Engine Coolant Temperature DTC P0409 (Flash Code 44) EGR Sensor Circuit......15E-40
Sensor Circuit High.....................................................15E-19 DTC P041C (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0122 (Flash Code 43) Throttle Position Sensor Sensor Circuit Low......................................................15E-41
Circuit Low..................................................................15E-20 DTC P041D (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0123 (Flash Code 43) Throttle Position Sensor Sensor Circuit High.....................................................15E-42
Circuit High.................................................................15E-21 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low Sensor 1...................................................15E-43
Circuit Low..................................................................15E-22 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High Sensor 1..................................................15E-44
Circuit High.................................................................15E-23 DTC P042C (Flash Code 49) Catalyst Temperature Sensor
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low Sensor 2...................................................15E-45
Circuit Low..................................................................15E-24
15E-2 DTC Information (4HK1 (Generator 12V))
DTC P042D (Flash Code 49) Catalyst Temperature Sensor DTC P1097 (Flash Code 213) Compressor Outlet
Circuit High Sensor 2..................................................15E-46 Temperature Sensor Circuit High................................15E-72
DTC P0521 (Flash Code 294) Engine Oil Pressure Sensor DTC P1098 (Flash Code 213) Compressor Outlet
Performance.................................................................15E-47 Temperature Sensor Circuit High................................15E-73
DTC P0522 (Flash Code 294) Engine Oil Pressure Sensor DTC P1236 (Flash Code 315) Charge Air Cooler
Circuit Low Input........................................................15E-48 Performance Failure....................................................15E-74
DTC P0523 (Flash Code 294) Engine Oil Pressure Sensor DTC P1261 (Flash Code 34) Injector Positive Voltage
Circuit High Input........................................................15E-49 Control Circuit Group 1...............................................15E-75
DTC P0545 (Flash Code 39) EGR Cooler Inlet 1 Temp DTC P1262 (Flash Code 34) Injector Positive Voltage
Sensor Circuit Low......................................................15E-50 Control Circuit Group 2...............................................15E-76
DTC P0546 (Flash Code 39) EGR Cooler Inlet 1 Temp DTC P1404 (Flash Code 45) EGR Position Fault.......15E-77
Sensor Circuit High.....................................................15E-51 DTC P1606 (Flash Code 51) SW-IC Internal failure
DTC P0563 (Flash Code 35) System Voltage High....15E-52 .....................................................................................15E-78
DTC P0601 (Flash Code 53) Internal Control Module DTC P160B (Flash Code 36) AD-IC Failure Error.....15E-79
Memory Check Sum Error..........................................15E-53 DTC P1621 (Flash Code 54) Control Module Long Term
DTC P0602 (Flash Code 154) Internal Control Module QR Memory Performance..................................................15E-80
Code Error...................................................................15E-54 DTC P1622 (Flash Code 54) Control Module EEPROM
DTC P0604 (Flash Code 153) Internal Control Module Hardware Error............................................................15E-81
RAM Error...................................................................15E-55 DTC P204F (Flash Code 611) SCR System Error (No
DTC P0606 (Flash Code 51) Internal Control Module CPU Inducement).................................................................15E-82
Error.............................................................................15E-56 DTC P207F (Flash Code 611) Urea Fluid Concentration
DTC P060A (Flash Code 51) Internal Control Module CPU Too Low......................................................................15E-83
IC Error........................................................................15E-57 DTC P20C9 (Flash Code 611) SCR System Error......15E-84
DTC P060C (Flash Code 36) Internal Control Module A/D DTC P2122 (Flash Code 121) Pedal Position Sensor 1
Processing Performance..............................................15E-58 Circuit Low Input........................................................15E-85
DTC P0615 (Flash Code 19) Starter Relay Circuit Error DTC P2123 (Flash Code 121) Pedal Position Sensor 1
.....................................................................................15E-59 Circuit High Input........................................................15E-86
DTC P0638 (Flash Code 61) Throttle Actuator Control DTC P2127 (Flash Code 122) Pedal Position Sensor 2
Range/Performance.....................................................15E-60 Circuit Low Input........................................................15E-87
DTC P0685 (Flash Code 416) ECM Power Relay Control DTC P2128 (Flash Code 122) Pedal Position Sensor 2
Circuit Open................................................................15E-61 Circuit High Input........................................................15E-88
DTC P0687 (Flash Code 416) ECM Power Relay Control DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Circuit High.................................................................15E-62 Voltage Correlation.....................................................15E-89
DTC P06A6 (Flash Code 55) Sensor Reference Voltage 1 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
Circuit..........................................................................15E-63 Voltage Circuit............................................................15E-90
DTC P06A8 (Flash Code 57) Sensor Reference Voltage 3 DTC P2228 (Flash Code 71) Barometric Pressure Sensor
Circuit..........................................................................15E-65 Circuit Low..................................................................15E-92
DTC P06A9 (Flash Code 59) Sensor Reference Voltage 4 DTC P2229 (Flash Code 71) Barometric Pressure Sensor
Circuit..........................................................................15E-66 Circuit High.................................................................15E-93
DTC P06AF (Flash Code 277) Torque Management System DTC P2457 (Flash Code 95) Exhaust Gas Recirculation
- Forced Engine Shutdown..........................................15E-67 (EGR) Cooling System Performance..........................15E-94
DTC P06D5 (Flash Code 56) Sensor Reference Voltage 5 DTC P2458 (Flash Code 139) Purge Time Out Error
Circuit..........................................................................15E-68 .....................................................................................15E-95
DTC P1076 (Flash Code 313) Charge Air Cooler (CAC) DTC P2BAA (Flash Code 611) SCR System Error
Temperature Sensor 1 Circuit Low Voltage................15E-69 (Inducement, No Purge)..............................................15E-96
DTC P1077 (Flash Code 313) Charge Air Cooler (CAC) DTC P3093 (Flash Code 227) Fuel Rail Pressure Too Low
Temperature Sensor 1 Circuit High Voltage...............15E-70 .....................................................................................15E-97
DTC P1093 (Flash Code 227) Fuel Rail Pressure Too Low DTC U0001 (Flash Code 84) CAN Bus Error (ISO-CAN)
.....................................................................................15E-71 .....................................................................................15E-98
DTC U0073 (Flash Code 84) Control Module

Communication Bus Off..............................................15E-99
DTC U0101 (Flash Code 85) Lost Communication With
CAN...........................................................................15E-100
DTC U010E (Flash Code 83) Lost Communications With
Dosing Control Module.............................................15E-101
VNT System..............................................................15E-102
DTC U0411 (Flash Code 87) Lost CAN Communications
With VNT Control Module.......................................15E-103
DTC mapping table...................................................15E-104
DTC P0016 (Flash Code 16)

Crankshaft Position - Camshaft Position Correlation Error
1. DTC P0016 description of DTC
The CKP sensor is installed to the flywheel housing. On
the flywheel, there are 56 sensing holes spaced 6°apart
and a 30° section that contains no sensing holes. Top
dead center of cylinder No. 1 can be detected through this
section that contains no sensing holes.
The CMP sensor is installed on the rear of the cylinder
head. The CMP sensor detects 5 projections in total per
engine 1 cycle. The camshaft gear has 4 projections
evenly spaced 90° apart and 1 reference projection. By
detecting the opening with the CKP sensor and the 1
reference projection with the CMP sensor, the ECM
determines compression top dead center of cylinder No. 1
to verify that they correlate with each other. If the ECM
detects that both signals are out of synchronization, the
DTC is set.
2. DTC P0016 condition for setting the DTC
DTCs P0335, P0336, and P0340 are not set.
The engine is running.
The ECM detects that the CKP sensor signal and CMP
sensor signal are not synchronized.
3. DTC P0016 action taken when the DTC sets
Failure is indicated in the monitor on the machine, or the
diagnostic light is turned on.
Note：
・ Depending on the manufacturer of the
machine, the failure indication may not be
shown.

Turbocharger Boost Control VNT Error
The opening angle of the variable nozzle on the
turbocharger is controlled by the turbo control unit
through operating the motor built into the actuator to
activate the control rod in accordance with the signal
received from the ECM. The ECM controls the variable
nozzle based on the boost pressure, and detects the
operation amount of the variable nozzle with the position
sensor built into the turbo actuator. When the engine is
not under load, the variable nozzle is in the open
condition, or the boost pressure is not present. When the
engine is under load, the turbo actuator is controlled to
close the variable nozzle. As the result, the boost pressure
increases. The ECM performs control that changes the
boost pressure in accordance with the load requirements
for the engine. The ECM communicates with the turbo
control unit through CAN communication to perform
control. The DTC is set when the ECM detects an open
circuit or short circuit in the circuit between the turbo
actuator and turbo control unit or an abnormality in
communication with the turbo control unit.
DTCs U0001 and U0110 are not set.
The battery voltage is 20 to 32 V.
The ignition switch is ON.
The turbo control unit detects a malfunction in the motor
circuit for 3 seconds or more.
Note：
・ Depending on the machine manufacturer, a
failure may not be indicated.
The fuel injection quantity is limited.
The EGR control is disabled.
The VGS control is disabled.
SCR purging is stopped.

Exhaust Valve Control Solenoid Circuit Low
If the ECM detects any abnormal voltage in the exhaust
throttle solenoid valve control circuit, the DTC is set.
The ECM detects a low voltage condition in the exhaust
throttle solenoid valve control circuit for 10 seconds or
more when the solenoid is commanded OFF.
Note：
The engine is stopped.

Exhaust Valve Control Solenoid Circuit High
If the ECM detects any abnormal voltage in the exhaust
throttle solenoid valve control circuit, the DTC is set.
The ECM detects a high voltage condition in the exhaust
throttle solenoid valve control circuit for 10 seconds or
more when the solenoid is commanded ON.
Note：

Fuel Rail/System Pressure - Too Low
The general common rail system is comprised of the
following two fuel pressure sections. The suction side
between the fuel tank and the supply pump and the high-
pressure side between the supply pump and the fuel
injectors. The fuel is drawn from the fuel tank and
supplied to the common rail by the two plungers located
inside the supply pump. The common rail pressure is
adjusted by the ECM through controlling the suction
control valve based on the signal from the common rail
pressure sensor. When the common rail pressure becomes
in excess, the common rail pressure limiter valve opens to
release the excessive pressure and return the fuel back to
the fuel tank. The ECM sets the DTC when the common
rail pressure increases more than necessary and then
drops drastically. This DTC detects that the pressure
limiter valve has been activated.
DTCs P0192, P0193, and P06A7 are not set.
The ECM detects that the pressure limiter valve is
activated due to excessive pressure in the common rail
(fuel rail).
The actual rail pressure is excessively lower than the
desired rail pressure.
The fuel flow rate is limited.

Fuel Pressure Regulator Performance
pressure sensor. This DTC is set when the ECM detects
that the fuel pressure is higher than the target fuel
pressure.
DTCs P0091, P0092, P0192, P0193, P060C, P06A7,
P0201-P0204, P1261, P1262, P2146, and P2149 are not
set.
The ECM detects that the common rail (fuel rail) pressure
is higher than the desired fuel pressure by 40 MPa {408
kgf/cm2 / 5800 psi} or more for 5 seconds or more.
Note：
shown.

Fuel Pressure Regulator Control Circuit Low
The suction control valve is installed on the supply pump,
and controls the fuel amount to be taken into the common
rail. The suction control valve is normally fully open, and
the opening of the regulator becomes smaller when the
drive current becomes larger. The ECM calculates the
common rail target pressure and fuel flow, and determine
the opening angle of the suction control valve by
comparing the calculated common rail pressure with the
actual pressure value. When the actual common rail
pressure is higher than the target pressure, the suction
control valve closes to reduce the fuel flow. The DTC is
set when the ECM detects that the feedback current of the
suction control valve is abnormally low.
The SCV duty ratio is 10% - 90%.
The ECM detects that the feedback current of the FRP
regulator is 50 mA or less, or lower than the desired
current by 1,000 mA or more, for 2 seconds or more.
Note：
shown.
The maximum engine speed is limited to 1200 rpm.

Fuel Pressure Regulator Control Circuit High
suction control valve is abnormally high.
regulator is 2,400 mA or more, or higher than the desired
Note：
shown.

Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage
The IMT sensor is installed to the intake manifold. The
IMT sensor is a thermistor type sensor and it measures
the temperature of the intake air mixed with EGR gas.
This sensor has a signal circuit and a GND circuit. The
ECM supplies 5 V to the signal circuit, and GNDs to the
GND circuit. When the IMT sensor is cold, the sensor
resistance is high. When the EGR gas amount increases,
the intake air temperature rises and the sensor resistance
decreases. The ECM detects a high voltage when the
when the sensor resistance is low.
DTCs P060C, P06A8, and P160B are not set.
The ECM detects that the IMT sensor signal voltage is
0.1 V or less for 5 seconds or more.
Note：
・ Depending on the machine manufacturer, the
failure indication may not be shown.
A default IMT sensor value is assumed.

Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage
The ECM supplies 5 V to the signal circuit, and GNDs to
the GND circuit. When the EGR gas amount increases,
when the sensor resistance is low. If the ECM detects an
excessively high signal voltage, the DTC is set.
DTCs P0112, P0113, P060C, P06A8, and P160B are not
set.
The engine speed is 1500 r/min or more.
The fuel injection quantity is more than or equal to the
predetermined value.
4.9 V or more for 5 seconds or more.
Note：

Mass Air Flow Sensor Circuit Low Input
The MAF sensor is an air flow meter to measure the
amount of air taken into the engine. It is installed between
the air cleaner and turbocharger. A small amount of air
taken into the engine indicates deceleration or idle speed.
A large amount of air indicates acceleration or high load.
The sensor has the following circuits.
12 V voltage circuit
GND circuit
MAF sensor signal circuit
The ECM monitors the voltage of the MAF sensor signal.
The scan tool displays the air flow as g/cyl for each
voltage and cylinder from this output voltage. When the
ECM detects that the signal voltage is absolutely low, it
sets DTC.
DTCs P0560 and P060C are not set.
The ECM detects that the MAF sensor signal voltage is
1.5 V or less for 5 seconds.
Note：
shown.
A default MAF value is assumed.

Mass Air Flow Sensor Circuit High Input
GND circuit
sets DTC.
4.9 V or more for 5 seconds.
Note：
shown.

Intake Air Temperature Sensor Circuit Low
The IAT sensor is a thermistor type sensor to measure the
temperature of air taken into the engine. This sensor has a
signal circuit and GND circuit. The ECM supplies 5 V to
the signal circuit, and the GND circuit connects to GND.
When the IAT sensor is cold, the resistance of the sensor
is high. When the air temperature rises, the resistance of
the sensor becomes low. The ECM detects the high
voltage when the sensor resistance is high. The ECM
detects the low voltage when the sensor resistance is low.
When the ECM detects that the DPD differential pressure
is abnormally low, it sets DTC.
The ECM detects that the IAT sensor signal voltage is 0.1
V or less for 5 seconds.
Note：
shown.
A default IAT value is assumed.

Intake Air Temperature Sensor Circuit High
the signal circuit, and the GND circuit connects to the
GND. When the IAT sensor is cold, the resistance of the
sensor is high. When the air temperature rises, the
resistance of the sensor becomes low. The ECM detects
the high voltage when the sensor resistance is high. The
ECM detects the low voltage when the sensor resistance
is low. When the ECM detects that the signal voltage is
abnormally high, it sets DTC.
The engine has been running for 3 minutes or more.
V or more for 5 seconds.
Note：
shown.

Engine Coolant Temperature Sensor Circuit Low
The engine coolant temperature sensor is installed to the
thermostat housing. The engine coolant temperature
sensor is a thermistor type sensor and measures the
temperature of the engine coolant. This sensor has a
signal circuit and a GND circuit. The ECM supplies 5 V
to the signal circuit, and the GND circuit connects to
GND. When the engine coolant temperature sensor is
cold, the sensor resistance is high. When the engine
coolant temperature increases, the sensor resistance
excessively low signal voltage, the DTC is set.
The ECM detects that the engine coolant temperature
sensor signal voltage is 0.1 V or less for 5 seconds.
Note：
shown.
A default water temperature value is assumed.

Engine Coolant Temperature Sensor Circuit High
sensor signal voltage is 4.9 V or more for 5 seconds.
Note：
shown.
A default water temperature value is assumed.

Throttle Position Sensor Circuit Low
The intake throttle position sensor is installed to the
intake throttle valve body together with the motor. The
intake throttle position sensor changes the signal voltage
in accordance with the intake throttle valve opening
position. The sensor has the following circuits.
5 V power supply circuit
GND circuit
Intake throttle position sensor signal circuit
The intake throttle position sensor sends the signals
indicating changes in the intake throttle valve opening
position to the ECM. If the ECM detects an excessively
low signal voltage, the DTC is set.
DTCs P060C, and P06A8 are not set.
The ECM detects that the intake throttle position sensor
signal voltage is 0.3 V or less for 5 seconds.
Note：
shown.

Throttle Position Sensor Circuit High
GND circuit
position to the ECM.
If the ECM detects an excessively high signal voltage, the
DTC is set.
signal voltage is 4.9 V or more for 5 seconds.
Note：
shown.

Fuel Temperature Sensor Circuit Low
pump. The fuel temperature sensor is a variable resistor
that measures the temperature of the fuel entering the
supply pump. This sensor has a signal circuit and a GND
circuit. The ECM supplies 5 V to the signal circuit, and
the GND circuit connects to GND. When the fuel
temperature sensor is cold, the resistance of the sensor is
high. As the fuel temperature rises, the sensor resistance
If the ECM detects an excessively low signal voltage, the
DTC is set.
The ECM detects that the fuel temperature sensor signal
voltage is 0.1 V or less for 5 seconds.
Note：
shown.
Substitute the default value of fuel temperature sensor.

Fuel Temperature Sensor Circuit High
pump. The fuel temperature sensor is a variable resistor,
and measures the temperature of the fuel entering the
supply pump. This sensor has a signal circuit and GND
high. When the fuel temperature rises, the resistance of
the sensor decreases. The ECM detects a high voltage
low voltage when the sensor resistance is low. The DTC
is set when the ECM detects an abnormally high signal
voltage.
voltage is 4.9 V or more for 5 seconds.
Note：
shown.

Fuel Rail Pressure Sensor Circuit Low
The common rail pressure sensor is installed on the
common rail, and it detects the fuel pressure in the
common rail to covert into the voltage signal. The sensor
has the following circuits.
GND circuit
Common rail pressure sensor signal circuit
The ECM monitors the voltage of the common rail
pressure sensor signal. The signal voltage becomes higher
when the pressure of the common rail is higher, and it
becomes lower when the pressure is lower. The ECM
calculates the actual common rail pressure from the
voltage signal, and uses the result for various controls
such as the fuel injection control.
The DTC is set when the ECM detects an abnormally low
signal voltage.
DTCs P060C and P06A7 are not set.
sensor signal voltage is 0.7 V or less.
Note：
shown.
A default common rail (fuel rail) pressure value is
assumed.

Fuel Rail Pressure Sensor Circuit High
GND circuit
voltage signal, and uses the result for controls such as the
fuel injection control.
The DTC is set when the ECM detects an abnormally
high signal voltage.
sensor signal voltage is 4.8 V or more.
Note：
shown.
assumed.

Injector Circuit Open - Cylinder 1
The ECM calculates the optimum fuel injection ON time
using data transmitted from the sensor. The injector
power circuit supplies the high voltage while the ECM
grounds the injector solenoid control circuit as well as
drives the injector of each cylinder. The ECM sets a DTC
when an abnormality is detected in the No.1 cylinder
injector circuit.
DTCs P06AF, P1261, and P2146 are not set.
The ECM detects an open circuit in the injector solenoid
Note：
shown.
The injection of the No. 1 cylinder is disabled.

using the data transmitted from the sensor. The injector
power supply circuit supplies the high voltage while the
ECM grounds the injector solenoid control circuit as well
as drives the injector of each cylinder. The ECM sets a
DTC when an abnormality is detected in the No.2
cylinder injector circuit.
The battery voltage is between 18 - 32 V.
Note：
shown.

Note：
shown.

Note：
shown.

Engine Coolant Over Temperature Condition
sensor is a thermistor type and measures the temperature
of the engine coolant.
If the ECM detects an excessively high temperature in the
coolant, the DTC is set.
The ECM detects that the engine coolant temperature is
101°C (214°F) or more for 10 seconds.

Engine Overspeed Condition
The CKP sensor is installed to the flywheel housing. The
ECM calculates the engine speed and accurate crankshaft
position based on the signal pulse from the CKP sensor.
If the ECM detects that the engine is in an overrun
condition, the DTC is set.
DTCs P06A6 and P06A7 are not set.
Shovel car
The ECM detects that the engine speed is 2500 rpm or
more for 5 seconds or more.
Note：
shown.

Turbocharger Overboost Condition
The boost pressure sensor is located within the air intake
pipe. This sensor changes the signal voltage in
accordance with changes in air pressure in the air intake
pipe. The ECM monitors the boost pressure sensor signal.
If the ECM detects an excessively high sensor signal
voltage, the DTC is set. This indicates that the boost
pressure is abnormally high.
DTCs P0045, P0237, P0238, P06A8, and U0001 are not
set.
The ECM detects that the boost pressure is more than the
desired boost pressure by 20 kPa {3 psi} or more for 5
seconds or more.
Note：
shown.
The maximum engine speed is limited to 1200 r/min.

Turbocharger Boost Sensor Circuit Low
The boost sensor is located in the air intake pipe. This
sensor changes the signal voltage in accordance with the
change in the air pressure inside the air intake pipe. The
boost sensor has the following circuits.
GND circuit Boost sensor circuit
The boost sensor sends the change signal of the pressure
inside the air intake pipe to the ECM. The ECM detects
an high voltage signal when the air pressure is high due
to the high load applied to the engine, etc.
signal voltage.
The ECM detects that the boost pressure sensor signal
Note：
shown.
A default boost pressure value is assumed.

Turbocharger Boost Sensor Circuit High
Note：
shown.
Substitute the default value of boost pressure.
Stop the EGR control.

Crankshaft Position Sensor Circuit
section that contains no sensing holes. The CKP sensor
generates pulse signals. The sensor has the following
circuits.
GND circuit
CKP sensor signal circuit
The ECM monitors the signal pulses of the CKP sensor
and the CMP sensor to make sure they correlate with
each other. If the ECM receives a certain amount of CMP
sensor signal pulses without a CKP sensor signal pulse,
the DTC is set.
The CMP sensor signal pulse is detected.
The ECM detects that no CKP sensor signal pulse is
generated while the engine is running.
Note：
shown.

Crankshaft Position Sensor Circuit Range/Performance
section that contains no sensing holes. The ECM
monitors the signal pulses of the CKP sensor and the
CMP sensor to verify that they correlate with each other.
If the ECM receives excessive or short CKP sensor signal
pulses, the DTC is set.
The CKP sensor signal pulse is detected.
The ECM detects excessive or short CKP sensor signal
pulses while the engine is running.
Note：
shown.

Camshaft Position Sensor Circuit
head on which the camshaft gear is located. The CMP
sensor detects 5 projections in total per engine 1 cycle.
The camshaft gear has 4 protrusions evenly spaced 90°
apart and 1 reference protrusion. The CMP sensor
circuits.
GND circuit
CMP sensor signal circuit
and the CMP sensor to verify that they correlate with
each other.
If the ECM receives a certain amount of CKP sensor
signal pulses without a CMP sensor signal pulse, the
DTC is set.
The ECM detects that no CMP sensor signal pulse is
Note：
shown.

Glow Relay Circuit Error
The glow relay stops providing power supply voltage (12
V) to the glow plug, and ON is displayed if the signal
from the ECM is entered. The ECM recognizes the
ignition switch ON signal, and outputs the ON signal to
the glow relay.
Key switch input voltage is 16 to 32 V.
There is no glow relay monitoring signal to the glow
relay drive instruction, or there is a glow relay monitoring
signal to the glow relay stop instruction, for 4 seconds or
more.
Note：

EGR Control Circuit Range/Performance
The ECM controls the opening and closing of the EGR
valve based on the driving condition of the engine by
controlling the EGR motor. The EGR valve lift amount is
detected by the position sensor and is sent to the ECM.
If the ECM detects a difference between the actual EGR
valve position and the desired EGR valve position for a
predetermined period of time with the EGR commanded
ON, the DTC is set.
DTCs P0409 and P06A9 are not set.
The desired EGR opening position does not change by
2% or more.
The ECM detects that the difference between the actual
and desired EGR valve positions is 20% or more for 10
seconds or more.
Note：
shown.

EGR Sensor Circuit
The EGR position sensor is located on the EGR valve
together with the motor. The sensor is made up of 3
individual sensors within 1 housing. EGR position sensor
1, EGR position sensor 2, and EGR position sensor 3 are
hall IC type sensors with the following circuits.
GND circuit
Signal circuit
The EGR position sensor sends a high and low signal
status regarding changes in the EGR valve position to the
ECM.
If the ECM detects that there is no correlation between
the signal statuses from the EGR position sensor, e.g., all
statuses are high or low, the DTC is set.
The ECM detects that the signals from the EGR valve
position sensor are stuck in a low or high state for 5
seconds or more.
Note：
shown.
DTC P041C (Flash Code 27)

EGR Cooler Outlet 1 Temp Sensor Circuit Low
1. DTC P041C description of DTC
resistor and measures the exhaust gas temperature at the
EGR cooler outlet. This sensor has a signal circuit and a
GND circuit. The ECM supplies 5 V to the signal circuit,
and the GND circuit connects to GND. The EGR gas
temperature sensor 2 resistance is high at low
temperatures. As the exhaust gas temperature rises, the
sensor resistance decreases. The ECM detects a high
detects a low voltage when the sensor resistance is low. If
the ECM detects an excessively low signal voltage, the
DTC is set.
2. DTC P041C condition for setting the DTC
The ECM detects that the EGT sensor 2 signal voltage is
3. DTC P041C action taken when the DTC sets
Note：
shown.
A default EGR gas temperature sensor 2 value is
assumed.
DTC P041D (Flash Code 27)

EGR Cooler Outlet 1 Temp Sensor Circuit High
1. DTC P041D description of DTC
the ECM detects an excessively high signal voltage, the
DTC is set.
2. DTC P041D condition for setting the DTC
DTCs P0112, P0113, P0409, P060C, P06A8, and P160B
are not set.
3. DTC P041D action taken when the DTC sets
Note：
shown.
assumed.

Catalyst Temperature Sensor Circuit Low Sensor 1
EGT sensor 1 is installed in the oxidation catalyst
housing. EGT sensor 1 is a variable resistor and measures
the temperature of the exhaust gas in front of oxidation
catalyst 2. This sensor has a signal circuit and a GND
the GND circuit connects to GND. When EGT sensor 1 is
cold, the sensor resistance is high. As the exhaust
ECM detects a high voltage when the sensor resistance is
high. The ECM detects a low voltage when the sensor
resistance is low.
DTC is set.
Note：
shown.
A default EGT sensor 1 value is assumed.

Catalyst Temperature Sensor Circuit High Sensor 1
resistance is low.
DTC is set.
DTCs P0112, P0113, P0117, P0118, P060C, P06A8,
P2228, and P2229 are not set.
The engine coolant temperature is 70°C (158°F) or more.
EGT sensor 2 is 240°C (464°F) or more.
Note：
shown.

resistance is low.
DTC is set.
DTCs P060C, P06D5, and P160B are not set.
Note：
shown.

resistance is low.
DTC is set.
DTCs P0112, P0113, P0117, P0118, P060C, P06D5,
P160B, P2228, and P2229 are not set.
Note：
shown.

Engine Oil Pressure Sensor Performance
The oil pressure sensor detects the engine oil pressure.
The oil pressure sensor is installed near the starter motor
on the cylinder block. The internal resistance of the oil
pressure sensor changes in accordance with changes in
pressure. The resistance is low when the pressure is high,
and the resistance is high when the pressure is low.
The ECM is connected to the oil pressure sensor through
the power supply circuit, the signal circuit, and the GND
circuit, and applies +5 V power to the power supply
circuit. The ECM detects changes in the signal voltage
(high voltage when the pressure is high, and low voltage
when the pressure is low), which occur according to
changes in resistance based on the pressure of the oil
pressure sensor, as a signal.
If the ECM detects an abnormally low engine oil
pressure, the DTC is set.
DTCs P0522 and P0523 are not set.
The engine has been running for 25 seconds or more.
The ECM detects that the engine oil pressure is 48 kPa
{0.49 kgf/cm2 / 7 psi} or less.

Engine Oil Pressure Sensor Circuit Low Input
and the resistance is high when the pressure is low. The
ECM is connected to the oil pressure sensor through the
power supply circuit, the signal circuit, and GND circuit,
and applies +5 V power to the power supply circuit.
The ECM detects changes in the signal voltage that occur
according to changes in resistance based on the pressure
of the oil pressure sensor as a signal.
The ECM detects that the oil pressure sensor signal
Note：
shown.
Substitute the default value of the oil pressure sensor.

Engine Oil Pressure Sensor Circuit High Input
Note：
shown.

EGR Cooler Inlet 1 Temp Sensor Circuit Low
at the EGR cooler inlet. This sensor has a signal circuit
and a GND circuit. The ECM supplies 5 V to the signal
circuit, and the GND circuit connects to GND. The EGR
gas temperature sensor 1 resistance is high at low
DTC is set.
Note：
assumed.

EGR Cooler Inlet 1 Temp Sensor Circuit High
DTC is set.
The EGR valve opening position is 30% or more.
3.5 seconds or more have passed since the above
conditions were met.
set.
The ECM detects that the EGR gas temperature sensor 1
Note：
assumed.

System Voltage High
The ECM monitors ignition voltage of the ignition feed
terminal and makes sure that the voltage stays within the
appropriate range.
When the ECM detects that the ignition power voltage is
DTC P060C is not set.
The ECM detects that the voltage of the ignition power
supply circuit is 32 V or more for 5 seconds.
Note：
shown.

Internal Control Module Memory Check Sum Error
This diagnosis applies to the microprocessor inside the
ECM.
The ECM detects that the calculated checksum does not
correspond with the checksum that is registered into
ROM.
Note：
shown.
Stop the engine.
Restrict the fuel flow.

Internal Control Module QR Code Error
The injector ID code information and fuel delivery rate
information are stored in the EEPROM within the ECM.
If the ECM detects that the injector ID code or fuel
delivery rate value is not programmed into the ECM, the
DTC is set. If the ECM detects an error in the
programmed injector ID code or fuel delivery rate value,
the DTC is set.
Any of the following are met:
The ECM detects that no injector ID code is
programmed.
The ECM detects an error in the programmed injector ID
code.
The ECM detects that no fuel delivery rate value is
programmed.
The ECM detects an error in the programmed fuel
delivery rate value.
When it is detected for 2 consecutive times, the failure is
displayed on the monitor of the machine or the diagnostic
light illuminates.
Note：
shown.

Internal Control Module RAM Error
ECM.
The ECM detects an internal RAM malfunction.
Note：
shown.
Stop the engine.

Internal Control Module CPU Error
ECM.
The battery voltage is 16 V or more.
The internal sub CPU detects a malfunction in the main
CPU.
Note：
At CPU recovery
DTC P060A (Flash Code 51)

Internal Control Module CPU IC Error
1. DTC P060A description of DTC
ECM.
2. DTC P060A condition for setting the DTC
CPU.
3. DTC P060A action taken when the DTC sets
Note：

Internal Control Module A/D Processing Performance
ECM.
The ECM detects a malfunction of the internal A/D
converter.
Note：
Default values for all analog sensors are assumed.

Starter Relay Circuit Error
The starter cut switch is installed to prevent the starter
from operating during engine revolution. The starter cut
relay is a relay in normal close, located between the main
relay and starter relay.
When the key switch is turned ON, the ECM sends a
signal to the starter cut relay to turn the relay OFF.
When the key switch is shifted to the START position at
engine starting, the ECM interrupts signal output to the
starter cut relay and the relay is turned ON. When the key
switch is returned to the ON position after engine
starting, the ECM sends a signal to the starter cut relay
again to turn the relay OFF. A monitor circuit is
incorporated inside the ECM, and this circuit monitors
the operation of the relay.
The ECM sets a DTC when the output to the starter cut
relay and operation of the starter cut relay are
inconsistent.
The key switch input voltage is 16 to 30 V.
There is no starter cut relay monitoring signal to the
starter cut relay drive signal, or there is a starter cut relay
monitoring signal to the starter cut relay stop instruction,
for 4 seconds or more.
Note：

Throttle Actuator Control Range/Performance
The ECM opens/closes the intake throttle valve by
controlling the intake throttle motor depending upon the
engine operating status. The intake throttle valve opening
position is detected by the position sensor, and is sent to
the ECM. If the ECM detects that the actual and desired
opening positions of the intake throttle are different while
the intake throttle motor is commanded ON, the DTC is
set.
The desired intake throttle opening position is constant.
The intake throttle motor is commanded ON.
and the desired opening positions of the intake throttle is
40% or more for 10 seconds or more.
Note：
shown.

ECM Power Relay Control Circuit Open
When the ECM has received the ignition switch ON
signal, power is applied to the ECM main relay and the
battery power is supplied to the ECM via the relay switch
side. When the ignition switch was turned to OFF, power
applied to the ECM main relay is discontinued after a
certain period of time.
If the ECM detects a low voltage with the relay voltage
supply circuit when the ON command is executed for the
ECM main relay, it sets DTC.
The ignition switch has been ON for 3 seconds or more.
When the ECM commands the relay ON, the ECM
detects that the main relay voltage supply circuit is 1 V or
less for 4 seconds.
Note：
shown.

ECM Power Relay Control Circuit High
When the ECM received the ignition switch ON signal,
power is applied to the ECM main relay and the battery
power is supplied to the ECM via the relay switch side.
When the ignition switch was turned to OFF, power
If the ECM detects that the ECM is ON when the OFF
command is executed for the ECM main relay, it sets
DTC.
The ECM detects that the relay is ON when the ECM
commands the relay OFF for 6 seconds.
Note：
shown.
DTC P06A6 (Flash Code 55)

Sensor Reference Voltage 1 Circuit
1. DTC P06A6 description of DTC
The ECM supplies 5 V power to the following sensors
through power supply circuit 1.
Accelerator position sensor
The ECM also supplies 5 V power to the following
sensor via power supply circuit 6.
CKP sensor
5 V power supply circuits 1 and 6 are independent of
each other outside the ECM but share the bus inside the
ECM. Therefore, the entire 5 V power supply circuits 1
and 6 may be affected by a short circuit in either of the
sensor 5 V power supply circuits. The ECM monitors the
voltage of 5 V power supply circuits 1 and 6, and if it
detects that the voltage is abnormally low or high, the
DTC is set.
2. DTC P06A6 condition for setting the DTC
The ECM detects that the voltage of 5 V power supply
circuit 1 or 6 is 4.5 V or less, or 5.5 V or more, for 0.4
seconds or more.
3. DTC P06A6 action taken when the DTC sets
Note：

The ECM supplies 5 V power to the following sensor
through 5 V power supply circuit 7.
CMP sensor
FRP sensor
ECM. Therefore, all of 5 V power supply circuits 2 and 7
may be affected by a short circuit in either of the sensor 5
V power supply circuits. The ECM monitors the voltage
of 5 V power supply circuits 2 and 7, and if it detects that
the voltage is abnormally low or high, the DTC is set.
seconds or more.
Note：

IAT sensor
EGT sensor 1
The ECM supplies 5 V power to the following sensor via
power supply circuit 8.
Intake throttle position sensor
IMT sensor
seconds or more.
Note：

EGR position sensor
Oil pressure sensor
seconds or more.
Note：
DTC P06AF (Flash Code 277)

Torque Management System - Forced Engine Shutdown
1. DTC P06AF description of DTC
This diagnosis applies to the injector IC inside the ECM.
2. DTC P06AF condition for setting the DTC
Note：
・ Injector Custom IC
An injector IC malfunction is detected for 1.2 seconds or
more.
Note：
・ Injector Custom IC Check Sum
An injector IC reset is detected for 2.6 seconds or more.
Note：
・ Injector IC communication malfunction
A communication failure with the injector IC is detected
for 2.6 seconds or more.
3. DTC P06AF action taken when the DTC sets
Note：
・When Injector IC malfunctions
All injectors are stopped.
DTC P06D5 (Flash Code 56)

1. DTC P06D5 description of DTC
Fuel filter clogging sensor
EGT sensor 2
ECM. Therefore, all of 5 V power supply circuits 5 and
10 may be affected by a short circuit in either of the
DTC is set.
2. DTC P06D5 condition for setting the DTC
seconds or more.
3. DTC P06D5 action taken when the DTC sets
Note：

Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage
inlet side of the intercooler. Charge air cooler temperature
sensor 1 is a variable resistor and measures the
temperature of the air flowing into the intercooler. This
sensor has a signal circuit and a GND circuit. The ECM
supplies 5 V to the signal circuit, and the GND circuit
connects to GND. The charge air cooler temperature
sensor 1 resistance is high at low temperatures. As the
intake air temperature rises, the sensor resistance
The ECM detects that the charge air cooler temperature
sensor 1 signal voltage is 0.1 V or less for 10 seconds.
Note：
A default boost temperature sensor value is assumed.

Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage
when the sensor resistance is low. The ECM detects a low
voltage when the sensor resistance is low. If the ECM
detects an excessively high signal voltage, the DTC is set.
DTCs P0112, P0113, P060C, P06A8, P160B are not set.
Note：

Fuel Rail Pressure Too Low
between the fuel tank and the fuel supply pump and the
high-pressure side between the fuel supply pump and the
injectors. The fuel is drawn from the fuel tank through the
fuel supply pump and supplied to the common rail by the
two plungers located inside the fuel supply pump. The
common rail pressure is regulated by the ECM through
controlling the suction control valve based on the signal
from the common rail pressure sensor.
This DTC is set when the ECM detects that the actual
fuel pressure is lower than the target fuel pressure.
DTCs P0087, P0091, P0092, P0192, P0193, P0201-
P0204, P06A7, P1261, P1262, P2146, and P2149 are not
set.
is lower than the desired fuel pressure by 50 MPa (7250
psi) or more for 5 seconds or more.
Note：
shown.

Compressor Outlet Temperature Sensor Circuit High
The boost temperature sensor is installed to the inlet pipe.
The boost temperature sensor changes its resistance
according to the temperature in the inlet pipe. The
resistance becomes lower when the intake air temperature
is high, and higher when the intake air temperature is
low. The ECM applies 5 V to the boost temperature
sensor through the pull-up resistor, and calculates the
boost temperature from changes in the voltage. This value
is used in various control mechanisms, such as for fuel
injection control. The voltage becomes lower when
resistance is small (temperature is high), and higher when
resistance is large (temperature is low).
The intake air temperature is -25°C (-13°F) or more.
The ECM detects that the boost temperature sensor
voltage is 0.1 V or less for 5 seconds or more.
Note：

DTCs P0112, P0113, P060C, and P06A8 are not set.
voltage is 4.9 V or more for 5 seconds or more.
Note：

Charge Air Cooler Performance Failure
sensor 1 measures the temperature of the air flowing into
the intercooler. The boost temperature sensor is installed
to the inlet pipe. The boost temperature sensor measures
the temperature of the air flowing into the inlet pipe. The
ECM continually monitors the difference between the
temperatures input from both sensors. If the ECM detects
that the difference between the temperatures input from
both sensors is less than the calculated value, the DTC is
set.
DTCs P0045, P0102, P0103, P0112, P0113, P0117,
P0118, P0122, P0123, P0182, P0183, P0237, P0238,
P0545, P0546, P0638, P06A8, P1076, P1077, P1097,
P1098, P2228, P2229, and U0001 are not set.
10 minutes or more have passed since start up.
5 seconds or more have passed since completion of SCR
purging.
The ECM detects that the difference between the
temperatures detected by charge air cooler temperature
sensor 1 and those detected by the boost temperature
sensor is lower than the calculated value for 10 seconds.
Note：

Injector Positive Voltage Control Circuit Group 1
The charge voltage circuit within the ECM increases the
voltage applied to the injector. The charge voltage circuit
is divided into 2 banks: common power supply 1 and
common power supply 2. Common power supply 1
serves the injectors of the No. 1 and No. 4 cylinders,
while common power supply 2 serves the injectors of the
No. 2 and No. 3 cylinders.
If an open circuit occurs in the injector charge voltage
circuit of common power supply 1 in the ECM, the DTC
is set.
The ECM detects a low voltage in the common power
supply 1 injector charge voltage circuit for 3 seconds.
Note：
shown.
The fuel injection for the No. 1 and No. 4 cylinders is
disabled.

is set.
Note：
shown.
disabled.

EGR Position Fault
controlling the EGR motor. The EGR opening position is
For a closed position error DTC, if the ECM detects that
the actual EGR valve opening position is higher than the
predetermined value, this DTC is set.
For a learned position error DTC, if the ECM detects a
difference between the learned closed position and the
actual closed position, the DTC is set.
DTC P06A9 is not set.
The ECM detects that the EGR learned closed position is
not within the predetermined range when the ignition
switch is turned OFF.
Note：
shown.

SW-IC Internal failure
This diagnosis applies to the SW-IC1 inside the ECM.
Note：
・ SW-IC internal malfunction
A malfunction in the SW-IC circuit is detected.
Note：
・ SW-IC communication circuit malfunction
A communication error with the SW-IC is detected.
Note：
DTC P160B (Flash Code 36)

AD-IC Failure Error
1. DTC P160B description of DTC
This diagnosis applies to the AD-IC inside the ECM.
2. DTC P160B condition for setting the DTC
The ECM detects a malfunction in the signal from the
AD-IC.
3. DTC P160B action taken when the DTC sets
Note：
A default charge air cooler temperature sensor 1 value is
assumed.
A default engine coolant temperature sensor value is
assumed.
A default fuel temperature sensor value is assumed.
Default EGR gas temperature sensor 1 and 2 values are
assumed.
A default IAT sensor value is assumed.

Control Module Long Term Memory Performance
ECM.
The ignition switch is ON
match the check sum internally registered in the
EEPROM
Note：
shown.

Control Module EEPROM Hardware Error
ECM.
agree with the EEPROM internal registered checksum.
Note：
DTC P204F (Flash Code 611)

SCR System Error (No Inducement)
1. DTC P204F description of DTC
The ECM communicates with the DCU via CAN
communication. If the ECM receives a failure message
from the DCU, the DTC is set.
2. DTC P204F condition for setting the DTC
The ECM receives an error message from the DCU.
3. DTC P204F action taken when the DTC sets
Note：

Urea Fluid Concentration Too Low
Note：
DTC P20C9 (Flash Code 611)

SCR System Error
1. DTC P20C9 description of DTC
2. DTC P20C9 condition for setting the DTC
3. DTC P20C9 action taken when the DTC sets
Note：

Pedal Position Sensor 1 Circuit Low Input
The accelerator position sensor consists of 2 sensors
installed within a single housing. The ECM uses the
accelerator position sensor to calculate the desired
acceleration and deceleration amounts. The accelerator
position sensor 1 has the following circuits
GND circuit
Accelerator position sensor 1 signal circuit
The accelerator position sensor 1 transmits the signal
related to changes of the accelerator pedal angle position
to the ECM via the signal circuit. When the ECM has
detected that the signal voltage is abnormally low, it sets
DTC.
The ECM detects that the accelerator pedal position
sensor 1 signal voltage is 0.2 V or less.
If both sensors of accelerator position sensors 1 and 2
malfunction, the accelerator opening position is limited to
0%.

Pedal Position Sensor 1 Circuit High Input
position sensor 1 has the following circuits.
GND circuit
detected that the signal voltage is abnormally high, it sets
DTC.
sensor 1 signal voltage is 4.9 V or more.
0%.

GND circuit
DTC.
0%.

GND circuit
to the ECM via the signal circuit. When the ECM detects
that the signal voltage is abnormally high, it sets DTC.
0%.

Pedal Position Sensor 1 - 2 Voltage Correlation
installed within a single housing. The accelerator position
sensor 1 and accelerator position sensor 2 are hall IC type
sensors and each has the following circuits.
GND circuit
Signal circuit
The ECM supplies 5 V to the accelerator position sensor
via the 5 V power supply circuit and the GND circuit
connects to the GND. The accelerator position sensor
transmits the signal related to changes of the accelerator
pedal angle position to the ECM via the signal circuit.
The signal voltage of the accelerator position sensor 1 is
kept low first, and then increases as the pedal is
depressed. The signal voltage of the accelerator position
sensor 2 is kept high first, and then decreases as the pedal
is depressed. When the ECM has detected that the
accelerator position sensor 1 signal and accelerator
position sensor 2 signal voltages are not related to each
other, it sets DTC.
DTCs P060C, P06A6, P2122, P2123, P2127, and P2128
are not set.
accelerator pedal position sensor 1 and 2 opening
positions is 45% or more for 3 seconds or more.
0%.

Fuel Injector Group 1 Supply Voltage Circuit
using the data transmitted from the various sensors. The
injector charge voltage circuits of the common power
supplies 1 and 2 supply the high voltage while the ECM
drives the injector of each cylinder. The common power
supply 1 supplies power to the injectors of the No. 1 and
No. 4 cylinders while the common power supply 2
supplies power to the injectors of the No. 2 and No. 3
cylinders.
When the injector charge voltage circuit of the common
power supply 1 or 2 has been opened or shorted to the
GND or voltage circuit, the faulty injector common
power supply circuit sets DTC.
Also when the injector solenoid control circuit has been
shorted to the GND, the ECM sets DTC.
DTCs P0201, P0204, and P06AF are not set.
The ECM detects that the injector charge voltage circuit
for cylinder No. 1 or No. 4 has an open circuit, is shorted
to GND or shorted to the voltage circuit, or that the
injector solenoid coil control circuit for cylinder No. 1 or
No. 4 is shorted to GND, for 3 seconds or more.
Note：
shown.
disabled.

based on the data sent from various sensors. The injector
charge voltage circuits of common power supplies 1 and
2 supply high voltage, while the ECM grounds the
injector solenoid control circuit and drives the injector of
each cylinder. Common power supply 1 serves the
injectors of the No. 1 and No. 4 cylinders, while common
power supply 2 serves the injectors of the No. 2 and No.
3 cylinders.
If the injector charge voltage circuit for common power
supply 1 or 2 has an open circuit, is shorted to GND or
shorted to the voltage circuit, the DTC is set depending
upon the defective injector common power supply circuit.
Also, if the injector solenoid control circuit is shorted to
GND, the DTC is set.
Note：
shown.
disabled.

Barometric Pressure Sensor Circuit Low
The barometric pressure sensor is installed in the ECM.
The barometric pressure sensor changes the signal
voltage according to changes in the barometric pressure.
The barometric pressure sensor sends signals related to
barometric pressure change to the ECM. The ECM
detects a low signal voltage when the altitude is high and
the barometric pressure is low. The ECM detects a high
signal voltage when the barometric pressure is high. The
ECM uses this voltage signal to adjust the fuel injection
quantity and injection timing, as well as make altitude
corrections. If the ECM detects an excessively low signal
voltage, the DTC is set.
The ECM detects that the barometric pressure sensor
Note：
shown.
A default barometric pressure value is assumed.

Barometric Pressure Sensor Circuit High
corrections. If the ECM detects an excessively high signal
Note：
shown.

Exhaust Gas Recirculation (EGR) Cooling System Performance
cooler duct. EGR gas temperature sensor 1 measures the
temperature of the exhaust gas at the EGR cooler inlet.
exhaust gas temperature of the EGR cooler outlet. The
set.
5 seconds or more have passed since the completion of
SCR purging.
The EGR valve opening position is 30% or more.
30 seconds or more have passed since the above
conditions were met.
DTCs P0045, P0112, P0113, P0122, P0123, P0182,
P0183, P0237, P0238, P0409, P041C, P041D, P0545,
P0546, P0638, P06A8, P2228, P2229, and U0001 are not
set.
temperatures detected by EGR gas temperature sensor 1
and those detected by EGR gas temperature sensor 2 is
lower than the calculated value for 10 seconds.
Note：

Purge Time Out Error
If the SCR automatic purging starts but does not
complete for some reason, the indicator light in the
display flashes to request that the machinery operator
manually perform the regeneration. Once the SCR
purging starts, it must finish within a predetermined
length of time.
If the SCR purging is conducted consecutively for more
than the predetermined length of time, the DTC is set.
The ECM detects that the SCR purging exceeds a
predetermined length of time 3 consecutive times.
Note：
shown.
DTC P2BAA (Flash Code 611)

SCR System Error (Inducement, No Purge)
1. DTC P2BAA description of DTC
2. DTC P2BAA condition for setting the DTC
3. DTC P2BAA action taken when the DTC sets
Note：

A typical common rail (fuel rail) system is composed of
the following 2 fuel pressure sections. The sections are a
suction side between the fuel tank and the fuel supply
pump, and a high pressure side between the fuel supply
pump and the injectors. The fuel is drawn from the fuel
tank via the fuel supply pump and then pumped into the
common rail (fuel rail) by 2 plungers that are located
inside the fuel supply pump. The common rail (fuel rail)
pressure is controlled by the ECM controlling the FRP
regulator based on signals from the common rail (fuel
rail) pressure sensor.
If the ECM detects that the actual fuel pressure is less
than the desired fuel pressure when the outside air
temperature is low, the DTC is set.
DTCs P0087, P0091, P0092, P0192, P0193, P0201-
set.
The fuel temperature is lower than or equal to the
is lower than the desired fuel pressure by 50 MPa (7250
DTC U0001 (Flash Code 84)

CAN Bus Error (ISO-CAN)
1. DTC U0001 description of DTC
The ECM communicates with the turbo control unit and
DCU via the CAN communication circuit. The ECM data
is output via the CAN-High circuit and the data from
other ECUs is input via the CAN-Low circuit. CAN
communication is continuously performed at a constant
rate and the data output count and input count are always
identical. The ECM sets a DTC when CAN
communication fails.
2. DTC U0001 condition for setting the DTC
The ECM detects a failure in the CAN communication
3. DTC U0001 action taken when the DTC sets
Note：
shown.

Control Module Communication Bus Off
The ECM communicates with the machine control unit
via the CAN communication circuit. The ECM outputs
data via the CAN-High circuit and input data from other
ECUs from the CAN-Low circuit. CAN communication
is continuously performed at a constant rate and the data
output count and input count are always identical. The
ECM sets DTC when it detects a CAN communication
failure.
The battery voltage is 22V or more.
Note：
shown.

Lost Communication With CAN
ECM sets DTC when it lost CAN communication with
the machine control unit.
The battery voltage is 22 V or higher
The ECM detects that CAN data reception for 5 seconds
or longer is not satisfied
Note：
shown.
DTC U010E (Flash Code 83)

Lost Communications With Dosing Control Module
1. DTC U010E description of DTC
The ECM and DCU communicate the control information
and diagnosis information via CAN communication. The
ECM monitors the CAN operational status by expecting a
constant message flow from the DCU. If the ECM fails to
receive an expected message, the DTC is set.
2. DTC U010E condition for setting the DTC
DTC U0001 is not set.
The ECM detects that CAN messages from the DCU are
not received for 5 seconds or more.
3. DTC U010E action taken when the DTC sets
Note：

Lost Communication With VNT System
The ECM and turbo control unit communicate the control
ECM data is output via the CAN-High circuit and the
data from other ECUs is input via the CAN-Low circuit.
CAN communication is continuously performed at a
constant rate and the data output count and input count
are always identical. The ECM sets a DTC if CAN
communication with the turbo control unit is lost.
The ECM detects that the CAN Bus messages from the
turbo control unit are not being received for 5 seconds or
more.
Note：

Lost CAN Communications With VNT Control Module
and diagnostic information via CAN communication. The
ECM outputs data via the CAN-High circuit and input
data from other ECUs from the CAN-Low circuit. CAN
identical. ECM sets DTC when it has received a CAN
communication failure message from the turbo control
unit.
The ECM receives an error message from the turbo
control unit.
Note：
DTC mapping table

1. DTC mapping table
P code
SPN-FMI
P00** - P03**
636-7 P0016 Crankshaft Position - Camshaft Position Correlation Error
10023-12 P0045 Turbocharger Boost Control VNT Error
10035-4 P0079 Exhaust Valve Control Solenoid Circuit Low
10035-3 P0080 Exhaust Valve Control Solenoid Circuit High
633-7 P0087 Fuel Rail/System Pressure - Too Low
157-15 P0089 Fuel Pressure Regulator Performance
1347-4 P0091 Fuel Pressure Regulator Control Circuit Low
1347-3 P0092 Fuel Pressure Regulator Control Circuit High
1131-4 P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage
1131-3 P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage
132-4 P0102 Mass Air Flow Sensor Circuit Low Input
132-3 P0103 Mass Air Flow Sensor Circuit High Input
172-4 P0112 Intake Air Temperature Sensor Circuit Low
172-3 P0113 Intake Air Temperature Sensor Circuit High
110-4 P0117 Engine Coolant Temperature Sensor Circuit Low
110-3 P0118 Engine Coolant Temperature Sensor Circuit High
10022-4 P0122 Throttle Position Sensor Circuit Low
10022-3 P0123 Throttle Position Sensor Circuit High
174-4 P0182 Fuel Temperature Sensor Circuit Low
174-3 P0183 Fuel Temperature Sensor Circuit High
157-4 P0192 Fuel Rail Pressure Sensor Circuit Low
157-3 P0193 Fuel Rail Pressure Sensor Circuit High
651-5 P0201 Injector Circuit Open - Cylinder 1
110-0 P0217 Engine Coolant Over Temperature Condition
190-0 P0219 Engine Overspeed Condition
102-0 P0234 Turbocharger Overboost Condition
102-4 P0237 Turbocharger Boost Sensor Circuit Low
102-3 P0238 Turbocharger Boost Sensor Circuit High
723-2 P0335 Crankshaft Position Sensor Circuit
723-8 P0336 Crankshaft Position Sensor Circuit Range/Performance
636-2 P0340 Camshaft Position Sensor Circuit
676-5 P0380 Glow Relay Circuit Error
P code
SPN-FMI
P04** - P12**
10002-2 P0404 EGR Control Circuit Range/Performance
10001-2 P0409 EGR Sensor Circuit
10014-4 P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low
10014-3 P041D EGR Cooler Outlet 1 Temp Sensor Circuit High
173-4 P0427 Catalyst Temperature Sensor Circuit Low Sensor 1
173-3 P0428 Catalyst Temperature Sensor Circuit High Sensor 1
10024-4 P042C Catalyst Temperature Sensor Circuit Low Sensor 2
10024-3 P042D Catalyst Temperature Sensor Circuit High Sensor 2
- P0521 Engine Oil Pressure Sensor Performance
100-4 P0522 Engine Oil Pressure Sensor Circuit Low Input
100-3 P0523 Engine Oil Pressure Sensor Circuit High Input
10053-4 P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low
10053-3 P0546 EGR Cooler Inlet 1 Temp Sensor Circuit High
158-3 P0563 System Voltage High
628-2 P0601 Internal Control Module Memory Check Sum Error
10032-2 P0602 Internal Control Module QR Code Error
10033-2 P0604 Internal Control Module RAM Error
1077-2 P0606 Internal Control Module CPU Error
10007-2 P060A Internal Control Module CPU IC Error
10008-2 P060C Internal Control Module A/D Processing Performance
677-5 P0615 Starter Relay Circuit Error
10022-2 P0638 Throttle Actuator Control Range/Performance
1485-5 P0685 ECM Power Relay Control Circuit Open
1485-6 P0687 ECM Power Relay Control Circuit High
1079-2 P06A6 Sensor Reference Voltage 1 Circuit
10050-2 Injector Custom IC
10082-2 P06AF Injector Custom IC Communication Line
10083-2 Injector Custom IC Check Sum
10011-2 P06D5 Sensor Reference Voltage 5 Circuit
10051-4 P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage
10051-3 P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage
1239-17 P1093 Fuel Rail Pressure Too Low
105-4 P1097 Compressor Outlet Temperature Sensor Circuit Low
105-3 P1098 Compressor Outlet Temperature Sensor Circuit High
5285-1 P1236 Charge Air Cooler Performance Failure
10005-2 P1261 Injector Positive Voltage Control Circuit Group 1
P code
SPN-FMI
P14** - P30**
10001-13 P1404 EGR Position Fault
10046-2 SWIC-1 Internal Failure
P1606
10048-2 SW-IC 1 Communication Line Failure
10045-2 P160B AD-IC Failure Error
10013-2 P1621 Control Module Long Term Memory Performance
10013-12 P1622 Control Module EEPROM Hardware Error
10043-2 P204F SCR System Error (No Inducement)
4332-12 P207F Urea Fluid Concentration Too Low
10044-1 P20C9 SCR System Error
91-4 P2122 Pedal Position Sensor 1 Circuit Low Input
91-3 P2123 Pedal Position Sensor 1 Circuit High Input
91-2 P2138 Pedal Position Sensor 1 - 2 Voltage Correlation
10003-2 P2146 Fuel Injector Group 1 Supply Voltage Circuit
108-4 P2228 Barometric Pressure Circuit Low Input
108-3 P2229 Barometric Pressure Circuit High Input
10054-17 P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance
10029-0 P2458 Purge Time Out Error
10042-12 P2BAA SCR System Error (Inducement, No Purge)
SPN-FMI U code
10040-19 U0001 CAN Bus Error (ISO-CAN)
639-19 U0073 Control Module Communication Bus Off
639-2 U0101 Lost Communication With CAN
10041-2 U010E Lost Communications With Dosing Control Module
10023-2 U0110 Lost Communication With VNT System
10023-19 U0411 Lost CAN Communications With VNT Control Module
DTC Information (4HK1 (24V)) 15E-1
Description Engine
DTC Information
(4HK1 (24V))
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit Open -
Position Correlation Error.............................................15E-4 Cylinder 2....................................................................15E-25
VNT Error......................................................................15E-5 Cylinder 3....................................................................15E-26
Too Low........................................................................15E-6 Cylinder 4....................................................................15E-27
Performance...................................................................15E-7 Temperature Condition................................................15E-28
Control Circuit Low.......................................................15E-8 .....................................................................................15E-29
Control Circuit High......................................................15E-9 Condition.....................................................................15E-30
Sensor 2 Circuit Low Voltage.....................................15E-10 Circuit Low..................................................................15E-31
Sensor 2 Circuit High Voltage.....................................15E-11 Circuit High.................................................................15E-32
Low Input....................................................................15E-12 Circuit..........................................................................15E-33
High Input....................................................................15E-13 Circuit Range/Performance.........................................15E-34
Circuit Low..................................................................15E-14 Circuit..........................................................................15E-35
Circuit High.................................................................15E-15 .....................................................................................15E-36
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0401 (Flash Code 93) EGR Flow Insufficient
Sensor Circuit Low......................................................15E-16 Detected.......................................................................15E-37
Sensor Circuit High.....................................................15E-17 Performance.................................................................15E-38
DTC P0122 (Flash Code 43) Throttle Position Sensor DTC P0409 (Flash Code 44) EGR Sensor Circuit......15E-39
Circuit Low..................................................................15E-18 DTC P041C (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0123 (Flash Code 43) Throttle Position Sensor Sensor Circuit Low......................................................15E-40
Circuit High.................................................................15E-19 DTC P041D (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Sensor Circuit High.....................................................15E-41
Circuit Low..................................................................15E-20 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit Low Sensor 1...................................................15E-42
Circuit High.................................................................15E-21 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High Sensor 1..................................................15E-43
Circuit Low..................................................................15E-22 DTC P042C (Flash Code 49) Catalyst Temperature Sensor
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low Sensor 2...................................................15E-44
Circuit High.................................................................15E-23 DTC P042D (Flash Code 49) Catalyst Temperature Sensor
DTC P0201 (Flash Code 271) Injector Circuit Open - Circuit High Sensor 2..................................................15E-45
Cylinder 1....................................................................15E-24
15E-2 DTC Information (4HK1 (24V))
Circuit Low Input........................................................15E-46 Temperature Sensor Circuit High................................15E-72
Circuit High Input........................................................15E-47 Performance Failure....................................................15E-73
Sensor Circuit Low......................................................15E-48 Control Circuit Group 1...............................................15E-74
Sensor Circuit High.....................................................15E-49 Control Circuit Group 2...............................................15E-75
DTC P0560 (Flash Code 155) 12Volt Circuit Error....15E-50 DTC P1404 (Flash Code 45) EGR Position Fault.......15E-76
DTC P0563 (Flash Code 35) System Voltage High....15E-51 DTC P1606 (Flash Code 51) SW-IC Internal failure
DTC P0601 (Flash Code 53) Internal Control Module .....................................................................................15E-77
Memory Check Sum Error..........................................15E-52 DTC P160B (Flash Code 36) AD-IC Failure Error.....15E-78
DTC P0602 (Flash Code 154) Internal Control Module QR DTC P160C (Flash Code 36) AD-IC2 Failure Error...15E-79
Code Error...................................................................15E-53 DTC P1621 (Flash Code 54) Control Module Long Term
DTC P0604 (Flash Code 153) Internal Control Module Memory Performance..................................................15E-80
RAM Error...................................................................15E-54 DTC P1622 (Flash Code 54) Control Module EEPROM
DTC P0606 (Flash Code 51) Internal Control Module CPU Hardware Error............................................................15E-81
Error.............................................................................15E-55 DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P060A (Flash Code 51) Internal Control Module CPU .....................................................................................15E-82
IC Error........................................................................15E-56 DTC P204F (Flash Code 611) SCR System Error (No
DTC P060C (Flash Code 36) Internal Control Module A/D Inducement).................................................................15E-83
Processing Performance..............................................15E-57 DTC P207F (Flash Code 611) Urea Fluid Concentration
DTC P0615 (Flash Code 19) Starter Relay Circuit Error Too Low......................................................................15E-84
.....................................................................................15E-58 DTC P20C9 (Flash Code 611) SCR System Error......15E-85
DTC P0638 (Flash Code 61) Throttle Actuator Control DTC P2122 (Flash Code 121) Pedal Position Sensor 1
Range/Performance.....................................................15E-59 Circuit Low Input........................................................15E-86
Circuit Open................................................................15E-60 Circuit High Input........................................................15E-87
Circuit High.................................................................15E-61 Circuit Low Input........................................................15E-88
DTC P06A6 (Flash Code 55) Sensor Reference Voltage 1 DTC P2128 (Flash Code 122) Pedal Position Sensor 2
Circuit..........................................................................15E-62 Circuit High Input........................................................15E-89
DTC P06A7 (Flash Code 56) Sensor Reference Voltage 2 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Circuit..........................................................................15E-63 Voltage Correlation.....................................................15E-90
DTC P06AF (Flash Code 277) Torque Management System DTC P2228 (Flash Code 71) Barometric Pressure Sensor
- Forced Engine Shutdown..........................................15E-66 Circuit Low..................................................................15E-93
DTC P06D5 (Flash Code 56) Sensor Reference Voltage 5 DTC P2229 (Flash Code 71) Barometric Pressure Sensor
Circuit..........................................................................15E-67 Circuit High.................................................................15E-94
DTC P1076 (Flash Code 313) Charge Air Cooler (CAC) DTC P2457 (Flash Code 95) Exhaust Gas Recirculation
Temperature Sensor 1 Circuit Low Voltage................15E-68 (EGR) Cooling System Performance..........................15E-95
DTC P1077 (Flash Code 313) Charge Air Cooler (CAC) DTC P2458 (Flash Code 139) Purge Time Out Error
Temperature Sensor 1 Circuit High Voltage...............15E-69 .....................................................................................15E-96
DTC P1093 (Flash Code 227) Fuel Rail Pressure Too Low DTC P2BA7 (Flash Code 611) Urea Fluid Quantity Too
.....................................................................................15E-70 Low..............................................................................15E-97
DTC P1097 (Flash Code 213) Compressor Outlet DTC P2BAA (Flash Code 611) SCR System Error
Temperature Sensor Circuit High................................15E-71 (Inducement, No Purge)..............................................15E-98
DTC P3093 (Flash Code 227) Fuel Rail Pressure Too Low
.....................................................................................15E-99
DTC U0001 (Flash Code 84) CAN Bus Error (ISO-CAN)
...................................................................................15E-100
Communication Bus Off............................................15E-101
CAN...........................................................................15E-102
Dosing Control Module.............................................15E-103
VNT System..............................................................15E-104
With VNT Control Module.......................................15E-105
...................................................................................15E-106
DTC mapping table...................................................15E-107

section that contains no sensing holes.
The CMP sensor is installed behind the cylinder head.
The CMP sensor detects 5 projections in total per engine
1 cycle. The camshaft gear has 4 projections evenly
spaced 90° apart and 1 reference projection. By detecting
the opening with the CKP sensor and the 1 reference
projection with the CMP sensor, the ECM determines
compression top dead center of cylinder No. 1 to verify
that they correlate with each other. If the ECM detects
that both signals are out of synchronization, the DTC is
set.
The ECM detects that the CKP sensor signal and CMP
sensor signal are not synchronized.
Note：
shown.

The opening angle of the variable nozzle on the
turbocharger is controlled by the turbo control unit
through operating the motor built into the actuator to
activate the control rod in accordance with the signal
received from the ECM. The ECM controls the variable
nozzle based on the boost pressure, and detects the
operation amount of the variable nozzle with the position
sensor built into the turbo actuator. When the engine is
not under load, the variable nozzle is in the open
condition, or the boost pressure is not present. When the
engine is under load, the turbo actuator is controlled to
close the variable nozzle. As the result, the boost pressure
increases. The ECM performs control that changes the
boost pressure in accordance with the load requirements
for the engine. The ECM communicates with the turbo
control unit through CAN communication to perform
control. The DTC is set when the ECM detects an open
circuit or short circuit in the circuit between the turbo
actuator and turbo control unit or an abnormality in
The turbo control unit detects a malfunction in the motor
Note：
shown.

pressure sensor. When the common rail pressure becomes
in excess, the common rail pressure limiter valve opens to
release the excessive pressure and return the fuel back to
the fuel tank. The ECM sets the DTC when the common
rail pressure increases more than necessary and then
drops drastically. This DTC detects that the pressure
limiter valve has been activated.
The ECM detects that the pressure limiter valve is
activated due to excessive pressure in the common rail
(fuel rail).
Note：
shown.

pressure sensor. This DTC is set when the ECM detects
that the fuel pressure is higher than the target fuel
pressure.
DTCs P0091, P0092, P0192, P0193, P060C, P06A7,
P0201-P0204, P1261, P1262, P2146, and P2149 are not
set.
is higher than the desired fuel pressure by 40 MPa {408
kgf/cm2 / 5800 psi} or more for 5 seconds or more.
Note：
shown.

suction control valve is abnormally low.
regulator is 50 mA or less, or lower than the desired
Note：
shown.

suction control valve is abnormally high.
regulator is 2,400 mA or more, or higher than the desired
Note：
shown.

ECM supplies 5 V to the signal circuit, and GNDs to the
GND circuit. When the IMT sensor is cold, the sensor
resistance is high. When the EGR gas amount increases,
Note：

The ECM supplies 5 V to the signal circuit, and GNDs to
the GND circuit. When the EGR gas amount increases,
set.
Note：

GND circuit
sets DTC.
Note：
shown.

GND circuit
sets DTC.
Note：
shown.

the signal circuit, and the GND circuit connects to GND.
When the IAT sensor is cold, the resistance of the sensor
is high. When the air temperature rises, the resistance of
the sensor becomes low. The ECM detects the high
detects the low voltage when the sensor resistance is low.
When the ECM detects that the DPD differential pressure
is abnormally low, it sets DTC.
V or less for 5 seconds.
Note：
shown.

the signal circuit, and the GND circuit connects to the
GND. When the IAT sensor is cold, the resistance of the
sensor is high. When the air temperature rises, the
resistance of the sensor becomes low. The ECM detects
the high voltage when the sensor resistance is high. The
ECM detects the low voltage when the sensor resistance
is low. When the ECM detects that the signal voltage is
V or more for 5 seconds.
Note：
shown.

sensor signal voltage is 0.1 V or less for 5 seconds.
Note：
shown.
A default engine coolant temperature value is assumed.

Note：
shown.
A default engine coolant temperature value is assumed.

GND circuit
position to the ECM. If the ECM detects an excessively
low signal voltage, the DTC is set.
Note：
shown.

GND circuit
position to the ECM.
DTC is set.
Note：
shown.

pump. The fuel temperature sensor is a variable resistor
that measures the temperature of the fuel entering the
supply pump. This sensor has a signal circuit and a GND
high. As the fuel temperature rises, the sensor resistance
DTC is set.
Note：
shown.

pump. The fuel temperature sensor is a variable resistor,
and measures the temperature of the fuel entering the
supply pump. This sensor has a signal circuit and GND
high. When the fuel temperature rises, the resistance of
the sensor decreases. The ECM detects a high voltage
low voltage when the sensor resistance is low. The DTC
is set when the ECM detects an abnormally high signal
voltage.
Note：
shown.

GND circuit
voltage signal, and uses the result for various controls
such as the fuel injection control.
signal voltage.
sensor signal voltage is 0.7 V or less.
Note：
shown.
assumed.

GND circuit
voltage signal, and uses the result for controls such as the
fuel injection control.
sensor signal voltage is 4.8 V or more.
Note：
shown.
assumed.

using data transmitted from the sensor. The injector
power circuit supplies the high voltage while the ECM
drives the injector of each cylinder. The ECM sets a DTC
when an abnormality is detected in the No.1 cylinder
injector circuit.
Note：
shown.

Note：
shown.

Note：
shown.

Note：
shown.

sensor is a thermistor type and measures the temperature
of the engine coolant.
If the ECM detects an excessively high temperature in the
coolant, the DTC is set.
The ECM detects that the engine coolant temperature is
101°C (214°F) or more for 10 seconds.

The CKP sensor is installed to the flywheel housing. The
ECM calculates the engine speed and accurate crankshaft
position based on the signal pulse from the CKP sensor.
If the ECM detects that the engine is in an overrun
condition, the DTC is set.
DTCs P06A6 and P06A7 are not set.
Shovel car
Wheel loader
Note：
shown.

The boost pressure sensor is located within the air intake
pipe. This sensor changes the signal voltage in
accordance with changes in air pressure in the air intake
pipe. The ECM monitors the boost pressure sensor signal.
If the ECM detects an excessively high sensor signal
voltage, the DTC is set. This indicates that the boost
pressure is abnormally high.
DTCs P0045, P0237, P0238, P06A8, U0001, U0110, and
U0411 are not set.
The ECM detects that the boost pressure is more than the
desired boost pressure by 20 kPa {3 psi} or more for 5
seconds or more.
Note：
shown.

signal voltage.
Note：
shown.
A default boost pressure value is assumed.

Note：
shown.
Substitute the default value of boost pressure.
Stop the EGR control.

section that contains no sensing holes. The CKP sensor
circuits.
GND circuit
CKP sensor signal circuit
each other. If the ECM receives a certain amount of CMP
sensor signal pulses without a CKP sensor signal pulse,
the DTC is set.
The CMP sensor signal pulse is detected.
The ECM detects that no CKP sensor signal pulse is
Note：
shown.

section that contains no sensing holes. The ECM
monitors the signal pulses of the CKP sensor and the
CMP sensor to verify that they correlate with each other.
If the ECM receives excessive or short CKP sensor signal
pulses, the DTC is set.
The CKP sensor signal pulse is detected.
The ECM detects excessive or short CKP sensor signal
pulses while the engine is running.
Note：
shown.

head on which the camshaft gear is located. The CMP
sensor detects 5 projections in total per engine 1 cycle.
The camshaft gear has 4 protrusions evenly spaced 90°
apart and 1 reference protrusion. The CMP sensor
circuits.
GND circuit
CMP sensor signal circuit
each other.
If the ECM receives a certain amount of CKP sensor
signal pulses without a CMP sensor signal pulse, the
DTC is set.
The ECM detects that no CMP sensor signal pulse is
Note：
shown.

The glow relay stops providing power supply voltage (24
V) to the glow plug, and ON is displayed if the signal
from the ECM is input. The ECM recognizes the ignition
switch ON signal, and outputs the ON signal to the glow
relay.
Key switch input voltage is 16 to 32 V.
There is no glow relay monitoring signal to the glow
relay drive instruction, or there is a glow relay monitoring
signal to the glow relay stop instruction, for 4 seconds or
more.
Note：

EGR Flow Insufficient Detected
When the proper enabling conditions are met, the ECM
opens the EGR valve while monitoring the MAF sensor
signal. The ECM predicts a MAF difference for when the
EGR valve is open and when it is closed.
If the ECM detects a MAF difference that is less than
expected, this DTC is set.
DTCs P0102, P0103, P0112, P0113, P0117, P0118,
P0122, P0123, P0404, P0409, P045B, P0560, P0638,
The ECM detects that the MAF does not change in
accordance with changes in the EGR valve opening
position.
Note：

If the ECM detects a difference between the actual EGR
valve position and the desired EGR valve position for a
predetermined period of time with the EGR commanded
ON, the DTC is set.
DTCs P0409 and P06A9 are not set.
The desired EGR opening position does not change by
2% or more.
and desired EGR valve positions is 20% or more for 10
seconds or more.
Note：
shown.

EGR Sensor Circuit
The EGR position sensor is located on the EGR valve
together with the motor. The sensor is made up of 3
individual sensors within 1 housing. EGR position sensor
1, EGR position sensor 2, and EGR position sensor 3 are
hall IC type sensors with the following circuits.
GND circuit
Signal circuit
The EGR position sensor sends a high and low signal
status regarding changes in the EGR valve position to the
ECM.
If the ECM detects that there is no correlation between
the signal statuses from the EGR position sensor, e.g., all
statuses are high or low, the DTC is set.
The ECM detects that the signals from the EGR valve
position sensor are stuck in a low or high state for 5
seconds or more.
Note：
shown.

DTC is set.
Note：
shown.
assumed.

DTC is set.
DTCs P0112, P0113, P0409, P060C, P06A8, and P160B
are not set.
Note：
shown.
assumed.

resistance is low.
DTC is set.
Note：
shown.

resistance is low.
DTC is set.
DTCs P0112, P0113, P0117, P0118, P060C, P06A8,
P2228, and P2229 are not set.
Note：
shown.

resistance is low.
DTC is set.
DTCs P060C, P06D5, and P160B are not set.
Note：
shown.

resistance is low.
DTC is set.
DTCs P0112, P0113, P0117, P0118, P060C, P06D5,
Note：
shown.

Note：
shown.

Note：
shown.

DTC is set.
Note：
assumed.

DTC is set.
set.
Note：
assumed.

12Volt Circuit Error
The ECM supplies 12 V power to the MAF sensor. The
ECM monitors the voltage of the 12 V power supply
circuit.
If the ECM detects an excessively low or high voltage,
the DTC is set.
The ECM detects that the voltage of the 12 V power
supply circuit is 7 V or less for 2 seconds or more.
The ECM detects that the voltage of the 12 V power
supply circuit is 19 V or more for 2 seconds or more.
Note：
shown.

System Voltage High
The ECM monitors ignition voltage of the ignition feed
terminal and makes sure that the voltage stays within the
appropriate range.
When the ECM detects that the ignition power voltage is
The ECM detects that the voltage of the ignition power
supply circuit is 32 V or more for 5 seconds.
Note：
shown.

ECM.
correspond with the checksum that is registered into
ROM.
Note：
shown.
Stop the engine.

The injector ID code information and fuel delivery rate
information are stored in the EEPROM within the ECM.
If the ECM detects that the injector ID code or fuel
delivery rate value is not programmed into the ECM, the
DTC is set. If the ECM detects an error in the
programmed injector ID code or fuel delivery rate value,
the DTC is set.
The ECM detects that no injector ID code is
programmed.
The ECM detects an error in the programmed injector ID
code.
The ECM detects that no fuel delivery rate value is
programmed.
The ECM detects an error in the programmed fuel
delivery rate value.
When it is detected for 2 consecutive times, the failure is
displayed on the monitor of the machine or the diagnostic
light illuminates.
Note：
shown.

ECM.
The ECM detects an internal RAM malfunction.
Note：
shown.
Stop the engine.

ECM.
CPU.
Note：
At CPU recovery

ECM.
The ignition switch has been ON for 480 seconds or
more.
CPU.
Note：
At CPU recovery

ECM.
The ECM detects a malfunction of the internal A/D
converter.
Note：
Default values for all analog sensors are assumed.

The starter cut switch is provided to prevent the starter
from operating when the engine is running. The starter
cut relay is a normal closed relay and is positioned
between the main relay and starter relay.
When the key switch is turned ON, the ECM sends a
signal to the starter cut relay, and the relay is turned OFF.
When the engine is started, the ECM stops signal output
to the starter cut relay when the key switch is in the
START position, and the relay is turned ON.
After the engine is started, the ECM restarts sending
signals to the starter cut relay when the key switch is
returned to the ON position, and the relay is turned OFF.
A monitor circuit is incorporated inside the ECM, and
this circuit monitors the operation of the relay.
The ECM sets a DTC if the output to the starter cut relay
and the operation of the starter cut relay do not match.
There is no starter cut relay monitoring signal to the
starter cut relay drive signal, or there is a starter cut relay
monitoring signal to the starter cut relay stop instruction,
Note：

The ECM opens/closes the intake throttle valve by
controlling the intake throttle motor depending upon the
engine operating status. The intake throttle valve opening
position is detected by the position sensor, and is sent to
the ECM. If the ECM detects that the actual and desired
opening positions of the intake throttle are different while
the intake throttle motor is commanded ON, the DTC is
set.
The desired intake throttle opening position is constant.
The intake throttle motor is commanded ON.
and the desired opening positions of the intake throttle is
40% or more for 10 seconds or more.
Note：
shown.

When the ECM has received the ignition switch ON
signal, power is applied to the ECM main relay and the
battery power is supplied to the ECM via the relay switch
side. When the ignition switch was turned to OFF, power
If the ECM detects a low voltage with the relay voltage
supply circuit when the ON command is executed for the
ECM main relay, it sets DTC.
The ignition switch has been ON for 3 seconds or more.
When the ECM commands the relay ON, the ECM
detects that the main relay voltage supply circuit is 1 V or
less for 4 seconds.
Note：
shown.

When the ECM received the ignition switch ON signal,
power is applied to the ECM main relay and the battery
power is supplied to the ECM via the relay switch side.
When the ignition switch was turned to OFF, power
If the ECM detects that the ECM is ON when the OFF
command is executed for the ECM main relay, it sets
DTC.
The ECM detects that the relay is ON when the ECM
commands the relay OFF for 6 seconds.
Note：
shown.

The ECM also supplies 5 V power to the following
sensor via power supply circuit 6.
CKP sensor
ECM. Therefore, the entire 5 V power supply circuits 1
and 6 may be affected by a short circuit in either of the
DTC is set.
seconds or more.
Note：

The ECM supplies 5 V power to the following sensor
through 5 V power supply circuit 7.
CMP sensor
FRP sensor
seconds or more.
Note：

IAT sensor
EGT sensor 1
The ECM supplies 5 V power to the following sensor via
power supply circuit 8.
Intake throttle position sensor
IMT sensor
seconds or more.
Note：

EGR position sensor
Oil pressure sensor
seconds or more.
Note：

1. DTC P06AF description of DTC
based on the data sent from various engine sensors. The
common 1 and 2 fuel injector charge voltage circuits
supply high voltage, and the fuel injectors of each
cylinder are driven along with grounding of the fuel
injector solenoid control circuit by the ECM. If the ECM
detects a malfunction of the internal injector drive custom
IC, the DTC is set. (Injector drive custom IC DTC)
If the ECM detects an error of the internal injector drive
custom IC communication circuit, the DTC is set.
(Injector drive custom IC communication line circuit
DTC)
If the ECM detects that the calculated checksum does not
match the checksum registered in the ROM, the DTC is
set. (Injector drive custom IC checksum DTC)
2. DTC P06AF condition for setting the DTC
Injector drive custom IC DTC
The ECM detects a malfunction in the injector drive
custom IC for 2 seconds.
Injector drive custom IC communication line circuit DTC
The ECM detects an error in the injector drive custom IC
communication circuit for 3 seconds.
Injector drive custom IC checksum DTC
match the ROM internal registered checksum for 3
seconds.
3. DTC P06AF action taken when the DTC sets
Note：
Fuel injection is stopped. (Injector drive custom IC DTC)

1. DTC P06D5 description of DTC
Fuel filter clogging sensor
EGT sensor 2
ECM. Therefore, all of 5 V power supply circuits 5 and
10 may be affected by a short circuit in either of the
DTC is set.
2. DTC P06D5 condition for setting the DTC
seconds or more.
3. DTC P06D5 action taken when the DTC sets
Note：

sensor 1 signal voltage is 0.1 V or less for 10 seconds.
Note：

set.
The ECM detects that the intercooler temperature sensor
Note：

between the fuel tank and the fuel supply pump and the
high-pressure side between the fuel supply pump and the
injectors. The fuel is drawn from the fuel tank through the
fuel supply pump and supplied to the common rail by the
two plungers located inside the fuel supply pump. The
common rail pressure is regulated by the ECM through
controlling the suction control valve based on the signal
from the common rail pressure sensor.
This DTC is set when the ECM detects that the actual
fuel pressure is lower than the target fuel pressure.
DTCs P0087, P0091, P0092, P0192, P0193, P0201-
set.
is lower than the desired fuel pressure by 50 MPa (7,250
Note：
shown.

voltage is 0.1 V or less for 5 seconds or more.
Note：

DTCs P0112, P0113, P060C, and P06A8 are not set.
voltage is 4.9 V or more for 5 seconds or more.
Note：

sensor 1 measures the temperature of the air flowing into
the intercooler. The boost temperature sensor is installed
to the inlet pipe. The boost temperature sensor measures
the temperature of the air flowing into the inlet pipe. The
set.
DTCs P0045, P0102, P0103, P0112, P0113, P0117,
P0118, P0122, P0123, P0182, P0183, P0237, P0238,
P0545, P0546, P0638, P06A8, P1076, P1077, P1097,
P1098, P2228, P2229, U0001, U0110, and U0411 are not
set.
SCR purging.
temperatures detected by charge air cooler temperature
sensor 1 and those detected by the boost temperature
sensor is lower than the calculated value for 10 seconds.
Note：

is set.
Note：
shown.
disabled.

is set.
Note：
shown.
disabled.

EGR Position Fault
controlling the EGR motor. The EGR opening position is
For a closed position error DTC, if the ECM detects that
the actual EGR valve opening position is higher than the
predetermined value, this DTC is set.
For a learned position error DTC, if the ECM detects a
difference between the learned closed position and the
actual closed position, the DTC is set.
DTC P06A9 is not set.
The ECM detects that the EGR learned closed position is
not within the predetermined range when the ignition
switch is turned OFF.
Note：
shown.

This diagnosis applies to the SW-IC inside the ECM.
SW-IC1 malfunction
The ECM detects an internal SW-IC1 malfunction.
SW-IC1 communication malfunction
The ECM detects a communication error with the internal
SW-IC1.
SW-IC2 malfunction
The ECM detects an internal SW-IC2 malfunction.
SW-IC2 communication malfunction
The ECM detects a communication error with the internal
SW-IC2.
diagnostic light illuminates. (SW-IC1 malfunction, SW-
IC1 communication malfunction)
Note：
The switch controlled by SW-IC2 assumes a default
value. (SW-IC2 malfunction, SW-IC2 communication
malfunction)

AD-IC Failure Error
This diagnosis applies to the AD-IC inside the ECM.
AD-IC.
Note：
A default charge air cooler temperature sensor 1 value is
assumed.
A default engine coolant temperature sensor value is
assumed.
A default fuel temperature sensor value is assumed.
Default EGR gas temperature sensor 1 and 2 values are
assumed.
A default IAT sensor value is assumed.

AD-IC2 Failure Error
This diagnosis applies to the AD-IC2 inside the ECM.
AD-IC2.

ECM.
The ignition switch is ON
match the check sum internally registered in the
EEPROM
Note：
shown.

ECM.
agree with the EEPROM internal registered checksum.
Note：

DPD Lamp Control Circuit
The DPD amber indicator light is installed in the display
and informs the machinery operator that the manual
regeneration is necessary because of incomplete
automatic regeneration.
The ECM monitors for any status that is different from
the DPD amber indicator light command status in the
DPD amber indicator light control circuit.
For example, the circuit is defective if the ECM detects
low voltage when the DPD amber indicator light is
commanded OFF, or if it detects high voltage when the
light is commanded ON.
If the ECM detects any abnormal value in the control
circuit voltage, the DTC is set.
When the DPD amber indicator light is commanded OFF,
the ECM detects a low voltage condition in the DPD
amber indicator light control circuit.
When the DPD amber indicator light is commanded ON,
the ECM detects a high voltage condition in the DPD
amber indicator light control circuit.
Note：

Note：

Note：

SCR System Error
1. DTC P20C9 description of DTC
2. DTC P20C9 condition for setting the DTC
3. DTC P20C9 action taken when the DTC sets
Note：

position sensor 1 has the following circuits
GND circuit
DTC.
0%.

GND circuit
detected that the signal voltage is abnormally high, it sets
DTC.
0%.

GND circuit
DTC.
0%.

GND circuit
to the ECM via the signal circuit. When the ECM detects
that the signal voltage is abnormally high, it sets DTC.
0%.

installed within a single housing. The accelerator position
sensor 1 and accelerator position sensor 2 are hall IC type
sensors and each has the following circuits.
GND circuit
Signal circuit
The ECM supplies 5 V to the accelerator position sensor
via the 5 V power supply circuit and the GND circuit
connects to the GND. The accelerator position sensor
transmits the signal related to changes of the accelerator
pedal angle position to the ECM via the signal circuit.
The signal voltage of the accelerator position sensor 1 is
kept low first, and then increases as the pedal is
depressed. The signal voltage of the accelerator position
sensor 2 is kept high first, and then decreases as the pedal
is depressed. When the ECM has detected that the
accelerator position sensor 1 signal and accelerator
position sensor 2 signal voltages are not related to each
other, it sets DTC.
DTCs P060C, P06A6, P2122, P2123, P2127, and P2128
are not set.
accelerator pedal position sensor 1 and 2 opening
positions is 45% or more for 3 seconds or more.
0%.

using the data transmitted from the various sensors. The
injector charge voltage circuits of the common power
supplies 1 and 2 supply the high voltage while the ECM
drives the injector of each cylinder. The common power
supply 1 supplies power to the injectors of the No. 1 and
No. 4 cylinders while the common power supply 2
supplies power to the injectors of the No. 2 and No. 3
cylinders.
When the injector charge voltage circuit of the common
power supply 1 or 2 has been opened or shorted to the
GND or voltage circuit, the faulty injector common
power supply circuit sets DTC.
Also when the injector solenoid control circuit has been
shorted to the GND, the ECM sets DTC.
Note：
shown.
disabled.

based on the data sent from various sensors. The injector
charge voltage circuits of common power supplies 1 and
2 supply high voltage, while the ECM grounds the
injector solenoid control circuit and drives the injector of
each cylinder. Common power supply 1 serves the
injectors of the No. 1 and No. 4 cylinders, while common
power supply 2 serves the injectors of the No. 2 and No.
3 cylinders.
If the injector charge voltage circuit for common power
supply 1 or 2 has an open circuit, is shorted to GND or
shorted to the voltage circuit, the DTC is set depending
upon the defective injector common power supply circuit.
Also, if the injector solenoid control circuit is shorted to
GND, the DTC is set.
Note：
shown.
disabled.

corrections. If the ECM detects an excessively low signal
Note：
shown.

corrections. If the ECM detects an excessively high signal
Note：
shown.

temperature of the exhaust gas at the EGR cooler inlet.
exhaust gas temperature of the EGR cooler outlet. The
set.
DTCs P0112, P0113, P0122, P0123, P0182, P0183,
P0237, P0238, P0409, P041C, P041D, P0545, P0546,
P0548, P0549, P0638, P06A8, P2228, P2229, U0001,
U0110, and U0411 are not set.
SCR purging.
temperatures detected by EGR gas temperature sensor 1
and those detected by EGR gas temperature sensor 2 is
lower than the calculated value for 10 seconds.
Note：

If the SCR automatic purging starts but does not
complete for some reason, the indicator light in the
display flashes to request that the machinery operator
manually perform the regeneration. Once the SCR
purging starts, it must finish within a predetermined
length of time.
If the SCR purging is conducted consecutively for more
than the predetermined length of time, the DTC is set.
The ECM detects that the SCR purging exceeds a
predetermined length of time 3 consecutive times.
Note：
shown.
DTC P2BA7 (Flash Code 611)

Urea Fluid Quantity Too Low
1. DTC P2BA7 description of DTC
2. DTC P2BA7 condition for setting the DTC
3. DTC P2BA7 action taken when the DTC sets

1. DTC P2BAA description of DTC
2. DTC P2BAA condition for setting the DTC
3. DTC P2BAA action taken when the DTC sets
Note：

A typical common rail (fuel rail) system is composed of
the following 2 fuel pressure sections. The sections are a
suction side between the fuel tank and the fuel supply
pump, and a high pressure side between the fuel supply
pump and the injectors. The fuel is drawn from the fuel
tank via the fuel supply pump and then pumped into the
common rail (fuel rail) by 2 plungers that are located
inside the fuel supply pump. The common rail (fuel rail)
pressure is controlled by the ECM controlling the FRP
regulator based on signals from the common rail (fuel
rail) pressure sensor.
If the ECM detects that the actual fuel pressure is less
than the desired fuel pressure when the outside air
temperature is low, the DTC is set.
DTCs P0087, P0091, P0092, P0192, P0193, P0201-
set.
The fuel temperature is lower than or equal to the
is lower than the desired fuel pressure by 50 MPa (7,250

The ECM communicates with the turbo control unit and
DCU via the CAN communication circuit. The ECM data
is output via the CAN-High circuit and the data from
other ECUs is input via the CAN-Low circuit. CAN
identical. The ECM sets a DTC when CAN
communication fails.
Note：
shown.

ECM sets DTC when it detects a CAN communication
failure.
The battery voltage is 22V or more.
Note：
shown.

ECM sets DTC when it lost CAN communication with
the machine control unit.
The battery voltage is 22 V or higher
The ECM detects that CAN data reception for 5 seconds
or longer is not satisfied
Note：
shown.

The ECM and DCU communicate the control information
ECM monitors the CAN operational status by expecting a
constant message flow from the DCU. If the ECM fails to
receive an expected message, the DTC is set.
The ECM detects that CAN messages from the DCU are
not received for 5 seconds or more.
Note：

identical. ECM sets DTC when it has lost CAN
The ECM detects that the CAN Bus messages from the
turbo control unit are not being received for 5 seconds or
more.
Note：
shown.
The maximum engine speed is limited to 1,700 rpm.

identical. ECM sets DTC when it has received a CAN
communication failure message from the turbo control
unit.
The ECM receives an error message from the turbo
control unit.
Note：
shown.

Lost CAN Communications
The ECM communicates with the control unit of the
machine via the CAN communication circuit. The ECM
outputs data via the CAN-High circuit and inputs data
from other ECUs via the CAN-Low circuit. CAN
identical. The ECM sets a DTC if CAN communication
with the control unit of the machine is lost.
The engine is not cranking.
The ECM detects that CAN data reception is not
established for 5 seconds or more.
Note：
DTC mapping table

SPN-FMI P code
636-7 P0016 Crankshaft Position - Camshaft Position Correlation Error
10023-12 P0045 Turbocharger Boost Control VNT Error
633-7 P0087 Fuel Rail/System Pressure - Too Low
157-15 P0089 Fuel Pressure Regulator Performance
1347-4 P0091 Fuel Pressure Regulator Control Circuit Low
1347-3 P0092 Fuel Pressure Regulator Control Circuit High
1131-4 P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage
1131-3 P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage
132-4 P0102 Mass Air Flow Sensor Circuit Low Input
132-3 P0103 Mass Air Flow Sensor Circuit High Input
172-4 P0112 Intake Air Temperature Sensor Circuit Low
172-3 P0113 Intake Air Temperature Sensor Circuit High
110-4 P0117 Engine Coolant Temperature Sensor Circuit Low
110-3 P0118 Engine Coolant Temperature Sensor Circuit High
10022-4 P0122 Throttle Position Sensor Circuit Low
10022-3 P0123 Throttle Position Sensor Circuit High
174-4 P0182 Fuel Temperature Sensor Circuit Low
174-3 P0183 Fuel Temperature Sensor Circuit High
157-4 P0192 Fuel Rail Pressure Sensor Circuit Low
157-3 P0193 Fuel Rail Pressure Sensor Circuit High
110-0 P0217 Engine Coolant Over Temperature Condition
190-0 P0219 Engine Overspeed Condition
102-0 P0234 Turbocharger Overboost Condition
102-4 P0237 Turbocharger Boost Sensor Circuit Low
102-3 P0238 Turbocharger Boost Sensor Circuit High
723-2 P0335 Crankshaft Position Sensor Circuit
723-8 P0336 Crankshaft Position Sensor Circuit Range/Performance
636-2 P0340 Camshaft Position Sensor Circuit
676-5 P0380 Glow Relay Circuit Error
2791-2 P0401 EGR Flow Insufficient Detected
10002-2 P0404 EGR Control Circuit Range/Performance
10001-2 P0409 EGR Sensor Circuit
10014-4 P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low
10014-3 P041D EGR Cooler Outlet 1 Temp Sensor Circuit High
173-4 P0427 Catalyst Temperature Sensor Circuit Low Sensor 1
173-3 P0428 Catalyst Temperature Sensor Circuit High Sensor 1
10024-4 P042C Catalyst Temperature Sensor Circuit Low Sensor 2
10024-3 P042D Catalyst Temperature Sensor Circuit High Sensor 2
100-4 P0522 Engine Oil Pressure Sensor Circuit Low Input
100-3 P0523 Engine Oil Pressure Sensor Circuit High Input
10053-4 P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low

10053-3 P0546 EGR Cooler Inlet 1 Temp Sensor Circuit High
10012-2 P0560 12Volt Circuit Error
158-3 P0563 System Voltage High
628-2 P0601 Internal Control Module Memory Check Sum Error
10032-2 P0602 Internal Control Module QR Code Error
10033-2 P0604 Internal Control Module RAM Error
1077-2 P0606 Internal Control Module CPU Error
10007-2 P060A Internal Control Module CPU IC Error
10008-2 P060C Internal Control Module A/D Processing Performance
677-5 P0615 Starter Relay Circuit Error
10022-2 P0638 Throttle Actuator Control Range/Performance
1485-5 P0685 ECM Power Relay Control Circuit Open
1485-6 P0687 ECM Power Relay Control Circuit High
10050-2
10082-2 P06AF Injector Custom IC
10083-2
10011-2 P06D5 Sensor Reference Voltage 5 Circuit
10051-4 P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage
10051-3 P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage
105-4 P1097 Compressor Outlet Temperature Sensor Circuit Low
105-3 P1098 Compressor Outlet Temperature Sensor Circuit High
5285-1 P1236 Charge Air Cooler Performance Failure
10001-13 P1404 EGR Position Fault
10046-2
10048-2
P1606 SWIC-1 Internal Failure
10047-2
10049-2
10045-2 P160B AD-IC Failure Error
10078-12 P160C AD-IC2 Failure Error
10013-2 P1621 Control Module Long Term Memory Performance
10013-2 P1622 Control Module EEPROM Hardware Error
10025-5 P1669 DPD Lamp Control Circuit
10043-2 P204F SCR System Error (No Inducement)
4332-12 P207F Urea Fluid Concentration Too Low
10044-1 P20C9 SCR System Error

91-2 P2138 Pedal Position Sensor 1 - 2 Voltage Correlation
108-4 P2228 Barometric Pressure Circuit Low Input
108-3 P2229 Barometric Pressure Circuit High Input
10054-17 P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance
10029-0 P2458 Purge Time Out Error
4332-12 P2BA7 Urea Fluid Quantity Too Low
10042-12 P2BAA SCR System Error (Inducement, No Purge)
10040-19 U0001 CAN Bus Error (ISO-CAN)
639-19 U0073 Control Module Communication Bus Off
639-2 U0101 Lost Communication With CAN
10041-2 U010E Lost Communications With Dosing Control Module
10023-2 U0110 Lost Communication With VNT System
10023-19 U0411 Lost CAN Communications With VNT Control Module
10034-2 U2106 Lost Communication with Wheel Loader Transmission Control System
Engine Control (4HK1 (Generator 12V)) 1A-1
Engine Control
Engine Control
(4HK1 (Generator 12V))
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor
Position Correlation Error...............................................1A-4 Circuit High...................................................................1A-30
VNT Error.......................................................................1A-5 Cylinder 1......................................................................1A-32
Solenoid Circuit Low......................................................1A-7 Cylinder 2......................................................................1A-33
Solenoid Circuit High.....................................................1A-8 Cylinder 3......................................................................1A-34
Too Low..........................................................................1A-9 Cylinder 4......................................................................1A-35
Performance..................................................................1A-12 Temperature Condition.................................................1A-36
Control Circuit Low......................................................1A-14 .......................................................................................1A-37
Control Circuit High.....................................................1A-15 Condition.......................................................................1A-38
Sensor 2 Circuit Low Voltage.......................................1A-16 Circuit Low...................................................................1A-40
Sensor 2 Circuit High Voltage......................................1A-17 Circuit High...................................................................1A-41
Low Input......................................................................1A-18 Circuit............................................................................1A-42
High Input.....................................................................1A-19 Circuit Range/Performance...........................................1A-44
Circuit Low...................................................................1A-20 Circuit............................................................................1A-45
Circuit High...................................................................1A-21 .......................................................................................1A-47
Sensor Circuit Low.......................................................1A-22 Performance..................................................................1A-48
DTC P0118 (Flash Code 23) Engine Coolant Temperature DTC P0409 (Flash Code 44) EGR Sensor Circuit........1A-49
Sensor Circuit High.......................................................1A-23 DTC P041C (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0122 (Flash Code 43) Throttle Position Sensor Sensor Circuit Low.......................................................1A-51
Circuit Low...................................................................1A-24 DTC P041D (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0123 (Flash Code 43) Throttle Position Sensor Sensor Circuit High.......................................................1A-52
Circuit High...................................................................1A-25 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low Sensor 1....................................................1A-54
Circuit Low...................................................................1A-26 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High Sensor 1....................................................1A-55
Circuit High...................................................................1A-27 DTC P042C (Flash Code 49) Catalyst Temperature Sensor
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low Sensor 2....................................................1A-56
Circuit Low...................................................................1A-29
1A-2 Engine Control (4HK1 (Generator 12V))
DTC P042D (Flash Code 49) Catalyst Temperature Sensor DTC P1097 (Flash Code 213) Compressor Outlet
Circuit High Sensor 2....................................................1A-57 Temperature Sensor Circuit High.................................1A-88
Performance..................................................................1A-59 Temperature Sensor Circuit High.................................1A-89
Circuit Low Input..........................................................1A-60 Performance Failure......................................................1A-90
DTC P0523 (Flash Code 294) Engine Oil Pressure Sensor DTC P1261 (Flash Code 34) Injector Positive Voltage
Circuit High Input.........................................................1A-61 Control Circuit Group 1................................................1A-91
Sensor Circuit Low.......................................................1A-62 Control Circuit Group 2................................................1A-92
DTC P0546 (Flash Code 39) EGR Cooler Inlet 1 Temp DTC P1404 (Flash Code 45) EGR Position Fault........1A-93
Sensor Circuit High.......................................................1A-63 DTC P1606 (Flash Code 51) SW-IC Internal failure....1A-94
DTC P0563 (Flash Code 35) System Voltage High.....1A-65 DTC P160B (Flash Code 36) AD-IC Failure Error......1A-95
DTC P0601 (Flash Code 53) Internal Control Module DTC P1621 (Flash Code 54) Control Module Long Term
Memory Check Sum Error............................................1A-66 Memory Performance....................................................1A-96
DTC P0602 (Flash Code 154) Internal Control Module QR DTC P1622 (Flash Code 54) Control Module EEPROM
Code Error.....................................................................1A-67 Hardware Error..............................................................1A-97
DTC P0604 (Flash Code 153) Internal Control Module DTC P204F (Flash Code 611) SCR System Error (No
RAM Error....................................................................1A-68 Inducement)...................................................................1A-98
DTC P0606 (Flash Code 51) Internal Control Module CPU DTC P207F (Flash Code 611) Urea Fluid Concentration
Error..............................................................................1A-69 Too Low........................................................................1A-99
DTC P060A (Flash Code 51) Internal Control Module CPU DTC P20C9 (Flash Code 611) SCR System Error.....1A-100
IC Error.........................................................................1A-70
DTC P2122 (Flash Code 121) Pedal Position Sensor 1
DTC P060C (Flash Code 36) Internal Control Module A/D Circuit Low Input........................................................1A-101
Processing Performance................................................1A-71
DTC P0615 (Flash Code 19) Starter Relay Circuit Error Circuit High Input.......................................................1A-102
.......................................................................................1A-72
DTC P0638 (Flash Code 61) Throttle Actuator Control Circuit Low Input........................................................1A-103
Range/Performance.......................................................1A-73
DTC P0685 (Flash Code 416) ECM Power Relay Control Circuit High Input.......................................................1A-104
Circuit Open..................................................................1A-75
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
DTC P0687 (Flash Code 416) ECM Power Relay Control Voltage Correlation.....................................................1A-105
Circuit High...................................................................1A-76
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
DTC P06A6 (Flash Code 55) Sensor Reference Voltage 1 Voltage Circuit............................................................1A-106
Circuit............................................................................1A-77
Circuit............................................................................1A-78
DTC P2228 (Flash Code 71) Barometric Pressure Sensor
DTC P06A8 (Flash Code 57) Sensor Reference Voltage 3 Circuit Low.................................................................1A-108
Circuit............................................................................1A-79
DTC P06A9 (Flash Code 59) Sensor Reference Voltage 4 Circuit High.................................................................1A-109
Circuit............................................................................1A-80
DTC P2457 (Flash Code 95) Exhaust Gas Recirculation
DTC P06AF (Flash Code 277) Torque Management System (EGR) Cooling System Performance..........................1A-110
- Forced Engine Shutdown............................................1A-81
DTC P2458 (Flash Code 139) Purge Time Out Error.1A-111
DTC P06D5 (Flash Code 56) Sensor Reference Voltage 5
DTC P2BAA (Flash Code 611) SCR System Error
Circuit............................................................................1A-82
(Inducement, No Purge)..............................................1A-112
DTC P1076 (Flash Code 313) Charge Air Cooler (CAC)
Temperature Sensor 1 Circuit Low Voltage.................1A-83
.....................................................................................1A-113
Temperature Sensor 1 Circuit High Voltage.................1A-84
.....................................................................................1A-116
.......................................................................................1A-85
Communication Bus Off.............................................1A-118

CAN............................................................................1A-120
Dosing Control Module...............................................1A-121
VNT System................................................................1A-122
With VNT Control Module.........................................1A-123

1. DTC P0016 priority DTC 4. Perform a test-run under the conditions for running
the DTC.
DTC P0335
Note：
DTC P0336
・ Conditions for setting the DTCs such as
DTC P0340 engine run time or coolant temperature, etc.,
2. DTC P0016 diagnostics vary depending on the DTCs.
1. Inspect the CKP sensor. ・ For the conditions for setting the DTC, refer to
the applicable code listed in 15E DTC
Refer to "1.Engine 1B.Mechanical(4HK1) CKP information.
sensor inspection".
5. Observe the DTC information with the trouble
2. If a problem is found, replace the CKP sensor. diagnosis scan tool. A DTC should not be set.
Refer to "1.Engine 1B.Mechanical(4HK1) CKP
sensor removal".
sensor installation".
3. Inspect the CMP sensor.
Refer to "1.Engine 1B.Mechanical(4HK1) CMP
sensor inspection".
4. If a problem is found, replace the CMP sensor.
sensor removal".
5. Inspect the flywheel.
Note：
・ There should be no damage on the flywheel.
・ There should be no improper installation of the
ring gear.
6. If a problem is found, repair the flywheel.
7. Inspect the camshaft gear.
Note：
・ The camshaft gear should not be damaged.
camshaft gear.
8. If a problem is found, repair the camshaft gear.
3. DTC P0016 confirm resolution
1. Clear the DTC using the trouble diagnosis scan tool.
2. Turn OFF the ignition switch for 1 minute or more.
Note：
・ When the engine does not start, crank the
engine for 10 seconds.

1. DTC P0045 priority DTC 13. Measure the voltage between the position sensor
power supply terminal of the turbo actuator harness
DTC P0563
connector and the GND.
2. DTC P0045 diagnostics
voltage： 8.0 to 11.0 V
14. If the voltage is outside the specified range, inspect
2. Inspect the turbocharger assembly. the position sensor power supply circuit between the
turbo actuator and the turbo control unit.
Refer to "1.Engine 1F.Induction(4HK1) Turbocharger
assembly inspection". ・There should be no open circuit or high resistance.
・There should be no short to the battery power supply or
3. If a problem is found, replace the turbocharger
ignition power supply circuit.
assembly.
・There should be no short to GND.
15. If a problem is found, repair the position sensor
assembly removal".
power supply circuit.
16. If the circuit is normal, inspect for poor connections
assembly installation".
at the turbo control unit harness connector.
4. Remove the harness connector from the turbo
17. If a problem is found, repair the harness connector.
actuator.
18. If the harness connector is normal, replace the turbo
5. Connect a test lamp between the motor operation
control unit.
terminal of the turbo actuator harness connector and
the GND. 19. If the voltage is within the specified range, measure
the voltage between the position sensor signal
7. Check whether the test lamp does not illuminate or the GND.
remains ON.
Note：
Note：・ Measure the voltage at each terminal.
・ Inspect each terminal using a test lamp.
・ When it is normal, the test light comes on after
the key switch is turned ON, and then goes out 20. If the voltage is outside the specified range, inspect
after a few seconds. the position sensor signal circuit between the turbo
actuator and the turbo control unit.
8. If the test lamp does not illuminate or remains ON,
inspect the motor operation circuit between the turbo ・There should be no open circuit or high resistance.
actuator and the turbo control unit. ・There should be no short to the battery power supply or
・There should be no open circuit or high resistance. ・There should be no short to GND.
ignition power supply circuit. 21. If a problem is found, repair the position sensor
・There should be no short to GND. signal circuit.
9. If a problem is found, repair the motor operation 22. If the circuit is normal, inspect for poor connections
circuit. at the turbo control unit harness connector.
10. If the test lamp operates normally, inspect the motor 23. If a problem is found, repair the harness connector.
operation circuit between the turbo actuator and the 24. If the harness connector is normal, replace the turbo
turbo control unit for a short circuit. control unit.
11. If a problem is found, repair the motor operation 25. If the voltage is within the specified range, inspect
circuit. the position sensor signal circuit between the turbo
12. Turn ON the ignition switch. actuator and the turbo control unit for a short circuit.
signal circuit.
28. Measure the voltage between the position sensor
power supply terminal of the turbo actuator harness
connector and the position sensor GND terminal.
the position sensor GND circuit between the turbo
・There should be no open circuit or high resistance.
GND circuit.
31. If the circuit is normal, inspect for poor connections
at the turbo control unit harness connector.
control unit.
34. If the voltage is within the specified range, inspect
for poor connections at the turbo actuator harness
connector.
36. If the harness connector is normal, replace the
turbocharger.
assembly removal".
1. Clear the DTC with a trouble diagnosis scan tool.
4. Perform a test-run under the conditions for running
the DTC.
Note：
engine run time or coolant temperature, etc.,
vary depending on the DTCs.
・ For the conditions for setting the DTC, refer to
information.
5. Observe the DTC information with a trouble
diagnosis scan tool. A DTC should not be set.

Exhaust Valve Control Solenoid Circuit Low
1. DTC P0079 diagnostics Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
20. Set the Injector ID Code and engine No. on the
2. Remove the harness connector from the exhaust
ECM.
throttle solenoid valve.
21. Perform SCR purging with a trouble diagnosis scan
3. Connect a test lamp between the ignition power
tool.
supply terminal of the exhaust throttle solenoid valve
harness connector and the GND. 2. DTC P0079 confirm resolution
4. Turn ON the ignition switch. 1. Clear the DTC with a scan tool.
5. If the test lamp does not illuminate, repair the open 2. Perform an exhaust throttle test with a scan tool.
circuit or high resistance in the ignition power supply
3. Command the exhaust throttle solenoid valve ON
circuit of the exhaust throttle solenoid valve.
and OFF.
6. If the test lamp illuminates, connect the test lamp
4. Check whether an operation sound of the exhaust
between the ignition power supply circuit of the
throttle solenoid valve is made upon execution of
exhaust throttle solenoid valve harness connector and
each command.
the control terminal.
and OFF with a scan tool.
Note：
・ The test lamp illuminates when commanded
ON, and turns OFF when commanded OFF.
8. If the test lamp operates properly, inspect for poor
connections at the exhaust throttle solenoid valve
harness connector.
exhaust throttle solenoid valve.
11. If the test lamp remains ON, inspect the control
circuit between the ECM and the exhaust throttle
solenoid valve for a short to GND.
12. If a problem is found, repair the control circuit.
13. If the test lamp remains OFF, inspect the control
circuit between the ECM and the exhaust throttle
solenoid valve for an open circuit or high resistance.
16. Remove the ECM harness connector.
17. Inspect for poor connections at the ECM harness
connector.
19. If the ECM harness connector is normal, replace the
ECM.
ECM removal".

Exhaust Valve Control Solenoid Circuit High
2. Remove the harness connector from the exhaust
throttle solenoid valve.
3. Observe the DTC information with a scan tool.
4. If DTC P0080 is not set and P0079 is set with a scan
tool, replace the exhaust throttle solenoid valve.
5. If DTC P0079 is not set and P0080 is set, inspect the
control circuit between the ECM and the exhaust
throttle solenoid valve for a short to the battery or a
short to the ignition power supply.
7. If the circuit is normal, replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
1. Clear the DTC with a scan tool.
2. Perform an exhaust throttle test with a scan tool.
and OFF.
4. Check whether an operation sound of the exhaust
throttle solenoid valve is heard upon execution of
each command.

1. DTC P0087 priority DTC 12. If a problem is found, repair the harness connector.
DTC P0089 13. Inspect each circuit for high resistance.
DTC P0091 14. If a problem is found, repair the circuit.
DTC P0092 15. If the harness connector and each circuit are normal,
replace the fuel pressure sensor.
DTC P0192
Refer to "1.Engine 1C.Fuel System(4HK1) Common
DTC P0193
rail assembly removal".
DTC P0201
DTC P0202 rail assembly installation".
DTC P0203 Note：
DTC P0204 ・ Do not replace the fuel pressure sensor
separately. If a problem is found, replace the
DTC P2146 common rail assembly.
DTC P2149 16. If the fuel rail pressure sensor display is within the
2. DTC P0087 diagnostics specified range, start the engine.
1. Start the engine. 17. Perform the injector stop test with the trouble
2. Increase the engine speed while observing the DTC
information with a trouble diagnosis scan tool. 18. Command each injector OFF, and confirm that the
engine speed changes on each injector.
3. Check to see if the DTC P0087 is detected.
19. If any injector does not change the engine speed
4. If DTC P0087 is not set, replace the fuel filter. when OFF is instructed, replace the relevant injector.
Note： Refer to "1.Engine 1C.Fuel System(4HK1)
・ An intermittent problem due to foreign matter Injector removal".
in the fuel is suspected.
Refer to "1.Engine 1C.Fuel System(4HK1)
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel Injector installation".
filter removal".
20. When the injector has been replaced, set the injector
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel ID code on the ECM.
filter installation".
21. Inspect to see if there is clogging with the fuel
5. Turn OFF the ignition switch. system between the fuel tank and the fuel supply
6. Wait for the specified period of time until the fuel pump.
pressure is released from the common rail. 22. If a problem is found, repair the clogging of the fuel
specified time： 2 min system.
7. Turn ON the ignition switch. 23. Inspect the fuel hose between the fuel tank and the
fuel supply pump for a cut and crack.
8. Check the fuel rail pressure sensor display with the
trouble diagnosis scan tool. 24. If a problem is found, replace the fuel hose.
voltage： 0.9 to 1.0 V Note：

・ The fuel hose between the fuel tank and the
9. If the fuel rail pressure sensor display is outside the
fuel supply pump becomes negative pressure
specified range, inspect the fuel pressure sensor
state when the engine is running.
harness connector for a poor connection.
・ When the fuel hose is not connected securely,
10. If a problem is found, repair the harness connector. the air can enter.
11. Inspect the ECM harness connector for a poor ・ When the engine speed or the engine load
connection. increases while the air has intruded in the fuel
system, fluctuation in the common rail 35. Leave the engine idling for the specified period of
pressure is caused, and DTC P0087 may be time or longer.
detected. specified time： 1 min
25. Check that an appropriate clamp is used between the 36. While allowing the engine to keep the specified
fuel tank and the fuel supply pump. duration and the maximum engine speed, observe the
26. If a problem is found, replace the clamp. pressure gauge.
27. Operate the priming pump until the handle becomes specified time： 1 min
heavy. 37. Check if the pressure gauge shows a negative
Note： pressure value at or above the specified value during
inspection.
・ When a leak exists in the fuel system between
the priming pump and the fuel supply pump, values: (-17.0) kPa {5 inHg / (-2) psi}
the pressing weight of the priming pump does
Note：
not become heavy.
・ Fuel clogging is checked with the negative
28. Start the engine. pressure amount in the fuel system.
29. Inspect the high-pressure side of the fuel system and 38. If the negative pressure is more than or equal to the
check for fuel leak between the fuel supply pump specified value, inspect to see if there is damage or
and common rail. twisting with the fuel system between the fuel supply
Note： pump and the fuel tank.
・ The fuel may leak to the bottom section of the 39. If a problem is found, repair the fuel system.
cylinder head cover from the high pressure
40. Inspect the fuel tank bent hose.
hose inlet.
・ The engine oil level increases when the fuel 41. If a problem is found, repair the bent hose.
leaks to the bottom portion of the cylinder head 42. Check to see if there is any foreign matter in the fuel
cover. tank or any foreign matter which can cause fuel
・ Inspect for fuel leaks into the engine oil. clogging.
30. If fuel leak if found, fix the problem. 43. If a problem is found, repair it.
31. Turn OFF the ignition switch. 44. Replace the fuel filter.
32. Remove the fuel hose on the fuel supply pump side Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
from the fuel filter. filter removal".
Note： Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
・ Use a pan to catch the fuel from the removed filter installation".
fuel hose. 45. If the negative pressure is less than or equal to the
・ Clean the pressure gauge and connection specified value, pinch the fuel hose at a position as
hose before connecting to the fuel pipe. close as possible to the fuel tank, so that the fuel
・ The fuel supply pump may be damaged due to does not flow.
foreign matter that has entered in the Note：
connection hose.
・ The fuel pipe can be disconnected and
33. Connect the pressure gauge between the fuel filter clogged with a plug.
and the removed fuel hose.
46. Start the engine and increase the engine speed up to
Note： the maximum engine speed.
・ Confirm that the fuel system is connected 47. Check the pressure gauge.
securely.
values: (-27.0) kPa {8 inHg / (-4) psi}
34. Remove the air using the priming pump, and crank
the engine for the specified period of time or shorter. Note：
・ When the pressure gauge is likely to indicate a
specified time： 5 s
value exceeding the specified value during
Note： inspection, release the fuel being blocked.
・ Repeat this until the engine starts.
・ Air mixture is checked with the negative ・ For the conditions for setting the DTC, refer to
pressure amount while the fuel flow is being the applicable code listed in 15E DTC
blocked. information.
48. If the specified negative pressure cannot be 5. Observe the DTC information with the trouble
generated, inspect to see if there is a cut or crack diagnosis scan tool. A DTC should not be set.
with the fuel hose.
49. If a problem is found, replace the fuel hose.
50. Inspect to see if appropriate clamp is used.
51. If a problem is found, replace the clamp with an
appropriate one.
53. Inspect the suction control valve harness connector
for a poor connection.
55. Inspect the ECM harness connector for a poor
connection.
57. Inspect each circuit for high resistance.
59. If the FRP regulator harness connector and the ECM
harness connector are normal and there is no high
resistance in each circuit, replace the fuel supply
pump and the fuel filter.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
pump removal".
pump installation".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
filter removal".
Note：
・ When replacing the fuel supply pump, the fuel
filter must be replaced at the same time.
the DTC.
Note：

1. DTC P0089 priority DTC 12. Inspect the ECM harness connector for a poor
connection.
DTC P0091
DTC P0092
DTC P0192
DTC P0193
DTC P0201
DTC P0202
18. Increase the engine speed while observing the fuel
DTC P0203
rail pressure display on a trouble diagnosis scan tool.
DTC P0204
19. Compare the fuel rail pressure display with the
DTC P2146 desired fuel rail pressure display on the trouble
diagnosis scan tool and observe whether the
DTC P2149
difference is within the specified range.
values： less than 5 MPa { less than 725 psi }
1. Wait for the specified period of time until the fuel
pressure is released from the common rail. Note：
・ If possible, compare with other machine
specified time： 2 min equipped with the same model engine.
2. Check the fuel rail pressure sensor display with the 20. If the reading is within the specified range, replace
trouble diagnosis scan tool. the fuel filter.
voltage： 0.9 to 1.0 V Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
3. If the fuel rail pressure sensor display is outside the filter removal".
specified range, inspect the fuel pressure sensor Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
harness connector for a poor connection. filter installation".
4. If a problem is found, repair the harness connector. 21. If the reading is outside the specified range, replace
5. Inspect the ECM harness connector for a poor the fuel supply pump and the fuel filter.
connection. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
6. If a problem is found, repair the harness connector. pump removal".
7. Inspect each circuit for high resistance. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
pump installation".
9. If the harness connector and each circuit are normal, filter removal".
Refer to "1.Engine 1C.Fuel System(4HK1) Common filter installation".
Note：
rail assembly installation". ・ When replacing the fuel supply pump, the fuel
Note：
・ Do not replace the fuel pressure sensor
separately. If a problem is found, replace the 1. Clear the DTC using the trouble diagnosis scan tool.
common rail assembly. 2. Turn OFF the ignition switch for 1 minute or more.
10. Inspect the suction control valve harness connector 3. Start the engine.
the DTC.
Note：
information.

1. DTC P0091 diagnostics 19. Set the Injector ID Code and engine No. on the
ECM.
1. Disconnect the harness connector from the suction
control valve. 20. Perform SCR purging with a trouble diagnosis scan
tool.
2. Connect the test light between the suction control
valve High side circuit and a normal GND. 2. DTC P0091 confirm resolution
3. Turn ON the ignition switch. 1. Clear the DTC using the trouble diagnosis scan tool.
4. Check if the test light comes on and then goes off. 2. Turn OFF the ignition switch for 1 minute or more.
5. If it does not turn off, inspect the High side circuit 3. Start the engine.
between the ECM and the suction control valve.
・There should be no open circuit or high resistance. the DTC.
Note：
・There should be no short to the LOW side circuit.
6. If a problem is found, repair the High side circuit. engine run time or coolant temperature, etc.,
7. Turn OFF the ignition switch for 1 minute or more. vary depending on the DTCs.
valve Low side circuit and battery power supply.
information.
10. Check if the test light comes on and then goes off. diagnosis scan tool. A DTC should not be set.
11. If it does not turn off, inspect the Low side circuit
between the ECM and suction control valve.
・There should be no short to the battery or ignition
power supply.
12. If a problem is found, repair the Low side circuit.
suction control valve.
Refer to "1.Engine 1C.Fuel System(4HK1) Suction
control valve removal".
control valve installation".
connection.
18. If the harness connector is normal, replace the ECM.
ECM removal".
ECM installation".

1. DTC P0092 diagnostics Refer to "1.Engine 1C.Fuel System(4HK1) Suction
1. Inspect the High side circuit between the ECM and
the FRP regulator for a short to the battery or a short Refer to "1.Engine 1C.Fuel System(4HK1) Suction
to the ignition power supply. control valve installation".
Note： 21. Inspect the ECM harness connector for a poor
・ When the High side circuit is shorted to the connection.
voltage, the engine stalls and does not start. 22. If a problem is found, repair the harness connector.
2. If a problem is found, repair the High side circuit. 23. If the harness connector is normal, replace the ECM.
3. If it is within the specified range, inspect to see if Refer to "1.Engine 1J.Electrical(4HK1)
there is a short circuit to the GND with the Low side ECM removal".
circuit between the ECM and the suction control
valve. Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
5. Turn OFF the ignition switch for 1 minute or more. ECM.
6. Disconnect the harness connector from the suction 25. Perform SCR purging with a trouble diagnosis scan
control valve. tool.
7. Connect the test light between the suction control 2. DTC P0092 confirm resolution
valve High side circuit and a normal GND.
9. Check if the test light comes on and then goes off.
10. If it does not turn off, inspect the High side circuit
between the ECM and the suction control valve. 4. Perform a test-run under the conditions for running
the DTC.
・There should be no short to GND. Note：
・There should be no short to the Low side circuit. ・ Conditions for setting the DTCs such as
11. If a problem is found, repair the High side circuit.
12. Turn OFF the ignition switch for 1 minute or more. ・ For the conditions for setting the DTC, refer to
13. Connect the test light between the suction control the applicable code listed in 15E DTC
valve Low side circuit and battery power supply. information.
14. Turn ON the ignition switch. 5. Observe the DTC information with the trouble
power supply.

1. DTC P0097 priority DTC Note：
DTC P06A8 ・ Conditions for setting the DTCs such as
1. Turn OFF the ignition switch. ・ For the conditions for setting the DTC, refer to
2. Disconnect the harness connector from the IMT the applicable code listed in 15E DTC
sensor. information.
4. Observe the 5 V adjustment display of intake air
temperature sensor 3 on the trouble diagnosis scan
tool.
voltage： 4.5 V
5. If the reading is more than or equal to the specified
value, replace the IMT sensor.
Refer to "1.Engine 1F.Induction(4HK1) IMT
sensor removal".
6. Inspect the signal circuit between the ECM and IMT
sensor for a short to GND.
7. If a problem is found, repair the signal circuit.
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P0098 priority DTC 16. If the reading is less than or equal to the specified
value, inspect the GND circuit between the ECM and
DTC P06A8
IMT sensor for an open circuit or high resistance.
Note：
1. Turn OFF the ignition switch. ・ The IMT sensor shares the GND circuit with
2. Disconnect the harness connector from the IMT other sensors.
sensor. ・ DTCs on sensors that share this circuit may be
3. Turn ON the ignition switch. set.
17. If a problem is found, repair the GND circuit.
4. Measure the voltage between the IMT sensor signal
circuit and a known good GND. 18. Inspect the signal circuit between the ECM and the
voltage： 5.5 V
value, inspect the signal circuit between the ECM 20. Inspect for poor connections at the ECM harness
and IMT sensor for a short to the battery or a short to connector.
the ignition power supply.
7. Connect a fused jumper wire between the IMT
sensor signal circuit and GND circuit.
ECM removal".
ECM installation".
tool.
voltage： 0.1 V
ECM.
value, inspect the signal circuit between the ECM
tool.
and IMT sensor for a short to the 5 V power supply
circuit. 3. DTC P0098 confirm resolution
10. If a problem is found, repair the signal circuit. 1. Clear the DTC with a trouble diagnosis scan tool.
11. Inspect for poor connections at the IMT sensor 2. Turn OFF the ignition switch for 1 minute or more.
harness connector.
13. If the harness connector is normal, replace the IMT the DTC.
sensor.
Note：
Refer to "1.Engine 1F.Induction(4HK1) IMT ・ Conditions for setting the DTCs such as
sensor removal". engine run time or coolant temperature, etc.,
Refer to "1.Engine 1F.Induction(4HK1) IMT vary depending on the DTCs.
sensor installation". ・ For the conditions for setting the DTC, refer to
information.
sensor signal circuit and a known good GND.
tool.
voltage： 0.1 V

1. DTC P0102 priority DTC 17. Perform SCR purging with a trouble diagnosis scan
tool.
DTC P0560
2. Disconnect the harness connector from the MAF
sensor. 3. Start the engine.
3. Inspect to see if there is an open circuit or high 4. Perform a test-run under the conditions for running
resistance in the 12 V power supply circuit between the DTC.
the ECM and the MAF sensor.
Note：
4. If a problem is found, repair the 12 V power supply ・ Conditions for setting the DTCs such as
circuit. engine run time or coolant temperature, etc.,
5. Connect the test cable with fuse between the 12 V vary depending on the DTCs.
power supply circuit and the signal circuit of the ・ For the conditions for setting the DTC, refer to
MAF sensor harness connector. the applicable code listed in 15E DTC
information.
7. Check the MAF sensor display with the trouble
voltage： 4.9 V
value, inspect to see if there is a poor connection
with the MAF sensor harness connector.
10. If the harness connector is normal, replace the MAF
sensor.
11. Inspect the signal circuit between the ECM and the
MAF sensor.
Note：
・ There should be no open circuit or high
resistance.
・ There should be no short to GND.
connection.
ECM removal".
ECM installation".
ECM.

1. DTC P0103 priority DTC 1. Clear the DTC using the trouble diagnosis scan tool.
DTC P0560 2. Turn OFF the ignition switch for 1 minute or more.
2. DTC P0103 diagnostics 3. Start the engine.
1. Turn OFF the ignition switch. 4. Perform a test-run under the conditions for running
the DTC.
sensor. Note：
3. Turn ON the ignition switch. ・ Conditions for setting the DTCs such as
4. Check the MAF sensor display with the trouble vary depending on the DTCs.
voltage： 0.1 V the applicable code listed in 15E DTC
5. If the reading is more than or equal to the specified information.
value, inspect the signal circuit between the ECM 5. Observe the DTC information with the trouble
and the MAF sensor. diagnosis scan tool. A DTC should not be set.
Note：
・ There should be no short to the battery or no
・ There should be no short to the 12 V power
supply or no short to the 5 V power supply.
7. Inspect to see if there is an open circuit or high
resistance in the GND circuit between the ECM and
the MAF sensor.
9. Inspect the MAF sensor harness connector for a poor
connection.
sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0112 priority DTC ・ For the conditions for setting the DTC, refer to
DTC P06A8 the applicable code listed in 15E DTC
information.
1. Turn OFF the ignition switch. diagnosis scan tool. A DTC should not be set.
2. Disconnect the harness connector from the IAT
sensor.
4. Observe the intake air temperature sensor display on
the trouble diagnosis scan tool.
voltage： 4.5 V
value, replace the IAT sensor.
6. Inspect the signal circuit between the ECM and IAT
9. Disconnect the harness connector from the ECM.
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

DTC P06A8 ・ The IAT sensor shares the GND circuit with
other sensors.
・ DTCs on sensors that share this circuit may be
1. Turn OFF the ignition switch. set.
2. Disconnect the harness connector from the IAT 17. If a problem is found, repair the GND circuit.
sensor.
3. Turn ON the ignition switch. IAT sensor for an open circuit or high resistance.
4. Measure the voltage between the IAT sensor signal 19. If a problem is found, repair the signal circuit.
circuit and a known good GND.
voltage： 5.5 V connector.
5. If the reading is more than or equal to the specified 21. If a problem is found, repair the harness connector.
and the IAT sensor.
Note：
ECM removal".
short to the ignition power supply. Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
supply. 23. Set the Injector ID Code and engine No. on the
ECM.
7. Connect a fused jumper wire between the IAT sensor
tool.
signal circuit and GND circuit.
the trouble diagnosis scan tool. 1. Clear the DTC using the trouble diagnosis scan tool.
voltage： 0.1 V 2. Turn OFF the ignition switch for 1 minute or more.
9. If the reading is less than or equal to the specified 3. Start the engine.
and IAT sensor for a short to the 5 V power supply
the DTC.
circuit.
Note：
11. Inspect for poor connections at the IAT sensor engine run time or coolant temperature, etc.,
harness connector. vary depending on the DTCs.
12. If a problem is found, repair the harness connector. ・ For the conditions for setting the DTC, refer to
13. If the harness connector is normal, replace the IAT
information.
sensor.
signal circuit and a known good GND.
voltage： 0.1 V
the IAT sensor for an open circuit or high resistance.

2. Disconnect the harness connector from the engine the applicable code listed in 15E DTC
coolant temperature sensor. information.
4. Observe the engine coolant temperature sensor
display on a trouble diagnosis scan tool.
voltage： 4.5 V
value, replace the engine coolant temperature sensor.
Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant
temperature sensor removal".
temperature sensor installation".
6. Inspect to see if there is a short circuit to the GND
with the signal circuit between the ECM and the
engine coolant temperature sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P0118 priority DTC voltage： 0.1 V
DTC P06A8 16. If the reading is less than or equal to the specified
value, inspect to see if there is an open circuit or high
resistance with the engine coolant temperature sensor
1. Turn OFF the ignition switch. GND circuit.
2. Disconnect the harness connector from the engine Note：
coolant temperature sensor. ・ The engine coolant temperature sensor shares
3. Turn ON the ignition switch. the GND circuit with other sensors.
4. Measure the voltage between the engine coolant ・ The DTC set on a sensor which shares this
temperature sensor signal circuit and normal GND. circuit may be detected.
voltage： 5.5 V
18. Inspect to see if there is a breakage or high resistance
in the signal circuit of the engine coolant temperature
value, inspect to see if there is a short circuit to the
sensor.
battery or ignition power supply with the signal
circuit between the ECM and the engine coolant 19. If a problem is found, repair the signal circuit.
temperature sensor.
6. If a problem is found, repair the signal circuit. connection.
7. Connect the test cable with fuse between the engine 21. If a problem is found, repair the harness connector.
coolant temperature sensor signal circuit and GND
circuit.
ECM removal".
voltage： 0.1 V
ECM installation".
value, inspect to see if there is a short circuit to the 5
ECM.
V power supply circuit with the signal circuit
between the ECM and the engine coolant 24. Perform SCR purging with a trouble diagnosis scan
temperature sensor. tool.
10. If a problem is found, repair the signal circuit. 3. DTC P0118 confirm resolution
11. Inspect to see if there is a poor connection with the 1. Clear the DTC using the trouble diagnosis scan tool.
engine coolant temperature sensor harness connector.
13. If the harness connector is normal, replace the engine
coolant temperature sensor.
the DTC.
Note：
Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant engine run time or coolant temperature, etc.,
temperature sensor installation". vary depending on the DTCs.
14. Connect the test cable with fuse between the engine ・ For the conditions for setting the DTC, refer to
coolant temperature sensor signal circuit and normal the applicable code listed in 15E DTC
GND. information.
15. Observe the engine coolant temperature sensor 5. Observe the DTC information with the trouble
display on a trouble diagnosis scan tool. diagnosis scan tool. A DTC should not be set.

1. DTC P0122 priority DTC ・ There should be no short to GND.
DTC P06A8 13. If a problem is found, repair the signal circuit.
2. DTC P0122 diagnostics 14. Inspect the ECM harness connector for a poor
1. Turn OFF the ignition switch. connection.
2. Disconnect the harness connector from the intake 15. If a problem is found, repair the harness connector.
throttle valve. 16. If the harness connector is normal, replace the ECM.
3. Turn ON the ignition switch. Refer to "1.Engine 1J.Electrical(4HK1)
4. Measure the voltage between the intake throttle ECM removal".
position sensor 5 V power supply circuit and a Refer to "1.Engine 1J.Electrical(4HK1)
normal GND. ECM installation".
voltage： 4.9 V 17. Set the Injector ID Code and engine No. on the
5. If the reading is less than or equal to the specified ECM.
value, inspect to see if there is an open circuit or high 18. Perform SCR purging with a trouble diagnosis scan
resistance with the 5 V power supply circuit between tool.
the ECM and the intake throttle position sensor.
Note：
・ The intake throttle position sensor shares the 5
V power supply circuit with other sensors. 2. Turn OFF the ignition switch for 1 minute or more.
・ The DTC set on a sensor which shares this 3. Start the engine.
circuit may be detected.
6. If a problem is discovered, repair the 5 V power the DTC.
supply circuit.
Note：
7. Connect the test cable with fuse between the intake
throttle position sensor 5 V power supply circuit and
the signal circuit.
8. Observe the intake throttle sensor display on the ・ For the conditions for setting the DTC, refer to
trouble diagnosis scan tool. the applicable code listed in 15E DTC
voltage： 4.9 V information.
9. If the reading is more than or equal to the specified 5. Observe the DTC information with the trouble
value, inspect to see if there is a poor connection diagnosis scan tool. A DTC should not be set.
with the intake throttle valve harness connector.
11. If the harness connector is normal, replace the intake
throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake
throttle valve removal".
throttle valve installation".
12. Inspect the signal circuit between the ECM and
intake throttle position sensor.
Note：
resistance.

1. DTC P0123 priority DTC Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
DTC P06A8
ECM installation".
2. Disconnect the harness connector from the intake ECM.
throttle valve.
3. Turn ON the ignition switch. tool.
4. Observe the intake throttle sensor display on the 3. DTC P0123 confirm resolution
voltage： 0.1 V
and the intake throttle position sensor. 4. Perform a test-run under the conditions for running
the DTC.
Note：
・ There should be no short to the battery or no Note：
short to the ignition power supply. ・ Conditions for setting the DTCs such as
・ There should be no short to the 5 V power engine run time or coolant temperature, etc.,
supply. vary depending on the DTCs.
7. Inspect the intake throttle valve harness connector information.
8. If a problem is found, repair the harness connector. diagnosis scan tool. A DTC should not be set.
throttle valve.
the intake throttle position sensor.
Note：
・ The intake throttle position sensor shares the
GND circuit with other sensors.
・ The DTC set on a sensor which shares this
12. Check the ECM harness connector for a poor
connection.

1. DTC P0182 priority DTC 4. Perform a test-run under the conditions for running
the DTC.
DTC P06A9
Note：
1. Turn OFF the ignition switch. engine run time or coolant temperature, etc.,
2. Disconnect the harness connector from the fuel vary depending on the DTCs.
temperature sensor. ・ For the conditions for setting the DTC, refer to
3. Turn ON the ignition switch. the applicable code listed in 15E DTC
information.
4. Observe the fuel temperature sensor display on the
voltage： 4.5 V
value, replace the fuel temperature sensor.
pump removal".
pump installation".
Note：
・ Do not replace the fuel temperature sensor
fuel supply pump.
with the signal circuit between the ECM and fuel
temperature sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0183 priority DTC 15. Observe the fuel temperature sensor display on the
DTC P06A9
voltage： 0.1 V
2. Disconnect the harness connector from the fuel resistance with the GND circuit between the ECM
temperature sensor. and fuel temperature sensor.
3. Turn ON the ignition switch. Note：
4. Measure the voltage between the fuel temperature ・ The fuel temperature sensor shares the GND
sensor signal circuit and normal GND. circuit with other sensors.
voltage： 5.5 V ・ The DTC set on a sensor which shares this
battery or ignition power supply with the signal 18. Inspect to see if there is an open circuit or high
circuit between the ECM and the fuel temperature resistance in the signal circuit between the ECM and
sensor. the fuel temperature sensor.
6. If a problem is found, repair the signal circuit. 19. If a problem is found, repair the signal circuit.
7. Connect the test cable with fuse between the fuel 20. Inspect the ECM harness connector for a poor
temperature sensor signal circuit and GND circuit. connection.
8. Observe the fuel temperature sensor display on the 21. If a problem is found, repair the harness connector.
voltage： 0.1 V
9. If the reading is less than or equal to the specified ECM removal".
ECM installation".
between the ECM and the fuel temperature sensor.
ECM.
11. Inspect to see if there is a poor connection with the
fuel temperature sensor harness connector.
tool.
13. If the harness connector is normal, replace the fuel
temperature sensor.
pump removal". 3. Start the engine.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply 4. Perform a test-run under the conditions for running
pump installation". the DTC.
Note： Note：
・ Do not replace the fuel temperature sensor ・ Conditions for setting the DTCs such as
separately. If a problem is found, replace the engine run time or coolant temperature, etc.,
fuel supply pump. vary depending on the DTCs.
14. Connect the test cable with fuse between the fuel ・ For the conditions for setting the DTC, refer to
temperature sensor signal circuit and normal GND. the applicable code listed in 15E DTC
information.

connection.
DTC P06A7
2. Disconnect the harness connector from the fuel
ECM removal".
pressure sensor.
ECM installation".
ECM.
voltage： 4.5 V
5. If the reading is less than or equal to the specified tool.
GND with the signal circuit between the ECM and
the fuel pressure sensor. 1. Clear the DTC using the trouble diagnosis scan tool.
6. If a problem is found, repair the signal circuit. 2. Turn OFF the ignition switch for 1 minute or more.
7. Measure the voltage between the fuel pressure sensor 3. Start the engine.
5 V power supply circuit and normal GND.
voltage： 4.5 V the DTC.
8. If the reading is more than or equal to the specified Note：
value, inspect to see if there is a poor connection ・ Conditions for setting the DTCs such as
with the fuel pressure sensor harness connector. engine run time or coolant temperature, etc.,
9. If a problem is found, repair the harness connector. vary depending on the DTCs.
pressure sensor.
information.
rail assembly installation".
Note：
common rail assembly.
resistance with the 5 V power supply circuit between
the ECM and fuel pressure sensor.
Note：
・ The fuel pressure sensor shares the 5 V power
supply circuit with other sensors.
12. If a problem is found, repair the 5 V power supply
circuit.

DTC P06A7 ・ Do not replace the fuel pressure sensor
2. DTC P0193 diagnostics common rail assembly.
1. Turn OFF the ignition switch. 15. Inspect to see if there is an open circuit or high
2. Disconnect the harness connector from the fuel resistance in the GND circuit between the ECM and
pressure sensor. the fuel pressure sensor.
4. Measure the voltage between the fuel pressure sensor ・ The fuel pressure sensor shares the GND
signal circuit and normal GND. circuit with other sensors.
voltage： 5.5 V circuit may be detected.
5. If the reading is more than or equal to the specified 16. If a problem is found, repair the GND circuit.
circuit between the ECM and the fuel pressure resistance in the signal circuit between the ECM and
sensor. the fuel pressure sensor.
7. Measure the voltage between the fuel pressure sensor 19. Inspect the ECM harness connector for a poor
signal circuit and normal GND. connection.
voltage： 4.5 V 20. If a problem is found, repair the harness connector.
8. If the reading is more than or equal to the specified 21. If the harness connector is normal, replace the ECM.
value, inspect to see if there is a short circuit to the 5 Refer to "1.Engine 1J.Electrical(4HK1)
V power supply circuit with the signal circuit ECM removal".
between the ECM and the fuel pressure sensor.
9. If a problem is found, repair the signal circuit. ECM installation".
10. Connect the test cable with fuse between the fuel 22. Set the Injector ID Code and engine No. on the
pressure sensor signal circuit and GND circuit. ECM.
11. Check the fuel rail pressure sensor display with the 23. Perform SCR purging with a trouble diagnosis scan
trouble diagnosis scan tool. tool.
voltage： 0.1 V 3. DTC P0193 confirm resolution
12. If the reading is less than or equal to the specified 1. Clear the DTC using the trouble diagnosis scan tool.
with the fuel pressure sensor harness connector. 2. Turn OFF the ignition switch for 1 minute or more.
13. If a problem is found, repair the harness connector. 3. Start the engine.
14. If the harness connector is normal, replace the fuel 4. Perform a test-run under the conditions for running
pressure sensor. the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1) Common Note：

rail assembly removal". ・ Conditions for setting the DTCs such as
information.

1. DTC P0201 diagnostics 1. Clear the DTC using the trouble diagnosis scan tool.
1. Turn OFF the ignition switch. 2. Turn OFF the ignition switch for 1 minute or more.
2. Disconnect the harness connector from the No. 1 3. Start the engine.
cylinder injector.
3. Measure the resistance in the charge voltage circuit the DTC.
between the ECM and the No. 1 cylinder injector.
Note：
4. If a problem is found, repair the harness connector. ・ Conditions for setting the DTCs such as
5. If the reading is more than or equal to the specified engine run time or coolant temperature, etc.,
value, repair the charge voltage circuit between the vary depending on the DTCs.
ECM and the No. 1 cylinder injector for an open ・ For the conditions for setting the DTC, refer to
circuit or high resistance. the applicable code listed in 15E DTC
information.
Note：
・ Turn ON the ignition switch. 5. Observe the DTC information with the trouble
・ Measure the voltage between the charge
voltage circuit of the No. 1 cylinder injector
harness connector and the frame ground.
value, inspect the control circuit between the ECM
and the No. 1 cylinder injector.
Injector removal".
Injector installation".
Note：
・ If the reading is less than or equal to the
specified value, measure the voltage between
the No. 1 cylinder injector harness connector
solenoid control circuit and the frame ground.
connector.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0202 diagnostics 2. Turn OFF the ignition switch for 1 minute or more.
1. Turn OFF the ignition switch. 3. Start the engine.
2. Disconnect the harness connector from the No. 2 4. Perform a test-run under the conditions for running
cylinder injector. the DTC.
3. Measure the resistance in the charge voltage circuit Note：
between the ECM and the No. 2 cylinder injector. ・ Conditions for setting the DTCs such as
4. If a problem is found, repair the harness connector. engine run time or coolant temperature, etc.,
value, repair the charge voltage circuit between the
ECM and the No. 2 cylinder injector for an open
information.
circuit or high resistance.
Note：
resistance.
・ There should be no short to the charge voltage
circuit.
7. Measure the voltage between the charge voltage
circuit of the No. 2 cylinder injector harness
connector and the frame ground.
Injector removal".
Note：
・ If the injector has been replaced, set the
Injector ID Code to the ECM.
connector.
ECM removal".
ECM installation".
ECM.
tool.

the DTC.
2. Disconnect the harness connector from the No. 3
cylinder injector. Note：
3. Measure the resistance in the charge voltage circuit ・ Conditions for setting the DTCs such as
between the ECM and the No. 3 cylinder injector. engine run time or coolant temperature, etc.,
5. Turn ON the ignition switch. the applicable code listed in 15E DTC
information.
Note：
・ There should be no open circuit or high 5. Observe the DTC information with the trouble
resistance. diagnosis scan tool. A DTC should not be set.
circuit.
and the No. 3 cylinder injector.
Injector removal".
Note：
connector.
ECM removal".
ECM installation".
ECM.
tool.

1. Turn OFF the ignition switch. 3. Start the engine.
2. Disconnect the harness connector from the No. 4 4. Perform a test-run under the conditions for running
cylinder injector. the DTC.
3. Measure the resistance in the charge voltage circuit Note：
between the ECM and the No. 4 cylinder injector. ・ Conditions for setting the DTCs such as
value, repair the charge voltage circuit between the
ECM and the No. 4 cylinder injector for an open
information.
Note：
resistance.
circuit.
Injector removal".
Note：
connector.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0217 priority DTC values： 101 ℃ { 214 °F }
DTC P0117 5. Observe the DTC information with the trouble
1. Inspect the engine cooling system.
Refer to "1.Engine 1D.Cooling(4HK1)
Coolant inspection".
Refer to "1.Engine 1D.Cooling(4HK1) Cooling fan
belt inspection".
Thermostat inspection".
Radiator inspection".
2. While observing the coolant temperature display
with the trouble diagnosis scan tool, start the engine.
3. Wait until the engine has been completely warmed
up.
4. Check whether the engine coolant temperature
display is more than or equal to the specified value
with the trouble diagnosis scan tool.
values： 101 ℃ { 214 °F }
5. If the reading is less than the specified value, check
the operator if the overheat has occurred due to low
engine coolant level, etc.
6. Make sure to inspect the engine if it has experienced
engine overheat in the past.
temperature sensor inspection".
8. If any abnormality is found in the inspection results,
replace the engine coolant temperature sensor.
3. While observing the engine coolant temperature
display with the trouble diagnosis scan tool, start the
engine and wait until it is completely warmed up.
4. Observe that the engine coolant temperature display
is not more than or equal to the specified value.

1. DTC P0219 priority DTC
DTC P0335
DTC P0336
1. Turn OFF the ignition switch for 1 minute.
3. Check the engine speed display with the trouble
4. Increase the engine speed, as needed.
values： 2070 r/min
6. If the maximum speed without load has not been
exceeded, check with the operator if an operation
failure has occurred due to the overrun.
engine overrun in the past.
8. Inspect the CKP sensor.
sensor inspection".
replace the CKP sensor.
sensor removal".
3. Start the engine and increase the engine speed
between idling and no-load maximum speed while
observing the engine speed display on the trouble
4. Confirm that the engine speed display does not
exceed the specified value.
values： 2070 r/min

1. DTC P0234 priority DTC 9. Make sure oil does not enter the intake piping.
DTC P0045 10. If there is oil inside the piping, intercooler, or
turbocharger, wipe it off.
DTC P0237
11. Make sure the boost pressure sensor signal is normal
DTC P0238
with a trouble diagnosis scan tool.
DTC P0638
12. Compare the sensor values under various load
DTC P2228 conditions and check for abnormally high values.
DTC P2229 13. If the reading is more than or equal to the specified
value, compare the barometric pressure value with
the surrounding barometric pressure.
14. Observe whether the barometric pressure display is
2. Check the difference between the boost pressure within the specified range on the trouble diagnosis
display and the barometric pressure display with the scan tool.
Note：
values： 10.0 kPa { 0.1 kgf/cm2 / 1 psi } ・ Normally, the barometric pressure on the scan
Note： tool indicates a value close to the surrounding
・ If the boost pressure on the scan tool shows a barometric pressure.
value close to the barometric pressure while 15. If the barometric pressure display is within the
the ignition switch is ON and the engine not specified range, turn OFF the ignition switch.
running, it is considered normal.
16. Disconnect the harness connector from the boost
3. If the reading is less than or equal to the specified pressure sensor.
value, inspect the turbocharger nozzle actuator hose
17. Inspect for poor connections at the boost pressure
for improper installation.
sensor harness connector.
4. If a problem is found, repair the improper hose
installation.
5. Inspect the actuator that controls the turbocharger
nozzle for malfunctions. 20. Inspect for poor connections at the ECM harness
connector.
assembly inspection". 21. If a problem is found, repair the harness connector.
6. If a problem is found, repair or replace the 22. Inspect the GND circuit between the ECM and the
turbocharger assembly. boost pressure sensor.
Refer to "1.Engine 1F.Induction(4HK1) Turbocharger Note：
assembly removal". ・ There should be no high resistance.
Refer to "1.Engine 1F.Induction(4HK1) Turbocharger 23. If a problem is found, repair the GND circuit.
24. Inspect the boost pressure sensor.
7. Perform an intake throttle test with the trouble
diagnosis scan tool and check if the intake throttle Refer to "1.Engine 1F.Induction(4HK1) Pressure
valve is stuck. sensor/boost temperature sensor inspection".
8. If a problem is found, replace the intake throttle 25. If a problem is found, replace the boost pressure
valve. sensor.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake Refer to "1.Engine 1F.Induction(4HK1) Pressure

throttle valve removal". sensor/boost temperature sensor removal".
Refer to "1.Engine 1B.Mechanical(4HK1) Intake Refer to "1.Engine 1F.Induction(4HK1) Pressure

throttle valve installation". sensor/boost temperature sensor installation".
26. If the barometric pressure data display is outside the
specified range, replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
connector.
the DTC.
Note：
information.

1. DTC P0237 priority DTC ・ There should be no short to GND.
DTC P06A8 13. If a problem is found, repair the signal circuit.
1. Turn OFF the ignition switch. connection.
2. Disconnect the harness connector from the boost 15. If a problem is found, repair the harness connector.
sensor. 16. If the harness connector is normal, replace the ECM.
3. Turn ON the ignition switch. Refer to "1.Engine 1J.Electrical(4HK1)
4. Measure the voltage between the 5 V power supply ECM removal".
circuit of the boost sensor harness connector and a Refer to "1.Engine 1J.Electrical(4HK1)
normal GND. ECM installation".
voltage： 4.5 V 17. Set the Injector ID Code and engine No. on the
value, inspect to see if there is an open circuit or high 18. Perform SCR purging with a trouble diagnosis scan
resistance with the 5 V power supply circuit between tool.
the ECM and the boost sensor.
Note：
・ The boost sensor shares the 5 V power supply
circuit with other sensors. 2. Turn OFF the ignition switch for 1 minute or more.
・ The DTC set on a sensor which shares this 3. Start the engine.
6. If a problem is found, repair the 5 V power supply the DTC.
circuit.
Note：
7. Connect the test cable with fuse between the 5 V
power supply circuit and the signal circuit of the
boost sensor harness connector.
8. Check the boost pressure sensor display with the ・ For the conditions for setting the DTC, refer to
trouble diagnosis scan tool. the applicable code listed in 15E DTC
with the boost sensor harness connector.
11. If the harness connector is normal, replace the boost
sensor.
Refer to "1.Engine 1F.Induction(4HK1) Pressure
sensor/boost temperature sensor removal".
sensor/boost temperature sensor installation".
boost sensor.
Note：
resistance.

ECM removal".
DTC P06A8
ECM installation".
2. Disconnect the harness connector from the boost ECM.
sensor.
4. Check the boost pressure sensor display with the 3. DTC P0238 confirm resolution
voltage： 0.1 V
and the boost sensor. 4. Perform a test-run under the conditions for running
the DTC.
Note：
7. Inspect to see if there is an open circuit or high information.
the boost sensor.
Note：
・ The boost sensor shares the GND circuit with
other sensors.
9. Inspect the boost sensor harness connector for a poor
connection.
sensor.
connection.

1. DTC P0335 priority DTC 12. If a problem is found, repair the signal circuit.
DTC P0340 13. Connect the test light between the signal circuit and
normal GND of the CKP sensor harness connector.
DTC P06A6
14. Measure the voltage between the probe of the test
light and a normal GND.
voltage： 4.5 V
2. Disconnect the harness connector from the CKP
sensor.
3. Turn ON the ignition switch. V power supply circuit with the signal circuit
between the ECM and the CKP sensor.
4. Measure the voltage between the 5 V power supply
circuit and normal GND of the CKP sensor harness 16. If a problem is found, repair the signal circuit.
connector.
voltage： 4.5 V circuit and GND circuit of the CKP sensor harness
connector.
value, inspect to see if there is an open circuit or high voltage： 4.5 V
the ECM and the CKP sensor.
Note： with the CKP sensor harness connector.
・ The CKP sensor shares the 5 V power supply 19. If a problem is found, repair the harness connector.
circuit with other sensors.
20. If the harness connector is normal, inspect the CKP
sensor.
sensor inspection".
circuit.
21. If a problem is found, replace the CKP sensor.
7. Measure the voltage between the signal circuit and
normal GND of the CKP sensor harness connector. Refer to "1.Engine 1B.Mechanical(4HK1) CKP
sensor removal".
voltage： 5.5 V
battery or ignition power supply with the signal 22. Inspect the GND circuit between the ECM and the
circuit between the ECM and the CKP sensor. CKP sensor for an open circuit and high resistance.
9. If a problem is found, repair the signal circuit. Note：
10. Measure the voltage between the signal circuit of the ・ The CKP sensor shares the GND circuit with
CKP sensor harness connector and a normal GND other sensors.
again. ・ The DTC set on a sensor which shares this
voltage： 4.5 V
value, inspect the signal circuit between the ECM 24. Inspect the ECM harness connector for a poor
and the CKP sensor. connection.
Note： 25. If a problem is found, repair the harness connector.
・ There should be no open circuit or high 26. If the harness connector is normal, replace the ECM.
resistance.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

DTC P0335 ・ Conditions for setting the DTCs such as
DTC P0340 vary depending on the DTCs.
DTC P06A6 ・ For the conditions for setting the DTC, refer to
2. DTC P0336 diagnostics the applicable code listed in 15E DTC
information.
1. Inspect the CKP sensor circuit.
Note： diagnosis scan tool. A DTC should not be set.
・ It should not be too close to the wiring or parts
of the fuel injection device
・ It should not be too close to any electronic
device additionally installed.
・ It should not be too close to the solenoid and
relay.
2. If a problem is found, repair the CKP sensor circuit.
connection.
sensor.
8. Inspect the CKP sensor harness connector for a poor
connection.
sensor inspection".
sensor removal".
the DTC.

DTC P0601 15. If the reading is more than or equal to the specified
DTC P06A7
2. DTC P0340 diagnostics between the ECM and the CMP sensor.
1. Turn OFF the ignition switch. 16. If a problem is found, repair the signal circuit.
2. Disconnect the harness connector from the CMP 17. Measure the voltage between the 5 V power supply
sensor. circuit and GND circuit of the CMP sensor harness
connector.
voltage： 4.5 V
circuit and normal GND of the CMP sensor harness 18. If the reading is more than or equal to the specified
connector. value, inspect to see if there is a poor connection
with the CMP sensor harness connector.
voltage： 4.5 V
value, inspect to see if there is an open circuit or high 20. If the harness connector is normal, inspect the CMP
resistance with the 5 V power supply circuit between sensor.
the ECM and the CMP sensor.
6. If a problem is found, repair the 5 V power supply sensor inspection".
circuit.
normal GND of the CMP sensor harness connector.
sensor removal".
voltage： 5.5 V
8. If the reading is more than or equal to the specified sensor installation".
circuit between the ECM and the CMP sensor. Note：
9. If a problem is found, repair the signal circuit. ・ The camshaft gear should not be damaged.
10. Measure the voltage between the signal circuit of the
camshaft gear.
CMP sensor harness connector and a normal GND
again. 23. If a problem is found, repair the camshaft gear.
voltage： 4.5 V 24. Inspect the GND circuit between the ECM and the
CMP sensor for an open circuit and high resistance.
value, inspect the signal circuit between the ECM Note：
and the CMP sensor. ・ The CMP sensor shares the GND circuit with
Note： other sensors.
・ There should be no open circuit or high ・ The DTC set on a sensor which shares this
resistance. circuit may be detected.
・ There should be no short to GND. 25. If a problem is found, repair the GND circuit.
12. If a problem is found, repair the signal circuit. 26. Inspect the ECM harness connector for a poor
connection.
13. Connect the test light between the signal circuit and
normal GND of the CMP sensor harness connector. 27. If a problem is found, repair the harness connector.
14. Measure the voltage between the probe of the test 28. If the harness connector is normal, replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

the DTC.
2. Replace the glow relay with a known good relay.
Note：
3. Perform the glow relay test with the trouble
diagnosis scan tool. ・ Conditions for setting the DTCs such as
4. Command the glow relay ON and OFF. vary depending on the DTCs.
5. Check whether an operation sound is heard from the ・ For the conditions for setting the DTC, refer to
glow relay upon execution of each command. the applicable code listed in 15E DTC
6. If the operating sound of the glow relay can be information.
heard, remove the glow relay. 5. Observe the DTC information with the trouble
7. Inspect for poor connections at the glow relay
terminal.
8. If a problem is found, repair the glow relay terminal.
9. If the glow relay terminal is normal, replace the glow
relay.
11. Inspect between the ignition switch and the glow
relay coil side for an open circuit or high resistance.
12. If a problem is found, repair the circuit between the
ignition switch and glow relay coil side.
13. Inspect the control circuit between the ECM and
glow relay.
connector.
ECM.
ECM removal".
ECM installation".
ECM.
tool.
1. Clear the DTC with the trouble diagnosis scan tool.

1. DTC P0404 priority DTC Refer to "1.Engine 1H.Aux. Emission Control
DTC P0409
15. Restore the machine.
1. Remove the EGR valve assembly from the engine.
Devices(4HK1) EGR valve removal". 18. Turn OFF the ignition switch for 1 minute or more.
2. Inspect the EGR valve. 19. Start the engine.
Note： 20. Perform a test-run.
・ There should be nothing to restrict the flow 21. Check the DTC using the trouble diagnosis scan tool.
inside the EGR valve.
22. If the DTC P0404 has been detected, replace the
・ There should not be excessive deposits in the
ECM.
EGR valve.
・ There should be no bend in the EGR valve or Refer to "1.Engine 1J.Electrical(4HK1)
valve shaft. ECM removal".
3. Turn OFF the ignition switch. Refer to "1.Engine 1J.Electrical(4HK1)

ECM installation".
4. Disconnect the harness connector from the EGR
valve. 23. Set the Injector ID Code and engine No. on the
ECM.
5. Inspect the EGR valve harness connector for a poor
connection. 24. Perform SCR purging with a trouble diagnosis scan
tool.
connection. 2. Turn OFF the ignition switch for 1 minute or more.
10. Inspect to see if there is an open circuit or high 4. Perform a test-run under the conditions for running
resistance in the EGR control circuit. the DTC.
11. If a problem is found, repair the EGR control circuit. Note：

12. Inspect the EGR motor circuit between the ECM and
EGR valve.
Note：・ For the conditions for setting the DTC, refer to
・ There should be no short to GND. the applicable code listed in 15E DTC
・ There should be no short to the battery or no information.
short to the ignition power supply circuit. 5. Observe the DTC information with the trouble
・ There should be no short together between diagnosis scan tool. A DTC should not be set.
circuits.
・ There should be no short to the EGR position
sensor circuit.
13. If a problem is found, repair the EGR motor circuit.
14. If the EGR motor circuit is normal, replace the EGR
valve.

EGR Sensor Circuit
1. DTC P0409 priority DTC ・ The DTC set on a sensor which shares this
DTC P06A9 circuit may be detected.
2. DTC P0409 diagnostics 12. If a problem is found, repair the GND circuit.
1. Turn OFF the ignition switch. 13. While momentarily disconnecting the test cable with
fuse from the EGR position sensor 1 signal circuit
2. Disconnect the harness connector from the EGR and 5 V power supply circuit, check the EGR
valve. position 1 display with the trouble diagnosis scan
4. Use the trouble diagnosis scan tool to check if any of 14. While momentarily disconnecting the test cable with
the EGR position 1, EGR position 2, and EGR fuse from the EGR position sensor 2 signal circuit
position 3 shows ON. and 5 V power supply circuit, check the EGR
position 2 display with the trouble diagnosis scan
5. If there is a data display showing ON, inspect the tool.
signal circuit between the ECM and EGR valve of
the EGR showing ON. 15. While momentarily disconnecting the test cable with
Note： and 5 V power supply circuit, check the EGR
・ There should be no short to the battery or no position 3 display with the trouble diagnosis scan
short to the ignition power supply. tool.
・ There should be no short to the 5 V power 16. Check to see if there is a data display which does not
supply circuit. display ON when the EGR position sensor signal
6. If a problem is found, repair the signal circuit. circuit and 5 V power supply circuit are shorted.
7. Measure the voltage between the EGR position 17. If there is a data display which does not display ON,
sensor 5 V power supply circuit and a normal GND. inspect the EGR position sensor circuit which does
not display ON.
voltage： 4.5 V
Note：
value, inspect to see if there is an open circuit or high ・ There should be no open circuit or high
resistance with the 5 V power supply circuit between resistance between the ECM and the EGR
the ECM and the EGR position sensor. position sensor.
・ There should be no short to GND between the
Note： ECM and the EGR position sensor.
・ The EGR position sensor shares the 5 V
power supply circuit with other sensors. 18. If a problem is found, repair the EGR position sensor
circuit.
circuit may be detected. 19. Inspect the EGR valve harness connector for a poor
connection.
circuit. 20. If a problem is found, repair the harness connector.
10. Measure the voltage between the EGR position 21. Inspect the EGR motor circuit between the ECM and
sensor 5 V power supply circuit and the GND circuit. the EGR valve for a short to the EGR position
sensor.
voltage： 4.5 V
value, inspect to see if there is an open circuit or high 23. If the EGR motor circuit is normal, replace the EGR
resistance with the GND circuit between the ECM valve.
and EGR position sensor. Refer to "1.Engine 1H.Aux. Emission Control
Note： Devices(4HK1) EGR valve removal".
・ The EGR position sensor shares the GND Refer to "1.Engine 1H.Aux. Emission Control
circuit with other sensors. Devices(4HK1) EGR valve installation".
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. DTC P041C priority DTC Note：
2. DTC P041C diagnostics vary depending on the DTCs.
2. Disconnect the harness connector from EGR gas the applicable code listed in 15E DTC
temperature sensor 2. information.
4. Observe the 5 V adjustment display of EGR gas
tool.
voltage： 4.5 V
value, replace EGR gas temperature sensor 2.
Devices(4HK1) EGR gas temperature sensor
2 removal".
2 installation".
6. Inspect the signal circuit between the ECM and EGR
gas temperature sensor 2 for a short to GND.
connector.
ECM removal".
ECM installation".
ECM.
tool.
3. DTC P041C confirm resolution
the DTC.

1. DTC P041D priority DTC 15. Observe the 5 V adjustment display of EGR gas
DTC P06A8
tool.
2. DTC P041D diagnostics
voltage： 0.1 V
2. Disconnect the harness connector from EGR gas value, inspect the EGR gas temperature sensor 2
temperature sensor 2. GND circuit for an open circuit or high resistance.
4. Measure the voltage between the EGR gas ・ EGR gas temperature sensor 2 shares the
temperature sensor 2 signal circuit and a known good GND circuit with other sensors.
GND. ・ DTCs on sensors that share this circuit may be
voltage： 5.5 V set.
value, inspect the signal circuit between the ECM 18. Inspect the EGR gas temperature sensor 2 signal
and EGR gas temperature sensor 2 for a short to the circuit for an open circuit or high resistance.
battery or a short to the ignition power supply.
7. Connect a fused jumper wire between the EGR gas connector.
temperature sensor 2 signal circuit and the GND
circuit.
temperature sensor 2 on the trouble diagnosis scan Refer to "1.Engine 1J.Electrical(4HK1)
tool. ECM removal".
voltage： 0.1 V Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
value, inspect the signal circuit between the ECM 23. Set the Injector ID Code and engine No. on the
and the EGR gas temperature sensor for a short to ECM.
the 5 V power supply circuit.
10. If a problem is found, repair the signal circuit. tool.
11. Inspect for poor connections at the EGR gas 3. DTC P041D confirm resolution
temperature sensor 2 harness connector.
13. If the harness connector is normal, replace EGR gas
temperature sensor 2.
the DTC.
2 removal". Note：
Refer to "1.Engine 1H.Aux. Emission Control ・ Conditions for setting the DTCs such as
Devices(4HK1) EGR gas temperature sensor engine run time or coolant temperature, etc.,
2 installation". vary depending on the DTCs.
14. Connect a fused jumper wire between the EGR gas
temperature sensor 2 signal circuit and a known good
information.
GND.

2. Disconnect the harness connector from the exhaust the applicable code listed in 15E DTC
gas temperature sensor 1. information.
4. Check the exhaust temperature sensor (before the
filter) display with the trouble diagnosis scan tool.
voltage： 4.5 V
value, replace the exhaust gas temperature sensor 1.
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas
exhaust gas temperature sensor 1.
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

DTC P06A8 16. If the reading is more than or equal to the specified
resistance with the signal circuit between the ECM
1. Turn OFF the ignition switch. and the exhaust gas temperature sensor 1.
2. Disconnect the harness connector from the exhaust 17. If a problem is found, repair the signal circuit.
gas temperature sensor 1.
3. Turn ON the ignition switch. resistance in the GND circuit between the ECM and
the exhaust gas temperature sensor 1.
4. Measure the voltage between the exhaust gas
temperature sensor 1 signal circuit and normal GND. Note：
voltage： 5.5 V ・ The exhaust gas temperature sensor 1 shares
the GND circuit with other sensors.
value, inspect to see if there is a short circuit to the ・ The DTC may be detected on a sensor which
battery or ignition power supply with the signal shares this circuit.
circuit between the ECM and the exhaust gas 19. If a problem is found, repair the GND circuit.
7. Connect the test cable with fuse between the exhaust 21. If a problem is found, repair the harness connector.
gas temperature sensor 1 signal circuit and GND
circuit.
ECM removal".
voltage： 0.1 V
ECM installation".
ECM.
between the ECM and the exhaust gas temperature 24. Perform SCR purging with a trouble diagnosis scan
sensor 1. tool.
exhaust gas temperature sensor 1 harness connector.
13. If the harness connector is normal, replace the temperature exceeds the specified value.
values： 70 ℃ { 158 °F }
4. Increase the engine speed while observing the
exhaust temperature sensor (in front of the filter)
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas display with the trouble diagnosis scan tool.
5. Use the trouble diagnosis scan tool to confirm that
14. Connect the test cable with fuse between the exhaust the exhaust temperature sensor (before the filter)
gas temperature sensor 1 signal circuit and normal display does not exceed the specified value.
GND.
voltage： 4.8 V

DTC P06D5 ・ Conditions for setting the DTCs such as
2. Disconnect the harness connector from the exhaust the applicable code listed in 15E DTC
gas temperature sensor 2. information.
oxidation catalyst) display with the trouble diagnosis
scan tool.
voltage： 4.5 V
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P042D priority DTC 15. Check the exhaust temperature sensor (before the
DTC P06D5
scan tool.
voltage： 0.1 V
2. Disconnect the harness connector from the exhaust value, inspect to see if there is an open circuit or high
gas temperature sensor 2. resistance with the signal circuit between the ECM
and the exhaust gas temperature sensor 2.
temperature sensor 2 signal circuit and normal GND. 18. Inspect to see if there is an open circuit or high
voltage： 5.5 V
value, inspect to see if there is a short circuit to the Note：
battery or ignition power supply with the signal ・ The exhaust gas temperature sensor 2 shares
circuit between the ECM and the exhaust gas the GND circuit with other sensors.
temperature sensor 2. ・ The DTC may be detected on a sensor which
6. If a problem is found, repair the signal circuit. shares this circuit.
7. Connect the test cable with fuse between the exhaust
gas temperature sensor 2 signal circuit and GND 20. Inspect the ECM harness connector for a poor
circuit. connection.
8. Check the exhaust temperature sensor (before the 21. If a problem is found, repair the harness connector.
scan tool.
voltage： 0.1 V
ECM removal".
ECM installation".
between the ECM and the exhaust gas temperature 23. Set the Injector ID Code and engine No. on the
sensor 2. ECM.
10. If a problem is found, repair the signal circuit. 24. Perform SCR purging with a trouble diagnosis scan
tool.
exhaust gas temperature sensor 2 harness connector. 3. DTC P042D confirm resolution
12. If a problem is found, repair the harness connector. 1. Clear the DTC using the trouble diagnosis scan tool.
13. If the harness connector is normal, replace the 2. Turn OFF the ignition switch for 1 minute or more.
3. Start the engine, and warm it up until the coolant
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature reaches the specified value.
values： 70 ℃ { 158 °F }
exhaust temperature sensor (in front of the oxidation
14. Connect the test cable with fuse between the exhaust catalyst) display with the trouble diagnosis scan tool.
gas temperature sensor 2 signal circuit and normal
GND.
the exhaust temperature sensor (before the oxidation
catalyst) display does not exceed the specified value.
voltage： 4.9 V

Engine Oil Pressure Sensor Performance
DTC P0522 the applicable code listed in 15E DTC
information.
1. Inspect the following parts for engine oil leakage. diagnosis scan tool. A DTC should not be set.
Note：
・ Oil pump
・ Oil pressure sensor
・ Oil cooler
・ Oil filter
・ Pipe between the oil cooler and the oil filter
2. If a problem is found, repair the applicable oil
leakage.
4. Disconnect the harness connector from the oil
pressure sensor.
5. Inspect for poor connections at the oil pressure
connector.
10. Inspect the each circuit between the ECM and the oil
pressure sensor for high resistance.
11. If a problem is found, repair the applicable circuit.
12. Replace the oil pressure sensor.
Refer to "1.Engine 1E.Lubrication(4HK1) Oil pressure
sensor removal".
the DTC.
Note：

DTC P06A9 16. If the harness connector is normal, replace the ECM.
ECM removal".
ECM installation".
pressure sensor.
ECM.
circuit and normal GND of the oil pressure sensor
tool.
harness connector.
voltage： 4.5 V
value, inspect to see if there is an open circuit or high 2. Turn OFF the ignition switch for 1 minute or more.
the ECM and the oil pressure sensor.
the DTC.
circuit.
Note：
power supply circuit and signal circuit of the oil ・ Conditions for setting the DTCs such as
pressure sensor harness connector. engine run time or coolant temperature, etc.,
8. Observe the oil pressure sensor display on the
with the oil pressure sensor harness connector.
11. If the harness connector is normal, replace the oil
pressure sensor.
sensor removal".
oil pressure sensor.
Note：
resistance.
connection.

ECM removal".
DTC P06A9
ECM installation".
2. Disconnect the harness connector from the oil ECM.
pressure sensor.
4. Observe the oil pressure sensor display on the 3. DTC P0523 confirm resolution
voltage： 0.1 V
and the oil pressure sensor. 4. Perform a test-run under the conditions for running
the DTC.
Note：
7. Inspect to see if there is an open circuit or high information.
the oil pressure sensor.
Note：
・ The oil pressure sensor shares the GND circuit
with other sensors.
9. Inspect the oil pressure sensor harness connector for
a poor connection.
pressure sensor.
sensor removal".
connection.

temperature sensor with a trouble diagnosis scan
tool.
voltage： 4.5 V
1 removal".
1 installation".
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P0546 priority DTC 15. Observe the EGR gas temperature sensor 5 V
adjustment display on the trouble diagnosis scan
DTC P06A8
tool.
voltage： 0.1 V
circuit.
8. Observe the EGR gas temperature sensor 5 V
adjustment display on the trouble diagnosis scan Refer to "1.Engine 1J.Electrical(4HK1)
tool. ECM removal".
ECM installation".
11. Inspect for poor connections at the EGR gas 3. DTC P0546 confirm resolution
the DTC.
1 removal". Note：
information.
GND.

System Voltage High
1. Check if the battery charger has been recently
connected to the battery.
2. Start the engine, and idle it.
3. Check the ignition voltage display with the trouble
voltage： 32.0 V
value, inspect the charging system.
Generator inspection".
5. If a problem is found, repair the charging system.
Generator removal".
Generator installation".
6. If the charging system is normal, replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
diagnosis scan tool, and confirm that the value does
not exceed the specified value.
voltage： 32.0 V

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Confirm that the connecting sections of all tools are
securely connected.
2. Confirm that the programming device is operating
normally.
3. Observe that the correct injector ID code is input into
the ECM with a trouble diagnosis scan tool.
Note：
・ If the injector ID code is correctly input, clear
the DTC with a trouble diagnosis scan tool.
6. Use the trouble diagnosis scan tool to check if a DTC
has been detected.
7. If a DTC has been detected, replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. DTC P060A diagnostics
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
2. DTC P060A confirm resolution
the DTC.
Note：
information.

1. DTC P060C diagnostics
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Connect a trouble diagnosis scan tool. 4. Perform a test-run under the conditions for running
the DTC.
Note：
3. Turn ON the ignition switch. The engine must not be
started. ・ Conditions for setting the DTCs such as
4. Observe the DTC information for DTC P0615 with a vary depending on the DTCs.
5. If a DTC is not set, start the engine. the applicable code listed in 15E DTC
6. Observe the DTC information for DTC P0615 with a information.
trouble diagnosis scan tool. 5. Observe the DTC information with the trouble
7. If a DTC is not set, an intermittent condition is
suspected.
8. If a DTC is set, inspect for a short to the battery
power supply circuit or ignition power supply circuit
in the control circuit of the ECM and starter cut
relay.
9. If a problem is found, repair the control circuit of the
ECM and starter cut relay.
10. If a DTC is set in [4.], replace with another known
good starter cut relay.
started.
12. Observe the DTC information for DTC P0615 with a
13. If a DTC is not set, replace the starter cut relay.
14. If a DTC is set, inspect for a short to GND in the
control circuit of the ECM and starter cut relay.
16. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0638 priority DTC ・ There should be no short together between
DTC P0122 motor circuits.
・ There should be no short to the intake throttle
DTC P0123
position sensor circuit.
14. If a problem is found, repair the motor circuit.
1. Remove the air intake hose from the intake throttle
15. If the motor circuit is normal, replace the intake
valve.
throttle valve.
2. Inspect the intake throttle valve.
Note： throttle valve installation".
・ The flow in the intake throttle valve should not 16. Restore the machine.
be restricted.
・ There should not be excessive deposits in the
throttle bore of the intake throttle valve. 18. Turn OFF the ignition switch for 1 minute or more.
・ There should be no bending in the butterfly Note：
valve of the intake throttle valve.
・ The ignition switch must be once turned ON
・ The intake throttle valve should not be stuck. and then turned OFF before clearing the DTC.
3. If a problem is found, replace the intake throttle 19. Clear the DTC using the trouble diagnosis scan tool.
valve.
throttle valve removal". 21. Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake 22. Use the trouble diagnosis scan tool to check if a DTC
throttle valve installation". has been detected.
4. Turn OFF the ignition switch. 23. If a DTC has been detected, replace the ECM.
5. Disconnect the harness connector from the intake Refer to "1.Engine 1J.Electrical(4HK1)
throttle valve. ECM removal".
6. Inspect the intake throttle valve harness connector Refer to "1.Engine 1J.Electrical(4HK1)
for a poor connection. ECM installation".
7. If a problem is found, repair the harness connector. 24. Set the Injector ID Code and engine No. on the
ECM.
9. Inspect the ECM harness connector for a poor tool.
connection.
11. Inspect the intake throttle valve circuit for high
resistance. 2. Turn OFF the ignition switch for 1 minute or more.
12. If a problem is found, repair the circuit. Note：

13. Inspect the motor circuit between the ECM and the
and then turned OFF before clearing the DTC.
intake throttle valve.
Note：
・ There should be no short to GND. 4. Turn OFF the ignition switch for 1 minute or more.
・ There should be no short to the battery or no 5. Start the engine.
6. Perform a test-run while the intake throttle motor
drive duty is 20% or more.

2. Replace the main relay with a known good relay.
is detected.
5. If a DTC has not been detected, replace the main
relay.
6. Inspect the body grounding terminal for a poor
connection.
7. If a problem is found, repair the terminal.
8. Inspect the slow blow fuse.
9. If a problem is found, replace the slow blow fuse.
Note：
・ When the fuse is blown again, repair the cause
of slow-blow fuse blowout.
connection.
ECM removal".
ECM installation".
ECM.
tool.

2. Remove the main relay.
4. Use the trouble diagnosis scan tool to see if DTC
P0685 is detected.
5. If the DTC P0685 is not detected, repair the short
circuit to the battery power supply of the power
supply circuit between the ECM and main relay.
9. Use the trouble diagnosis scan tool to check if DTC
P0687 has been detected.
10. If the DTC P0687 is not detected, replace the main
relay.

1. DTC P06A6 diagnostics 2. DTC P06A6 confirm resolution
1. Turn OFF the ignition switch. 1. Clear the DTC with the trouble diagnosis scan tool.
2. Disconnect the harness connector from the CKP 2. Turn OFF the ignition switch for 1 minute or more.
sensor
4. Measure the voltage between the CKP sensor 5 V the DTC.
power supply circuit of the CKP sensor harness
Note：
voltage： 5.5 V engine run time or coolant temperature, etc.,
5. If the reading is more than or equal to the specified vary depending on the DTCs.
value, inspect the CKP sensor 5 V power supply ・ For the conditions for setting the DTC, refer to
circuit between the ECM and the CKP sensor for a the applicable code listed in 15E DTC
short to the battery or a short to the ignition power information.
supply.
6. If a problem is found, repair the CKP sensor 5 V diagnosis scan tool. A DTC should not be set.
power supply circuit between the ECM and the CKP
sensor.
value, measure the voltage between the 5 V power
supply circuit of the CKP sensor harness connector
and the GND.
voltage： 4.5 V
value, replace the CKP sensor.
sensor removal".
value, inspect the CKP sensor 5 V power supply
circuit between the ECM and the CKP sensor for a
short to GND.
10. If a problem is found, repair the CKP sensor 5 V
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P06A7 diagnostics Refer to "1.Engine 1C.Fuel System(4HK1) Common
2. Disconnect the harness connector from the CMP
sensor.
value, inspect the CMP sensor 5 V power supply
4. Measure the voltage between the CMP sensor 5 V circuit between the ECM and the CMP sensor for a
power supply circuit of the CMP sensor harness short to GND.
17. If a problem is found, repair the CMP sensor 5 V
voltage： 5.5 V power supply circuit.
5. If the reading is more than or equal to the specified 18. Inspect the FRP sensor 5 V power supply circuit
value, inspect the CMP sensor 5 V power supply between the ECM and the FRP sensor for a short to
circuit between the ECM and the CMP sensor for a GND.
short to the battery or a short to the ignition power
19. If a problem is found, repair the FRP sensor 5 V
supply.
7. Inspect the FRP sensor 5 V power supply circuit
ECM removal".
between the ECM and the FRP sensor for a short to
the battery or a short to the ignition power supply. Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
power supply circuit. 21. Set the Injector ID Code and engine No. on the
ECM.
value, measure the voltage between the CMP sensor 22. Perform SCR purging with a trouble diagnosis scan
5 V power supply circuit of the CMP sensor harness tool.
2. DTC P06A7 confirm resolution
voltage： 4.5 V
value, replace the CMP sensor.
sensor removal". 4. Perform a test-run under the conditions for running
the DTC.
sensor installation". Note：
11. If the reading is less than or equal to the specified ・ Conditions for setting the DTCs such as
value, turn OFF the ignition switch. engine run time or coolant temperature, etc.,
pressure sensor.
13. Turn ON the ignition switch. information.
14. Measure the voltage between the CMP sensor 5 V 5. Observe the DTC information with the trouble
power supply circuit of the CMP sensor harness diagnosis scan tool. A DTC should not be set.
voltage： 4.5 V
value, replace the FRP sensor.

1. DTC P06A8 diagnostics 15. If the reading is more than or equal to the specified
value, replace the intake throttle valve.
pressure sensor.
4. Measure the voltage between the boost pressure
sensor 5 V power supply circuit of the boost pressure
value, inspect the boost pressure sensor 5 V power
sensor harness connector and the GND.
supply circuit between the ECM and the boost
voltage： 5.5 V pressure sensor for a short to GND.
5. If the reading is more than or equal to the specified 17. If a problem is found, repair the boost pressure
value, inspect the boost pressure sensor 5 V power sensor 5 V power supply circuit.
18. Inspect the intake throttle position sensor 5 V power
pressure sensor for a short to the battery or a short to
supply circuit between the ECM and intake throttle
position sensor for a short to GND.
6. If a problem is found, repair the boost pressure
19. If a problem is found, repair the intake throttle
sensor 5 V power supply circuit.
position sensor 5 V power supply circuit.
position sensor for a short to the battery or a short to Refer to "1.Engine 1J.Electrical(4HK1)
the ignition power supply. ECM removal".
8. If a problem is found, repair the intake throttle Refer to "1.Engine 1J.Electrical(4HK1)
position sensor 5 V power supply circuit. ECM installation".
9. If the reading is less than or equal to the specified 21. Set the Injector ID Code and engine No. on the
value, measure the voltage between the boost ECM.
pressure sensor 5 V power supply circuit of the boost
pressure sensor harness connector and the GND.
tool.
voltage： 4.5 V
value, replace the boost pressure sensor.
sensor/boost temperature sensor removal". 3. Start the engine.
Refer to "1.Engine 1F.Induction(4HK1) Pressure 4. Perform a test-run under the conditions for running
sensor/boost temperature sensor installation". the DTC.
11. If the reading is less than or equal to the specified Note：
value, turn OFF the ignition switch. ・ Conditions for setting the DTCs such as
12. Disconnect the harness connector from the intake engine run time or coolant temperature, etc.,
throttle position sensor. vary depending on the DTCs.
14. Measure the voltage between the boost pressure information.
voltage： 4.5 V

value, replace the oil pressure sensor.
2. Remove the harness connector from the EGR valve
sensor removal".
position sensor.
4. Measure the voltage between the EGR valve position
sensor 5 V power supply terminal of the EGR valve
value, inspect the EGR valve position sensor 5 V
position sensor harness connector and the GND.
power supply circuit between the ECM and the EGR
voltage： 5.5 V valve position sensor for a short to GND.
5. If the reading is more than or equal to the specified 17. If a problem is found, repair the EGR valve position
value, inspect the EGR valve position sensor 5 V sensor 5 V power supply circuit.
18. Inspect the oil pressure sensor 5 V power supply
valve position sensor for a short to the battery or a
circuit between the ECM and oil pressure sensor for
a short to GND.
6. If a problem is found, repair the EGR valve position
19. If a problem is found, repair the oil pressure sensor 5
V power supply circuit.
a short to the battery or a short to the ignition power Refer to "1.Engine 1J.Electrical(4HK1)
supply. ECM removal".
8. If a problem is found, repair the oil pressure sensor 5 Refer to "1.Engine 1J.Electrical(4HK1)
V power supply circuit. ECM installation".
value, measure the voltage between the EGR valve ECM.
position sensor 5 V power supply terminal of the
EGR valve position sensor harness connector and the
tool.
GND.
voltage： 4.5 V
value, replace the EGR valve. 2. Turn OFF the ignition switch for 1 minute or more.
Refer to "1.Engine 1H.Aux. Emission Control 3. Start the engine.
Refer to "1.Engine 1H.Aux. Emission Control the DTC.
Note：
12. Remove the harness connector from the oil pressure vary depending on the DTCs.
sensor. ・ For the conditions for setting the DTC, refer to
information.
14. Measure the voltage between the oil pressure sensor
5 V power supply terminal of the oil pressure sensor
harness connector and the GND.
voltage： 4.5 V

1. DTC P06AF diagnostics
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
2. DTC P06AF confirm resolution
the DTC.
Note：
information.

1. DTC P06D5 diagnostics
2. Measure the voltage of the ECM SP-5V5 terminal.
3. If the reading is outside the specified range, replace
the ECM.
ECM removal".
ECM installation".
ECM.
tool.
2. DTC P06D5 confirm resolution
the DTC.
Note：
information.

2. Disconnect the harness connector from charge air the applicable code listed in 15E DTC
cooler temperature sensor 1. information.
4. Observe the charge air cooler intake air temperature
sensor 5 V display on the trouble diagnosis scan tool.
voltage： 4.5 V
value, replace charge air cooler temperature sensor 1.
Refer to "1.Engine 1F.Induction(4HK1) Charge air
cooler temperature sensor 1 removal".
cooler temperature sensor 1 installation".
charge air cooler temperature sensor 1 for a short to
GND.
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

value, inspect the charge air cooler temperature
DTC P06A8
sensor 1 GND circuit for an open circuit or high
2. DTC P1077 diagnostics resistance.
1. Turn OFF the ignition switch. Note：
2. Disconnect the harness connector from charge air ・ Charge air cooler temperature sensor 1 shares
cooler temperature sensor 1. the GND circuit with other sensors.
3. Turn ON the ignition switch. ・ DTCs on sensors that share this circuit may be
set.
4. Measure the voltage between the charge air cooler
GND. 18. Inspect the charge air cooler temperature sensor 1
signal circuit for an open circuit or high resistance.
voltage： 5.5 V
and charge air cooler temperature sensor 1 for a short connector.
to the battery or a short to the ignition power supply.
7. Connect a fused jumper wire between the charge air
cooler temperature sensor 1 signal circuit and the
ECM removal".
GND circuit.
ECM installation".
voltage： 0.1 V
ECM.
tool.
and charge air cooler temperature sensor 1 for a short
to the 5 V power supply circuit. 3. DTC P1077 confirm resolution
11. Inspect for poor connections at the charge air cooler 2. Turn OFF the ignition switch for 1 minute or more.
13. If the harness connector is normal, replace charge air the DTC.
cooler temperature sensor 1.
Note：
Refer to "1.Engine 1F.Induction(4HK1) Charge air ・ Conditions for setting the DTCs such as
cooler temperature sensor 1 removal". engine run time or coolant temperature, etc.,
Refer to "1.Engine 1F.Induction(4HK1) Charge air vary depending on the DTCs.
cooler temperature sensor 1 installation". ・ For the conditions for setting the DTC, refer to
information.
cooler temperature sensor 1 signal circuit and a
known good GND. 5. Observe the DTC information with the trouble
voltage： 0.1 V

DTC P0092 12. Inspect to see if there is clogging with the fuel
DTC P0192 system between the fuel tank and the fuel supply
pump.
DTC P0193
13. If a problem is found, repair the clogging of the fuel
DTC P0201 system.
DTC P0202 14. Inspect the fuel hose between the fuel tank and the
DTC P0203 fuel supply pump for a cut and crack.
DTC P0204 15. If a problem is found, replace the fuel hose.
DTC P2146 Note：
DTC P2149 ・ The fuel hose between the fuel tank and the
2. DTC P1093 diagnostics state when the engine is running.
1. Turn OFF the ignition switch. ・ When the fuel hose is not connected securely,
the air can enter.
pressure is released from the common rail. ・ When the engine speed or the engine load
increases while the air has intruded in the fuel
specified time： 2 min system, fluctuation in the common rail
3. Turn ON the ignition switch. pressure is caused, and DTC P1093 may be
detected.
4. Use the trouble diagnosis scan tool to check if the
fuel rail pressure sensor display is within the 16. Check that an appropriate clamp is used between the
specified range. fuel tank and the fuel supply pump.
voltage： 0.9 to 1.0 V 17. If a problem is found, replace the clamp.
5. If the fuel rail pressure sensor display is outside the 18. Operate the priming pump until the handle becomes
specified range, inspect the fuel pressure sensor heavy.
harness connector for a poor connection. Note：
6. If a problem is found, repair the harness connector. ・ When a leak exists in the fuel system between
the priming pump and the fuel supply pump,
connection.
not become heavy.
20. Inspect the high-pressure side of the fuel system and
10. If a problem is found, repair the circuit. check for fuel leak between the fuel supply pump
and common rail.
11. If the harness connector and each circuit are normal,
replace the fuel pressure sensor. Note：
Refer to "1.Engine 1C.Fuel System(4HK1) Common ・ The fuel may leak to the bottom section of the
rail assembly removal". cylinder head cover from the high pressure
hose inlet.
・ The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder head
cover.
・ Inspect for fuel leaks into the engine oil.
22. Turn OFF the ignition switch. 35. Replace the fuel filter.
23. Remove the fuel hose on the fuel supply pump side Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
from the fuel filter. filter removal".
Note： Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
・ Use a pan to catch the fuel from the removed filter installation".
connection hose.
securely.
・ If the pressure gauge is likely to indicate a
・ Repeat this until the engine starts. ・ Air mixture is checked with the negative
pressure amount while the fuel flow is being
26. Leave the engine idling for the specified period of
blocked.
time or longer.
39. If the specified negative pressure cannot be
specified time： 1 min
generated, inspect to see if there is a cut or crack
27. While allowing the engine to keep the specified with the fuel hose.
duration and the maximum engine speed, observe the
pressure gauge.
28. Check if the pressure gauge shows a negative
appropriate one.
pressure value at or above the specified value during
inspection. 43. Turn OFF the ignition switch.
values: (-17.0) kPa {5 inHg / (-2) psi} 44. Inspect the suction control valve harness connector
Note：
・ Fuel clogging is checked with the negative 45. If a problem is found, repair the harness connector.
pressure amount in the fuel system. 46. Inspect the ECM harness connector for a poor
29. If the negative pressure is more than or equal to the connection.
specified value, inspect to see if there is damage or 47. If a problem is found, repair the harness connector.
twisting with the fuel system between the fuel supply
pump and the fuel tank. 48. Inspect each circuit for high resistance.
30. If a problem is found, repair the fuel system. 49. If a problem is found, repair the circuit.
31. Inspect the fuel tank bent hose. 50. If the FRP regulator harness connector and the ECM
32. If a problem is found, repair the bent hose. resistance in each circuit, replace the fuel supply
33. Check to see if there is any foreign matter in the fuel pump and the fuel filter.
tank or any foreign matter which can cause fuel Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
clogging. pump removal".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply Note：
pump installation". ・ Conditions for setting the DTCs such as
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel engine run time or coolant temperature, etc.,
filter removal". vary depending on the DTCs.
information.
Note：
・ When replacing the fuel supply pump, the fuel diagnosis scan tool. A DTC should not be set.
51. If the negative pressure is normal, turn OFF the
ignition switch.
52. Restore the fuel system.
54. Perform the injector stop test with the trouble
55. Check to see if any injector does not change the
engine speed when OFF is instructed.
when OFF is instructed, replace the relevant injector.
Injector removal".
ID code on the ECM.
58. If the engine speed changes when OFF is instructed
to all injectors, replace the pressure limiter valve.
Note：
・ The pressure limiter valve may be fixed open,
or the operation pressure may decrease.
・ Do not replace the pressure limiter valve
the DTC.

information.
temperature sensor.
4. Observe the boost temperature sensor display on the
voltage： 4.5 V
value, replace the boost temperature sensor.
6. Inspect the signal circuit between the ECM and boost
temperature sensor signal circuit for a short to GND.
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

1. DTC P1098 priority DTC the boost temperature sensor for an open circuit or
high resistance.
DTC P06A8
Note：
・ The boost temperature sensor shares the
1. Turn OFF the ignition switch. GND circuit with other sensors.
2. Disconnect the harness connector from the boost ・ DTCs on sensors that share this circuit may be
temperature sensor. set.
3. Turn ON the ignition switch. 17. If a problem is found, repair the GND circuit.
4. Measure the voltage between the boost temperature 18. Inspect the signal circuit between the ECM and the
sensor signal circuit and a known good GND. boost temperature sensor for an open circuit or high
resistance.
voltage： 5.5 V
and the boost temperature sensor for a short to the connector.
7. Connect a fused jumper wire between the boost
temperature sensor signal circuit and GND circuit.
ECM removal".
ECM installation".
voltage： 0.1 V
and the boost temperature sensor for a short to the 5
tool.
11. Inspect for poor connections at the boost temperature
sensor harness connector. 2. Turn OFF the ignition switch for 1 minute or more.
13. If the harness connector is normal, replace the boost 4. Perform a test-run under the conditions for running
temperature sensor. the DTC.
Refer to "1.Engine 1F.Induction(4HK1) Pressure Note：
sensor/boost temperature sensor removal". ・ Conditions for setting the DTCs such as
Refer to "1.Engine 1F.Induction(4HK1) Pressure engine run time or coolant temperature, etc.,
sensor/boost temperature sensor installation". vary depending on the DTCs.
temperature sensor signal circuit and a known good
information.
GND.
voltage： 0.1 V

1. DTC P1236 priority DTC Refer to "1.Engine 1F.Induction(4HK1) Pressure
sensor/boost temperature sensor inspection".
DTC P1076
20. If a problem is found, replace the boost temperature
DTC P1077
sensor.
DTC P1097
DTC P1098 sensor/boost temperature sensor removal".
2. DTC P1236 diagnostics Refer to "1.Engine 1F.Induction(4HK1) Pressure
2. Inspect the intercooler.
Refer to "1.Engine 1F.Induction(4HK1)
Intercooler inspection". 2. Turn OFF the ignition switch for 1 minute or more.
3. If a problem is found, repair or replace the 3. Start the engine.
intercooler.
4. Disconnect the harness connector from charge air the DTC.
Note：
5. Inspect for poor connections at the charge air cooler ・ Conditions for setting the DTCs such as
temperature sensor 1 harness connector. engine run time or coolant temperature, etc.,
6. If a problem is found, repair the harness connector. vary depending on the DTCs.
7. Disconnect the harness connector from the boost ・ For the conditions for setting the DTC, refer to
temperature sensor. the applicable code listed in 15E DTC
information.
connector.
13. Inspect the circuit between the ECM and the charge
air cooler temperature sensor 1 for high resistance.
15. Inspect the circuit between the ECM and the boost
temperature sensor for high resistance.
17. Inspect the charge air cooler temperature sensor 1.
18. If a problem is found, replace the charge air cooler
19. Inspect the boost temperature sensor.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

EGR Position Fault
1. DTC P1404 priority DTC ・ There should be no short to the EGR position
DTC P0404 sensor circuit.
DTC P0409 14. If a problem is found, repair the motor circuit.
2. DTC P1404 diagnostics 15. If the circuit is normal, replace the EGR valve.
1. Remove the EGR valve assembly from the engine. Refer to "1.Engine 1H.Aux. Emission Control
Devices(4HK1) EGR valve removal". Refer to "1.Engine 1H.Aux. Emission Control
2. Inspect the EGR valve.
Note：
・ There should be nothing to restrict the flow
inside the EGR valve. 2. Turn OFF the ignition switch for 1 minute or more.
・ There should not be excessive deposits in the 3. Start the engine.
EGR valve.
・ There should be no bend in the EGR valve or
the DTC.
valve shaft.
Note：
3. If a problem is found, repair or replace the EGR
valve. ・ Conditions for setting the DTCs such as
Refer to "1.Engine 1H.Aux. Emission Control vary depending on the DTCs.
Refer to "1.Engine 1H.Aux. Emission Control the applicable code listed in 15E DTC
Devices(4HK1) EGR valve installation". information.
4. Turn OFF the ignition switch. 5. Observe the DTC information with the trouble
valve.
connection.
connection.
11. Inspect the EGR valve circuit between the ECM and
the EGR valve for an open circuit and high
resistance.
12. If a problem is found, repair the EGR valve circuit.
13. Inspect the motor circuit between the ECM and EGR
valve.
Note：
・ There should be no short to any other circuit.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

AD-IC Failure Error
1. DTC P160B diagnostics
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
2. DTC P160B confirm resolution
the DTC.
Note：
information.

ECM.
1. Connect a trouble diagnosis scan tool.
tool.
5. If DTC P1621 is not set, terminate the diagnosis.
6. If DTC P1621 is set, turn OFF the ignition switch.
the DTC.
7. Store the DRM data.
Note：
8. Upload the Injector ID Code to the trouble diagnosis ・ Conditions for setting the DTCs such as
scan tool from the ECM. engine run time or coolant temperature, etc.,
9. Perform the EEPROM error clearing with the trouble vary depending on the DTCs.
diagnosis scan tool. ・ For the conditions for setting the DTC, refer to
Caution：
information.
・ Store the DRM data before clearing the
EEPROM error. 4. Observe the DTC information with the trouble
・ Upload the data in the ECM to a trouble
diagnosis scan tool before clearing the
EEPROM error.
・ The trouble diagnosis scan tool used for the
procedure must be same from start to finish. If
the trouble diagnosis scan tool is changed
midway, information cannot be written
correctly.
10. Download the Injector ID Code to the ECM from the
11. Observe that the Injector ID Code and engine No. are
correctly displayed with the trouble diagnosis scan
tool.
Note：
・ If each item is not displayed, or if it is incorrect,
input the correct value.
15. If DTC P1621 is set, replace the ECM.
ECM removal".
ECM installation".

ECM.
tool.
the DTC.
Note：
Caution：
information.
EEPROM error. 4. Observe the DTC information with a trouble
EEPROM error.
correctly.
tool.
Note：
ECM removal".
ECM installation".

1. DTC P204F diagnostics
1. Observe the DCU DTC information with a trouble
2. Diagnose the applicable DTC if a DTC is set.
2. DTC P204F confirm resolution
the DTC.
Note：
information.

the DTC.
Note：
information.

SCR System Error
1. DTC P20C9 diagnostics
1. Observe the DTU DTC information with a trouble
2. DTC P20C9 confirm resolution
the DTC.
Note：
information.

ECM removal".
DTC P06A6
ECM installation".
accelerator position sensor.
4. Measure the voltage between the 5 V power supply 3. DTC P2122 confirm resolution
circuit and GND of the accelerator position sensor.
voltage： 4.5 V
3. Start the engine and fully depress and release the
accelerator pedal while observing the accelerator
pedal sensor 1 display on the trouble diagnosis scan
the ECM and the accelerator position sensor.
tool.
4. Confirm that the trouble diagnosis scan tool does not
circuit.
show a value at or below the specified value while
7. Connect the test cable with fuse between the 5 V depressing and then releasing the pedal.
power supply circuit and sensor 1 signal circuit of
voltage： 0.2 V
the accelerator position sensor.
8. Observe the accelerator pedal sensor 1 display on the
voltage： 4.5 V
with the accelerator position sensor harness
connector.
value, inspect the sensor 1 signal circuit between the
ECM and accelerator position sensor.
Note：
resistance.
13. If a problem is found, repair the sensor 1 signal
circuit.
connection.

1. DTC P2123 priority DTC 16. Set the Injector ID Code and engine No. on the
ECM.
DTC P06A6
tool.
2. Disconnect the harness connector from the
voltage： 0.1 V tool.
5. If the reading is more than or equal to the specified 4. Confirm that the trouble diagnosis scan tool does not
value, inspect the sensor 1 signal circuit between the show a value at or above the specified value while
ECM and the accelerator position sensor. depressing and then releasing the pedal.
Note： voltage： 4.9 V
・ There should be no short to the battery or no 5. Observe the DTC information with the trouble
short to the ignition power supply. diagnosis scan tool. A DTC should not be set.
supply.
circuit.
7. Connect the test light between the accelerator
position sensor GND circuit and battery power
supply.
8. If the test light comes on, inspect the accelerator
position sensor harness connector for a poor
connection.
11. If the test light does not come on, inspect to see if
there is an open circuit or high resistance with the
GND circuit between the ECM and the accelerator
position sensor.
connection.
ECM removal".
ECM installation".

ECM removal".
DTC P06A6
ECM installation".
voltage： 4.5 V
tool.
circuit.
7. Connect the test cable with fuse between the 5 V depressing and then releasing the pedal.
voltage： 0.2 V
voltage： 4.5 V
connector.
Note：
resistance.
circuit.
connection.

ECM.
DTC P06A6
tool.
voltage： 0.1 V tool.
5. If the reading is more than or equal to the specified 4. Confirm that the trouble diagnosis scan tool does not
value, inspect the sensor 2 signal circuit between the show a value at or above the specified value while
ECM and the accelerator position sensor. depressing and then releasing the pedal.
Note： voltage： 4.9 V
・ There should be no short to the battery or no 5. Observe the DTC information with the trouble
short to the ignition power supply. diagnosis scan tool. A DTC should not be set.
supply.
circuit.
supply.
connection.
position sensor.
connection.
ECM removal".
ECM installation".

tool.
DTC P06A6
DTC P2122
DTC P2123
DTC P2127
DTC P2128
4. While checking the DTC information with the
trouble diagnosis scan tool, fully depress and then
1. Turn OFF the ignition switch. release the accelerator pedal.
2. Disconnect the harness connector from the 5. Observe the DTC information with the trouble
accelerator position sensor. diagnosis scan tool. A DTC should not be set.
3. Inspect the accelerator position sensor harness
connector for a poor connection.
connection.
8. Inspect to see if there is high resistance in the circuit
between the ECM and accelerator position sensor.
10. Inspect to see if there is a short between circuits in
the signal circuit between the ECM and the
12. If the circuit is normal, replace the accelerator
position sensor.
17. While checking for a DTC with the trouble diagnosis
scan tool, fully depress and then release the
accelerator pedal.
ECM removal".
ECM installation".
ECM.

connection.
2. Disconnect the harness connector from the injector.
17. Inspect the charge voltage circuit between the ECM
and the injector harness connector for an open circuit
4. Measure the voltage between the solenoid control or high resistance.
circuit and GND.
18. If a problem is found, repair the charge voltage
Note： circuit.
・ Solenoid control circuit and GND of the No.1 19. Check if insulation resistance of the No.1 cylinder
cylinder injector and No.4 cylinder injector is at or above the
・ Solenoid control circuit and GND of the No.4 specified value.
cylinder injector
resistance： 1.0 MΩ
voltage： 12.0 V
5. If the reading is less than or equal to the specified value, replace the relevant injector.
and the injector harness connector for a short to
Injector removal".
GND.
21. Set the injector ID code on the ECM.
and the injector harness connector.
Note：
value, repair or replace the injector harness.
・ No short circuit to the battery or ignition power
is present. 2. DTC P2146 confirm resolution
・ No short circuit to GND is present. 1. Clear the DTC using the trouble diagnosis scan tool.
8. If a problem is found, repair the charge voltage 2. Turn OFF the ignition switch for 1 minute or more.
circuit.
9. If the charge voltage circuit between the ECM and
the injector harness connector is normal, replace the
the DTC.
ECM.
Note：
ECM removal". ・ Conditions for setting the DTCs such as
Refer to "1.Engine 1J.Electrical(4HK1) vary depending on the DTCs.
ECM installation".
10. Set the Injector ID Code and engine No. on the the applicable code listed in 15E DTC
ECM. information.
11. Perform SCR purging with a trouble diagnosis scan 5. Observe the DTC information with the trouble
tool. diagnosis scan tool. A DTC should not be set.
12. Inspect for poor connections at the injector harness
connector.
13. If a problem is found, repair the injector harness
connector.

connection.
2. Disconnect the harness connector from the injector.
and the injector harness connector for an open circuit
4. Measure the voltage between the solenoid control or high resistance.
circuit and GND.
Note： circuit.
・ Solenoid control circuit and GND of the No.2 19. Check if the insulation resistance of the No.2
cylinder injector cylinder injector and No.3 cylinder injector is more
・ Solenoid control circuit and GND of the No.3 than or equal to the specified value.
cylinder injector
voltage： 12.0 V
5. If the reading is less than or equal to the specified value, replace the relevant injector.
and the injector harness connector for a short to
Injector removal".
GND.
and the injector harness connector.
Note：
value, repair or replace the injector harness.
is present. 2. DTC P2149 confirm resolution
・ No short circuit to GND is present. 1. Clear the DTC using the trouble diagnosis scan tool.
8. If a problem is found, repair the charge voltage 2. Turn OFF the ignition switch for 1 minute or more.
circuit.
the injector harness connector is normal, replace the
the DTC.
ECM.
Note：
ECM removal". ・ Conditions for setting the DTCs such as
Refer to "1.Engine 1J.Electrical(4HK1) vary depending on the DTCs.
ECM installation".
10. Set the Injector ID Code and engine No. on the the applicable code listed in 15E DTC
ECM. information.
11. Perform SCR purging with a trouble diagnosis scan 5. Observe the DTC information with the trouble
tool. diagnosis scan tool. A DTC should not be set.
connector.
connector.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. DTC P2457 priority DTC 17. If a problem is found, repair the applicable circuit.
DTC P040B 18. Inspect the circuit between the ECM and EGR gas
temperature sensor 2 for high resistance.
DTC P040C
DTC P040D
20. Replace the EGR cooler.
DTC P041C
DTC P041D
1. Turn OFF the ignition switch. Devices(4HK1) EGR valve installation".
2. Inspect the EGR cooler. 3. DTC P2457 confirm resolution
Refer to "1.Engine 1H.Aux. Emission Control 1. Clear the DTC with a trouble diagnosis scan tool.
Devices(4HK1) EGR valve inspection".
3. Inspect the engine coolant system.
・Engine coolant level
・Engine coolant leakage
the DTC.
4. If a problem is found, repair the applicable area.
Note：
5. Inspect the EGR system. ・ Conditions for setting the DTCs such as
Note： engine run time or coolant temperature, etc.,
・ Exhaust gas leakage
・ Engine coolant leakage into the EGR gas
passage
information.
・ Breakage or damage of the EGR cooler
・ Misdetection or delayed response of EGR gas
temperature sensor 1 or 2
7. Disconnect the harness connector from EGR gas
8. Inspect for poor connections at the EGR gas
connector.
16. Inspect the circuit between the ECM and EGR gas

DTC P0427
DTC P0428
DTC P042C
DTC P042D
1. Inspect the exhaust system.
Note：
・ The exhaust pipe gasket should not be lost or
damaged.
・ There should be no exhaust gas leakage from
the exhaust system.
・ The exhaust system should not be modified.
・ There should be no misdetection or delayed
response of the EGT sensor.
2. If a problem is found, repair or replace the exhaust
system.

1. DTC P2BAA diagnostics
2. DTC P2BAA confirm resolution
the DTC.
Note：
information.

1. DTC P3093 priority DTC Refer to "1.Engine 1C.Fuel System(4HK1) Common
DTC P0087
DTC P0091
DTC P0092
Note：
DTC P0193 separately. If a problem is found, replace the
common rail (fuel rail) assembly.
DTC P0201
14. Inspect the fuel system between the fuel tank and the
DTC P0202 fuel supply pump for clogging.
DTC P0203 15. If a problem is found, repair the clogging of the fuel
DTC P0204 system.
DTC P2146 16. Inspect the fuel hoses between the fuel tank and the
fuel supply pump for cuts or cracks.
DTC P2149
Note：
1. Inspect the fuel quality.
・ A slight vacuum is applied to the fuel hoses
Note： between the fuel tank and the fuel supply
・ Check whether the fuel is being used in pump when the engine is running.
accordance with the outside air temperature ・ If the fuel hose is not connected securely, air
when the weather is cold. can get inside.
2. If the fuel quality is inadequate, replace it. ・ If the engine speed or the engine load
increases when air has entered the fuel
system, fluctuation in the common rail (fuel
4. Wait for the specified time to reduce the fuel rail) pressure occurs, and DTC P3093 may be
pressure from the common rail (fuel rail). set.
specified time： 2 min 18. Check that an appropriate clamp is used between the
fuel tank and the fuel supply pump.
19. If a problem is found, replace the clamp.
fuel rail pressure sensor display is within the 20. Operate the priming pump until the force required
specified range. for pressing increases.
7. If the fuel rail pressure sensor display is outside the ・ When a leakage exists in the fuel system
specified range, inspect for poor connections at the between the priming pump and the fuel supply
FRP sensor harness connector. pump, the pressing weight of the priming pump
does not become heavy.
connector. 22. Inspect the high-pressure side of the fuel system and
check for a fuel leakage between the fuel supply
10. If a problem is found, repair the harness connector. pump and the common rail (fuel rail).
11. Inspect each circuit for high resistance. Note：
12. If a problem is found, repair the circuit. ・ The fuel may leak under the cylinder head
cover from the inlet of the high pressure hose.
replace the FRP sensor. ・ If the fuel leaks under the cylinder head cover,
the engine oil level will increase.
・ Inspect for fuel leakage into the engine oil. 35. Check for foreign material in the fuel tank or for
foreign material that may clog the fuel.
23. If fuel leak is found, repair it.
37. Replace the fuel filter.
25. Remove the fuel hose on the fuel supply pump side
from the fuel filter. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel
filter removal".
Note：
・ Use a pan to catch the fuel from the removed
fuel hose.
・ Clean the pressure gauge and connection 38. If the vacuum is less than or equal to the specified
hose before connecting to the fuel piping. value, pinch the fuel hose at a position as close as
possible to the fuel tank, so that the fuel does not
・ The fuel supply pump may be damaged due to
flow.
the foreign material that has intruded into the
connection hose. Note：
26. Connect a pressure gauge between the fuel filter and ・ The fuel pipe can be disconnected and
the removed fuel hose. clogged with a plug.
Note： 39. Start the engine and increase the engine speed up to
the maximum engine speed.
・ Check whether the fuel system is securely
connected. 40. Check the pressure gauge.
27. Bleed the air with the priming pump, and crank the Specified value: (-27.0) kPa {8 inHg / (-4) psi}
engine within the specified period of time.
Note：
specified time： 5 s ・ When the pressure gauge is likely to indicate a
Note： value exceeding the specified value during
inspection, release the fuel being blocked.
・ Repeat the process until the engine starts.
・ Air mixture is checked with the vacuum
28. Allow the engine to idle for at least the specified amount while the fuel flow is being blocked.
duration.
41. If the specified vacuum cannot be maintained,
specified time： 1 min inspect the fuel hoses for cuts or cracks.
29. While allowing the engine to keep the specified 42. If a problem is found, replace the fuel hose.
pressure gauge. 43. Inspect to see if appropriate clamp is used.
specified time： 1 min 44. If a problem is found, replace with an appropriate

clamp.
30. Check if the vacuum reading displayed is the
specified value or more when inspecting the pressure 45. Turn OFF the ignition switch.
gauge. 46. Inspect for poor connections at the FRP regulator
Specified value: (-17.0) kPa {5 inHg / (-2) psi} harness connector.

・ Fuel clogging is checked with the vacuum 48. Inspect for poor connections at the ECM harness
amount in the fuel system. connector.
31. If the vacuum is more than or equal to the specified 49. If a problem is found, repair the harness connector.
value, inspect the fuel system between the fuel
supply pump and the fuel tank for damage or
twisting. 51. If a problem is found, repair the circuit.
32. If a problem is found, repair the fuel system. 52. If the FRP regulator harness connector and the ECM
33. Inspect the fuel tank vent hose.
34. If a problem is found, repair the vent hose. pump and the fuel filter.
pump removal". the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel engine run time or coolant temperature, etc.,
filter removal". vary depending on the DTCs.
information.
Note：
53. If the vacuum is normal, turn OFF the ignition
switch.
56. Perform the injector stop test with a trouble
57. Check for any injectors that do not change the engine
speed when commanded OFF.
58. If there are any injectors that do no change the
engine speed when commanded OFF, replace the
applicable injectors.
Injector removal".
59. If an injector has been replaced, set the Injector ID
Code on the ECM.
60. If the engine speed changes for all injectors when the
OFF command is given, replace the pressure limiter
valve.
Note：
・ Do not replace the pressure limiter with a
separate unit. If a problem is found, replace
the common rail (fuel rail) assembly.

1. DTC U0001 diagnostics Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
2. Measure the resistance between the terminals of the
ECM.
termination resistor harness connector.
Note：
tool.
・ Measure from behind while the harness
connector is connected. 16. Turn OFF the ignition switch.
・ Verify that the parallel resistance of the 120 Ω 17. Disconnect the harness connector from the DCU and
resistor in the termination resistor and that of ECM.
the 120 Ω resistor in the ECM are both 60 Ω.
18. Inspect the CAN-Low circuit and the CAN-High
resistance： 50 to 70 Ω circuit between each control unit.
3. Disconnect the harness connector from the Note：
termination resistor if the resistance is outside the ・ There should be no short to the battery or no
specified range. short to the ignition power supply.
4. Measure the resistance of the termination resistor. ・ There should be no open circuit or high
resistance.
resistance： 110 to 130 Ω
5. If the resistance is outside the specified range,
replace the termination resistor. 19. If the CAN circuit is normal, turn OFF the ignition
switch.
6. Connect the harness connector to the termination
resistor. 20. Connect the harness connector to the DCU.
7. Disconnect the harness connector from the DCU. 21. Measure the voltage between the CAN-High
terminal of the termination resistor harness connector
8. Measure the resistance between the terminals of the and the GND.
22. Measure the voltage between the CAN-Low terminal
Note： of the termination resistor harness connector and the
・ Measure from behind while the harness GND.
connector is connected.
23. If the voltage is outside the specified range, replace
9. Replace the DCU if the resistance is within the the DCU.
specified range.
10. Connect the harness connector to the DCU.
25. Measure the voltage between the CAN-High
11. Disconnect the harness connector from the ECM. terminal of the termination resistor harness connector
and the GND.
termination resistor harness connector. 26. Measure the voltage between the CAN-Low terminal
of the termination resistor harness connector and the
Note：
GND.
connector is connected. voltage： 1.5 to 3.5 V
resistance： 110 to 130 Ω 27. If the voltage is outside the specified range, replace
the ECM.
13. If the resistance is within the specified range, replace
the ECM. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
ECM removal". Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
ECM.
tool.
30. If the voltage is within the specified range, replace
the termination resistor.
2. DTC U0001 confirm resolution
the DTC.
Note：
information.

ECM installation".
ECM.
Note：
tool.
・ Make a measurement from the back with the
harness connector connected. 15. Turn OFF the ignition switch.
・ Confirm that the parallel resistance of the 120 16. Connect the harness connector to the ECM.
Ω resistor in the termination resistor and that of
the 120 Ω resistor in the ECM are both 60Ω.
resistance： 50.0 to 70.0 Ω
3. Disconnect the harness connector from termination and the GND.
resistor if the resistance value is outside the specified
range.
4. Measure the resistance of the termination resistor. GND.
resistance： 110.0 to 130.0 Ω voltage： 1.5 to 3.5 V
5. If the resistance value is outside the specified range, 20. If the voltage is outside the specified range, replace
replace the termination resistor. the ECM.
6. Connect the harness connector to the termination Refer to "1.Engine 1J.Electrical(4HK1)
resistor . ECM removal".
7. Disconnect the harness connector from the control Refer to "1.Engine 1J.Electrical(4HK1)
unit of the machine. ECM installation".
8. Measure the resistance between the terminals of the 21. Set the Injector ID Code and engine No. on the
termination resistor harness connector. ECM.
Note： 22. Perform SCR purging with a trouble diagnosis scan
・ Make a measurement from the back with the tool.
harness connector connected. 23. Turn OFF the ignition switch.
resistance： 50.0 to 70.0 Ω 24. Connect the harness connector to the control unit of
9. If the resistance value is within the specified range, the machine.
replace the control unit of the machine. 25. Turn ON the ignition switch.
10. Disconnect the harness connector from the ECM. 26. Measure the voltage between the CAN-High
11. Measure the resistance between the terminals of the terminal of the termination resistor harness connector
termination resistor harness connector. and the GND.
Note： 27. Measure the voltage between the CAN-Low terminal

GND.
harness connector connected.
12. Replace the ECM if the resistance value is within the
the control unit of the machine.
range of specified value.
ECM removal".
1. Use the trouble diagnosis scan tool to clear the DTC.
the DTC.
Note：
information.

ECM installation".
1. Inspect the CAN-Low circuit and CAN-High circuit
between the ECM and the control unit of the 15. Set the Injector ID Code and engine No. on the
machine. ECM.
Note： 16. Perform SCR purging with a trouble diagnosis scan
・ There should be no short to the battery or no tool.
short to the ignition power supply. 2. DTC U0101 confirm resolution
resistance.
・ There should be no short to GND. 2. Turn OFF the ignition switch for 1 minute or more.
2. If a problem is found, repair the CAN circuit. 3. Start the engine.
3. If the CAN circuit is normal, connect all harnesses. 4. Perform a test-run under the conditions for running
the DTC.
Note：
6. Perform a test-run under the conditions for running engine run time or coolant temperature, etc.,
the DTC. vary depending on the DTCs.
information.
vary depending on the DTCs. 5. Observe the DTC information with the trouble
・ For the conditions for setting the DTC, refer to diagnosis scan tool. A DTC should not be set.
information.
7. Check the DTC.
8. If a DTC has been detected, replace the control unit
of the machine.
9. Connect all harnesses.
the DTC.
Note：
information.
13. Check the DTC.
ECM removal".

1. DTC U010E diagnostics 5. Observe the DTC information with the trouble
2. Disconnect the harness connector from the DCU.
4. Measure the voltage between the DCU harness
connector CAN High circuit and a known good
GND.
5. If the reading is outside the specified range, inspect
the CAN High circuit between the DCU and the
ECM for an open circuit or high resistance.
6. If a problem is found, repair the CAN High circuit.
connector CAN Low circuit and a known good
GND.
the CAN Low circuit between the DCU and the
9. If a problem is found, repair the CAN Low circuit.
10. Inspect for poor connections at the DCU harness
connector.
12. Replace the DCU.
Devices(4HK1) DCU removal".
Devices(4HK1) DCU installation".
2. DTC U010E confirm resolution
the DTC.
Note：
information.

1. DTC U0110 priority DTC
DTC P0045
DTC U0001
2. DTC U0110 diagnostics
2. Disconnect the harness connector from the turbo
control unit.
4. Measure the voltage between the turbo control unit
harness connector CAN-Low circuit and the GND.
5. Measure the voltage between the turbo control unit
harness connector CAN-High circuit and the GND.
the CAN-High circuit between the turbo control unit
and the ECM for an open circuit or high resistance.
7. If a problem is found, repair the CAN-High circuit.
8. Inspect the CAN-Low circuit between the turbo
control unit and the ECM for an open circuit or high
resistance.
9. If a problem is found, repair the CAN-Low circuit.
10. Inspect for poor connections at the turbo control unit
harness connector.
12. Replace the turbo control unit.
the DTC.
Note：
information.

1. DTC U0411 priority DTC 3. Start the engine.
DTC P0045 4. Perform a test-run under the conditions for running
the DTC.
DTC U0001
Note：
1. Inspect the CAN circuit between the turbo control engine run time or coolant temperature, etc.,
unit and the ECM. vary depending on the DTCs.
・There should be no short to the battery or the ignition ・ For the conditions for setting the DTC, refer to
power supply. the applicable code listed in 15E DTC
・There should be no open circuit or high resistance. information.
2. If a problem is found, repair the CAN circuit. diagnosis scan tool. A DTC should not be set.
3. Inspect for poor connections at the turbo control unit
harness connector.
7. Turn OFF the ignition switch for 30 seconds or
more.
9. Perform a test-run.
10. Observe the DTC information.
11. If a DTC is set, replace the turbo control unit.
14. Turn OFF the ignition switch for 30 seconds or
more.
17. Observe the DTC information.
18. If a DTC is set, replace the ECM.
ECM removal".
ECM installation".
Engine Control (4HK1 (24V)) 1A-1
Engine Control
Engine Control
(4HK1 (24V))
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit Open -
Position Correlation Error...............................................1A-4 Cylinder 2......................................................................1A-31
VNT Error.......................................................................1A-5 Cylinder 3......................................................................1A-32
Too Low..........................................................................1A-7 Cylinder 4......................................................................1A-33
Performance..................................................................1A-10 Temperature Condition.................................................1A-34
Control Circuit Low......................................................1A-12 .......................................................................................1A-35
Control Circuit High.....................................................1A-13 Condition.......................................................................1A-36
Sensor 2 Circuit Low Voltage.......................................1A-14 Circuit Low...................................................................1A-37
Sensor 2 Circuit High Voltage......................................1A-15 Circuit High...................................................................1A-38
Low Input......................................................................1A-16 Circuit............................................................................1A-39
High Input.....................................................................1A-17 Circuit Range/Performance...........................................1A-41
Circuit Low...................................................................1A-18 Circuit............................................................................1A-42
Circuit High...................................................................1A-19 .......................................................................................1A-44
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0401 (Flash Code 93) EGR Flow Insufficient
Sensor Circuit Low.......................................................1A-20 Detected.........................................................................1A-45
Sensor Circuit High.......................................................1A-21 Performance..................................................................1A-46
DTC P0122 (Flash Code 43) Throttle Position Sensor DTC P0409 (Flash Code 44) EGR Sensor Circuit........1A-47
Circuit Low...................................................................1A-22 DTC P041C (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0123 (Flash Code 43) Throttle Position Sensor Sensor Circuit Low.......................................................1A-49
Circuit High...................................................................1A-23 DTC P041D (Flash Code 27) EGR Cooler Outlet 1 Temp
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Sensor Circuit High.......................................................1A-50
Circuit Low...................................................................1A-24 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit Low Sensor 1....................................................1A-52
Circuit High...................................................................1A-25 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High Sensor 1....................................................1A-53
Circuit Low...................................................................1A-27 DTC P042C (Flash Code 49) Catalyst Temperature Sensor
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low Sensor 2....................................................1A-54
Circuit High...................................................................1A-28 DTC P042D (Flash Code 49) Catalyst Temperature Sensor
DTC P0201 (Flash Code 271) Injector Circuit Open - Circuit High Sensor 2....................................................1A-55
Cylinder 1......................................................................1A-30
1A-2 Engine Control (4HK1 (24V))
Circuit Low Input..........................................................1A-57 Temperature Sensor Circuit High.................................1A-86
Circuit High Input.........................................................1A-58 Performance Failure......................................................1A-87
Sensor Circuit Low.......................................................1A-59 Control Circuit Group 1................................................1A-88
Sensor Circuit High.......................................................1A-60 Control Circuit Group 2................................................1A-89
DTC P0560 (Flash Code 155) 12Volt Circuit Error.....1A-62 DTC P1404 (Flash Code 45) EGR Position Fault........1A-90
DTC P0563 (Flash Code 35) System Voltage High.....1A-63 DTC P1606 (Flash Code 51) SW-IC Internal failure....1A-91
DTC P0601 (Flash Code 53) Internal Control Module DTC P160B (Flash Code 36) AD-IC Failure Error......1A-92
Memory Check Sum Error............................................1A-64 DTC P160C (Flash Code 36) AD-IC2 Failure Error....1A-93
DTC P0602 (Flash Code 154) Internal Control Module QR DTC P1621 (Flash Code 54) Control Module Long Term
Code Error.....................................................................1A-65 Memory Performance....................................................1A-94
DTC P0604 (Flash Code 153) Internal Control Module DTC P1622 (Flash Code 54) Control Module EEPROM
RAM Error....................................................................1A-66 Hardware Error..............................................................1A-95
DTC P0606 (Flash Code 51) Internal Control Module CPU DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
Error..............................................................................1A-67 .......................................................................................1A-96
DTC P060A (Flash Code 51) Internal Control Module CPU DTC P204F (Flash Code 611) SCR System Error (No
IC Error.........................................................................1A-68 Inducement)...................................................................1A-97
DTC P060C (Flash Code 36) Internal Control Module A/D DTC P207F (Flash Code 611) Urea Fluid Concentration
Processing Performance................................................1A-69 Too Low........................................................................1A-98
DTC P0615 (Flash Code 19) Starter Relay Circuit Error DTC P20C9 (Flash Code 611) SCR System Error.......1A-99
.......................................................................................1A-70
DTC P0638 (Flash Code 61) Throttle Actuator Control Circuit Low Input........................................................1A-100
Range/Performance.......................................................1A-71
DTC P0685 (Flash Code 416) ECM Power Relay Control Circuit High Input.......................................................1A-101
Circuit Open..................................................................1A-72
DTC P0687 (Flash Code 416) ECM Power Relay Control Circuit Low Input........................................................1A-102
Circuit High...................................................................1A-73
DTC P06A6 (Flash Code 55) Sensor Reference Voltage 1 Circuit High Input.......................................................1A-103
Circuit............................................................................1A-74
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
DTC P06A7 (Flash Code 56) Sensor Reference Voltage 2 Voltage Correlation.....................................................1A-104
Circuit............................................................................1A-75
Circuit............................................................................1A-76
Circuit............................................................................1A-77
DTC P06AF (Flash Code 277) Torque Management System Circuit Low.................................................................1A-109
- Forced Engine Shutdown............................................1A-78
DTC P06D5 (Flash Code 56) Sensor Reference Voltage 5 Circuit High.................................................................1A-110
Circuit............................................................................1A-79
DTC P2457 (Flash Code 95) Exhaust Gas Recirculation
DTC P1076 (Flash Code 313) Charge Air Cooler (CAC) (EGR) Cooling System Performance..........................1A-111
Temperature Sensor 1 Circuit Low Voltage.................1A-80
DTC P2458 (Flash Code 139) Purge Time Out Error.1A-112
DTC P2BA7 (Flash Code 611) Urea Fluid Quantity Too
Temperature Sensor 1 Circuit High Voltage.................1A-81
Low.............................................................................1A-113
DTC P2BAA (Flash Code 611) SCR System Error
.......................................................................................1A-82
(Inducement, No Purge)..............................................1A-114
DTC P1097 (Flash Code 213) Compressor Outlet
Temperature Sensor Circuit High.................................1A-85
.....................................................................................1A-115

.....................................................................................1A-118
Communication Bus Off.............................................1A-120
CAN............................................................................1A-122
Dosing Control Module...............................................1A-123
VNT System................................................................1A-124
With VNT Control Module.........................................1A-125
With Wheel Loader Transmission Control System....1A-126

DTC P0335 ・ Conditions for setting the DTCs such as
DTC P0336 vary depending on the DTCs.
DTC P0340 ・ For the conditions for setting the DTC, refer to
2. DTC P0016 diagnostics the applicable code listed in 15E DTC
information.
Refer to "1.Engine 1B.Mechanical(4HK1) CKP diagnosis scan tool. A DTC should not be set.
sensor inspection".
sensor removal".
3. Inspect the CMP sensor.
sensor inspection".
sensor removal".
5. Inspect the flywheel.
・There should be no damage on the flywheel.
・There should be no improper installation of the ring
gear.
6. If a problem is found, repair the flywheel.
・The camshaft gear should not be damaged
・The camshaft gear should be installed correctly.
Note：
・ When the engine does not start, crank the
engine for 10 seconds.
the DTC.

1. DTC P0045 priority DTC 13. Measure the voltage between the position sensor
power supply terminal and GND of the turbo
DTC P0563
actuator harness connector.
2. Inspect the turbocharger assembly. the position sensor power supply circuit between the
turbo actuator and the turbo control unit.
assembly inspection". ・There should be no open circuit or high resistance.
3. If a problem is found, replace the turbocharger
assembly.
assembly removal".
16. If the circuit is normal, inspect to the turbo control
unit harness connector for a poor connection.
actuator.
5. Connect the test light between the motor operation
control unit.
terminal and GND of the turbo actuator harness
connector. 19. If the voltage is within the specified range, measure
the voltage between the position sensor signal
7. Check if the test light does not come on or remains GND.
on.
Note：
Note：・ Measurement of voltage value should be taken
・ The inspection with a test light should be on each terminal.
performed on each terminal.
・ When it is normal, the test light comes on after
the key switch is turned ON, and then goes out 20. If the voltage is outside the specified range, inspect
after a few seconds. the position sensor signal circuit between the turbo
8. If the test light does not come on or remains on,
inspect the motor operation circuit between the turbo ・There should be no open circuit or high resistance.
actuator and turbo control unit. ・There should be no short to the battery power supply or
・There should be no open circuit or high resistance. ・There should be no short to GND.
ignition power supply circuit. 21. If a problem is found, repair the position sensor
・There should be no short to GND. signal circuit.
9. If a problem is found, repair the motor operation 22. If the circuit is normal, inspect to the turbo control
circuit. unit harness connector for a poor connection.
10. If the test light operates properly, inspect to see if a 23. If a problem is found, repair the harness connector.
short with other circuit exists in the motor operation 24. If the harness connector is normal, replace the turbo
circuit between the turbo actuator and turbo control control unit.
unit.
25. If the voltage is within the specified range, inspect to
11. If a problem is found, repair the motor operation see if there is a short circuit with the position sensor
circuit. signal circuit between the turbo actuator and turbo
12. Turn ON the ignition switch. control unit.
signal circuit.
28. Measure the voltage between the position sensor
power supply terminal and position sensor GND
terminal of the turbo actuator harness connector.
the position sensor GND circuit between the turbo
GND circuit.
31. If the circuit is normal, inspect to the turbo control
unit harness connector for a poor connection.
control unit.
34. If the voltage is within the specified range, inspect to
see if there is a poor connection with the turbo
actuator harness connector.
turbocharger.
assembly removal".
the DTC.
Note：
information.

connection.
DTC P0089
DTC P0091
DTC P0092
DTC P0192
DTC P0193
DTC P0201
DTC P0202 rail assembly removal".
DTC P0203 Refer to "1.Engine 1C.Fuel System(4HK1) Common
DTC P0204
DTC P2146 Note：
1. Start the engine. 16. If the fuel rail pressure sensor display is within the
specified range, start the engine.
2. Increase the engine speed while observing the DTC
information with a trouble diagnosis scan tool. 17. Perform the injector stop test with the trouble
3. Check to see if the DTC P0087 is detected.
18. Command each injector OFF, and confirm that the
4. If the DTC P0087 is not detected, replace the fuel engine speed changes on each injector.
filter element.
Note： when OFF is instructed, replace the relevant injector.
・ An intermittent problem due to foreign matter
in the fuel is suspected. Refer to "1.Engine 1C.Fuel System(4HK1)
Injector removal".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
element removal". Refer to "1.Engine 1C.Fuel System(4HK1)
element installation". 20. When the injector has been replaced, set the injector
ID code on the ECM.
21. Inspect to see if there is clogging with the fuel
6. Wait for the specified period of time until the fuel system between the fuel tank and the fuel supply
pressure is released from the common rail. pump.
specified time： 2 min 22. If a problem is found, repair the clogging of the fuel
7. Turn ON the ignition switch. system.
8. Check the fuel rail pressure sensor display with the 23. Inspect the fuel hose between the fuel tank and the
trouble diagnosis scan tool. fuel supply pump for a cut and crack.
voltage： 0.9 to 1.0 V 24. If a problem is found, replace the fuel hose.
9. If the fuel rail pressure sensor display is outside the Note：

specified range, inspect the fuel pressure sensor ・ The fuel hose between the fuel tank and the
harness connector for a poor connection. fuel supply pump becomes negative pressure
state when the engine is running.
・ When the fuel hose is not connected securely,
the air can enter.
・ When the engine speed or the engine load Note：

increases while the air has intruded in the fuel ・ Repeat this until the engine starts.
system, fluctuation in the common rail
pressure is caused, and DTC P0087 may be
time or longer.
detected.
25. Check that an appropriate clamp is used between the
fuel tank and the fuel supply pump. 36. While allowing the engine to keep the specified
pressure gauge.
27. Operate the priming pump until the handle becomes
heavy.
Note：
・ When a leak exists in the fuel system between inspection.
the pressing weight of the priming pump does values: (-17.0) kPa {5 inHg / (-2) psi}
not become heavy. Note：
28. Start the engine. ・ Fuel clogging is checked with the negative
pressure amount in the fuel system.
check for fuel leak between the fuel supply pump 38. If the negative pressure is more than or equal to the
and common rail. specified value, inspect to see if there is damage or
Note：
pump and the fuel tank.
・ The fuel may leak to the bottom section of the
cylinder head cover from the high pressure 39. If a problem is found, repair the fuel system.
hose inlet. 40. Inspect the fuel tank bent hose.
・ The engine oil level increases when the fuel 41. If a problem is found, repair the bent hose.
cover. 42. Check to see if there is any foreign matter in the fuel
・ Inspect for fuel leaks into the engine oil. tank or any foreign matter which can cause fuel
clogging.
30. If fuel leak if found, fix the problem.
44. Replace the fuel filter element.
from the fuel filter. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
element removal".
Note：
・ Use a pan to catch the fuel from the removed element installation".
fuel hose.
・ Clean the pressure gauge and connection 45. If the negative pressure is less than or equal to the
hose before connecting to the fuel pipe. specified value, pinch the fuel hose at a position as
close as possible to the fuel tank, so that the fuel
foreign matter that has entered in the
33. Connect the pressure gauge between the fuel filter ・ The fuel pipe can be disconnected and
and the removed fuel hose. clogged with a plug.
・ Confirm that the fuel system is connected
securely. 47. Check the pressure gauge.
34. Remove the air using the priming pump, and crank values: (-27.0) kPa {8 inHg / (-4) psi}
the engine for the specified period of time or shorter.
Note： Note：
・ When the pressure gauge is likely to indicate a ・ Conditions for setting the DTCs such as
value exceeding the specified value during engine run time or coolant temperature, etc.,
inspection, release the fuel being blocked. vary depending on the DTCs.
・ Air mixture is checked with the negative ・ For the conditions for setting the DTC, refer to
pressure amount while the fuel flow is being the applicable code listed in 15E DTC
blocked. information.
48. If the specified negative pressure cannot be 5. Observe the DTC information with the trouble
generated, inspect to see if there is a cut or crack diagnosis scan tool. A DTC should not be set.
with the fuel hose.
appropriate one.
connection.
59. If the suction control valve harness connector and the
ECM harness connector are normal and there is no
high resistance in each circuit, replace the fuel
supply pump and the fuel filter element.
pump removal".
pump installation".
element removal".
element installation".
Note：
・ When replacing the fuel supply pump, it is
required to also replace the fuel filter element
at the same time.
the DTC.

connection.
DTC P0091
DTC P0092
DTC P0192
DTC P0193
DTC P0201
DTC P0202
18. Increase the engine speed while observing the fuel
DTC P0203
rail pressure display on a trouble diagnosis scan tool.
DTC P0204
19. Compare the fuel rail pressure display with the
DTC P2146 desired fuel rail pressure display on the trouble
DTC P2149
values： less than 5 MPa { less than 725 psi }
pressure is released from the common rail. Note：
・ If possible, compare with other machine
specified time： 2 min equipped with the same model engine.
2. Check the fuel rail pressure sensor display with the 20. If it is within the specified range, replace the fuel
trouble diagnosis scan tool. filter element.
voltage： 0.9 to 1.0 V Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
3. If the fuel rail pressure sensor display is outside the element removal".
specified range, inspect the fuel pressure sensor Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
harness connector for a poor connection. element installation".
4. If a problem is found, repair the harness connector. 21. If it is outside the specified range, replace the fuel
5. Inspect the ECM harness connector for a poor supply pump and the fuel filter element.
connection. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
6. If a problem is found, repair the harness connector. pump removal".
7. Inspect each circuit for high resistance. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
pump installation".
9. If the harness connector and each circuit are normal, element removal".
Refer to "1.Engine 1C.Fuel System(4HK1) Common element installation".
Note：
rail assembly installation". ・ When replacing the fuel supply pump, it is
Note： at the same time.
・ Do not replace the fuel pressure sensor 3. DTC P0089 confirm resolution
common rail assembly. 1. Clear the DTC using the trouble diagnosis scan tool.
10. Inspect the suction control valve harness connector 2. Turn OFF the ignition switch for 1 minute or more.
for a poor connection. 3. Start the engine.
the DTC.
Note：
information.

ECM.
1. Disconnect the harness connector from the suction
control valve. 20. Perform SCR purging with a trouble diagnosis scan
tool.
valve High side circuit and a normal GND. 2. DTC P0091 confirm resolution
3. Turn ON the ignition switch. 1. Clear the DTC using the trouble diagnosis scan tool.
4. Check if the test light comes on and then goes off. 2. Turn OFF the ignition switch for 1 minute or more.
5. If it does not turn off, inspect the High side circuit 3. Start the engine.
between the ECM and the suction control valve.
・There should be no open circuit or high resistance. the DTC.
Note：
・There should be no short to the LOW side circuit.
6. If a problem is found, repair the High side circuit. engine run time or coolant temperature, etc.,
7. Turn OFF the ignition switch for 1 minute or more. vary depending on the DTCs.
valve Low side circuit and battery power supply.
information.
10. Check if the test light comes on and then goes off. diagnosis scan tool. A DTC should not be set.
power supply.
control valve installation".
connection.
ECM removal".
ECM installation".

1. DTC P0092 diagnostics Refer to "1.Engine 1C.Fuel System(4HK1) Suction
1. Inspect the High side circuit between the ECM and
the FRP regulator for a short to the battery or a short Refer to "1.Engine 1C.Fuel System(4HK1) Suction
to the ignition power supply. control valve installation".
Note： 21. Inspect the ECM harness connector for a poor
・ When the High side circuit is shorted to the connection.
voltage, the engine stalls and does not start. 22. If a problem is found, repair the harness connector.
2. If a problem is found, repair the High side circuit. 23. If the harness connector is normal, replace the ECM.
3. If it is within the specified range, inspect to see if Refer to "1.Engine 1J.Electrical(4HK1)
there is a short circuit to the GND with the Low side ECM removal".
circuit between the ECM and the suction control
valve. Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
5. Turn OFF the ignition switch for 1 minute or more. ECM.
6. Disconnect the harness connector from the suction 25. Perform SCR purging with a trouble diagnosis scan
control valve. tool.
7. Connect the test light between the suction control 2. DTC P0092 confirm resolution
valve High side circuit and a normal GND.
10. If it does not turn off, inspect the High side circuit
between the ECM and the suction control valve. 4. Perform a test-run under the conditions for running
the DTC.
・There should be no short to GND. Note：
・There should be no short to the Low side circuit. ・ Conditions for setting the DTCs such as
11. If a problem is found, repair the High side circuit.
12. Turn OFF the ignition switch for 1 minute or more. ・ For the conditions for setting the DTC, refer to
13. Connect the test light between the suction control the applicable code listed in 15E DTC
valve Low side circuit and battery power supply. information.
14. Turn ON the ignition switch. 5. Observe the DTC information with the trouble
power supply.

information.
2. Disconnect the harness connector from the IMT
sensor.
tool.
voltage： 4.5 V
value, replace the IMT sensor.
sensor removal".
5. Inspect the signal circuit between the ECM and IMT
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

DTC P06A8
Note：
1. Turn OFF the ignition switch. ・ The IMT sensor shares the GND circuit with
2. Disconnect the harness connector from the IMT other sensors.
sensor. ・ DTCs on sensors that share this circuit may be
3. Turn ON the ignition switch. set.
4. Measure the voltage between the IMT sensor signal
circuit and a known good GND. 18. Inspect the signal circuit between the ECM and the
voltage： 5.5 V
and IMT sensor for a short to the battery or a short to connector.
sensor signal circuit and GND circuit.
ECM removal".
ECM installation".
tool.
voltage： 0.1 V
ECM.
tool.
and IMT sensor for a short to the 5 V power supply
circuit. 3. DTC P0098 confirm resolution
11. Inspect for poor connections at the IMT sensor 2. Turn OFF the ignition switch for 1 minute or more.
harness connector.
13. If the harness connector is normal, replace the IMT the DTC.
sensor.
Note：
Refer to "1.Engine 1F.Induction(4HK1) IMT ・ Conditions for setting the DTCs such as
sensor removal". engine run time or coolant temperature, etc.,
Refer to "1.Engine 1F.Induction(4HK1) IMT vary depending on the DTCs.
sensor installation". ・ For the conditions for setting the DTC, refer to
information.
sensor signal circuit and a known good GND.
tool.
voltage： 0.1 V

1. DTC P0102 priority DTC 1. Clear the DTC using the trouble diagnosis scan tool.
DTC P0560 2. Turn OFF the ignition switch for 1 minute or more.
the DTC.
sensor. Note：
3. Inspect to see if there is an open circuit or high ・ Conditions for setting the DTCs such as
resistance in the 12 V power supply circuit between engine run time or coolant temperature, etc.,
the ECM and the MAF sensor. vary depending on the DTCs.
circuit.
information.
power supply circuit and the signal circuit of the
MAF sensor harness connector.
6. Check the MAF sensor display with the trouble
voltage： 4.9 V
with the MAF sensor harness connector.
sensor.
MAF sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0103 priority DTC 3. Start the engine.
the DTC.
Note：
2. Disconnect the harness connector from the MAF engine run time or coolant temperature, etc.,
sensor. vary depending on the DTCs.
3. Check the MAF sensor display with the trouble ・ For the conditions for setting the DTC, refer to
diagnosis scan tool. the applicable code listed in 15E DTC
and the MAF sensor.
power supply.
・There should be no short to the 12 V or 5 V power
supply.
the MAF sensor.
8. Inspect the MAF sensor harness connector for a poor
connection.
sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0112 priority DTC 5. Observe the DTC information with the trouble
DTC P06A8
2. Disconnect the harness connector from the IAT
sensor.
voltage： 4.5 V
value, replace the IAT sensor.
5. Inspect the signal circuit between the ECM and IAT
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

DTC P06A8 ・ The IAT sensor shares the GND circuit with
other sensors.
1. Turn OFF the ignition switch. set.
2. Disconnect the harness connector from the IAT 17. If a problem is found, repair the GND circuit.
sensor.
3. Turn ON the ignition switch. IAT sensor for an open circuit or high resistance.
4. Measure the voltage between the IAT sensor signal 19. If a problem is found, repair the signal circuit.
circuit and a known good GND.
voltage： 5.5 V connector.
5. If the reading is more than or equal to the specified 21. If a problem is found, repair the harness connector.
and the IAT sensor.
・There should be no short to the battery or the ignition
ECM removal".
power supply.
・There should be no short to the 12 V power supply. Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
ECM.
signal circuit and GND circuit.
tool.
voltage： 0.1 V
value, inspect the signal circuit between the ECM 2. Turn OFF the ignition switch for 1 minute or more.
and IAT sensor for a short to the 5 V power supply
circuit.
the DTC.
11. Inspect for poor connections at the IAT sensor
Note：
harness connector.
13. If the harness connector is normal, replace the IAT vary depending on the DTCs.
information.
signal circuit and a known good GND.
voltage： 0.1 V
the IAT sensor for an open circuit or high resistance.

information.
2. Disconnect the harness connector from the engine
voltage： 4.5 V
value, replace the engine coolant temperature sensor.
engine coolant temperature sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

DTC P06A8 16. If the reading is less than or equal to the specified
resistance with the engine coolant temperature sensor
1. Turn OFF the ignition switch. GND circuit.
2. Disconnect the harness connector from the engine Note：
coolant temperature sensor. ・ The engine coolant temperature sensor shares
3. Turn ON the ignition switch. the GND circuit with other sensors.
4. Measure the voltage between the engine coolant ・ The DTC set on a sensor which shares this
temperature sensor signal circuit and normal GND. circuit may be detected.
voltage： 5.5 V
18. Inspect to see if there is a breakage or high resistance
in the signal circuit of the engine coolant temperature
sensor.
circuit between the ECM and the engine coolant 19. If a problem is found, repair the signal circuit.
temperature sensor.
7. Connect the test cable with fuse between the engine 21. If a problem is found, repair the harness connector.
coolant temperature sensor signal circuit and GND
circuit.
ECM removal".
voltage： 0.1 V
ECM installation".
ECM.
between the ECM and the engine coolant 24. Perform SCR purging with a trouble diagnosis scan
temperature sensor. tool.
engine coolant temperature sensor harness connector.
13. If the harness connector is normal, replace the engine
the DTC.
Note：
Refer to "1.Engine 1D.Cooling(4HK1) Engine coolant engine run time or coolant temperature, etc.,
temperature sensor installation". vary depending on the DTCs.
14. Connect the test cable with fuse between the engine ・ For the conditions for setting the DTC, refer to
coolant temperature sensor signal circuit and normal the applicable code listed in 15E DTC
GND. information.
15. Observe the engine coolant temperature sensor 5. Observe the DTC information with the trouble
display on a trouble diagnosis scan tool. diagnosis scan tool. A DTC should not be set.

DTC P06A8 14. Inspect the ECM harness connector for a poor
connection.
2. Disconnect the harness connector from the intake
throttle valve. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
4. Measure the voltage between the intake throttle
ECM installation".
position sensor 5 V power supply circuit and a
normal GND. 17. Set the Injector ID Code and engine No. on the
ECM.
voltage： 4.9 V
tool.
resistance with the 5 V power supply circuit between 3. DTC P0122 confirm resolution
the ECM and the intake throttle position sensor.
Note：
・ The intake throttle position sensor shares the 5
V power supply circuit with other sensors. 3. Start the engine.
・ The DTC set on a sensor which shares this 4. Perform a test-run under the conditions for running
circuit may be detected. the DTC.
6. If a problem is discovered, repair the 5 V power Note：
supply circuit. ・ Conditions for setting the DTCs such as
7. Connect the test cable with fuse between the intake engine run time or coolant temperature, etc.,
throttle position sensor 5 V power supply circuit and vary depending on the DTCs.
the signal circuit. ・ For the conditions for setting the DTC, refer to
8. Observe the intake throttle sensor display on the
information.
voltage： 4.9 V
with the intake throttle valve harness connector.
throttle valve.
intake throttle position sensor.

ECM.
DTC P06A8
tool.
2. Disconnect the harness connector from the intake
throttle valve.
3. Observe the intake throttle sensor display on the
trouble diagnosis scan tool. 3. Start the engine.
voltage： 0.1 V 4. Perform a test-run under the conditions for running
the DTC.
and the intake throttle position sensor. ・ Conditions for setting the DTCs such as
・There should be no short to the battery or ignition engine run time or coolant temperature, etc.,
power supply. vary depending on the DTCs.
・There should be no short to the 5 V power supply. ・ For the conditions for setting the DTC, refer to
information.
6. Inspect the intake throttle valve harness connector
throttle valve.
the intake throttle position sensor.
Note：
・ The intake throttle position sensor shares the
11. Check the ECM harness connector for a poor
connection.
ECM removal".
ECM installation".

2. Disconnect the harness connector from the fuel the applicable code listed in 15E DTC
temperature sensor. information.
3. Observe the fuel temperature sensor display on the
voltage： 4.5 V
value, replace the fuel temperature sensor.
pump removal".
pump installation".
Note：
・ Do not replace the fuel temperature sensor
fuel supply pump.
with the signal circuit between the ECM and fuel
temperature sensor.
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P0183 priority DTC 15. Observe the fuel temperature sensor display on the
DTC P06A9
voltage： 0.1 V
2. Disconnect the harness connector from the fuel resistance with the GND circuit between the ECM
temperature sensor. and fuel temperature sensor.
4. Measure the voltage between the fuel temperature ・ The fuel temperature sensor shares the GND
sensor signal circuit and normal GND. circuit with other sensors.
voltage： 5.5 V ・ The DTC set on a sensor which shares this
circuit between the ECM and the fuel temperature resistance in the signal circuit between the ECM and
sensor. the fuel temperature sensor.
7. Connect the test cable with fuse between the fuel 20. Inspect the ECM harness connector for a poor
temperature sensor signal circuit and GND circuit. connection.
8. Observe the fuel temperature sensor display on the 21. If a problem is found, repair the harness connector.
voltage： 0.1 V
9. If the reading is less than or equal to the specified ECM removal".
ECM installation".
between the ECM and the fuel temperature sensor.
ECM.
fuel temperature sensor harness connector.
tool.
temperature sensor.
pump removal". 3. Start the engine.
pump installation". the DTC.
Note： Note：
・ Do not replace the fuel temperature sensor ・ Conditions for setting the DTCs such as
separately. If a problem is found, replace the engine run time or coolant temperature, etc.,
fuel supply pump. vary depending on the DTCs.
14. Connect the test cable with fuse between the fuel ・ For the conditions for setting the DTC, refer to
temperature sensor signal circuit and normal GND. the applicable code listed in 15E DTC
information.

DTC P06A7 14. If the harness connector is normal, replace the ECM.
ECM removal".
ECM installation".
pressure sensor.
ECM.
voltage： 4.5 V
tool.
GND with the signal circuit between the ECM and 1. Clear the DTC using the trouble diagnosis scan tool.
the fuel pressure sensor.
6. Measure the voltage between the fuel pressure sensor
5 V power supply circuit and normal GND.
the DTC.
voltage： 4.5 V
Note：
7. If the reading is more than or equal to the specified ・ Conditions for setting the DTCs such as
value, inspect to see if there is a poor connection engine run time or coolant temperature, etc.,
with the fuel pressure sensor harness connector. vary depending on the DTCs.
8. If a problem is found, repair the harness connector. ・ For the conditions for setting the DTC, refer to
information.
pressure sensor.
Note：
the ECM and fuel pressure sensor.
Note：
・ The fuel pressure sensor shares the 5 V power
supply circuit with other sensors.
circuit.
connection.

DTC P06A7 ・ Do not replace the fuel pressure sensor
1. Turn OFF the ignition switch. 15. Inspect to see if there is an open circuit or high
2. Disconnect the harness connector from the fuel resistance in the GND circuit between the ECM and
pressure sensor. the fuel pressure sensor.
4. Measure the voltage between the fuel pressure sensor ・ The fuel pressure sensor shares the GND
signal circuit and normal GND. circuit with other sensors.
voltage： 5.5 V circuit may be detected.
5. If the reading is more than or equal to the specified 16. If a problem is found, repair the GND circuit.
circuit between the ECM and the fuel pressure resistance in the signal circuit between the ECM and
sensor. the fuel pressure sensor.
7. Measure the voltage between the fuel pressure sensor 19. Inspect the ECM harness connector for a poor
signal circuit and normal GND. connection.
voltage： 4.5 V 20. If a problem is found, repair the harness connector.
8. If the reading is more than or equal to the specified 21. If the harness connector is normal, replace the ECM.
value, inspect to see if there is a short circuit to the 5 Refer to "1.Engine 1J.Electrical(4HK1)
V power supply circuit with the signal circuit ECM removal".
between the ECM and the fuel pressure sensor.
9. If a problem is found, repair the signal circuit. ECM installation".
10. Connect the test cable with fuse between the fuel 22. Set the Injector ID Code and engine No. on the
pressure sensor signal circuit and GND circuit. ECM.
11. Check the fuel rail pressure sensor display with the 23. Perform SCR purging with a trouble diagnosis scan
trouble diagnosis scan tool. tool.
12. If the reading is less than or equal to the specified 1. Clear the DTC using the trouble diagnosis scan tool.
with the fuel pressure sensor harness connector. 2. Turn OFF the ignition switch for 1 minute or more.
14. If the harness connector is normal, replace the fuel 4. Perform a test-run under the conditions for running
pressure sensor. the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1) Common Note：

rail assembly removal". ・ Conditions for setting the DTCs such as
information.

connection.
2. Disconnect the injector harness intermediate
connector from the cylinder head cover case. 19. If the harness connector is normal, replace the ECM.
3. Measure the resistance between No. 1 cylinder Refer to "1.Engine 1J.Electrical(4HK1)
injector power supply terminal and No. 1 cylinder ECM removal".
injector drive signal terminal of the injector harness
intermediate connector.
ECM installation".
resistance： 2.0 Ω
value, inspect the circuit between the ECM and the
injector harness intermediate connector for an open
tool.
6. Remove the cylinder head cover.
Refer to "1.Engine 1B.Mechanical(4HK1) Cylinder
head cover removal". 3. Start the engine.
7. Inspect the tightening nut of No. 1 cylinder injector 4. Perform a test-run under the conditions for running
harness for looseness. the DTC.
8. If looseness is found in the tightening nut of No. 1 Note：
cylinder injector harness, tighten it. ・ Conditions for setting the DTCs such as
9. Inspect for foreign material coming in contact with engine run time or coolant temperature, etc.,
No. 1 cylinder injector terminal. vary depending on the DTCs.
10. If foreign material comes in contact with No. 1
cylinder injector terminal, remove it.
information.
12. If a problem is found, repair the connector.
13. Inspect the circuit between No.1 cylinder injector
and the intermediate connector.
・There should be no short together between the injector
circuits.
15. If the circuit is normal, replace No. 1 cylinder
injector.
Injector removal".
Code on the ECM.

connection.
ECM installation".
tool.
information.
13. Inspect the circuit between No. 2 cylinder injector
circuits.
injector.
Injector removal".
Code on the ECM.

connection.
ECM installation".
tool.
information.
circuits.
injector.
Injector removal".
Code on the ECM.

connection.
ECM installation".
tool.
information.
circuits.
injector.
Injector removal".
Code on the ECM.

1. DTC P0217 priority DTC 4. Observe that the engine coolant temperature display
is not more than or equal to the specified value.
DTC P0117
values： 101 ℃ { 214 °F }
1. Inspect the engine cooling system.
Coolant inspection".
Refer to "1.Engine 1D.Cooling(4HK1) Cooling fan
belt inspection".
Thermostat inspection".
Refer to "1.Engine 1D.Cooling(4HK1) Water pump
assembly inspection".
Radiator inspection".
2. While observing the coolant temperature display
with the trouble diagnosis scan tool, start the engine.
3. Wait until the engine has been completely warmed
up.
4. Check whether the engine coolant temperature
display is more than or equal to the specified value
with the trouble diagnosis scan tool.
values： 101 ℃ { 214 °F }
5. If the reading is less than the specified value, check
the operator if the overheat has occurred due to low
engine coolant level, etc.
engine overheat in the past.
temperature sensor inspection".
replace the engine coolant temperature sensor.
3. While observing the engine coolant temperature
display with the trouble diagnosis scan tool, start the
engine and wait until it is completely warmed up.

DTC P0335
DTC P0336
1. Turn OFF the ignition switch for 30 seconds.
4. Increase the engine speed, as needed.
rotational speed： 2500 r/min Shovel car
rotational speed： 2800 r/min Wheel loader
6. If the specified value has not been exceeded, check
with the operator if an operation failure has occurred
due to the overrun.
engine overrun in the past.
sensor inspection".
replace the CKP sensor.
sensor removal".
3. Start the engine and increase the engine speed
between idling and no-load maximum speed while
observing the engine speed display on the trouble
4. Confirm that the engine speed display does not
exceed the specified value.
rotational speed： 2500 r/min Shovel car
rotational speed： 2800 r/min Wheel loader

DTC P0045 ・ The barometric pressure in the trouble
diagnosis scan tool normally indicates a value
DTC P0237 close to the surrounding barometric pressure.
DTC P0238 13. If the barometric pressure display is within the
DTC P0638 specified range, inspect the boost sensor system.
DTC P2228 Refer to "1.Engine 1F.Induction(4HK1) Pressure
DTC P2229
14. If the inspection result of the boost sensor has a
2. DTC P0234 diagnostics problem, replace the boost sensor.
1. Turn ON the ignition switch. Refer to "1.Engine 1F.Induction(4HK1) Pressure
2. Check the difference between the boost pressure sensor/boost temperature sensor removal".
display and the barometric pressure display with the Refer to "1.Engine 1F.Induction(4HK1) Pressure
trouble diagnosis scan tool. sensor/boost temperature sensor installation".
values： 10.0 kPa { 0.1 kgf/cm2 / 1 psi } 15. If the Barometric Pressure data display is outside the
Note： specified range, replace the ECM.
・ The value is normal if the boost pressure Refer to "1.Engine 1J.Electrical(4HK1)
indicated by the trouble diagnosis scan tool is ECM removal".
close to the barometric pressure when the
ignition switch is ON and the engine is
ECM installation".
stopped.
ECM.
value, inspect to see if there is a failure with the
actuator which controls the turbocharger nozzle. 17. Perform SCR purging with a trouble diagnosis scan
tool.
4. If a problem is found, repair the actuator.
5. Perform the intake throttle test with the trouble
diagnosis scan tool to check the intake throttle valve 1. Clear the DTC using the trouble diagnosis scan tool.
for fixing.
6. If a problem is found, repair the intake throttle valve.
7. Check to see if there is oil mixing in the air intake
piping.
the DTC.
8. If oil is attached inside the pipe, the intercooler, or
Note：
the turbocharger, wipe it off.
9. Use the trouble diagnosis scan tool to confirm that engine run time or coolant temperature, etc.,
the boost sensor signal is normal. vary depending on the DTCs.
10. Compare the sensor values under various load ・ For the conditions for setting the DTC, refer to
conditions to check for an abnormally high value. the applicable code listed in 15E DTC
11. If the reading is more than or equal to the specified information.
value, compare the value of the barometric pressure 5. Observe the DTC information with the trouble
with the surrounding barometric pressure. diagnosis scan tool. A DTC should not be set.
barometric pressure display is within the specified
range.

DTC P06A8 14. Inspect the ECM harness connector for a poor
connection.
sensor. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
ECM installation".
circuit of the boost sensor harness connector and a
normal GND. 17. Set the Injector ID Code and engine No. on the
ECM.
voltage： 4.5 V
tool.
resistance with the 5 V power supply circuit between 3. DTC P0237 confirm resolution
the ECM and the boost sensor.
Note：
・ The boost sensor shares the 5 V power supply
circuit with other sensors. 3. Start the engine.
・ The DTC set on a sensor which shares this 4. Perform a test-run under the conditions for running
circuit may be detected. the DTC.
6. If a problem is found, repair the 5 V power supply Note：
circuit. ・ Conditions for setting the DTCs such as
7. Connect the test cable with fuse between the 5 V engine run time or coolant temperature, etc.,
power supply circuit and the signal circuit of the vary depending on the DTCs.
boost sensor harness connector. ・ For the conditions for setting the DTC, refer to
8. Check the boost pressure sensor display with the
information.
voltage： 4.5 V
with the boost sensor harness connector.
sensor.
boost sensor.

ECM.
DTC P06A8
tool.
sensor.
3. Check the boost pressure sensor display with the
the DTC.
and the boost sensor. ・ Conditions for setting the DTCs such as
information.
the boost sensor.
Note：
・ The boost sensor shares the GND circuit with
other sensors.
8. Inspect the boost sensor harness connector for a poor
connection.
sensor.
connection.
ECM removal".
ECM installation".

1. DTC P0335 priority DTC 13. Connect the test light between the signal circuit and
DTC P0340
14. Measure the voltage between the probe of the test
DTC P06A6
voltage： 4.5 V
2. Disconnect the harness connector from the CKP value, inspect to see if there is a short circuit to the 5
sensor. V power supply circuit with the signal circuit
between the ECM and the CKP sensor.
circuit and normal GND of the CKP sensor harness 17. Measure the voltage between the 5 V power supply
connector. circuit and GND circuit of the CKP sensor harness
connector.
voltage： 4.5 V
voltage： 4.5 V
value, inspect to see if there is an open circuit or high 18. If the reading is more than or equal to the specified
resistance with the 5 V power supply circuit between value, inspect to see if there is a poor connection
the ECM and the CKP sensor. with the CKP sensor harness connector.
・ The CKP sensor shares the 5 V power supply 20. If the harness connector is normal, inspect the CKP
circuit with other sensors. sensor.
sensor inspection".
circuit.
sensor removal".
voltage： 5.5 V
22. Inspect the GND circuit between the ECM and the
CKP sensor for an open circuit and high resistance.
circuit between the ECM and the CKP sensor. Note：
9. If a problem is found, repair the signal circuit. ・ The CKP sensor shares the GND circuit with
other sensors.
CKP sensor harness connector and a normal GND
again.
voltage： 4.5 V
connection.
and the CKP sensor. 25. If a problem is found, repair the harness connector.
・There should be no open circuit or high resistance. 26. If the harness connector is normal, replace the ECM.
12. If a problem is found, repair the signal circuit. ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

DTC P0335 the applicable code listed in 15E DTC
information.
DTC P0340
DTC P06A6 diagnosis scan tool. A DTC should not be set.
1. Inspect the CKP sensor circuit.
・There should be enough clearing from the wiring or
component of the fuel injection unit.
・There should be enough clearing from additionally
installed electronic components.
・There should be enough clearing from the solenoids and
relays.
2. If a problem is found, repair the CKP sensor circuit.
connection.
sensor.
8. Inspect the CKP sensor harness connector for a poor
connection.
sensor inspection".
sensor removal".
the DTC.
Note：

1. DTC P0340 priority DTC 15. If the reading is more than or equal to the specified
DTC P0601
DTC P06A7 between the ECM and the CMP sensor.
2. DTC P0340 diagnostics 16. If a problem is found, repair the signal circuit.
1. Turn OFF the ignition switch. 17. Measure the voltage between the 5 V power supply
circuit and GND circuit of the CMP sensor harness
connector.
sensor.
voltage： 4.5 V
circuit and normal GND of the CMP sensor harness
with the CMP sensor harness connector.
connector.
voltage： 4.5 V
20. If the harness connector is normal, inspect the CMP
sensor.
resistance with the 5 V power supply circuit between Refer to "1.Engine 1B.Mechanical(4HK1) CMP
the ECM and the CMP sensor. sensor inspection".
6. If a problem is found, repair the 5 V power supply 21. If a problem is found, replace the CMP sensor.
circuit.
7. Measure the voltage between the signal circuit and sensor removal".
normal GND of the CMP sensor harness connector.
voltage： 5.5 V sensor installation".
8. If the reading is more than or equal to the specified 22. Inspect the camshaft gear.
・The camshaft gear should not be damaged
・The camshaft gear should be installed correctly.
circuit between the ECM and the CMP sensor.
24. Inspect the GND circuit between the ECM and the
CMP sensor for an open circuit and high resistance.
CMP sensor harness connector and a normal GND
again. Note：
voltage： 4.5 V ・ The CMP sensor shares the GND circuit with
other sensors.
and the CMP sensor.
・There should be no short to GND. 26. Inspect the ECM harness connector for a poor
connection.
13. Connect the test light between the signal circuit and
normal GND of the CMP sensor harness connector. 28. If the harness connector is normal, replace the ECM.
14. Measure the voltage between the probe of the test Refer to "1.Engine 1J.Electrical(4HK1)
light and a normal GND. ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

the DTC.
2. Replace the glow relay with a known good relay.
Note：
3. Perform the glow relay test with the trouble
diagnosis scan tool. ・ Conditions for setting the DTCs such as
4. Command the glow relay ON and OFF. vary depending on the DTCs.
5. Check whether an operation sound is heard from the ・ For the conditions for setting the DTC, refer to
glow relay upon execution of each command. the applicable code listed in 15E DTC
6. If the operating sound of the glow relay can be information.
heard, remove the glow relay. 5. Observe the DTC information with the trouble
7. Inspect for poor connections at the glow relay
terminal.
8. If a problem is found, repair the glow relay terminal.
9. If the glow relay terminal is normal, replace the glow
relay.
11. Inspect between the ignition switch and the glow
relay coil side for an open circuit or high resistance.
12. If a problem is found, repair the circuit between the
ignition switch and glow relay coil side.
13. Inspect the control circuit between the ECM and
glow relay.
connector.
ECM.
ECM removal".
ECM installation".
ECM.
tool.

EGR Flow Insufficient Detected
1. DTC P0401 priority DTC 10. If a problem is found, repair or replace the exhaust
system.
DTC P0102
11. Perform the EGR with a scan tool.
DTC P0103
12. While observing the EGR Position 1 value,
DTC P0560
command the desired EGR opening position to
2. DTC P0401 diagnostics increase and decrease.
1. Inspect the air cleaner element. 13. Compare the EGR position 1 display with the desired
EGR opening position display on the trouble
2. If a problem is found, replace the air cleaner
element.
3. Inspect the EGR system.
values： less than 5 %
Note：
・ Do not lose or damage the EGR gasket. the EGR valve.
・ The EGR valve should not be stuck.
・ There should be no EGR gas leakage from the Devices(4HK1) EGR valve removal".
EGR passage between the exhaust manifold
and the intake manifold. Refer to "1.Engine 1H.Aux. Emission Control
・ There should be no collapsed or restricted flow
in the EGR passage between the exhaust 3. DTC P0401 confirm resolution
manifold and the intake manifold.
4. If a problem is found, repair or replace the EGR
system.
5. Inspect the air intake system.
Note：
the DTC.
・ There should be no collapsing of the duct
between the air cleaner and intake manifold, or Note：
a state where flow is restricted or breakage is ・ Conditions for setting the DTCs such as
present. engine run time or coolant temperature, etc.,
・ There should be no leakage in the air intake vary depending on the DTCs.
system. ・ For the conditions for setting the DTC, refer to
・ There should be no water in the air intake the applicable code listed in 15E DTC
system. information.
6. If a problem is found, repair the air intake system. 5. Observe the DTC information with the trouble
7. Inspect the MAF sensor.
Note：
・ There should be no dirt or foreign material
blocking the ports of the MAF sensor.
・ There should be no misdetection or delayed
response of the MAF sensor.
8. If a problem is found, replace the MAF sensor.
Note：
・ Flow should not be in a restricted state.

1. DTC P0404 priority DTC 16. Turn ON the ignition switch.
DTC P0409 17. Clear the DTC using the trouble diagnosis scan tool.
1. Remove the EGR valve assembly from the engine. 19. Start the engine.
Refer to "1.Engine 1H.Aux. Emission Control 20. Perform a test-run.
21. Check the DTC using the trouble diagnosis scan tool.
22. If the DTC P0404 has been detected, replace the
・There should be nothing to limit flow inside the EGR ECM.
valve.
・There should be no excessive accumulates inside the
ECM removal".
EGR valve.
・There should be no bending with the valve shaft or Refer to "1.Engine 1J.Electrical(4HK1)
valve itself inside the EGR valve. ECM installation".
3. Turn OFF the ignition switch. 23. Set the Injector ID Code and engine No. on the
ECM.
valve. 24. Perform SCR purging with a trouble diagnosis scan
tool.
connection. 3. DTC P0404 confirm resolution
7. Disconnect the harness connector from the ECM. 2. Turn OFF the ignition switch for 1 minute or more.
8. Inspect the ECM harness connector for a poor 3. Start the engine.
connection.
9. If a problem is found, repair the harness connector. the DTC.
10. Inspect to see if there is an open circuit or high Note：
resistance in the EGR control circuit. ・ Conditions for setting the DTCs such as
11. If a problem is found, repair the EGR control circuit. engine run time or coolant temperature, etc.,
12. Inspect the EGR motor circuit between the ECM and
EGR valve.
・There should be no short to GND. information.
・There should be no short between the circuits.
・There should be no short to EGR position sensor
circuit.
14. If the EGR motor circuit is normal, replace the EGR
valve.

EGR Sensor Circuit
1. DTC P0409 priority DTC ・ The DTC set on a sensor which shares this
DTC P06A9 circuit may be detected.
2. DTC P0409 diagnostics 12. If a problem is found, repair the GND circuit.
1. Turn OFF the ignition switch. 13. While momentarily disconnecting the test cable with
2. Disconnect the harness connector from the EGR and 5 V power supply circuit, check the EGR
valve. position 1 display with the trouble diagnosis scan
4. Use the trouble diagnosis scan tool to check if any of 14. While momentarily disconnecting the test cable with
the EGR position 1, EGR position 2, and EGR fuse from the EGR position sensor 2 signal circuit
position 3 shows ON. and 5 V power supply circuit, check the EGR
position 2 display with the trouble diagnosis scan
5. If there is a data display showing ON, inspect the tool.
signal circuit between the ECM and EGR valve of
the EGR showing ON. 15. While momentarily disconnecting the test cable with
・There should be no short to the battery or ignition and 5 V power supply circuit, check the EGR
power supply. position 3 display with the trouble diagnosis scan
・There should be no short to the 5 V power supply tool.
circuit.
16. Check to see if there is a data display which does not
6. If a problem is found, repair the signal circuit. display ON when the EGR position sensor signal
7. Measure the voltage between the EGR position circuit and 5 V power supply circuit are shorted.
sensor 5 V power supply circuit and a normal GND. 17. If there is a data display which does not display ON,
voltage： 4.5 V inspect the EGR position sensor circuit which does
not display ON.
value, inspect to see if there is an open circuit or high ・There should be no open circuit or high resistance
resistance with the 5 V power supply circuit between between ECM and EGR position sensor.
the ECM and the EGR position sensor. ・There should be no short to GND between ECM and
EGR position sensor.
Note：
・ The EGR position sensor shares the 5 V 18. If a problem is found, repair the EGR position sensor
power supply circuit with other sensors. circuit.
・ The DTC set on a sensor which shares this 19. Inspect the EGR valve harness connector for a poor
circuit may be detected. connection.
9. If a problem is found, repair the 5 V power supply 20. If a problem is found, repair the harness connector.
circuit. 21. In the EGR solenoid circuit between the ECM and
10. Measure the voltage between the EGR position EGR valve, inspect to see if there is a short circuit
sensor 5 V power supply circuit and the GND circuit. with the EGR position sensor.
voltage： 4.5 V 22. If a problem is found, repair the EGR solenoid
circuit.
value, inspect to see if there is an open circuit or high 23. If the EGR solenoid circuit is normal, replace the
resistance with the GND circuit between the ECM EGR valve.
and EGR position sensor. Refer to "1.Engine 1H.Aux. Emission Control
Note： Devices(4HK1) EGR valve removal".
・ The EGR position sensor shares the GND Refer to "1.Engine 1H.Aux. Emission Control
circuit with other sensors. Devices(4HK1) EGR valve installation".
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

tool.
voltage： 4.5 V
2 removal".
2 installation".
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P041D priority DTC 15. Observe the 5 V adjustment display of EGR gas
DTC P06A8
tool.
voltage： 0.1 V
circuit.
temperature sensor 2 on the trouble diagnosis scan Refer to "1.Engine 1J.Electrical(4HK1)
tool. ECM removal".
ECM installation".
11. Inspect for poor connections at the EGR gas 3. DTC P041D confirm resolution
the DTC.
2 removal". Note：
information.
GND.

information.
2. Disconnect the harness connector from the exhaust
voltage： 4.5 V
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

DTC P06A8 16. If the reading is more than or equal to the specified
resistance with the signal circuit between the ECM
1. Turn OFF the ignition switch. and the exhaust gas temperature sensor 1.
2. Disconnect the harness connector from the exhaust 17. If a problem is found, repair the signal circuit.
3. Turn ON the ignition switch. resistance in the GND circuit between the ECM and
temperature sensor 1 signal circuit and normal GND. Note：
voltage： 5.5 V ・ The exhaust gas temperature sensor 1 shares
value, inspect to see if there is a short circuit to the ・ The DTC may be detected on a sensor which
battery or ignition power supply with the signal shares this circuit.
circuit between the ECM and the exhaust gas 19. If a problem is found, repair the GND circuit.
7. Connect the test cable with fuse between the exhaust 21. If a problem is found, repair the harness connector.
gas temperature sensor 1 signal circuit and GND
circuit.
ECM removal".
voltage： 0.1 V
ECM installation".
ECM.
between the ECM and the exhaust gas temperature 24. Perform SCR purging with a trouble diagnosis scan
sensor 1. tool.
exhaust gas temperature sensor 1 harness connector.
13. If the harness connector is normal, replace the temperature exceeds the specified value.
values： 70 ℃ { 158 °F }
exhaust temperature sensor (in front of the filter)
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas display with the trouble diagnosis scan tool.
14. Connect the test cable with fuse between the exhaust the exhaust temperature sensor (before the filter)
gas temperature sensor 1 signal circuit and normal display does not exceed the specified value.
GND.
voltage： 4.8 V

1. DTC P042C priority DTC ・ For the conditions for setting the DTC, refer to
DTC P06D5 the applicable code listed in 15E DTC
information.
2. Disconnect the harness connector from the exhaust
scan tool.
voltage： 4.5 V
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

1. DTC P042D priority DTC 15. Check the exhaust temperature sensor (before the
DTC P06D5
scan tool.
voltage： 0.1 V
2. Disconnect the harness connector from the exhaust value, inspect to see if there is an open circuit or high
gas temperature sensor 2. resistance with the signal circuit between the ECM
and the exhaust gas temperature sensor 2.
temperature sensor 2 signal circuit and normal GND. 18. Inspect to see if there is an open circuit or high
voltage： 5.5 V
value, inspect to see if there is a short circuit to the Note：
battery or ignition power supply with the signal ・ The exhaust gas temperature sensor 2 shares
circuit between the ECM and the exhaust gas the GND circuit with other sensors.
temperature sensor 2. ・ The DTC may be detected on a sensor which
6. If a problem is found, repair the signal circuit. shares this circuit.
7. Connect the test cable with fuse between the exhaust
gas temperature sensor 2 signal circuit and GND 20. Inspect the ECM harness connector for a poor
circuit. connection.
8. Check the exhaust temperature sensor (before the 21. If a problem is found, repair the harness connector.
scan tool.
voltage： 0.1 V
ECM removal".
ECM installation".
between the ECM and the exhaust gas temperature 23. Set the Injector ID Code and engine No. on the
sensor 2. ECM.
10. If a problem is found, repair the signal circuit. 24. Perform SCR purging with a trouble diagnosis scan
tool.
exhaust gas temperature sensor 2 harness connector. 3. DTC P042D confirm resolution
13. If the harness connector is normal, replace the 2. Turn OFF the ignition switch for 1 minute or more.
3. Start the engine, and warm it up until the coolant
Refer to "1.Engine 1G.Exhaust(4HK1) Exhaust gas temperature reaches the specified value.
values： 70 ℃ { 158 °F }
exhaust temperature sensor (in front of the oxidation
14. Connect the test cable with fuse between the exhaust catalyst) display with the trouble diagnosis scan tool.
gas temperature sensor 2 signal circuit and normal
GND.
the exhaust temperature sensor (before the oxidation
catalyst) display does not exceed the specified value.
voltage： 4.9 V

ECM removal".
DTC P06A9
ECM installation".
2. Disconnect the harness connector from the oil ECM.
pressure sensor.
circuit and normal GND of the oil pressure sensor
harness connector.
voltage： 4.5 V
value, inspect to see if there is an open circuit or high 4. Perform a test-run under the conditions for running
resistance with the 5 V power supply circuit between the DTC.
the ECM and the oil pressure sensor.
Note：
6. If a problem is found, repair the 5 V power supply ・ Conditions for setting the DTCs such as
circuit. engine run time or coolant temperature, etc.,
7. Connect the test cable with fuse between the 5 V vary depending on the DTCs.
power supply circuit and signal circuit of the oil ・ For the conditions for setting the DTC, refer to
pressure sensor harness connector. the applicable code listed in 15E DTC
information.
voltage： 4.5 V
with the oil pressure sensor harness connector.
pressure sensor.
sensor removal".
oil pressure sensor.
connection.

ECM.
DTC P06A9
tool.
pressure sensor.
the DTC.
and the oil pressure sensor. ・ Conditions for setting the DTCs such as
information.
the oil pressure sensor.
Note：
・ The oil pressure sensor shares the GND circuit
with other sensors.
8. Inspect the oil pressure sensor harness connector for
a poor connection.
pressure sensor.
sensor removal".
connection.
ECM removal".
ECM installation".

tool.
voltage： 4.5 V
1 removal".
1 installation".
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.

1. DTC P0546 priority DTC 15. Observe the EGR gas temperature sensor 5 V
DTC P06A8
tool.
voltage： 0.1 V
circuit.
adjustment display on the trouble diagnosis scan Refer to "1.Engine 1J.Electrical(4HK1)
tool. ECM removal".
ECM installation".
11. Inspect for poor connections at the EGR gas 3. DTC P0546 confirm resolution
the DTC.
1 removal". Note：
information.
GND.

12Volt Circuit Error
1. DTC P0560 diagnostics ・ For the conditions for setting the DTC, refer to
1. Turn OFF the ignition switch. the applicable code listed in 15E DTC
information.
sensor. 5. Observe the DTC information with the trouble
4. If a DTC has not been detected, inspect the MAF
sensor harness connector for a poor connection.
sensor.
7. Inspect the 12 V power supply circuit between the
ECM and the MAF sensor.
power supply.
circuit.
connection.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

System Voltage High
1. Check if the battery charger has been recently
connected to the battery.
voltage： 32.0 V
value, inspect the charging system.
Generator inspection".
5. If a problem is found, repair the charging system.
6. If the charging system is normal, replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
diagnosis scan tool, and confirm that the value does
not exceed the specified value.
voltage： 32.0 V

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Confirm that the connecting sections of all tools are
securely connected.
2. Confirm that the programming device is operating
normally.
3. Verify that the correct injector ID code and fuel
delivery rate are input into the ECM with a trouble
Note：
・ If the injector ID code and the fuel delivery rate
are correctly input, clear the DTC with a
4. Turn OFF the ignition switch for at least 30 seconds.
has been detected.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Connect a trouble diagnosis scan tool. 4. Perform a test-run under the conditions for running
the DTC.
Note：
started. ・ Conditions for setting the DTCs such as
4. Observe the DTC information for DTC P0615 with a vary depending on the DTCs.
5. If a DTC is not set, start the engine. the applicable code listed in 15E DTC
6. Observe the DTC information for DTC P0615 with a information.
7. If a DTC is not set, an intermittent condition is
suspected.
8. If a DTC is set, inspect for a short to the battery
power supply circuit or ignition power supply circuit
in the control circuit of the ECM and starter cut
relay.
10. If a DTC is set in [4.], replace with another known
good starter cut relay.
started.
13. If a DTC is not set, replace the starter cut relay.
14. If a DTC is set, inspect for a short to GND in the
control circuit of the ECM and starter cut relay.
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P0638 priority DTC 14. If a problem is found, repair the motor circuit.
DTC P0122 15. If the motor circuit is normal, replace the intake
throttle valve.
DTC P0123
1. Remove the air intake hose from the intake throttle
valve.
2. Inspect the intake throttle valve.
・The intake throttle valve flow should not be limited.
・There should be no excessive deposit inside the throttle Note：
bore of the intake throttle valve. ・ The ignition switch must be once turned ON
・There should be no bending with the butterfly valve of and then turned OFF before clearing the DTC.
the intake throttle valve.
・The intake throttle valve should not be locked. 19. Clear the DTC using the trouble diagnosis scan tool.
3. If a problem is found, replace the intake throttle 20. Turn OFF the ignition switch for 1 minute or more.
valve. 21. Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake 22. Use the trouble diagnosis scan tool to check if a DTC
throttle valve removal". has been detected.
Refer to "1.Engine 1B.Mechanical(4HK1) Intake 23. If a DTC has been detected, replace the ECM.
4. Turn OFF the ignition switch. ECM removal".
5. Disconnect the harness connector from the intake Refer to "1.Engine 1J.Electrical(4HK1)
throttle valve. ECM installation".
6. Inspect the intake throttle valve harness connector 24. Set the Injector ID Code and engine No. on the
for a poor connection. ECM.
7. If a problem is found, repair the harness connector. 25. Perform SCR purging with a trouble diagnosis scan
8. Disconnect the harness connector from the ECM. tool.
9. Inspect the ECM harness connector for a poor 3. DTC P0638 confirm resolution
connection. 1. Turn ON the ignition switch.
10. If a problem is found, repair the harness connector. 2. Turn OFF the ignition switch for at least 30 seconds.
11. Inspect the intake throttle valve circuit for high Note：
resistance.
12. If a problem is found, repair the circuit. and then turned OFF before clearing the DTC.
13. Inspect the motor circuit between the ECM and the 3. Clear the DTC using the trouble diagnosis scan tool.
intake throttle valve.
power supply. 6. Perform a test-run while the intake throttle motor
・There should be no short together between motor drive duty is 20% or more.
circuits. 7. Observe the DTC information with the trouble
・There should be no short to the intake throttle position diagnosis scan tool. A DTC should not be set.
sensor circuit.

is detected.
5. If a DTC has not been detected, replace the main
relay.
6. Inspect the body grounding terminal for a poor
connection.
7. If a problem is found, repair the terminal.
8. Inspect the slow blow fuse.
9. If a problem is found, replace the slow blow fuse.
Note：
・ When the fuse is blown again, repair the cause
of slow-blow fuse blowout.
connection.
ECM removal".
ECM installation".
ECM.
tool.

2. Remove the main relay.
4. Use the trouble diagnosis scan tool to see if DTC
P0685 is detected.
5. If the DTC P0685 is not detected, repair the short
circuit to the battery power supply of the power
supply circuit between the ECM and main relay.
9. Use the trouble diagnosis scan tool to check if DTC
P0687 has been detected.
10. If the DTC P0687 is not detected, replace the main
relay.

1. DTC P06A6 diagnostics 2. DTC P06A6 confirm resolution
2. Disconnect the harness connector from the CKP 2. Turn OFF the ignition switch for 1 minute or more.
sensor
4. Measure the voltage between the CKP sensor 5 V the DTC.
power supply circuit of the CKP sensor harness
Note：
voltage： 5.5 V engine run time or coolant temperature, etc.,
5. If the reading is more than or equal to the specified vary depending on the DTCs.
value, inspect the CKP sensor 5 V power supply ・ For the conditions for setting the DTC, refer to
circuit between the ECM and the CKP sensor for a the applicable code listed in 15E DTC
short to the battery or a short to the ignition power information.
supply.
6. If a problem is found, repair the CKP sensor 5 V diagnosis scan tool. A DTC should not be set.
power supply circuit between the ECM and the CKP
sensor.
value, measure the voltage between the 5 V power
supply circuit of the CKP sensor harness connector
and the GND.
voltage： 4.5 V
value, replace the CKP sensor.
sensor removal".
value, inspect the CKP sensor 5 V power supply
circuit between the ECM and the CKP sensor for a
short to GND.
10. If a problem is found, repair the CKP sensor 5 V
ECM removal".
ECM installation".
ECM.
tool.

1. DTC P06A7 diagnostics Refer to "1.Engine 1C.Fuel System(4HK1) Common
sensor.
value, inspect the CMP sensor 5 V power supply
4. Measure the voltage between the CMP sensor 5 V circuit between the ECM and the CMP sensor for a
power supply circuit of the CMP sensor harness short to GND.
voltage： 5.5 V power supply circuit.
5. If the reading is more than or equal to the specified 18. Inspect the FRP sensor 5 V power supply circuit
value, inspect the CMP sensor 5 V power supply between the ECM and the FRP sensor for a short to
circuit between the ECM and the CMP sensor for a GND.
short to the battery or a short to the ignition power
supply.
7. Inspect the FRP sensor 5 V power supply circuit
ECM removal".
between the ECM and the FRP sensor for a short to
the battery or a short to the ignition power supply. Refer to "1.Engine 1J.Electrical(4HK1)
ECM installation".
power supply circuit. 21. Set the Injector ID Code and engine No. on the
ECM.
value, measure the voltage between the CMP sensor 22. Perform SCR purging with a trouble diagnosis scan
5 V power supply circuit of the CMP sensor harness tool.
voltage： 4.5 V
value, replace the CMP sensor.
sensor removal". 4. Perform a test-run under the conditions for running
the DTC.
sensor installation". Note：
pressure sensor.
13. Turn ON the ignition switch. information.
14. Measure the voltage between the CMP sensor 5 V 5. Observe the DTC information with the trouble
power supply circuit of the CMP sensor harness diagnosis scan tool. A DTC should not be set.
voltage： 4.5 V
value, replace the FRP sensor.

value, replace the intake throttle valve.
pressure sensor.
4. Measure the voltage between the boost pressure
value, inspect the boost pressure sensor 5 V power
voltage： 5.5 V pressure sensor for a short to GND.
5. If the reading is more than or equal to the specified 17. If a problem is found, repair the boost pressure
value, inspect the boost pressure sensor 5 V power sensor 5 V power supply circuit.
pressure sensor for a short to the battery or a short to
position sensor for a short to GND.
6. If a problem is found, repair the boost pressure
19. If a problem is found, repair the intake throttle
position sensor 5 V power supply circuit.
position sensor for a short to the battery or a short to Refer to "1.Engine 1J.Electrical(4HK1)
the ignition power supply. ECM removal".
8. If a problem is found, repair the intake throttle Refer to "1.Engine 1J.Electrical(4HK1)
position sensor 5 V power supply circuit. ECM installation".
value, measure the voltage between the boost ECM.
pressure sensor 5 V power supply circuit of the boost
pressure sensor harness connector and the GND.
tool.
voltage： 4.5 V
value, replace the boost pressure sensor.
sensor/boost temperature sensor removal". 3. Start the engine.
Refer to "1.Engine 1F.Induction(4HK1) Pressure 4. Perform a test-run under the conditions for running
sensor/boost temperature sensor installation". the DTC.
11. If the reading is less than or equal to the specified Note：
value, turn OFF the ignition switch. ・ Conditions for setting the DTCs such as
12. Disconnect the harness connector from the intake engine run time or coolant temperature, etc.,
throttle position sensor. vary depending on the DTCs.
14. Measure the voltage between the boost pressure information.
voltage： 4.5 V

value, replace the oil pressure sensor.
2. Remove the harness connector from the EGR valve
sensor removal".
position sensor.
4. Measure the voltage between the EGR valve position
sensor 5 V power supply terminal of the EGR valve
value, inspect the EGR valve position sensor 5 V
position sensor harness connector and the GND.
voltage： 5.5 V valve position sensor for a short to GND.
5. If the reading is more than or equal to the specified 17. If a problem is found, repair the EGR valve position
value, inspect the EGR valve position sensor 5 V sensor 5 V power supply circuit.
valve position sensor for a short to the battery or a
a short to GND.
6. If a problem is found, repair the EGR valve position
19. If a problem is found, repair the oil pressure sensor 5
a short to the battery or a short to the ignition power Refer to "1.Engine 1J.Electrical(4HK1)
supply. ECM removal".
8. If a problem is found, repair the oil pressure sensor 5 Refer to "1.Engine 1J.Electrical(4HK1)
V power supply circuit. ECM installation".
value, measure the voltage between the EGR valve ECM.
position sensor 5 V power supply terminal of the
EGR valve position sensor harness connector and the
tool.
GND.
voltage： 4.5 V
value, replace the EGR valve. 2. Turn OFF the ignition switch for 1 minute or more.
Refer to "1.Engine 1H.Aux. Emission Control the DTC.
Note：
12. Remove the harness connector from the oil pressure vary depending on the DTCs.
information.
14. Measure the voltage between the oil pressure sensor
5 V power supply terminal of the oil pressure sensor
harness connector and the GND.
voltage： 4.5 V

1. DTC P06AF diagnostics
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
2. DTC P06AF confirm resolution
the DTC.
Note：
information.

1. DTC P06D5 diagnostics
2. Measure the voltage of the ECM SP-5V5 terminal.
the ECM.
ECM removal".
ECM installation".
ECM.
tool.
2. DTC P06D5 confirm resolution
the DTC.
Note：
information.

information.
2. Disconnect the harness connector from charge air
voltage： 4.5 V
value, replace charge air cooler temperature sensor 1.
charge air cooler temperature sensor 1 for a short to
GND.
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

value, inspect the charge air cooler temperature
DTC P06A8
sensor 1 GND circuit for an open circuit or high
2. DTC P1077 diagnostics resistance.
1. Turn OFF the ignition switch. Note：
2. Disconnect the harness connector from charge air ・ Charge air cooler temperature sensor 1 shares
cooler temperature sensor 1. the GND circuit with other sensors.
3. Turn ON the ignition switch. ・ DTCs on sensors that share this circuit may be
set.
4. Measure the voltage between the charge air cooler
GND. 18. Inspect the charge air cooler temperature sensor 1
signal circuit for an open circuit or high resistance.
voltage： 5.5 V
and charge air cooler temperature sensor 1 for a short connector.
cooler temperature sensor 1 signal circuit and the
ECM removal".
GND circuit.
ECM installation".
voltage： 0.1 V
ECM.
tool.
and charge air cooler temperature sensor 1 for a short
to the 5 V power supply circuit. 3. DTC P1077 confirm resolution
11. Inspect for poor connections at the charge air cooler 2. Turn OFF the ignition switch for 1 minute or more.
13. If the harness connector is normal, replace charge air the DTC.
Note：
Refer to "1.Engine 1F.Induction(4HK1) Charge air ・ Conditions for setting the DTCs such as
cooler temperature sensor 1 removal". engine run time or coolant temperature, etc.,
Refer to "1.Engine 1F.Induction(4HK1) Charge air vary depending on the DTCs.
cooler temperature sensor 1 installation". ・ For the conditions for setting the DTC, refer to
information.
cooler temperature sensor 1 signal circuit and a
known good GND. 5. Observe the DTC information with the trouble
voltage： 0.1 V

DTC P0092 12. Inspect to see if there is clogging with the fuel
DTC P0192 system between the fuel tank and the fuel supply
pump.
DTC P0193
13. If a problem is found, repair the clogging of the fuel
DTC P0201 system.
DTC P0202 14. Inspect the fuel hose between the fuel tank and the
DTC P0203 fuel supply pump for a cut and crack.
DTC P0204 15. If a problem is found, replace the fuel hose.
DTC P2146 Note：
DTC P2149 ・ The fuel hose between the fuel tank and the
2. DTC P1093 diagnostics state when the engine is running.
1. Turn OFF the ignition switch. ・ When the fuel hose is not connected securely,
the air can enter.
pressure is released from the common rail. ・ When the engine speed or the engine load
increases while the air has intruded in the fuel
specified time： 2 min system, fluctuation in the common rail
3. Turn ON the ignition switch. pressure is caused, and DTC P1093 may be
detected.
fuel rail pressure sensor display is within the 16. Check that an appropriate clamp is used between the
specified range. fuel tank and the fuel supply pump.
voltage： 0.9 to 1.0 V 17. If a problem is found, replace the clamp.
5. If the fuel rail pressure sensor display is outside the 18. Operate the priming pump until the handle becomes
specified range, inspect the fuel pressure sensor heavy.
harness connector for a poor connection. Note：
6. If a problem is found, repair the harness connector. ・ When a leak exists in the fuel system between
connection.
not become heavy.
10. If a problem is found, repair the circuit. check for fuel leak between the fuel supply pump
and common rail.
replace the fuel pressure sensor. Note：
Refer to "1.Engine 1C.Fuel System(4HK1) Common ・ The fuel may leak to the bottom section of the
rail assembly removal". cylinder head cover from the high pressure
hose inlet.
・ The engine oil level increases when the fuel
cover.
・ Inspect for fuel leaks into the engine oil.
22. Turn OFF the ignition switch. 35. Replace the fuel filter element.
23. Remove the fuel hose on the fuel supply pump side Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
from the fuel filter. element removal".
Note： Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
・ Use a pan to catch the fuel from the removed element installation".
connection hose.
securely.
・ If the pressure gauge is likely to indicate a
・ Repeat this until the engine starts. ・ Air mixture is checked with the negative
pressure amount while the fuel flow is being
blocked.
time or longer.
39. If the specified negative pressure cannot be
generated, inspect to see if there is a cut or crack
27. While allowing the engine to keep the specified with the fuel hose.
pressure gauge.
appropriate one.
inspection. 43. Turn OFF the ignition switch.
values: (-17.0) kPa {5 inHg / (-2) psi} 44. Inspect the suction control valve harness connector
Note：
・ Fuel clogging is checked with the negative 45. If a problem is found, repair the harness connector.
pressure amount in the fuel system. 46. Inspect the ECM harness connector for a poor
29. If the negative pressure is more than or equal to the connection.
specified value, inspect to see if there is damage or 47. If a problem is found, repair the harness connector.
pump and the fuel tank. 48. Inspect each circuit for high resistance.
30. If a problem is found, repair the fuel system. 49. If a problem is found, repair the circuit.
31. Inspect the fuel tank bent hose. 50. If the suction control valve harness connector and the
ECM harness connector are normal and there is no
32. If a problem is found, repair the bent hose. high resistance in each circuit, replace the fuel
33. Check to see if there is any foreign matter in the fuel supply pump and the fuel filter element.
tank or any foreign matter which can cause fuel Refer to "1.Engine 1C.Fuel System(4HK1) Fuel supply
clogging. pump removal".
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter engine run time or coolant temperature, etc.,
element removal". vary depending on the DTCs.
information.
Note：
・ When replacing the fuel supply pump, it is diagnosis scan tool. A DTC should not be set.
at the same time.
51. If the negative pressure is normal, turn OFF the
ignition switch.
54. Perform the injector stop test with the trouble
55. Check to see if any injector does not change the
engine speed when OFF is instructed.
when OFF is instructed, replace the relevant injector.
Injector removal".
ID code on the ECM.
58. If the engine speed changes when OFF is instructed
to all injectors, replace the pressure limiter valve.
Note：
・ Do not replace the pressure limiter valve
the DTC.

information.
temperature sensor.
voltage： 4.5 V
value, replace the boost temperature sensor.
5. Inspect the signal circuit between the ECM and boost
temperature sensor signal circuit for a short to GND.
connector.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：

1. DTC P1098 priority DTC the boost temperature sensor for an open circuit or
high resistance.
DTC P06A8
Note：
・ The boost temperature sensor shares the
1. Turn OFF the ignition switch. GND circuit with other sensors.
2. Disconnect the harness connector from the boost ・ DTCs on sensors that share this circuit may be
temperature sensor. set.
3. Turn ON the ignition switch. 17. If a problem is found, repair the GND circuit.
4. Measure the voltage between the boost temperature 18. Inspect the signal circuit between the ECM and the
sensor signal circuit and a known good GND. boost temperature sensor for an open circuit or high
resistance.
voltage： 5.5 V
and the boost temperature sensor for a short to the connector.
temperature sensor signal circuit and GND circuit.
ECM removal".
ECM installation".
voltage： 0.1 V
and the boost temperature sensor for a short to the 5
tool.
sensor harness connector. 2. Turn OFF the ignition switch for 1 minute or more.
13. If the harness connector is normal, replace the boost 4. Perform a test-run under the conditions for running
temperature sensor. the DTC.
Refer to "1.Engine 1F.Induction(4HK1) Pressure Note：
sensor/boost temperature sensor removal". ・ Conditions for setting the DTCs such as
Refer to "1.Engine 1F.Induction(4HK1) Pressure engine run time or coolant temperature, etc.,
sensor/boost temperature sensor installation". vary depending on the DTCs.
temperature sensor signal circuit and a known good
information.
GND.
voltage： 0.1 V

1. DTC P1236 priority DTC Refer to "1.Engine 1F.Induction(4HK1) Charge air
DTC P1076
19. Inspect the boost temperature sensor.
DTC P1077
DTC P1097
DTC P1098
20. If a problem is found, replace the boost pressure
2. DTC P1236 diagnostics sensor.
1. Turn OFF the ignition switch. Refer to "1.Engine 1F.Induction(4HK1) Pressure
2. Inspect the intercooler.
Refer to "1.Engine 1F.Induction(4HK1)
Intercooler inspection".
3. If a problem is found, repair or replace the
intercooler. 1. Clear the DTC with a trouble diagnosis scan tool.
4. Disconnect the harness connector from charge air 2. Turn OFF the ignition switch for 1 minute or more.
5. Inspect for poor connections at the charge air cooler
the DTC.
Note：
7. Disconnect the harness connector from the boost ・ Conditions for setting the DTCs such as
temperature sensor. engine run time or coolant temperature, etc.,
8. Inspect for poor connections at the boost temperature vary depending on the DTCs.
sensor harness connector. ・ For the conditions for setting the DTC, refer to
9. If a problem is found, repair the harness connector. the applicable code listed in 15E DTC
information.
11. Inspect for poor connections at the ECM harness diagnosis scan tool. A DTC should not be set.
connector.
13. Inspect the circuit between the ECM and the charge
air cooler temperature sensor 1 for high resistance.
15. Inspect the circuit between the ECM and the boost
temperature sensor for high resistance.
17. Inspect the charge air cooler temperature sensor 1.
cooler temperature sensor 1 inspection".
18. If a problem is found, replace the charge air cooler

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

EGR Position Fault
1. DTC P1404 priority DTC 14. If a problem is found, repair the motor circuit.
DTC P0404 15. If the circuit is normal, replace the EGR valve.
DTC P0409 Refer to "1.Engine 1H.Aux. Emission Control
1. Remove the EGR valve assembly from the engine.
・There should be nothing to limit flow inside the EGR
valve. 3. Start the engine.
・There should be no excessive accumulates inside the
EGR valve.
the DTC.
・There should be no bending with the valve shaft or
valve itself inside the EGR valve. Note：
3. If a problem is found, repair or replace the EGR ・ Conditions for setting the DTCs such as
valve. engine run time or coolant temperature, etc.,
Refer to "1.Engine 1H.Aux. Emission Control information.
valve.
connection.
connection.
11. Inspect the EGR valve circuit between the ECM and
the EGR valve for an open circuit and high
resistance.
12. If a problem is found, repair the EGR valve circuit.
13. Inspect the motor circuit between the ECM and EGR
valve.
power supply.
・There should be no short to other circuits.
・There should be no short to EGR position sensor
circuit.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

AD-IC Failure Error
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

AD-IC2 Failure Error
1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
・ Conditions for setting engine run time or
coolant temperature vary depending on the
DTCs.
information.

ECM.
tool.
the DTC.
Note：
Caution：
information.
EEPROM error. 4. Observe the DTC information with the trouble
EEPROM error.
correctly.
tool.
Note：
ECM removal".
ECM installation".

ECM.
tool.
the DTC.
Note：
Caution：
information.
EEPROM error. 4. Observe the DTC information with a trouble
EEPROM error.
correctly.
tool.
Note：
ECM removal".
ECM installation".

DPD Lamp Control Circuit
ECM.
1. Verify that the monitor panel operates properly.
tool.
3. Inspect the fuse.
24. If the DPD lamp is not illuminated, remove the DPD
4. If a problem is found, replace the fuse. lamp valve from the monitor panel.
Note： 25. Inspect the DPD lamp bulb.
・ If the fuse is blown again, repair the cause of 26. If a problem is found, replace the bulb.
fuse blowout.
27. Inspect the ignition power supply circuit between the
5. Turn OFF the ignition switch. fuse and the monitor panel for an open circuit or high
6. Disconnect the harness connector from the ECM. resistance.
7. Turn ON the ignition switch. 28. If a problem is found, repair the ignition power
supply circuit.
8. Check that the DPD lamp is turned OFF.
29. Inspect the DPD lamp control circuit between the
9. If the DPD lamp is not turned OFF, repair the short ECM and the monitor panel for an open circuit or
to GND in the DPD lamp control circuit between the high resistance.
ECM and the monitor panel.
31. Inspect for poor connections at the monitor panel
11. Remove the fuse. harness connector.
12. Turn ON the ignition switch. 32. If a problem is found, repair the harness connector.
13. Measure the voltage between the ECM harness 33. If the harness connector is normal, replace the
connector DPD lamp control circuit and the GND. monitor panel.
14. If the reading is more than or equal to the specified 1. Clear the DTC with the trouble diagnosis scan tool.
value, repair the short to the battery or the short to
the ignition power supply circuit in the DPD lamp 2. Turn OFF the ignition switch for 1 minute or more.
control circuit between the ECM and the monitor 3. Turn ON the ignition switch and wait for 40 seconds.
panel.
16. Install the fuse. diagnosis scan tool. A DTC should not be set.
17. Connect a fused jumper wire between the DPD lamp
control circuit of the ECM harness connector and the
GND.
19. If the DPD lamp illuminates, inspect for poor
connections at the ECM harness connector.
ECM removal".
ECM installation".

the DTC.
Note：
information.

the DTC.
Note：
information.

SCR System Error
1. DTC P20C9 diagnostics
1. Observe the DTU DTC information with a trouble
2. DTC P20C9 confirm resolution
the DTC.
Note：
information.

ECM installation".
DTC P06A6
ECM.
2. Disconnect the harness connector from the tool.
voltage： 4.5 V
5. If the reading is less than or equal to the specified pedal sensor 1 display on the trouble diagnosis scan
value, inspect to see if there is an open circuit or high tool.
6. If a problem is found, repair the 5 V power supply depressing and then releasing the pedal.
circuit.
voltage： 0.2 V
voltage： 4.5 V
connector.
circuit.
connection.
ECM removal".

tool.
DTC P06A6
accelerator position sensor. 3. Start the engine and fully depress and release the
tool.
voltage： 0.1 V
4. If the reading is more than or equal to the specified show a value at or above the specified value while
value, inspect the sensor 1 signal circuit between the depressing and then releasing the pedal.
ECM and the accelerator position sensor.
voltage： 4.9 V
power supply.
・There should be no short to the 5 V power supply.
circuit.
supply.
connection.
position sensor.
connection.
ECM removal".
ECM installation".
ECM.

ECM installation".
DTC P06A6
ECM.
2. Disconnect the harness connector from the tool.
voltage： 4.5 V
5. If the reading is less than or equal to the specified pedal sensor 2 display on the trouble diagnosis scan
value, inspect to see if there is an open circuit or high tool.
6. If a problem is found, repair the 5 V power supply depressing and then releasing the pedal.
circuit.
voltage： 0.2 V
voltage： 4.5 V
connector.
circuit.
connection.
ECM removal".

tool.
DTC P06A6
accelerator position sensor. 3. Start the engine and fully depress and release the
tool.
voltage： 0.1 V
4. If the reading is more than or equal to the specified show a value at or above the specified value while
value, inspect the sensor 2 signal circuit between the depressing and then releasing the pedal.
ECM and the accelerator position sensor.
voltage： 4.9 V
power supply.
・There should be no short to the 5 V power supply.
circuit.
supply.
connection.
position sensor.
connection.
ECM removal".
ECM installation".
ECM.

tool.
DTC P06A6
DTC P2122
DTC P2123
DTC P2127
DTC P2128
4. While checking the DTC information with the
trouble diagnosis scan tool, fully depress and then
1. Turn OFF the ignition switch. release the accelerator pedal.
2. Disconnect the harness connector from the 5. Observe the DTC information with the trouble
accelerator position sensor. diagnosis scan tool. A DTC should not be set.
3. Inspect the accelerator position sensor harness
connection.
8. Inspect to see if there is high resistance in the circuit
between the ECM and accelerator position sensor.
10. Inspect to see if there is a short between circuits in
the signal circuit between the ECM and the
12. If the circuit is normal, replace the accelerator
position sensor.
17. While checking for a DTC with the trouble diagnosis
scan tool, fully depress and then release the
accelerator pedal.
ECM removal".
ECM installation".
ECM.

connection.
2. Disconnect the harness connector from the cylinder
head injector harness intermediate connector. 17. Inspect to see if there is an open circuit or high
resistance with the charge voltage circuit between
the ECM and the injector harness intermediate
4. Measure the voltage between the solenoid control connector.
circuit and GND.
Note： circuit.
・ Solenoid control circuit and GND of the No.1 19. Remove the cylinder head cover.
cylinder injector
・ Solenoid control circuit and GND of the No.4
head cover removal".
cylinder injector
20. Inspect the injector harness tightening nut for
voltage： 12.0 V
looseness.
21. If the injector harness tightening nut is loose, tighten
it.
GND with the control circuit between the ECM and
injector harness intermediate connector. 22. Inspect to see if any foreign matter is attached to the
injector terminal.
23. If any foreign matter is attached to the injector
terminal, remove it.
and the injector harness intermediate connector.
24. Inspect the injector harness intermediate harness
Note：
is present. 25. If a problem is found, repair the intermediate harness
connector.
・ No short circuit to GND is present.
26. Check if insulation resistance of the No.1 cylinder
and No.4 cylinder injector is at or above the
circuit.
specified value.
the injector harness intermediate connector is
normal, replace the ECM. 27. If the reading is less than or equal to the specified
value, replace the relevant injector.
ECM removal". Refer to "1.Engine 1C.Fuel System(4HK1)
Injector removal".
ECM installation". Refer to "1.Engine 1C.Fuel System(4HK1)
ECM. 28. Set the injector ID code on the ECM.
11. Perform SCR purging with a trouble diagnosis scan 29. If the reading is more than or equal to the specified
tool. value, repair or replace the injector harness.
12. Inspect the injector harness intermediate connector 2. DTC P2146 confirm resolution
the DTC.
Note：
information.

connection.
2. Disconnect the harness connector from the cylinder
head injector harness intermediate connector. 17. Inspect to see if there is an open circuit or high
resistance with the charge voltage circuit between
the ECM and the injector harness intermediate
4. Measure the voltage between the solenoid control connector.
circuit and GND.
Note： circuit.
・ Solenoid control circuit and GND of the No.2 19. Remove the cylinder head cover.
cylinder injector
・ Solenoid control circuit and GND of the No.3
head cover removal".
cylinder injector
20. Inspect the injector harness tightening nut for
voltage： 12.0 V
looseness.
21. If the injector harness tightening nut is loose, tighten
it.
GND with the control circuit between the ECM and
injector harness intermediate connector. 22. Inspect to see if any foreign matter is attached to the
injector terminal.
23. If any foreign matter is attached to the injector
terminal, remove it.
and the injector harness intermediate connector.
24. Inspect the injector harness intermediate harness
Note：
is present. 25. If a problem is found, repair the intermediate harness
connector.
・ No short circuit to GND is present.
26. Check if the insulation resistance of the No.2
cylinder injector and No.3 cylinder injector is more
circuit.
than or equal to the specified value.
the injector harness intermediate connector is
normal, replace the ECM. 27. If the reading is less than or equal to the specified
value, replace the relevant injector.
ECM removal". Refer to "1.Engine 1C.Fuel System(4HK1)
Injector removal".
ECM installation". Refer to "1.Engine 1C.Fuel System(4HK1)
ECM. 28. Set the injector ID code on the ECM.
11. Perform SCR purging with a trouble diagnosis scan 29. If the reading is more than or equal to the specified
tool. value, repair or replace the injector harness.
12. Inspect the injector harness intermediate connector 2. DTC P2149 confirm resolution
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. Replace the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

1. DTC P2457 priority DTC 18. Inspect the circuit between the ECM and EGR gas
DTC P040B
DTC P040C
20. Replace the EGR cooler.
DTC P040D
DTC P041C
DTC P041D
2. DTC P2457 diagnostics Devices(4HK1) EGR valve installation".
1. Turn OFF the ignition switch. 3. DTC P2457 confirm resolution
2. Inspect the EGR cooler. 1. Clear the DTC with a trouble diagnosis scan tool.
Refer to "1.Engine 1H.Aux. Emission Control 2. Turn OFF the ignition switch for 1 minute or more.
Devices(4HK1) EGR valve inspection".
3. Inspect the engine coolant system.
・Engine coolant level the DTC.
・Engine coolant leakage
Note：
4. If a problem is found, repair the applicable area. ・ Conditions for setting the DTCs such as
5. Inspect the EGR system. engine run time or coolant temperature, etc.,
・Exhaust gas leakage
・Engine coolant leakage into the EGR gas passage ・ For the conditions for setting the DTC, refer to
・Breakage or damage of the EGR cooler the applicable code listed in 15E DTC
・Misdetection or delayed response of EGR gas information.
temperature sensor 1 or 2 5. Observe the DTC information with the trouble
connector.
16. Inspect the circuit between the ECM and EGR gas

DTC P0427
DTC P0428
DTC P042C
DTC P042D
・There should be no absence or damage of the exhaust
pipe gasket.
・There should be no exhaust gas leak from the exhaust
system.
・The exhaust system should not be modified.
・There should be no incorrect detection or slow response
from the exhaust gas temperature sensor.
2. If a problem is found, repair or replace the exhaust
system.
DTC P2BA7 (Flash Code 611)

Urea Fluid Quantity Too Low
1. DTC P2BA7 diagnostics
1. Check the remaining amount of urea fluid in the urea
fluid tank.
2. If the urea fluid is low, add the specified urea fluid.
2. DTC P2BA7 confirm resolution
the DTC.
Note：
information.

1. DTC P2BAA diagnostics
2. DTC P2BAA confirm resolution
the DTC.
Note：
information.

1. DTC P3093 priority DTC Refer to "1.Engine 1C.Fuel System(4HK1) Common
DTC P0087
DTC P0091
DTC P0092
Note：
common rail (fuel rail) assembly.
DTC P0201
14. Inspect the fuel system between the fuel tank and the
DTC P0202 fuel supply pump for clogging.
DTC P0203 15. If a problem is found, repair the clogging of the fuel
DTC P0204 system.
DTC P2146 16. Inspect the fuel hoses between the fuel tank and the
fuel supply pump for cuts or cracks.
DTC P2149
Note：
1. Inspect the fuel quality.
・ A slight vacuum is applied to the fuel hoses
Note： between the fuel tank and the fuel supply
・ Check whether the fuel is being used in pump when the engine is running.
accordance with the outside air temperature ・ If the fuel hose is not connected securely, air
when the weather is cold. can get inside.
2. If the fuel quality is inadequate, replace it. ・ If the engine speed or the engine load
increases when air has entered the fuel
system, fluctuation in the common rail (fuel
4. Wait for the specified time to reduce the fuel rail) pressure occurs, and DTC P3093 may be
pressure from the common rail (fuel rail). set.
specified time： 2 min 18. Check that an appropriate clamp is used between the
fuel tank and the fuel supply pump.
fuel rail pressure sensor display is within the 20. Operate the priming pump until the force required
specified range. for pressing increases.
7. If the fuel rail pressure sensor display is outside the ・ When a leakage exists in the fuel system
specified range, inspect for poor connections at the between the priming pump and the fuel supply
FRP sensor harness connector. pump, the pressing weight of the priming pump
does not become heavy.
connector. 22. Inspect the high-pressure side of the fuel system and
check for a fuel leakage between the fuel supply
10. If a problem is found, repair the harness connector. pump and the common rail (fuel rail).
11. Inspect each circuit for high resistance. Note：
12. If a problem is found, repair the circuit. ・ The fuel may leak under the cylinder head
cover from the inlet of the high pressure hose.
replace the FRP sensor. ・ If the fuel leaks under the cylinder head cover,
the engine oil level will increase.
・ Inspect for fuel leakage into the engine oil. 35. Check for foreign material in the fuel tank or for
foreign material that may clog the fuel.
23. If fuel leak is found, repair it.
37. Replace the fuel filter element.
from the fuel filter. Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter
element removal".
Note：
・ Use a pan to catch the fuel from the removed
fuel hose.
・ Clean the pressure gauge and connection 38. If the vacuum is less than or equal to the specified
hose before connecting to the fuel piping. value, pinch the fuel hose at a position as close as
possible to the fuel tank, so that the fuel does not
・ The fuel supply pump may be damaged due to
flow.
the foreign material that has intruded into the
26. Connect a pressure gauge between the fuel filter and ・ The fuel pipe can be disconnected and
the removed fuel hose. clogged with a plug.
・ Check whether the fuel system is securely
connected. 40. Check the pressure gauge.
27. Bleed the air with the priming pump, and crank the Specified value: (-27.0) kPa {8 inHg / (-4) psi}
engine within the specified period of time.
Note：
specified time： 5 s ・ When the pressure gauge is likely to indicate a
Note： value exceeding the specified value during
inspection, release the fuel being blocked.
・ Repeat the process until the engine starts.
・ Air mixture is checked with the vacuum
28. Allow the engine to idle for at least the specified amount while the fuel flow is being blocked.
duration.
41. If the specified vacuum cannot be maintained,
specified time： 1 min inspect the fuel hoses for cuts or cracks.
29. While allowing the engine to keep the specified 42. If a problem is found, replace the fuel hose.
pressure gauge. 43. Inspect to see if appropriate clamp is used.
specified time： 1 min 44. If a problem is found, replace with an appropriate

clamp.
30. Check if the vacuum reading displayed is the
specified value or more when inspecting the pressure 45. Turn OFF the ignition switch.
gauge. 46. Inspect for poor connections at the FRP regulator
Specified value: (-17.0) kPa {5 inHg / (-2) psi} harness connector.

・ Fuel clogging is checked with the vacuum 48. Inspect for poor connections at the ECM harness
amount in the fuel system. connector.
31. If the vacuum is more than or equal to the specified 49. If a problem is found, repair the harness connector.
value, inspect the fuel system between the fuel
supply pump and the fuel tank for damage or
twisting. 51. If a problem is found, repair the circuit.
32. If a problem is found, repair the fuel system. 52. If the FRP regulator harness connector and the ECM
33. Inspect the fuel tank vent hose.
34. If a problem is found, repair the vent hose. pump and the fuel filter element.
pump removal". the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1) Fuel filter engine run time or coolant temperature, etc.,
element removal". vary depending on the DTCs.
information.
Note：
filter element must be replaced at the same
time.
53. If the vacuum is normal, turn OFF the ignition
switch.
56. Perform the injector stop test with a trouble
57. Check for any injectors that do not change the engine
speed when commanded OFF.
58. If there are any injectors that do no change the
engine speed when commanded OFF, replace the
applicable injectors.
Injector removal".
Code on the ECM.
60. If the engine speed changes for all injectors when the
OFF command is given, replace the pressure limiter
valve.
Note：
・ Do not replace the pressure limiter with a
separate unit. If a problem is found, replace
the common rail (fuel rail) assembly.

1. DTC U0001 diagnostics 15. Disconnect the harness connector from the ECM.
1. Turn OFF the ignition switch. 16. Measure the resistance between the terminals of the
termination resistor harness connector. Note：
Note：・ Measure from behind while the harness
connector is connected.
connector is connected. resistance： 110 to 130 Ω
・ Verify that the parallel resistance of the 120 Ω 17. Replace the ECM if the resistance is within the
resistor in the termination resistor and that of specified range.
the 120 Ω resistor in the ECM are both 60 Ω.
resistance： 50 to 70 Ω ECM removal".
3. Disconnect the harness connector from the Refer to "1.Engine 1J.Electrical(4HK1)
termination resistor if the resistance is outside the ECM installation".
specified range.
18. Set the Injector ID Code on the ECM.
4. Measure the resistance of the termination resistor.
19. Set the engine No. for the ECM.
5. If the resistance is outside the specified range,
replace the termination resistor. 21. Disconnect the harness connector from the DCU,
turbo control unit, and ECM.
6. Connect the harness connector to the termination
resistor. 22. Inspect the CAN-Low circuit and the CAN-High
circuit between each control unit.
8. Measure the resistance between the terminals of the power supply.
termination resistor harness connector. ・There should be no open circuit or high resistance.
Note：・There should be no short to GND.
・ Measure from behind while the harness 23. If the CAN circuit is normal, turn OFF the ignition
connector is connected. switch.
resistance： 50 to 70 Ω 24. Connect the harness connector to the DCU.
9. Replace the DCU if the resistance is within the 25. Measure the voltage between the CAN-High
specified range. terminal of the termination resistor harness connector
and the GND.
10. Connect the harness connector to the DCU.
of the termination resistor harness connector and
control unit.
GND.
Note：
the DCU.
connector is connected. 28. Turn OFF the ignition switch.
resistance： 50 to 70 Ω 29. Connect the harness connector to the turbo control

unit.
13. If the resistance is within the specified range, replace
the turbo control unit. 30. Turn ON the ignition switch.
14. Connect the harness connector to the turbo control

unit.
and the GND.
GND.
the turbo control unit.
and the GND.
GND.
the ECM.
ECM removal".
ECM installation".
ECM.
tool.
the DTC.
Note：
information.

ECM installation".
termination resistor harness connector. 14. Set the engine No. for the ECM.
Note： 15. Turn OFF the ignition switch.
・ Make a measurement from the back with the 16. Disconnect the harness connector from the control
harness connector connected. unit of the machine or ECM.
・ Confirm that the parallel resistance of the 120
17. Inspect the CAN-Low circuit and the CAN-High
Ω resistor in the termination resistor and that of
circuit between each control unit.
the 120 Ω resistor in the ECM are both 60Ω.
power supply.
3. Disconnect the harness connector from termination ・There should be no open circuit or high resistance.
resistor if the resistance value is outside the specified ・There should be no short to GND.
range.
18. If the CAN circuit is normal, turn OFF the ignition
4. Measure the resistance of the termination resistor. switch.
resistance： 110.0 to 130.0 Ω 19. Connect the harness connector to the ECM.
5. If the resistance value is outside the specified range, 20. Turn ON the ignition switch.
replace the termination resistor.
6. Connect the harness connector to the termination terminal of the termination resistor harness connector
resistor . and the GND.
7. Disconnect the harness connector from the control 22. Measure the voltage between the CAN-Low terminal
unit of the machine. of the termination resistor harness connector and the
GND.
termination resistor harness connector. voltage： 1.5 to 3.5 V
Note： 23. If the voltage is outside the specified range, replace
・ Make a measurement from the back with the the ECM.
harness connector connected. Refer to "1.Engine 1J.Electrical(4HK1)
resistance： 50.0 to 70.0 Ω ECM removal".
9. If the resistance value is within the specified range, Refer to "1.Engine 1J.Electrical(4HK1)
replace the control unit of the machine. ECM installation".
10. Disconnect the harness connector from the ECM. 24. Set the Injector ID Code and engine No. on the
ECM.
termination resistor harness connector. 25. Perform SCR purging with a trouble diagnosis scan
tool.
Note：
harness connector connected. 27. Connect the harness connector to the control unit of
the machine.
12. Replace the ECM if the resistance value is within the
range of specified value. 29. Measure the voltage between the CAN-High
and the GND.
ECM removal".
GND.
the control unit of the machine.
1. Use the trouble diagnosis scan tool to clear the DTC.
the DTC.
Note：
information.

1. DTC U0101 diagnostics 15. Set the Injector ID Code and engine No. on the
ECM.
1. Inspect the CAN-Low circuit and CAN-High circuit
between the ECM and the control unit of the 16. Perform SCR purging with a trouble diagnosis scan
machine. tool.
・There should be no short to the battery or ignition 2. DTC U0101 confirm resolution
power supply.
・There should be no short to GND. 2. Turn OFF the ignition switch for 1 minute or more.
2. If a problem is found, repair the CAN circuit. 3. Start the engine.
3. If the CAN circuit is normal, connect all harnesses. 4. Perform a test-run under the conditions for running
the DTC.
Note：
6. Perform a test-run under the conditions for running engine run time or coolant temperature, etc.,
the DTC. vary depending on the DTCs.
・ Conditions for setting engine run time or the applicable code listed in 15E DTC
coolant temperature vary depending on the information.
DTCs. 5. Observe the DTC information with the trouble
・ For the conditions for setting the DTC, refer to diagnosis scan tool. A DTC should not be set.
information.
7. Check the DTC.
8. If a DTC has been detected, replace the control unit
of the machine.
the DTC.
Note：
・ Conditions for setting engine run time or
coolant temperature vary depending on the
DTCs.
information.
13. Check the DTC.
ECM removal".
ECM installation".

1. DTC U010E diagnostics 5. Observe the DTC information with the trouble
connector CAN High circuit and a known good
GND.
the CAN High circuit between the DCU and the
connector CAN Low circuit and a known good
GND.
the CAN Low circuit between the DCU and the
connector.
2. DTC U010E confirm resolution
the DTC.
Note：
information.

1. DTC U0110 priority DTC
DTC P0045
DTC U0001
2. Remove the harness connector from the turbo control
unit.
4. Measure the voltage between the CAN-High circuit
and GND of the turbo control unit harness connector.
5. Measure the voltage between the CAN-High circuit
and GND of the turbo control unit harness connector.
6. If it is outside the specified range, inspect to see if
CAN-High circuit between the turbo control unit and
the ECM.
7. If a problem is found, repair the CAN-High circuit.
resistance with the CAN-Low circuit between the
turbo control unit and the ECM.
9. If a problem is found, repair the CAN-Low circuit.
10. Inspect the turbo control unit harness connector for a
poor connection.
12. Replace the turbo control unit.
the DTC.
Note：
information.

1. DTC U0411 priority DTC 3. Start the engine.
the DTC.
DTC U0001
Note：
1. Inspect the CAN circuit between the turbo control engine run time or coolant temperature, etc.,
unit and the ECM. vary depending on the DTCs.
・There should be no short to the battery or ignition ・ For the conditions for setting the DTC, refer to
power supply. the applicable code listed in 15E DTC
・There should be no open circuit or high resistance. information.
2. If a problem is found, repair the CAN circuit. diagnosis scan tool. A DTC should not be set.
3. Inspect the turbo control unit harness connector for a
poor connection.
10. Check the DTC.
11. If a DTC is set, replace the turbo control unit.
17. Check the DTC.
ECM removal".
ECM installation".
ECM.
tool.

Lost CAN Communications With Wheel Loader Transmission Control System
2. Inspect the CAN circuit between the machine control
unit and the ECM for a short circuit, an open circuit,
or high resistance.
4. Inspect for poor connections at the harness
connector.
connector.
the DTC.
Note：
information.
Maintenance Information (Urea SCR System) 38B-1
Description Emission Control

Maintenance Information
(Urea SCR System)
Table of Contents
Function, structure, operation of emission control........38B-2
Introduction to the trouble diagnosis of emission control
.....................................................................................38B-34
38B-2 Maintenance Information (Urea SCR System)
Function, structure, operation of emission control

1. Function, structure, operation of emission control calculates the desired urea fluid injection quantity, and
then injects urea fluid pressurized by the urea fluid supply
Urea SCR system
module, from the dosing module installed in the exhaust
The urea SCR system converts NOx contained in the
pipe. Urea fluid injected into the muffler is hydrolyzed to
exhaust gas emitted from diesel engines into harmless
ammonia with heat of the exhaust gas, and the generated
nitrogen through a reduction reaction. This system
ammonia causes the reduction reaction with emitted
facilitates the reaction in the SCR catalyst, using the urea
NOx. Through this reaction, the ammonia decomposes
fluid that causes the reduction reaction.
the NOx into water and nitrogen, and reduces the amount
Using the information sent by the engine control module
of NOx.
(ECM), NOx sensors, etc., the dosing control unit (DCU)
Note： I/O table

・ Installation of NOx sensor 2 varies depending
on engine specifications.
Urea fluid ((NH2)2CO+H2O) is hydrolyzed by heat of without being purified through the reaction in
the exhaust gas, and ammonia (NH3) is generated. The the ammonia slip catalyst while the
generated ammonia (NH3) reduces the nitrogen oxide temperature is high.
(NOx) through the SCR catalyst, and decomposes the
NOx into nitrogen (N2) and water (H2O). NOx reduction mechanism
Excessive ammonia (4NH3) is oxidized and is Urea fluid ((NH2)2CO+H2O) injected by the dosing
decomposed into nitrogen (2N2) and water (6H2O) in the module is hydrolyzed by the heat of the exhaust gas, and
oxidation catalyst (for ammonia slip). ammonia (NH3) is generated. The generated ammonia
(NH3) reduces the nitrogen oxide (NOx), and
Note： decomposes the NOx into nitrogen (N2) and water
・ Ammonia slip is a phenomenon which induces (H2O).
ammonia odor in the surrounding area due to
Sensor location diagram
ammonia that is emitted from the exhaust pipe
1. Front chamber 7. NOx sensor 1

2. EGT sensor 3 8. Oxidation catalyst 2
3. SCR catalyst 9. EGT sensor 1
4. NOx sensor 2 10. EGT sensor 2
5. Exhaust silencer 11. Oxidation catalyst 1
6. Mixer chamber
Note：
DCU
The DCU monitors the information sent from each sensor
and ECM, and controls the urea SCR system.
The DCU also has a system diagnostic function. If this
function detects any problem in the system, it warns the
operator by way of an abnormal urea fluid injection
warning light, and sets a DTC (Diagnostic Trouble
Code).
Urea fluid supply module

When the engine starts and the operating conditions for
the urea fluid pump are met, the urea fluid supply module
operates the diaphragm pump and pressurizes the urea
fluid up to 900 kPa {131 psi}. Then, the DCU calculates Also, a supply module temperature sensor is embedded in
the pressure based on the value of the urea fluid pressure the urea fluid supply module, and when the engine is
sensor in the urea fluid supply module, and maintains the cold, engine coolant is circulated inside the urea fluid
urea fluid pressure at approx. 900 kPa {131 psi}. When supply module to defrost the urea fluid and keep it warm,
the engine stops, to prevent the dosing module, etc., from and heater control is performed to prevent the urea fluid
being broken due to freezing, the module returns any urea from freezing.
fluid remaining in the dosing module, urea fluid piping,
and urea fluid supply module to the urea fluid tank by
operating the urea fluid pump after switching the
reverting valve.
1. Supply module bracket 10. Urea fluid pressure sensor signal

2. Coolant inlet connector 11. Urea fluid pressure sensor GND
3. Coolant outlet connector 12. Urea fluid pump motor GND
4. Urea fluid backflow connector 13. Urea fluid pump motor power supply
5. Urea fluid outlet connector 14. Urea fluid pump motor PWM
6. Urea fluid inlet connector 15. Reverting valve power supply
7. Supply module filter (Internal) 16. Reverting valve signal
8. Air hole
9. Urea fluid pressure sensor power supply
Dosing module to signals from the DCU. To cool the injector, the engine
The dosing module is installed at the inlet of the SCR coolant is circulated in the dosing module.
catalyst. It injects urea fluid pressurized by the supply
module from the injector into the exhaust pipe according
1. Urea fluid connector 5. Injector High

2. Injector 6. Injector Low
3. Housing
4. Coolant connector
Urea fluid sensor

The urea fluid sensors are installed in the urea fluid tank,
and consist of the urea fluid temperature sensor, urea
fluid level sensor, and urea fluid quality sensor.
Information for the urea fluid in the urea fluid tank
obtained from each sensor is sent to the DCU via the
CAN circuit.
Note：
machine manufacturer.
1. Urea fluid level sensor

2. Urea fluid quality sensor
3. Urea fluid temperature sensor
The urea fluid temperature sensor measures the urea fluid

temperature using a thermistor that changes resistance
according to changes in temperature. The resistance 1. Pipe
becomes lower when the urea fluid temperature is high, 2. Float
and higher when the urea fluid temperature is low. The
DCU performs the urea fluid defrosting control and The urea fluid quality sensor measures the concentration
thermal control based on the signal from the urea fluid of urea fluid by applying ultrasonic waves to the urea
temperature sensor. fluid and measuring the time between the transmission
The urea fluid level sensor consists of a float and pipe. and reception of the waves. The DCU determines whether
The float contains a magnet, and a board mounted with the urea fluid quality is abnormal, based on the signal
reed switches with different resistances is built in the from the urea fluid quality sensor.
pipe. The fluid level is detected by reading the resistance Note：
when the reed switches mounted on the board are turned
ON according to the magnetic force of the float that
fluctuates synchronously with the surface level of urea
fluid. Based on signals from the urea fluid level sensor,
the DCU determines whether the urea fluid level warning
or the engine restart inhibition warning should be issued.
Note：
1. Urea fluid quality sensor
NOx sensor two NOx sensors. The signal from the NOx sensor is sent
NOx sensor consists of NOx sensor 1 and NOx sensor 2, to the DCU through the CAN communication circuits.
and they are installed to the front and rear of the SCR The DCU calculates the required urea fluid injection
catalyst. NOx sensor 1 is installed in the upstream of the quantity based on the signal from the NOx sensors.
SCR catalyst, and detects the concentration of NOx
Note：
flowing from the engine. NOx sensor 2 is installed in the
downstream of the SCR catalyst, and detects the ・ Installation of NOx sensor 2 varies depending
concentration of NOx converted by the catalyst. The on engine specifications.
DCU monitors NOx conversion efficiency, using these
1. NOx sensor power supply 4. CAN High

2. NOx sensor GND 5. -
3. CAN Low
EGT sensor 3 and sends the temperature signal to the DCU. Based on
EGT sensor 3 is a resistance temperature detector, and is the signal from the exhaust temperature sensor, the DCU
installed at the inlet of the SCR catalyst. It measures the controls the urea SCR.
temperature of exhaust gas in front of the SCR catalyst,
1. EGT sensor 3 GND 2. EGT sensor 3 signal
Coolant control valve However, the engine coolant that cools the injector in the
The opening and closing of the coolant control valve is dosing module branches off just in front of the coolant
controlled by signals from the DCU. The valve circulates control valve, and does not pass through the valve itself.
engine coolant in the urea fluid tank and the supply
module to defrost the urea fluid and keep it warm.
1. Coolant control valve power supply 2. Coolant control valve control
Urea fluid tank

The urea fluid tank is a lightweight and robust tank made 1. Tank body
of a special resin. The urea fluid sensor is installed in the 2. Breather hose
tank. A clear level gauge for checking the full fluid level 3. Urea fluid sensor
is installed outside of the urea fluid tank. 4. Filler cap
5. Urea fluid tank level gauge
Note：
6. Drain plug
machine manufacturer. Urea SCR piping
1. Urea fluid 7. Supply module filter

2. Engine coolant - for cooling the dosing module 8. Urea fluid sensor
3. Engine coolant - for defrosting the urea fluid 9. Urea fluid tank
4. Coolant control valve 10. Dosing module
5. Urea fluid supply module 11. SCR assembly
6. Supply module pump motor
Urea SCR control overview is performed by the DCU if the signals from the urea
fluid temperature sensor, supply module temperature
About the heater control
sensor, and outside air temperature sensor (MAF sensor)
When the ignition switch is turned ON, the DCU
are less than or equal to the specified values when the
determines whether the heater control is needed. Heater
ignition switch is turned ON.
control is the defrosting control or thermal control which
About defrosting control (MAF sensor) exceed the specified values, the defrosting
If any one of the signals from the urea fluid temperature control finishes by closing the coolant control valve.
sensor, supply module temperature sensor, or outside air
About thermal control
temperature sensor (MAF sensor) is less than or equal to
After a predetermined period of time has elapsed since
the specified value, the DCU judges that it needs to
the defrosting control was started, if the urea fluid
defrost the urea fluid, opens the coolant control valve,
temperature sensor or outside air temperature (MAF
and starts engine coolant circulation into the urea fluid
sensor) is less than or equal to the specified value, the
tank and the urea fluid supply module. When all signals
defrosting control transitions to the thermal control with
from the urea fluid temperature sensor, supply module
the coolant control valve opened.
temperature sensor, and outside air temperature sensor
About startup control to fill the urea fluid piping between the urea fluid supply
After the ignition switch is turned ON, if the heater module and the dosing module with urea fluid and
control defrosting control is completed (including if the pressurize the urea fluid up to 900 kPa {131 psi}. After
DCU judges that the defrosting control is not required), the pressure is increased, it is maintained at 900 kPa {131
the SCR catalyst temperature is the specified value or psi} using the urea fluid pressure sensor built into the
more, and the engine is running, then the DCU operates urea fluid supply module.
the urea fluid supply module and dosing module in order
Refilling the urea fluid
Urea fluid pressurization

About NOx sensor control exhaust gas temperature and the exhaust gas flow. If the
To protect the NOx sensors, moisture in the exhaust pipe amount of heat exceeds the required amount of heat for
must be removed immediately after the engine is started. moisture evaporation, dosing control by the NOx sensors
In order to do that, the DCU calculates the amount of heat is started.
required to evaporate the moisture. After that, the DCU
calculates the amount of heat actually generated using the
About dosing control the condition of the machine, either of two methods for
The DCU calculates the optimal urea fluid injection calculating the urea fluid injection quantity can be used:
quantity, and instructs the dosing module. Depending on
one is based on calculation of the ECM information, and
the other is based on values measured by NOx sensors.
Dosing control by means of calculation quantity based on information such as the temperature
No feedback from the NOx sensors is available until NOx before the SCR catalyst and ECM information.
sensor control is completed; therefore, the DCU
About the NH3 storage control
calculates and determines the urea fluid injection quantity
The DCU determines the urea fluid injection quantity by
based on information sent from the ECM (engine speed,
considering the amount of NH3 that can be absorbed in
fuel injection quantity, engine coolant temperature, and
the SCR catalyst in relation to the urea fluid injection
exhaust flow rate).
quantity calculated by the DCU itself (the dosing control
Dosing control based on NOx sensor information by means of the calculation and dosing control by the
After calculating the urea fluid injection quantity based NOx sensors).
on the value measured by the NOx sensors, the DCU Therefore, the urea fluid injection quantity may not
compensates and determines the urea fluid injection change in proportion to NOx concentration.
About after-run control these modules to the urea fluid tank. Although operation
When the engine stops, the DCM stops directing the urea noise can be heard from the urea fluid tank or the supply
fluid supply module to pressurize the dosing module. module after the engine stops, the noise stops after all
Then, to prevent the urea fluid from freezing while the urea fluid is returned to the tank (approx. 2 minutes).
engine is stopped, the urea dosing control unit (DCU) Finally, the DCU shuts down by switching OFF the
turns ON the reverting valve in the supply pump, and reverting valve.
returns the urea fluid filled in the dosing module, the urea
fluid supply module, and the piping between both of
About SCR purging function diagnostic light will be illuminated, and manual purging
In order to keep the SCR functioning, automatic SCR will not be possible by operating the machine. If manual
purging (cleaning of the SCR interior) is performed after purging is not possible, perform SCR purging using the
a predetermined period of time passes. If automatic actuator test function of a trouble diagnosis scan tool.
purging is not completed within a predetermined period
Urea fluid level display
of time, the indicator or light, etc., illuminates to request
The remaining urea fluid level in the urea fluid tank is
that the operator manually performs the purging.
displayed in levels by way of signals sent from the urea
If manual purging has not been performed within the
fluid level sensor installed in the urea fluid tank. The
predetermined period of time since the manual purging
level numbers displayed vary depending on the machine.
request, either the trouble display of the machine or the
Note： Urea fluid refill warning
・ The display varies depending on the machine If the level of urea fluid is low, the DCU displays the
manufacturer. warning on the monitor through the ECM and generates a
warning sound at the same time to warn the operator.
If the warning is disregarded and usage continues without
urea fluid being added, engine output and speed will be
limited. There are 3 warning stages based on how much
urea fluid remains in the urea fluid tank.
If urea fluid is added until the urea fluid level is more
than 10% of the urea fluid tank amount, the warning will
be released.
Note：
・ The display varies depending on the machine
manufacturer.
Abnormal urea fluid quality warning The DCU monitors the quality of urea fluid in the urea
fluid tank for any abnormal conditions, based on signals
sent from the urea fluid quality sensor installed in the stages based on how much time has elapsed since the
urea fluid tank. malfunction was detected.
If the DCU determines that substances other than the If a malfunction is not detected when changing the urea
specified urea fluid have been added or that the urea fluid fluid and starting the engine, the warning will be released.
has been diluted with water, etc., the DCU displays the
Note：
warning on the monitor through the ECM and generates a
warning sound at the same time to warn the operator. ・ The display varies depending on the machine
If the warning is disregarded and usage continues, engine manufacturer.
output and speed will be limited. There are 3 warning
Abnormal urea fluid injection warning If the DCU sets a DTC related to exhaust gas
performance, the DCU displays the warning on the
monitor through the ECM and generates a warning sound If this display illuminates, treatment in accordance with
at the same time to warn the operator. the DTC trouble diagnosis is necessary.
If the warning is disregarded and usage continues, engine
Note：
stages based on how much time has elapsed since the ・ The display varies depending on the machine
malfunction was detected. manufacturer.
NOx reduction system malfunction warning If the DCU sets a DTC related to exhaust gas
performance (EGR related DTC), the DCU displays the
warning on the monitor through the ECM and generates a If this display illuminates, treatment in accordance with
warning sound at the same time to warn the operator. the DTC trouble diagnosis is necessary.
If the warning is disregarded and usage continues, engine
Note：
stages based on how much time has elapsed since the ・ The display varies depending on the machine
malfunction was detected. manufacturer.
DCU wiring diagram DCU pin assignment

Note：
A connector (86 pin)

Pin No. Connection

1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 Coolant control valve power supply
9 -
10 -
11 -
12 Dosing module (Low)
13 -
14 -
15 -
16 -
17 Urea fluid pressure sensor signal
18 Urea fluid pressure sensor GND
19 Urea fluid pressure sensor power supply
20 -
21 -
22 -
23 -
24 Urea fluid pump motor PWM
25 -
26 Urea fluid pump motor GND
27 -
28 -
29 -
30 -
31 -
32 Dosing module (High)
33 EGT sensor signal
34 EGT sensor GND
35 -
36 -
37 -
38 -
39 -
40 -
41 -
42 -
43 -
44 -
45 -
46 Urea fluid pump motor power supply
47 -
48 -
49 -
50 -
51 -
52 -
53 -
54 -
55 -
56 -
57 -
58 Urea fluid tank level sensor, urea fluid tank temperature sensor GND
59 Urea fluid tank level sensor signal
60 -
61 -
62 -
63 -
64 -
65 Reverting valve control
66 -
67 -
68 -
69 -
70 -
71 -
72 -
73 -
74 -
75 -
76 -
77 -
78 -
79 Urea fluid tank temperature sensor signal
80 -
81 -
82 -
83 -
84 -
85 Coolant control valve GND
86 Reverting valve power supply
B connector (53 pin)
Pin No. Connection

1 DCU GND
2 DCU GND
3 DCU GND
4 DCU GND
5 DCU GND
6 DCU power supply
7 DCU power supply
8 DCU power supply
9 DCU power supply
10 -
11 CAN1 High
12 CAN1 Low
13 -
14 CAN0 High
15 CAN0 Low
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
24 -
25 -
26 -
27 -
28 -
29 -
30 -
31 -
32 -
33 -
34 -
35 -
36 -
37 -
38 -
39 -
40 -
41 -
42 -
43 -
44 -
45 -
46 CAN0 termination switch 1B
47 CAN0 termination switch 1A
48 CAN0 termination switch 2B
49 CAN0 termination switch 2A
50 -
51 -
52 Ignition switch
53 -
Introduction to the trouble diagnosis of emission control

1. Introduction to the trouble diagnosis of emission Diagnosis by symptom includes information regarding
control systems not displayed in the DTC. Therefore, because
Diagnosis by symptom enables the appropriate system
Urea SCR system diagnosis method
operation to be verified, the appropriate diagnosis method
The system diagnosis method is a standardized method
can be discovered.
applied for repairing all electric/electronic systems.
Failures in electric and electronic systems differ from Refer to related topics.
regular machine failures in that they often occur in the
If a DTC is stored:
following stages.
Accurately perform the repair according to the specified
Initial stage of failure DTC chart.
The failure occurs sporadically and for a short time, and
If no DTC is set:
often the customer does not notice it. At this stage, the
Select the symptom from Diagnosis by symptom.
customer's complaint is unclear, and the malfunction
Complete the repair according to the diagnostic
cannot be reproduced. However, the control unit may
procedure. It is also possible to perform the inspection by
have stored the failure.
referring to the functional inspection.
This is known as a past malfunction.
If there are no applicable symptoms:
Middle stage of failure
Investigate the complaint in detail.
The failure occurs sporadically and for a short time, but
Create a diagnosis plan.
may occur repeatedly at intervals, and invariably occurs
Utilize the schematics and operation principles.
under specific conditions. The customer's complaint and
When repair history for similar cases is available, request
failure content are clear, but the failure conditions are
technical assistance. Combine technical knowledge with
unclear.
effective utilization of available Service Bulletins.
And as such, by understanding the conditions the person
performing the diagnosis on the machine can reproduce If the condition is intermittent:
the failure. Failures that do not always appear are referred to as being
This is known as an intermittent failure or an intermittent intermittent. Take the following steps to resolve
condition. intermittent conditions.
Check the DTC information and system data.
Stage where failure is realistic
Evaluate the symptoms and conditions described by the
The failure occurs regularly, and the customer's
customer.
complaint is realistic and clear.
Use the check sheet or another method to check the
And as such, the person performing the diagnosis on the
circuit or electrical system components.
machine can reproduce the failure. However, there may
sometimes be multiple causes for the failure. If no trouble is detected:
This is known as a current malfunction. This status indicates that the machine is operating
normally. The condition reported by the customer may be
The diagnostic procedure is always used to solve
normal. Check the customer complaint by comparing to
problems with the electric and electronic control systems,
other machines that are operating properly. However,
and is the starting point if a repair is required. The
depending on the condition, it may be an intermittent
following items indicate how to proceed through the
condition. Before returning the machine, check the
diagnosis.
complaint under the conditions given by the customer.
Verify the customer's complaint.
Investigate the complaint again.
In order to verify the customer's complaint, the person
If the complaint cannot be adequately detected or
performing the diagnosis on the machine must know how
determined, it is necessary to perform the diagnosis again
the system normally operates.
to verify the complaint. The complaint may be
Perform a preliminary inspection. intermittent, or it may be a normal condition.
Perform a comprehensive visual inspection, review
Repair and verify.
service records, check for abnormal conditions such as
Perform the repair when the cause has been determined.
abnormal sounds or smells, and collect all DTC
Check that the vehicle is operating normally and that the
information.
symptom has been corrected. This includes a road test
Inspect for related Service Bulletins. and other methods to verify that the complaint has been
resolved under the following conditions.
Refer to Diagnosis by symptom.
Verify by testing under the conditions given by the accurate after repairing the machine. If this check is done
customer. insufficiently, the abnormal urea fluid injection warning
If a DTC is diagnosed, verify that the malfunction has may be displayed again when the machine is returned to
been repaired by duplicating the conditions when the the customer, or a problem with operation may occur. It
DTC was set. is necessary to perform checks by reproducing the
conditions of the customer complaint, especially in the
Machine repair verification
case of intermittent conditions.
When a repair has been performed for the electronic
control system, it is necessary to verify that the repair is
DTC check DTC display Clear the previous DTCs. Idle the engine to
verification after repair sufficiently warm it before raising the engine
1
speed to No Load Max. by racing the engine in
order to ensure the proper test conditions.
Check the data list. To perform a basic Monitor the data list, and check the values using
check of the urea SCR a typical value sheet. Check the typical values of
2
control and the data list.
communication status
Check of other systems To check whether the Check for an engine control malfunction.
3 engine control is
normal
Powerful To verify that no
Check whether turning electromagnetic
electromagnetic interfering waves are
transmitters such as a transceiver ON and OFF
transmitter check being emitted when an
causes the idling engine speed to change. If a
4 electromagnetic
malfunction is found, let the customer know that
transmitter such as a
the installation position and output of the
transceiver has been
electromagnetic transmitter need to be changed.
added to the vehicle
Supplementary information on the powerful In all trouble diagnoses, the system is adjusted to perform
electromagnetic transmitter check with genuine parts. Therefore, if a general aftermarket
If a problem is found as a result of this check, convey the sensor, switch, etc., is installed, a false diagnosis may be
following checked items to the customer as necessary. made, and the abnormal urea fluid injection warning may
Install the antenna in a location as far away as possible be displayed.
from the machine's electronic systems, such as the control Aftermarket electronics, such as mobile phones, stereos,
units and sensors. and anti-theft devices, may emit electromagnetic
Install the antenna cord at least 20 cm away from the interference into the control system if improperly
machine's electronic systems, such as the control units installed. As a result, erroneous sensor information may
and sensors. be generated, and the abnormal urea fluid injection
Do not place the antenna cord with other wiring. Also, warning will be displayed. Before performing trouble
place the antenna cord as far away from other wiring as diagnoses, either turn off the power to aftermarket parts,
possible. or remove them.
Make sure to install retrofitted equipment in accordance
Poor machine maintenance
with their respective installation manuals.
The high sensitivity of the system check will cause the
Do not install high-output mobile communication
abnormal urea fluid injection warning light to illuminate
devices.
if the machine is not properly maintained.
Caution： If you refill with an incorrect urea fluid, a clogged supply
・ Failure to follow these steps when verifying a module filter or deposits in the urea fluid tank can trigger
repair may result in unnecessary repairs. machine malfunctions. Poor machine maintenance cannot
be classified as a non-machine fault, but because of the
・ Review the data relating to the diagnosed DTC
high sensitivity of the failure diagnosis, machine
and make a record.
maintenance schedules must be more closely followed.
・ Clear the DTC.
Related system malfunctions
・ Operate the machine while checking the
Many system trouble diagnoses will stop operating if the
related data.
control unit detects a malfunction in a related system or
Non-OEM parts component.
Visual inspection
When performing the diagnostic procedure, visually
inspect the urea fluid supply module, etc., with caution.
This inspection can often lead to solving a problem
without taking extra steps. Use the following guidelines
when implementing a visual inspection.
Inspect all urea fluid piping, etc., for punched holes, cuts,
or disconnections, and check whether the piping is
appropriate.
Inspect hoses that are difficult to see behind other
components.
Inspect all harnesses for being properly connected, for
burned or worn areas, and for improper fastening or
contact with sharp edges, the hot exhaust manifold, or
pipes.
Basic knowledge of tools required
When performing the diagnostic procedure, lack of basic
knowledge regarding this powertrain could result in an
DLC
incorrect diagnosis or damage to the powertrain
The equipment for communicating with the control unit is
components. Do not attempt to diagnose a problem
the Data Link Connector (DLC). The DLC is also
related to the powertrain without having basic
provided to establish a connection with the trouble
knowledge.
diagnosis scan tool. The following are general uses of the
Basic understanding of hand tools is necessary to
effectively use the service manual.
Identification of recorded DTCs
About on-board diagnostic tests Clearing DTCs
Check the diagnostic results of problems using the Output control test implementation
following. Reading of serial data
The diagnostic tests of the previous ignition cycle have
been completed.
The diagnostic tests of the current ignition cycle were
passed.
Problems identified through the diagnostic tests do not
currently exist.
If the failure result arises in the diagnostic test, check the
following and record the data.
The diagnostic tests of the previous ignition cycle have
been completed.
Problems identified through the diagnostic tests currently
exist.
Problems existing in this ignition cycle
Operation status when the failure occurs
Ignition cycle
Because the machine activates with a method that
satisfies a predetermined diagnosis standard, an ignition
cycle is defined as turning the key ON, running, then
About the machine repair verification
turning the key OFF.
After the repair is complete, perform the following steps
SCR system malfunction warning to verify the machine repair.
Basically, the SCR system malfunction warning is Review either the data or the DTC that was diagnosed, or
displayed if the DCU determines that a malfunction has both, and make a record.
occurred in the SCR system. Clear the DTC.
Operate the machine based on the data.
Observe the information for the specified DTC that was
diagnosed until the diagnostic test related to that DTC is
implemented by the control unit.
The implementation of these steps is extremely important
when checking a repair. Failure to perform these steps
may result in unnecessary repairs.
About DTCs
Each time the ignition switch is turned ON, the DCU
performs self-tests on most of the wirings and
components. If any system failure is detected, it is stored
in the memory of the DCU, and the urea SCR control is
stopped. Also, if a fault that will affect the drivability of
the vehicle occurs in the system, the abnormal urea fluid
injection warning is displayed to notify the operator of
the fault.
Reading the DTC
DTCs can be read by operating the trouble diagnosis scan
tool.
Conditions for clearing the DTC
If an error occurs in the system and the DTC is recorded
in the DCU, that DTC is not cleared from the location of
the error, so use the following measures to delete. Also
perform DTC recording and clearing procedures before
an inspection, as DTCs may be observed during
inspection or repair.
Clearing the DTC
DTCs can be cleared by operating the trouble diagnosis
scan tool.
Functional Inspection (Urea SCR System) 38C-1

Functional Inspection
(Urea SCR System)
Table of Contents
Diagnostic system check-urea selective catalytic reduction
system............................................................................38C-2
38C-2 Functional Inspection (Urea SCR System)
Diagnostic system check-urea selective catalytic reduction system

1. Diagnostic system check-urea selective catalytic ・ When a DTC beginning with U is set, it
reduction system description of function indicates that there is no communication with
The urea SCR control system inspection is a systematic other ECUs.
method for checking problems caused by malfunctions in 4. Observe whether DCU DTC P0607, P060B, P062F,
the urea SCR control system. It is the starting point for or P1464 is set.
diagnosis related to drivability complaints. Move from
the system inspection to the next logical step to diagnose Note：
problems. Understanding and correctly using the ・ Inspect the applicable DTC if a DTC is set.
diagnostic chart reduces diagnostic time and prevents the
5. Observe whether DCU DTC P0641, P0658, or
replacement of good parts.
P0659 is set.
Note：
Note：
・ If there are no complaints on drivability, do not
・ Inspect the applicable DTC if a DTC is set.
perform these diagnostic steps unless
otherwise instructed in other sections. 6. Check all of the ECUs for DTC codes that have not
yet been diagnosed.
If there are no complaints on drivability, do not perform
these diagnostic steps unless otherwise instructed in other Note：
sections. ・ Inspect the applicable DTC if a DTC is set.
Do not clear the DTC unless instructed to do so in a 7. Check whether the customer's concern is related to
diagnostic step. the engine.
The battery should be fully charged. Note：
The battery cable should be normal and securely ・ If there is a concern relating to the engine,
connected. inspect the engine control system.
The GND of the DCU should be securely connected to 8. Check for excessive urea fluid consumption.
the correct position. 9. Check for a significant ammonia odor.
Verify that the DCU harness connector has no excessive 10. Check for the adherence of white crystal powder.
fouling and is correctly connected.
Verify that the DCU terminals have no excessive fouling
and are correctly connected.
The machine must be completely maintained.
Programming of the DCU must be performed correctly.
If a urea SCR system DTC is set, first diagnose the sensor
DTCs, solenoid DTCs, and actuator DTCs.
2. Diagnostic system check-urea selective catalytic
reduction system inspection
1. Turn ON the ignition switch without starting the
engine.
2. Observe the DCU and ECM DTC information with a
scan tool.
3. Check if a DTC beginning with U or a DTC related
to another ECU is set.
Note：
・ If a DTC beginning with U or a DTC related to
another ECU is set, inspect the applicable
DTC.
Symptom (Urea SCR System) 38D-1

Symptom
(Urea SCR System)
Table of Contents
Intermittent conditions of urea selective catalytic reduction
system............................................................................38D-2
Urea fluid consumption too high...................................38D-5
Ammonia smell noticeable............................................38D-6
White crystalline powder visible...................................38D-7
38D-2 Symptom (Urea SCR System)
Intermittent conditions of urea selective catalytic reduction system

1. Intermittent conditions of urea selective catalytic when the malfunction occurs, it can be determined that
reduction system description of symptom there is a problem in the monitored circuit. The trouble
diagnosis scan tool is useful in detecting intermittent
Note：
conditions. The trouble diagnosis scan tool has the
・ Important preliminary inspections before following convenient functions.
starting
The snapshot function records the engine parameters at
Before using the symptom list, inspect the urea SCR the time when a malfunction occurs. It is possible to
control system and verify all of the following items. review the recorded information and know the particular
The warning light and indicator light operate normally. operation condition that resulted in the malfunction.
The trouble diagnosis scan tool data is within the normal
range of operation values. By using the plot function on the trouble diagnosis scan
Verify the customer's complaint, and locate the tool, it is possible to graph the selected data parameters.
appropriate symptom in the table of contents. Inspect the This recorded information can be reviewed, and the
items presented for the symptom. location of the intermittent condition can be checked.
Note： Check for improper installation of optional electronic

accessories such as lights or mobile phones.
・ Visual inspection and actual inspection
Under the following conditions, DTCs are not recorded,
Careful visual inspection and actual inspection are and the warning light may illuminate intermittently.
required for some symptom procedures. This procedure is
The GND of the DCU is loose or dirty.
extremely important. By conducting visual and actual
Intermittent short circuit to the GND circuit in the
inspections, it is possible to save valuable time by fixing
warning light
problems without performing further inspections. Check
Interference exists in the electric system due to a failure
for the following items.
in a relay, in a solenoid driven by the DCU, or in a
The GND of the DCU should be clean and firmly secured
switch. Electronic components may cause sharp increases
in the correct position.
in voltage. Normally, a problem occurs when a
The exhaust pipe should not be crushed or damaged.
component that is malfunctioning is in operation.
The wiring and terminals of the urea SCR system harness
The diode has an open circuit.
should be appropriately connected, and they should not
be pinched or disconnected. In the following list of symptoms, causes for each
symptom are organized. There is no significance to the
Note：
order of this procedure. If the value on the trouble
・ Intermittent conditions diagnosis scan tool does not indicate a malfunction, the
If an intermittent condition exists, inspect for improper next procedure to perform should be the one that can be
installation of electronic equipment. Inspect for any most easily inspected or is most likely to be the cause.
additionally installed electronic equipment, lights, mobile Use the following list when diagnosing symptoms of
phones, wireless devices, etc. Verify that any device that complaints.
was additionally installed is not connected to a serial data Excessive urea fluid consumption
circuits such as CAN. Significant ammonia odor
Depending on the problem, the warning light may Adherence of white crystal powder
illuminate or DTCs may be recorded. An intermittent
condition is often caused by an improper electrical There is no current problem, but a past DTC exists. Or,
connection or wiring. Conduct a careful visual inspection, there is a complaint from the customer not related to a
or conduct an actual inspection to see whether the DTC, and that symptom cannot be reproduced.
following conditions exist in the suspected connector. 2. Intermittent conditions of urea selective catalytic
Incomplete connection between connectors reduction system diagnostics
Seating failure of terminal Note：
Damage or deformation of terminal
Repair or replace the connector terminal of the circuit
Inspect the urea SCR control system.
with the problem, and appropriately connect. Remove the
terminals from the connector body and inspect the wires Note：
of the terminals for poor connections. ・ Harness and connector
Connect the DMM to the suspected circuit and perform a
test-run of the machine. If an abnormal value is displayed
Intermittent open circuits or short circuits are often Test all control module GND circuits and system GND
caused by the harness or connector moving due to circuits. Some control modules have multiple GND
vibrations, engine torque, or bumps in the road. circuits. Other components in the system have a separate
Move the related connectors and wiring while observing GND that also needs to be tested. Inspect whether the
the applicable scan tool data. GND is clean and is securely connected to the ground
Command the components ON or OFF using the scan point. Inspect the connections of the components and the
tool, and move the related connectors and wiring. Check splice pack. Check whether sufficient current necessary
the operation of the components. to operate the components is flowing in the circuit.
With the engine operating, move the related connectors
Note：
and wiring while checking the operating status of the urea
SCR. ・ Effects caused by temperature
If the harness or connector movement affects the An intermittent condition may occur when a component
displayed data, component, system operation, or or connection reaches its operating temperature. For
operation of the engine, inspect the harness or intermittent conditions that may occur only when the
connection, and repair as necessary. components or connections are cold or only when they
Note： are hot, failure records or snapshot data can be helpful,
where possible.
・ Electrical connection of wiring
If an intermittent condition is related to heat, review the
An intermittent condition is often caused by an improper data relating to the following items.
electrical connection, terminal installation, or wiring. High outside air temperature
Defective connections between connectors or improper Heat given off by the engine
terminal seating to the connector body Heat emitted from the circuits due to defective
Terminal deformation or damage Test the terminals for connections or high loads
improper installation. Load conditions higher than normal
Defective connections between the terminals and wires, If an intermittent condition is related to low temperatures,
including pressure bonding terminals with insulation. review the data relating to the following items.
This requires the terminal to be removed from the Low outside air temperature In extremely low
connector body. temperatures, ice may form in a connection or
Corrosion or water intrusion Moisture can enter the component. Test for water intrusion.
wiring when the insulation area has holes or is damaged. This condition only occurs in a cold start.
The conductor inside the insulation area corrodes, but this This condition does not occur after the vehicle has been
usually cannot be checked visually. Look for any swollen warmed up.
or stiff sections in the wires of the suspected circuit. Based on the information from the customer, determine if
Wiring damaged inside the insulation area the failure is caused by temperature.
Wiring that is pinched, cut, or rubbed through
Note：
Verify that the wiring does not come in contact with a hot
exhaust system component. ・ EMI and electrical noise
Note： Certain electronic components and circuits may respond

sensitively to electrical noise from the EMI, etc.
・ Power supply and GND of the control module,
A harness is too close to high voltage or high current
and power supply and GND of the components
devices such as the injection part, motor, or generator,
Various symptoms can occur due to poor connections at due to incorrect wiring. These components may induce
the power supply or GND. electrical noise on a circuit that could interfere with
Test all control module power supply circuits. In many normal circuit operation.
machines, there are multiple circuits that supply power to Interference exists in the electric system due to a failure
the control module. Other components in the system have in a relay, in a solenoid driven by the DCU, or in a
separate power supply circuits that also need to be tested. switch. There may be cases where the voltage increases
Inspect the connections and fuses of the module and the sharply due to this condition. Normally, a problem occurs
component connectors, as well as intermediate when a component that is malfunctioning is in operation.
connections between the power supply, the module, and Improper installation of non-genuine or aftermarket add-
the components. A test lamp or a DMM may indicate that on accessories such as lights, 2-way radios, amplifiers,
voltage is present, but neither of them tests the ability of electric motors, remote starters, alarm systems, mobile
the circuit to carry sufficient current. Check whether phones, etc. These accessories may lead to an emission-
sufficient current necessary to operate the components is related failure when they are in use, but do not cause
flowing in the circuit. interference when not in use.
Test the diode for an open circuit. Certain relays include
clamping diodes.
Inspect the rectifier bridge of the generator for problems
that may cause AC noise in the electrical system.
Note：
・ Reproduction of failure conditions
If none of the previous tests are successful, attempt to
duplicate or record the failure conditions.
An alternative method is to perform a test-run of the
machine with the DMM connected to the suspect circuit.
If an abnormal value is displayed on the DMM when the
problem occurs, this can be helpful in identifying the
defective area.
Note：
・ Scan tool snapshot
By connecting a scan tool, it is possible to take parameter
snapshots available via serial data. The snapshot function
records actual data for a predetermined period of time.
The recorded data can be replayed and analyzed. Also,
the scan tool can display a single parameter or multiple
parameters as a graph for comparison. The snapshot
function can be set to start recording manually when the
symptom occurs, or to start recording when the DTC is
set. Abnormal values in the recorded data may indicate
systems or components that require further inspection.
Urea fluid consumption too high

1. Urea fluid consumption too high description of This symptom may be an effect of excessive fuel
symptom consumption. Refer to "Poor fuel economy" under
Diagnosis by symptom in the Engine workshop manual.
Although the usage condition is conventionally the same,
the number of refills is increasing.
2. Urea fluid consumption too high diagnostics
Note：
Check for the possibility of variations in the urea fluid
injection quantity due to the operating method of the
operator or the machine status.
Check the operating habits of the operator.
Inspect the urea fluid quality.
Check with the owner whether an ammonia odor has been
smelled from the exhaust pipe or around the tank
recently.
Check with the owner whether white crystals have been
found under the machine, in the urea fluid piping, or in
the muffler recently.
Instruct the owner to recheck the consumption after
refilling the urea fluid.
Inspect whether the hour meter is operating properly in
order to calculate the exact time unit of consumption.
Check whether the status of each sensor is correct.
Check for related Service Bulletins.
Note：
・ Urea fluid piping system inspection
Is the urea fluid tank drain off or loose?
Do white crystals remain around the urea fluid tank?
Is the urea fluid tank broken?
Is the urea fluid piping or the joint broken?
Is the urea fluid supply pump broken?
Note：
・ Sensor inspection
Is the NOx sensor value appropriate?
Is the EGT sensor 3 value appropriate?
Is the urea fluid level sensor value appropriate?
Is the MAF sensor value correct?
Note：
・ Dosing module inspection
Is the dosing module broken, damaged by heat, or
corroded?
Is the dosing module installed correctly?
Is it time for regular replacement of the dosing module?
Note：
・ Other inspections
Ammonia smell noticeable

1. Ammonia smell noticeable description of symptom
An abnormal odor is smelled from the exhaust gas
temporarily or continuously.
2. Ammonia smell noticeable diagnostics
Note：
Identify whether the abnormal odor originates from
around the tank or the exhaust gas.
Check whether the status of each sensor is correct.
Note：
Are the urea fluid piping and the coolant piping for the
urea fluid supply pump assembled incorrectly?
Is the coolant control valve stuck open?
Note：
Note：
corroded?
Note：
If the urea SCR-related parts have been replaced, was the
urea SCR system data reset as necessary?
Does SCR catalyst degradation or ammonia slip due to
ammonia storage amount saturation occur?
White crystalline powder visible

1. White crystalline powder visible description of
symptom
White crystal powder adheres to the exhaust pipe or the
urea SCR system-related parts.
2. White crystalline powder visible diagnostics
Note：
When refilling the urea fluid, verify it is not refilled
above the F line of the level gauge.
Note：
Is the urea fluid tank drain off or loose?
Is the urea fluid tank broken?
Is there urea fluid leaking from the urea fluid tank?
Is there urea fluid leaking from the urea fluid supply
pump?
Is the filter cover of the urea fluid supply pump loose?
Is the urea fluid piping or the joint broken?
Is there urea fluid leaking from the urea fluid piping or
the joint?
Are the urea fluid piping and the coolant piping for the
urea fluid supply pump assembled incorrectly?
If there are crystals adhering inside the urea fluid tank, is
the coolant control valve stuck open?
Note：
Note：
corroded?
Note：
If the urea SCR-related parts have been replaced, was the
urea SCR system data reset as necessary?
Has an SCR catalyst that was installed to another
machine been installed recently?
DTC Information (Urea SCR System (Generator 12V)) 38E-1

DTC Information
(Urea SCR System (Generator 12V))
Table of Contents
DTC P0607 Control Module Performance....................38E-3 DTC P206D Urea Fluid Quality Sensor Circuit Short
DTC P060B Internal Control Module A/D Processing .....................................................................................38E-28
Performance...................................................................38E-4 DTC P207F Urea Fluid Concentration Too Low........38E-29
DTC P062F Control Module EEPROM Error..............38E-5 DTC P208A Urea Fluid Pump Control Circuit...........38E-30
DTC P0641 Sensor Reference Voltage Circuit.............38E-6 DTC P208B Urea Fluid Pump Performance...............38E-31
DTC P0658 Actuator Supply Voltage Circuit...............38E-7 DTC P208C Urea Fluid Pump Control Circuit Low Voltage
DTC P0659 Actuator Supply Voltage Circuit...............38E-8 .....................................................................................38E-32
DTC P1462 Urea Fluid Quality Sensor Timeout Error DTC P208D Urea Fluid Pump Control Circuit High Voltage
.......................................................................................38E-9 .....................................................................................38E-33
DTC P1464 Main Relay Performance.........................38E-10 DTC P208E Urea Fluid Injector Stuck........................38E-34
DTC P1468 Urea Dosing Control Module (DCM) DTC P20A0 Urea Fluid Reverting Valve Circuit Open
Overtemperature..........................................................38E-11 .....................................................................................38E-35
DTC P1491 Urea Fluid Overpressure.........................38E-12 DTC P20A2 Urea Fluid Reverting Valve Circuit Low
Voltage.........................................................................38E-36
DTC P1493 Urea Dosing Control Module (DCM) Driver
Overtemperature..........................................................38E-13 DTC P20A3 Urea Fluid Reverting Valve Circuit High
Voltage.........................................................................38E-37
DTC P149C Urea Fluid Pressure Reduction Malfunction
.....................................................................................38E-14 DTC P20AC Urea Fluid Pump Temperature Sensor
Performance.................................................................38E-38
DTC P149D Urea Fluid Tank Overtemperature..........38E-15
DTC P20AD Urea Fluid Pump Module Temperature Sensor
DTC P203B Urea Fluid Tank Level Sensor Stuck......38E-16
Performance.................................................................38E-39
DTC P203D Urea Fluid Tank Level Sensor High Voltage
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve
.....................................................................................38E-17
Circuit Open................................................................38E-40
DTC P2048 Urea Fluid Injector Circuit Low Voltage
.....................................................................................38E-18
Circuit Low Voltage....................................................38E-41
DTC P2049 Urea Fluid Injector Circuit High Voltage
.....................................................................................38E-19
Circuit High Voltage...................................................38E-42
DTC P204B Urea Fluid Pressure Sensor Performance
DTC P20E8 Urea Fluid Pressure Underpressure........38E-43
.....................................................................................38E-20
DTC P20E9 Urea Fluid Overpressure.........................38E-44
DTC P204C Urea Fluid Pressure Sensor Circuit Low
Voltage.........................................................................38E-21 DTC P20EA Urea Fluid Pressure Reduction Malfunction
.....................................................................................38E-45
DTC P204D Urea Fluid Pressure Sensor Circuit High
Voltage.........................................................................38E-22 DTC P20FE Urea Fluid Pressure Build-Up Error.......38E-46
DTC P205B Urea Fluid Tank Temperature Sensor DTC P2201 Upstream Nox Sensor Performance........38E-47
Performance.................................................................38E-23 DTC P2206 Reading the error(open) information detected
DTC P205D Urea Fluid Tank Temperature Sensor High by Ft NOx sensor.........................................................38E-48
Voltage.........................................................................38E-24 DTC P2207 Reading the error(short) information detected
DTC P206A Urea Fluid Quality Sensor Circuit..........38E-25 by Ft NOx sensor.........................................................38E-49
DTC P206B Urea Sensor Over Temperature Condition DTC P242B Exhaust Gas Temperature (EGT) Sensor 3
.....................................................................................38E-26 Performance.................................................................38E-50
DTC P206C Urea Fluid Quality Sensor Circuit Open DTC P242C Exhaust Gas Temperature (EGT) Sensor 3
.....................................................................................38E-27 Circuit Low Voltage....................................................38E-51
38E-2 DTC Information (Urea SCR System (Generator 12V))
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3

DTC U0002 CAN Bus Off..........................................38E-53
DTC U0100 Lost Communication with Engine Control
Module (ECM)............................................................38E-54
DTC U029D CAN communication error between DCU and
Ft NOx sensor..............................................................38E-55
DTC mapping table.....................................................38E-56
DTC P0607
Control Module Performance
DCU.
The DCU is ON.
The DCU detects a malfunction of the internal CPU.
Failure is indicated on the monitor of the machine, or the
The abnormal urea fluid injection warning is displayed.
Urea SCR control is disabled.
DTC P060B
DCU.
The DCU is ON.
The DCU detects a malfunction of the internal A/D
converter.
DTC P062F
Control Module EEPROM Error
This diagnosis applies to the EEPROM inside the DCU.
If the DCU is unable to read, write, or clear the EEPROM
data, the DTC is set.
The DCU is ON.
The DCU detects a malfunction of the internal EEPROM.
DTC P0641
Sensor Reference Voltage Circuit
The DCU supplies 5 V power to the urea fluid pressure
sensor inside the urea fluid supply module via the 5 V
The DCU monitors the voltage of the 5 V power supply
circuit, and if it detects that the voltage is excessively low
or high, the DTC is set.
The DCU is ON.
The DCU detects a voltage outside the predetermined
range in the urea fluid pressure sensor 5 V power supply
circuit.
DTC P0658
Actuator Supply Voltage Circuit
The DCU supplies 24 V power to the coolant control
valve battery voltage supply circuit. It also supplies 24 V
power to the urea fluid supply pump and reverting valve
battery voltage supply circuit in the urea fluid supply
module. The DCU monitors the battery voltage supply
circuit, and if it detects an excessively low voltage, the
DTC is set.
The DCU is ON.
The DCU detects a low voltage in the battery voltage
supply circuit.
DTC P0659
circuit, and if it detects an excessively high voltage, the
DTC is set.
The DCU is ON.
The DCU detects high voltage in the battery voltage
supply circuit.
DTC P1462
Urea Fluid Quality Sensor Timeout Error
The DCU and the urea fluid sensor communicate signals
and diagnostic information via CAN communication. If
the DCU detects that no communication data can be
received from the urea fluid sensor for a predetermined
length of time, the DTC is set.
The DCU is ON.
The DCU detects that no CAN Bus message is received
from the urea fluid sensor for 10 seconds or more.
DTC P1464
Main Relay Performance
The DCU has the internal main relay in the power supply
control of the DCU. If the DCU detects that the main
relay is OFF during DCU operation or stuck ON after
completing after-run control, the DTC is set.
Note：
・ Relay shut-off malfunction
The DCU is ON.
When the main relay is commanded ON, the DCU detects
the OFF status.
Note：
・ Relay fixed to ON
The ignition switch is OFF.
The DCU detects the ON status when the main relay is
commanded OFF.
Note：
Note：
DTC P1468
Urea Dosing Control Module (DCM) Overtemperature
The DCU monitors the temperature inside itself by means
of the DCU internal temperature rise monitor. If the DCU
detects a DCU internal temperature that is more than or
equal to a predetermined temperature, the DTC is set.
The DCU is ON.
The DCU detects an abnormally high internal
temperature in the DCU for 5 seconds or more.
DTC P1491
Urea Fluid Overpressure
The urea fluid pressure in the pipe between the urea fluid
supply module and the dosing module is raised up to 900
kPa by the urea fluid supply module between the startup
control and the injection control. The DCU controls the
urea fluid supply module and maintains its pressure by
feeding back the signals from the pressure sensor built
into the urea fluid supply module. If the DCU detects a
urea fluid pressure higher than the specified value during
pressure control, the DTC is set.
The DCU is ON.
The intake air temperature is -10°C {14°F} or more.
The DCU detects a urea fluid pressure of 1,250 kPa {181
psi} or more for 5 seconds or more.
DTC P1493
Urea Dosing Control Module (DCM) Driver Overtemperature
The DCU controls the actuator drive circuit inside the
control module and operates the dosing module, urea
fluid supply module pump motor, reverting valve, and
coolant control valve. The DCU monitors the
temperatures of each actuator drive circuit, and if it
detects an excessively high temperature for a
predetermined length of time, the DTC is set.
The DCU is ON.
The DCU detects an abnormally high temperature in the
internal actuator drive circuit for 3 seconds or more.
DTC P149C
Urea Fluid Pressure Reduction Malfunction
The urea fluid is sent from the urea fluid tank to the urea
fluid supply module through the operation of an internal
diaphragm pump that is driven by the urea fluid supply
module pump motor.
Then, the urea fluid passes the main filter and pressure
line and is sent to the dosing module.
The excess pressurized urea fluid returns to the urea fluid
tank through the backflow line that branches off inside
the urea fluid supply module housing.
The urea fluid pressure sensor detects the urea fluid
pressure in the backflow line between the main filter and
the one-way valve.
The reverting valve switches the flow of urea fluid
according to commands from the DCU. When the
reverting valve is commanded ON during pressure-
reducing control or after-run control, the urea fluid flow
is reversed and the urea fluid supply module returns urea
fluid to the urea fluid tank via the suction line. When
pressure-reducing control or after-run control ends, the
urea fluid pressure should drop to approximately 0 kPa. If
the urea fluid pressure has not dropped to the specified
pressure or less during pressure-reducing control or after-
run control, the DCU sets the DTC.
The DCU is ON.
The DCU detects that the urea fluid pressure does not
decrease to 40 kPa {6 psi} or less within the specified
amount of time during urea fluid pressure-reducing
control.
DTC P149D
Urea Fluid Tank Overtemperature
The urea fluid sensor measures the urea fluid temperature
inside the urea fluid tank and sends it to the DCU. If the
DCU detects an excessively high temperature in the urea
fluid sensor, the DTC is set.
The DCU is ON.
The DCU detects a urea fluid tank temperature of 70°C
{158°F} or more for 10 seconds or more.
DTC P203B
Urea Fluid Tank Level Sensor Stuck
The urea fluid tank level sensor is installed to the urea
fluid tank.
If sticking of the urea fluid level sensor is detected, the
DTC is set.
The DCU is ON.
The DCU detects that the change in the urea fluid tank
level sensor position is small compared to the predicted
urea fluid consumption.
DTC P203D
Urea Fluid Tank Level Sensor High Voltage
fluid tank.
The urea fluid level signals are sent to the DCM via the
CAN circuit. If the DCU receives error information
concerning an open circuit or a short circuit from a
sensor, the DTC is set.
The DCU receives error information concerning a short
to GND from the urea tank level sensor circuit for 9
seconds or more.
The DCU receives error information concerning an open
circuit from the urea tank level sensor circuit for 9
seconds or more.
DTC P2048
Urea Fluid Injector Circuit Low Voltage
The dosing module operates based on injection signals
from the DCU and injects urea fluid.
The dosing module has the following circuits.
Injector drive circuit (High)
Injector drive circuit (Low)
If the DCU detects a short to GND or open circuit in the
injector drive circuit (High) or injector drive circuit
(Low) of the dosing module, the DTC is set.
The DCU is ON.
The DCU detects an open circuit or short to GND in the
dosing module circuit for 3 seconds or more when the
DCU outputs the injector signals.
DTC P2049
Urea Fluid Injector Circuit High Voltage
If the DCU detects a short to the battery or a short to the
ignition power supply in the injector drive circuit (High)
or injector drive circuit (Low) of the dosing module, the
DTC is set.
The DCU is ON.
The DCU detects a short to the battery or a short to the
ignition power supply in the dosing module circuit for 3
seconds or more.
DTC P204B
Urea Fluid Pressure Sensor Performance
The urea fluid pressure sensor is installed onto the
backflow line in the urea fluid supply module, and detects
the pressure of the urea fluid pressurized by the urea fluid
pump. If the DCU detects that there is a characteristic
malfunction in the urea fluid pressure sensor, the DTC is
set.
The DCU is ON.
The urea fluid pump temperature is -5°C {23°F} or more.
The DCU detects that the urea fluid pressure is -50 kPa
{-7 psi} or less, or 50 kPa {7 psi} or more, for 4 seconds
or more while the urea fluid pump is stopped.
If it is detected 2 consecutive times, the failure is
indicated on the monitor of the machine, or the diagnostic
light illuminates.
DTC P204C
Urea Fluid Pressure Sensor Circuit Low Voltage
pump.
The urea fluid pressure sensor has the following circuits.
GND circuit
Signal circuit
The urea fluid pressure sensor outputs a high voltage
signal when the pressure is high and a low voltage signal
when the pressure is low. If the DCU detects a urea fluid
pressure sensor output voltage that is lower than the
predetermined voltage, the DTC is set.
The DCU is ON.
The DCU detects that the urea fluid pressure sensor
signal voltage is 0.25 V or less for 5 seconds or more.
DTC P204D
Urea Fluid Pressure Sensor Circuit High Voltage
pump.
GND circuit
Signal circuit
pressure sensor output voltage that is higher than the
The DCU is ON.
signal voltage is 4.75 V or more for 5 seconds or more.
DTC P205B
Urea Fluid Tank Temperature Sensor Performance
The urea fluid sensor is comprised of the urea fluid tank
temperature sensor together with the urea fluid tank level
sensor and urea fluid quality sensor, and is installed to the
urea fluid tank. If the DCU detects that the urea fluid
temperature is excessively low or high compared with the
intake air temperature, the DTC is set.
When the ignition switch is ON, the differences between
the engine coolant temperature, intake air temperature,
and fuel temperature are each 5°C {9°F} or less.
The DCU detects that the urea fluid temperature is lower
than the intake air temperature by 30°C {54°F} or more
The DCU detects that the urea fluid temperature is higher
than the intake air temperature by 100°C {212°F} or
DTC P205D
Urea Fluid Tank Temperature Sensor High Voltage
The urea fluid tank temperature sensor is installed to the
urea fluid tank.
The urea fluid temperature signals are sent to the DCU
via the CAN circuit. If the DCU receives error
information concerning an open circuit or a short circuit
from a sensor, the DTC is set.
to GND from the urea tank temperature sensor circuit for
9 seconds or more.
circuit from the urea tank temperature sensor circuit for 9
seconds or more.
DTC P206A
Urea Fluid Quality Sensor Circuit
The urea fluid sensor includes the urea fluid tank level
sensor, urea fluid tank temperature sensor, and urea fluid
quality sensor. If the DCU receives a CAN message
indicating an open circuit, short circuit, or other
malfunction in any sensor from the urea fluid sensor, the
DTC is set.
The DCU receives a urea fluid sensor internal
malfunction message for 9 seconds or more.
DTC P206B
Urea Sensor Over Temperature Condition
quality sensor. If the urea fluid quality sensor detects a
high temperature, the DTC is set.
The urea fluid quality sensor detects that the urea fluid
sensor unit is at a high temperature.
DTC P206C
Urea Fluid Quality Sensor Circuit Open
The urea fluid quality sensor is installed to the urea fluid
tank. The urea fluid quality sensor measures the
concentration of urea fluid by applying ultrasonic waves
to the urea fluid and measuring the time between the
transmission and reception of the waves. If the ECM
receives error information concerning an open circuit or a
short circuit from a sensor, the DTC is set.
The ECM receives error information concerning a short
to GND from the urea fluid quality sensor circuit for 9
seconds or more.
The ECM receives error information concerning an open
circuit from the urea fluid quality sensor circuit for 9
seconds or more.
DTC P206D
Urea Fluid Quality Sensor Circuit Short
The urea fluid quality sensor is installed to the urea fluid
tank. The urea fluid quality sensor measures the
concentration of urea fluid by applying ultrasonic waves
to the urea fluid and measuring the time between the
transmission and reception of the waves. If the DCU
receives error information concerning an open circuit or a
short circuit from a sensor, the DTC is set.
to GND from the urea fluid quality sensor circuit for 9
seconds or more.
circuit from the urea fluid quality sensor circuit for 9
seconds or more.
DTC P207F
The urea fluid sensor monitors the quality based on the
urea fluid concentration. The DCU judges the urea fluid
quality based on the measured urea fluid concentration,
and sets the DTC if abnormal conditions are detected.
The engine run time is 5 minutes.
The urea fluid tank temperature is 0°C {32°F} or more.
The DCU detects an abnormal urea fluid concentration
for 10 minutes or more.
DTC P208A
Urea Fluid Pump Control Circuit
The urea fluid supply module contains the urea fluid
pump, and urea fluid is fed according to signals from the
DCU.
The urea fluid pump has the following circuits.
Battery voltage supply circuit
GND circuit
Pump control circuit
If the DCU detects an open circuit in the pump control
circuit, the DTC is set.
The DCU is ON.
The DCU detects an open circuit in the pump control
DTC P208B
Urea Fluid Pump Performance
DCU.
If the DCU detects abnormal rotation speed of the urea
fluid pump motor, the DTC is set.
The DCU is ON.
The DCU detects that the difference between the actual
and desired urea fluid pump motor speeds is a
predetermined value or more.
light illuminates.
DTC P208C
Urea Fluid Pump Control Circuit Low Voltage
DCU.
GND circuit
If the DCU detects a short to another GND circuit in the
pump control circuit, the DTC is set.
The DCU is ON.
The DCU detects a short to the GND circuit in the control
DTC P208D
Urea Fluid Pump Control Circuit High Voltage
DCU.
GND circuit
ignition power supply in the pump control circuit, the
DTC is set.
The DCU is ON.
ignition power supply circuit in the pump control circuit
DTC P208E
Urea Fluid Injector Stuck
1. DTC P208E description of DTC
If the DCU detects that the dosing module is stuck open
or closed, the DTC is set.
2. DTC P208E condition for setting the DTC
The DCU is ON.
When the DCU outputs injector signals, the dosing
module is detected as stuck open or closed.
3. DTC P208E action taken when the DTC sets
light illuminates.
DTC P20A0
Urea Fluid Reverting Valve Circuit Open
The reverting valve is installed in the urea fluid supply
module and operates based on signals from the DCU.
The reverting valve has the following circuits.
Power supply circuit
Control circuit
If the DCU detects an open circuit in the control circuit,
the DTC is set.
The DCU is ON.
The DCU detects an open circuit in the reverting valve
control circuit for 3 seconds or more.
DTC P20A2
Urea Fluid Reverting Valve Circuit Low Voltage
Control circuit
If the DCU detects that the control circuit is shorted to
another ground, the DTC is set.
The DCU is ON.
The DCU detects a short to GND in the reverting valve
DTC P20A3
Urea Fluid Reverting Valve Circuit High Voltage
Control circuit
ignition power supply circuit in the control circuit, the
DTC is set.
The DCU is ON.
ignition power supply in the reverting valve control
DTC P20AC
Urea Fluid Pump Temperature Sensor Performance
1. DTC P20AC description of DTC
The supply module temperature sensor is installed inside
the urea fluid supply module, and monitors the urea fluid
supply module internal temperature.
The temperature sensor signal shares the urea fluid pump
control circuit, and is sent to the DCU by a PWM signal.
If the DCU detects an abnormal signal in the supply
module temperature sensor, the DTC is set.
2. DTC P20AC condition for setting the DTC
Note：
・
The DCU is ON.
The urea fluid pump is stopped.
Note：
・ The DCU receives an abnormal supply module
temperature signal for 4 seconds or more.
3. DTC P20AC action taken when the DTC sets

Note：
・
Note：
・ Urea Fluid Pump Temperature Sensor
Performance
DTC P20AD
Urea Fluid Pump Module Temperature Sensor Performance
1. DTC P20AD description of DTC
The DCU controls the coolant control valve relay by
supplying voltage based on temperature signals. Remove
frost from the coolant control valve, and circulate engine
coolant to the urea fluid tank and supply module to
prevent its temperature from dropping to the specified
temperature or less. The supply module temperature
sensor is installed inside the supply module, and monitors
the supply module internal temperature. When the
coolant control valve is ON, if the DCU detects that the
temperature inside the supply module has not risen within
the specified time, the DTC is set.
2. DTC P20AD condition for setting the DTC
The DCU is ON.
The urea SCR system heater control is ON.
The engine coolant temperature is 60°C {140°F} or more.
A urea fluid pump module temperature increase of 3°C
{5°F} or less over a period of 500 seconds is detected.
3. DTC P20AD action taken when the DTC sets
DTC P20B1
Urea Fluid Tank Heater Coolant Control Valve Circuit Open
1. DTC P20B1 description of DTC
The coolant control valve is operated based on signals
from the DCU.
The coolant control valve has the following circuits.
Control circuit
the DTC is set.
2. DTC P20B1 condition for setting the DTC
The DCU is ON.
The DCU detects an open circuit in the control circuit for
3 seconds or more.
3. DTC P20B1 action taken when the DTC sets
DTC P20B3
Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage
from the DCU.
Control circuit
another GND circuit, the DTC is set.
The DCU is ON.
The DCU detects a short to GND in the control circuit for
3 seconds or more.
DTC P20B4
Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage
from the DCU.
Control circuit
ignition power supply in the control circuit, the DTC is
set.
The DCU is ON.
ignition power supply in the control circuit for 3 seconds
or more.
DTC P20E8
Urea Fluid Pressure Underpressure
1. DTC P20E8 description of DTC
The urea fluid pressure between the urea fluid supply
module and the dosing module is raised up to 900 kPa
{131 psi} by the urea fluid supply module between the
startup control and the injection control.
The DCU controls the urea fluid supply module and
maintains its pressure by feeding back the signals from
the urea fluid pressure sensor built into the urea fluid
supply module.
If the DCU detects a urea fluid pressure lower than the
specified value during pressure control, the DTC is set.
2. DTC P20E8 condition for setting the DTC
The DCU is ON.
The DCU detects a urea fluid pressure of 650 kPa {94
psi} or less for 240 seconds or more.
3. DTC P20E8 action taken when the DTC sets
light illuminates.
DTC P20E9
The DCU controls the urea fluid supply module and
maintains its pressure by feeding back the signals from
the urea fluid pressure sensor built into the urea fluid
supply module.
If the DCU detects a urea fluid pressure higher than the
The DCU is ON.
light illuminates.
DTC P20EA
1. DTC P20EA description of DTC
module pump motor. Then, the urea fluid passes the main
filter and pressure line and is sent to the dosing module.
the one-way valve.
2. DTC P20EA condition for setting the DTC
The DCU is ON.
decrease to the predetermined value or less within the
specified amount of time during urea fluid pressure-
reducing control.
3. DTC P20EA action taken when the DTC sets
DTC P20FE
Urea Fluid Pressure Build-Up Error
1. DTC P20FE description of DTC
startup control and the injection control. The DCU
controls the urea fluid supply module and maintains its
pressure by feeding back the signals from the urea fluid
pressure sensor built into the urea fluid supply module.
If the DCU detects that the urea fluid pressure has not
increased to the specified pressure within a predetermined
2. DTC P20FE condition for setting the DTC
The DCU is ON.
The urea fluid pressure is detected not to rise to 650 kPa
{94 psi} for 250 seconds or more during startup control.
3. DTC P20FE action taken when the DTC sets
light illuminates.
DTC P2201
Upstream Nox Sensor Performance
The NOx sensor is installed onto the mixer chamber, and
measures the NOx concentration in the exhaust gases
upstream of the SCR catalyst. The NOx sensors are
equipped with heaters to keep them in an active
condition. If the NOx sensors are valid, measurement of
NOx concentration in the exhaust gases begins, and the
DCU changes to the urea fluid injection control based on
the actual measured values from the NOx sensors. Before
the NOx sensors become valid, the NOx concentration
calculated from the engine start conditions is used for
control. NOx sensor signals are sent to the DCU via the
CAN circuit. The DCU calculates the required urea fluid
injection quantity based on the signals from the NOx
sensors. When the DCU compares the concentration from
the NOx sensor with the concentration that was
calculated from the engine start conditions and detects
that the former is much lower or higher than the latter, the
DTC is set.
The NOx sensor heater is ON.
The SCR catalyst upstream temperature is 190 to 400°C
{374 to 752°F}.
The engine speed is 1400 to 2200 rpm.
The desired fuel injection quantity is 80 mm3/st or more.
The EGR valve position is 3 to 100%.
It is detected that the NOx concentration measured by the
NOx sensor is extremely low or high compared to the
NOx concentration that was calculated based on
operating conditions for 70 seconds or more.
light illuminates.
DTC P2206
Reading the error(open) information detected by Ft NOx sensor
The NOx sensor is installed upstream of the SCR
catalyst, and measures the NOx concentration in the
exhaust gases before passing through the SCR catalyst.
The NOx sensor has the following circuits.
GND circuit
CAN High circuit
CAN Low circuit
If the DCU receives error information concerning an
open circuit from the NOx sensor, the DTC is set.
circuit from the NOx sensor for 9 seconds or more.
DTC P2207
Reading the error(short) information detected by Ft NOx sensor
The NOx sensor is installed upstream of the SCR
exhaust gases before passing through the SCR catalyst.
The NOx sensor has the following circuits.
GND circuit
CAN High circuit
CAN Low circuit
If the DCU receives error information concerning a short
circuit from the NOx sensor, the DTC is set.
circuit from the NOx sensor for 9 seconds or more.
DTC P242B
Exhaust Gas Temperature (EGT) Sensor 3 Performance
EGT sensor 3 is installed in the SCR front chamber. EGT
sensor 3 is a resistance temperature detector, and
measures the exhaust gas temperature upstream of the
SCR catalyst. EGT sensor 1 is installed in the catalyst
catalyst 2. The DCU continually monitors both
temperatures. If the DCU detects that the difference
between the temperature measured by EGT sensor 3 and
the calculated temperature is not within the specified
temperature range, the DTC is set.
The DCU is ON.
The exhaust gas temperature in front of oxidation catalyst
2 is 250°C {482°F}.
The EGT sensor 3 temperature is detected to be lower
than the EGT sensor 1 temperature by 200°C {392°F} or
light illuminates.
DTC P242C
Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage
EGT sensor 3 is installed in the SCR housing. EGT
SCR catalyst.
DCU supplies 5 V to the signal circuit, and the GND
circuit connects to GND. When EGT sensor 3 is cool, the
sensor resistance is low.
As the exhaust temperature rises, the sensor resistance
increases. The DCU detects a high voltage when the
sensor resistance is high. The DCU detects a low voltage
when the sensor resistance is low. If the DCU detects an
The DCU is ON.
The DCU detects that the EGT sensor 3 signal voltage is
DTC P242D
Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage
SCR catalyst.
when the sensor resistance is high. If the DCU detects an
The DCU is ON.
DTC U0002
CAN Bus Off
The DCU and ECM communicate control signals and
diagnostic information via CAN communication.
If the DCU detects that no communication data can be
sent to the ECM for a predetermined length of time, the
DTC is set.
The DCU detects that the CAN Bus messages are not sent
to the ECM for 8 seconds or more.
DTC U0100
Lost Communication with Engine Control Module (ECM)
If the DCU detects an interruption in communication
from the ECM, the DTC is set.
The DCU detects an interruption in communication with
the ECM for 9 seconds or more.
DTC U029D
CAN communication error between DCU and Ft NOx sensor
1. DTC U029D description of DTC
The DCU and the NOx sensor communicate control
information and diagnostic information via CAN
communication. If the DCU detects a CAN
communication interruption error or that no
communication data can be received from the NOx
sensor for a predetermined length of time, the DTC is set.
2. DTC U029D condition for setting the DTC
Note：
・ CAN bus open circuit
the NOx sensor for 8 seconds or more.
Note：
・ CAN communication malfunction
The DCU detects that CAN Bus messages are not being
received from the NOx sensor for 10 seconds or more.
3. DTC U029D action taken when the DTC sets
DTC mapping table

P code
SPN-FMI P06**-
P20**
10042-12 10514-12 P0607 Control Module Performance
10042-12 10514-12 P060B Internal Control Module A/D Processing Performance
10042-12 10514-12 P062F Control Module EEPROM Error
10514-12
10042-12 P0641 Sensor Reference Voltage Circuit
10515-12
10042-12 10515-12 P0658 Actuator Supply Voltage Circuit
10042-12 10526-12 P1462 Urea Fluid Quality Sensor Timeout Error
- 10534-12 Main Relay Performance
P1464
10043-2 10528-12 Main Relay Performance
- 10517-12 P1468 Urea Dosing Control Module (DCM) Overtemperature
- 10518-12 P1491 Urea Fluid Overpressure
- 10517-12 P1493 Urea Dosing Control Module (DCM) Driver Overtemperature
- 10519-12 P149C Urea Fluid Pressure Reduction Malfunction
10043-2 10521-12 P149D Urea Fluid Tank Overtemperature
10044-1 10522-12 P203B Urea Fluid Tank Level Sensor Stuck
10044-1 10531-12 P203D Urea Fluid Tank Level Sensor High Voltage
10042-12 10500-12 P2048 Urea Fluid Injector Circuit Low Voltage
10042-12 10500-12 P2049 Urea Fluid Injector Circuit High Voltage
10042-12 10512-12 P204B Urea Fluid Pressure Sensor Performance
10042-12 10511-12 P204C Urea Fluid Pressure Sensor Circuit Low Voltage
10042-12 10511-12 P204D Urea Fluid Pressure Sensor Circuit High Voltage
P code
SPN-FMI P20**-
P20**
- 10506-12 P205B Urea Fluid Tank Temperature Sensor Performance
10042-12 10532-12 P205D Urea Fluid Tank Temperature Sensor High Voltage
10042-12 10529-12 P206A Urea Fluid Quality Sensor Circuit
- 10535-12 P206B Urea Sensor Over Temperature Condition
10042-12 10529-12 P206C Urea Fluid Quality Sensor Circuit Open
10042-12 10529-12 P206D Urea Fluid Quality Sensor Circuit Short
4332-12 10523-12 P207F Urea Fluid Concentration Too Low
10042-12 10508-12 P208A Urea Fluid Pump Control Circuit
10042-12 10509-12 P208B Urea Fluid Pump Performance
10042-12 10508-12 P208C Urea Fluid Pump Control Circuit Low Voltage
10042-12 10508-12 P208D Urea Fluid Pump Control Circuit High Voltage
10042-12 10501-12 P208E Urea Fluid Injector Stuck
10043-2 10510-12 P20A0 Urea Fluid Reverting Valve Circuit Open
10042-12 10536-12 P20A2 Urea Fluid Reverting Valve Circuit Low Voltage
10043-2 10510-12 P20A3 Urea Fluid Reverting Valve Circuit High Voltage
10044-1 10513-12 Urea Fluid Pump Temperature Sensor Performance
10513-12 P20AC
10042-12 Urea Fluid Pump Temperature Sensor Performance
10508-12
- 10516-12 P20AD Urea Fluid Pump Module Temperature Sensor Performance
10042-12 10507-12 P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open
10042-12 10507-12 P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage
10042-12 10507-12 P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage
P code
SPN-FMI P20**-
P24**
10042-12 10533-12 P20E8 Urea Fluid Pressure Underpressure
10042-12 10530-12 P20E9 Urea Fluid Overpressure
- 10534-12 P20EA Urea Fluid Pressure Reduction Malfunction
10042-12 10520-12 P20FE Urea Fluid Pressure Build-Up Error
10044-1 10505-12 P2201 Upstream NOx Sensor Performance
10044-1 10504-12 P2206 Reading the error (open) information detected by Ft NOx sensor
10044-1 10504-12 P2207 Reading the error (short) information detected by Ft NOx sensor
10044-1 10503-12 P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance
10044-1 10502-12 P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage
10044-1 10502-12 P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage
SPN-FMI U code
10042-12 10525-12 U0002 CAN Bus Off
10042-12 10525-12 U0100 Lost Communication with Engine Control Module (ECM)
10527-12 CAN communication error between DCU and Ft NOx sensor
10044-1 U029D
DTC Information (Urea SCR System (24V)) 38E-1

DTC Information
(Urea SCR System (24V))
Table of Contents
DTC P0607 Control Module Performance....................38E-3 DTC P206A Urea Fluid Quality Sensor Circuit..........38E-28
DTC P060B Internal Control Module A/D Processing DTC P206B Urea Sensor Over Temperature Condition
Performance...................................................................38E-4 .....................................................................................38E-29
DTC P062F Control Module EEPROM Error..............38E-5 DTC P206C Urea Fluid Quality Sensor Circuit Open
DTC P0641 Sensor Reference Voltage Circuit.............38E-6 .....................................................................................38E-30
DTC P0658 Actuator Supply Voltage Circuit...............38E-7 DTC P206D Urea Fluid Quality Sensor Circuit Short
.....................................................................................38E-31
DTC P0659 Actuator Supply Voltage Circuit...............38E-8
DTC P207F Urea Fluid Concentration Too Low........38E-32
DTC P1462 Urea Fluid Quality Sensor Timeout Error
.......................................................................................38E-9 DTC P208A Urea Fluid Pump Control Circuit...........38E-33
DTC P1464 Main Relay Performance.........................38E-10 DTC P208B Urea Fluid Pump Performance...............38E-34
DTC P1468 Urea Dosing Control Module (DCM) DTC P208C Urea Fluid Pump Control Circuit Low Voltage
Overtemperature..........................................................38E-11 .....................................................................................38E-35
DTC P1491 Urea Fluid Overpressure.........................38E-12 DTC P208D Urea Fluid Pump Control Circuit High Voltage
.....................................................................................38E-36
Overtemperature..........................................................38E-13 DTC P208E Urea Fluid Injector Stuck........................38E-37
DTC P149C Urea Fluid Pressure Reduction Malfunction DTC P20A0 Urea Fluid Reverting Valve Circuit Open
.....................................................................................38E-14 .....................................................................................38E-38
DTC P149D Urea Fluid Tank Overtemperature..........38E-15 DTC P20A2 Urea Fluid Reverting Valve Circuit Low
Voltage.........................................................................38E-39
DTC P2000 Monitoring the NOx Efficiency..............38E-16
DTC P20A3 Urea Fluid Reverting Valve Circuit High
DTC P203B Urea Fluid Tank Level Sensor Stuck......38E-17
Voltage.........................................................................38E-40
DTC P203C Urea Fluid Tank Level Sensor Low Voltage
DTC P20AC Urea Fluid Pump Temperature Sensor
.....................................................................................38E-18
Performance.................................................................38E-41
.....................................................................................38E-19
Performance.................................................................38E-42
.....................................................................................38E-20
Circuit Open................................................................38E-43
.....................................................................................38E-21
.....................................................................................38E-22
DTC P20E8 Urea Fluid Pressure Underpressure........38E-46
Voltage.........................................................................38E-23
DTC P20E9 Urea Fluid Overpressure.........................38E-47
Voltage.........................................................................38E-24 DTC P20EA Urea Fluid Pressure Reduction Malfunction
.....................................................................................38E-48
DTC P205B Urea Fluid Tank Temperature Sensor
Performance.................................................................38E-25 DTC P20FE Urea Fluid Pressure Build-Up Error.......38E-49
DTC P205C Urea Fluid Tank Temperature Sensor Low DTC P2201 Upstream Nox Sensor Performance........38E-50
Voltage.........................................................................38E-26 DTC P2206 Reading the error(open) information detected
DTC P205D Urea Fluid Tank Temperature Sensor High by Ft NOx sensor.........................................................38E-51
Voltage.........................................................................38E-27 DTC P2207 Reading the error(short) information detected
by Ft NOx sensor.........................................................38E-52
38E-2 DTC Information (Urea SCR System (24V))
DTC P2210 Reading the error(open) information detected

by Rr NOx sensor........................................................38E-53
DTC P2211 Reading the error(short) information detected
by Rr NOx sensor........................................................38E-54
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3
Performance.................................................................38E-55
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3
DTC U0002 CAN Bus Off..........................................38E-58
Module (ECM)............................................................38E-59
Ft NOx sensor..............................................................38E-60
DTC U029E CAN communication error between DCU and
Rr NOx sensor.............................................................38E-61
DTC mapping table.....................................................38E-62
DTC P0607
DCU.
The DCU is ON.
The DCU detects a malfunction of the internal CPU.
DTC P060B
DCU.
The DCU is ON.
The DCU detects a malfunction of the internal A/D
converter.
DTC P062F
This diagnosis applies to the EEPROM inside the DCU.
The DTC is set if the DCU is unable to read, write, or
clear the EEPROM data.
The DCU is ON.
The DCU detects a malfunction of the internal EEPROM.
DTC P0641
The DCU supplies 5 V power to the urea fluid pressure
sensor inside the urea fluid supply module via the 5 V
The DCU monitors the voltage of 5 V power supply
circuit, and if it detects that the voltage is excessively low
or high, the DTC is set.
The DCU is ON.
The DCU detects a voltage outside the predetermined
range in the urea fluid pressure sensor 5 V power supply
circuit.
DTC P0658
circuit, and if it detects an excessively low voltage, the
DTC is set.
The battery voltage is 19 - 32 V.
The DCU is ON.
The DCU detects a low voltage in the battery voltage
supply circuit.
DTC P0659
circuit, and if it detects an excessively high voltage, the
DTC is set.
The DCU is ON.
The DCU detects high voltage in the battery voltage
supply circuit.
DTC P1462
The DCU and the urea fluid sensor communicate signals
and diagnostic information via CAN communication. If
the DCU detects that no communication data can be
received from the urea fluid sensor for a predetermined
The DCU is ON.
The DCU detects that no CAN Bus message is received
from the urea fluid sensor for 10 seconds or more.
DTC P1464
The DCU has the internal main relay in the power supply
control of the DCU. If the DCU detects that the main
relay is OFF during DCU operation or stuck ON after
completing after-run control, the DTC is set.
Note：
The DCU is ON.
The DCU detects the OFF status when the main relay is
commanded ON.
Note：
The ignition switch is OFF.
The DCU detects the ON status when the main relay is
commanded OFF.
Note：
If the diagnosis conditions are met, DTCs are stored in
the failure history.
Note：
DTC P1468
The DCU monitors the temperature inside itself by means
of the DCU internal temperature rise monitor. If the DCU
detects a DCU internal temperature that is more than or
equal to a predetermined temperature, the DTC is set.
The DCU is ON.
The DCU detects an abnormally high internal
temperature in the DCU for 5 seconds or more.
If the diagnosis conditions are met, it is stored in the
failure history.
DTC P1491
The urea fluid pressure in the pipe between the urea fluid
supply module and the dosing module is raised up to 900
kPa by the urea fluid supply module between the startup
control and the injection control. The DCU maintains
pressure by controlling the urea fluid supply module,
using the signals from the pressure sensor built into the
urea fluid supply module as feedback. If the DCU detects
a urea fluid pressure higher than the specified value
during pressure control, the DTC is set.
The DCU is ON.
psi} or more for several seconds or more.
failure history.
DTC P1493
The DCU controls the actuator drive circuit inside the
control module and operates the dosing module, urea
fluid supply module pump motor, reverting valve, and
coolant control valve. The DCU monitors the
temperatures of each actuator drive circuit, and if it
detects an excessively high temperature for a
predetermined length of time, the DTC is set.
The DCU is ON.
The DCU detects an abnormally high temperature in the
internal actuator drive circuit.
failure history.
DTC P149C
module pump motor.
Then, the urea fluid passes the main filter and pressure
line and is sent to the dosing module.
the one-way valve.
The DCU is ON.
decrease to 40 kPa {6 psi} or less within the specified
amount of time during urea fluid pressure-reducing
control.
failure history.
DTC P149D
The urea fluid sensor measures the urea fluid temperature
inside the urea fluid tank and sends it to the DCU. If the
DCU detects an excessively high temperature in the urea
fluid sensor, the DTC is set.
The DCU is ON.
The DCU detects a urea fluid tank temperature of 70°C
{158°F} or more for 10 seconds or more.
DTC P2000
Monitoring the NOx Efficiency
NOx sensor 1 is installed onto the mixer chamber, and
upstream of the SCR catalyst. NOx sensor 2 is installed
onto the silencer, and measures the NOx concentration in
the exhaust gases downstream of the SCR catalyst. The
NOx sensors are equipped with heaters to maintain them
in active conditions. If the NOx sensors are valid,
measurement of NOx concentration in the exhaust gases
begins, and the DCU changes to the urea fluid injection
control based on the actual measured values from the
NOx sensors. If the NOx sensors are not valid, the NOx
concentration calculated from the engine start conditions
is used for control. NOx sensor signals are sent to the
DCU via the CAN circuit. The DCU calculates the
required urea fluid injection quantity based on the signals
from the NOx sensors. If the DCU detects low NOx
conversion efficiency for a predetermined length of time,
the DTC is set.
The DCU detects that the NOx conversion efficiency
measured by each NOx sensor is below the specified
range.
light illuminates.
DTC P203B
fluid tank.
If sticking of the urea fluid level sensor is detected, the
DTC is set.
The DCU is ON.
The DCU detects that the change in the urea fluid tank
level sensor position is small compared to the predicted
urea fluid consumption.
DTC P203C
Urea Fluid Tank Level Sensor Low Voltage
fluid tank.
If the DCU detects that the signal voltage of the urea fluid
tank level sensor is abnormally low, the DTC is set.
The DCU detects that the urea fluid tank level sensor
signal voltage is low.
DTC P203D
fluid tank.
tank level sensor is abnormally high, the DTC is set.
The DCU detects that the urea fluid tank level sensor
signal voltage is high.
DTC P2048
The dosing module operates by injecting urea fluid based
on injection signals from the DCU.
If the DCU detects a short to GND or open circuit in the
injector drive circuit (High) or injector drive circuit
(Low) of the dosing module, the DTC is set.
The DCU is ON.
The DCU detects an open circuit or short to GND in the
dosing module circuit for 3 seconds or more when the
DCU outputs the injector signal.
DTC P2049
ignition power supply in the injector drive circuit (High)
or injector drive circuit (Low) of the dosing module, the
DTC is set.
The DCU is ON.
ignition power supply in the dosing module circuit for 3
seconds or more.
DTC P204B
the urea fluid pressure pressurized by the urea fluid
pump. If the DCU detects that there is a characteristic
malfunction in the urea fluid pressure sensor, the DTC is
set.
DTCs P204C, P204D, P20E8, P20E9, U0002, and U0100
are not set.
The DCU is ON.
The intake air temperature is -10°C {14 °F} or more.
The DCU detects that the urea fluid pressure is -50 kPa
{-7 psi} or less, or 50 kPa {7 psi} or more, for 4 seconds
or more while the urea fluid pump is stopped.
light illuminates.
DTC P204C
pump.
GND circuit
Signal circuit
pressure sensor output voltage that is lower than the
DTC P060B is not set.
The DCU is ON.
signal voltage is 0.25 V or less for 5 seconds or more.
DTC P204D
pump.
GND circuit
Signal circuit
pressure sensor output voltage that is higher than the
The DCU is ON.
signal voltage is 4.75 V or more for 5 seconds or more.
DTC P205B
The urea fluid tank temperature sensor is comprised of
the urea fluid sensor together with the urea fluid tank
level sensor and urea fluid quality sensor, and is installed
in the urea fluid tank. If the DCU detects that the urea
fluid temperature is excessively low or high compared
with the intake air temperature, the DTC is set.
ECM DTC P0016, P0112, P0113, P0117, P0118, P0182,
P0183, P0335, P0336, or P0340 is not set.
When the ignition switch is ON, the differences between
the engine coolant temperature, intake air temperature,
and fuel temperature are 5°C { 9 °F } or less.
The DCU detects that the intake air temperature is higher
than the urea fluid temperature by 30°C {54°F} or more
DTC P205C
Urea Fluid Tank Temperature Sensor Low Voltage
urea fluid tank.
tank temperature sensor is abnormally low, the DTC is
set.
The DCU detects that the urea fluid tank temperature
sensor signal voltage is low.
DTC P205D
urea fluid tank.
tank temperature sensor is abnormally high, the DTC is
set.
The DCU detects that the urea fluid tank temperature
sensor signal voltage is high.
DTC P206A
quality sensor. If the DCU receives a CAN message
indicating an open circuit, short circuit, or other
malfunction in any sensor from the urea fluid sensor, the
DTC is set.
The DCU receives a urea fluid sensor internal
malfunction message for 9 seconds or more.
DTC P206B
quality sensor. If the urea fluid quality sensor detects a
high temperature in the urea fluid quality sensor, the DTC
is set.
The urea fluid quality sensor detects that the urea fluid
sensor unit is at a high temperature.
failure history.
DTC P206C
If the DCU detects a short circuit in the urea fluid quality
sensor, the DTC is set.
Error information concerning a short circuit is received
from the urea fluid quality sensor.
DTC P206D
If the DCU detects an open circuit in the urea fluid
quality sensor, the DTC is set.
Error information concerning an open circuit is received
from the urea fluid quality sensor.
DTC P207F
The urea fluid sensor monitors the quality based on the
urea fluid concentration. The DCU judges the urea fluid
quality based on the measured urea fluid concentration,
and sets the DTC if abnormal conditions are detected.
The engine run time is 5 minutes.
The DCU detects an abnormal urea fluid concentration
for 10 minutes or more.
DTC P208A
DCU.
GND circuit
If the DCU detects an open circuit in the pump control
circuit, the DTC is set.
The DCU is ON.
The DCU detects an open circuit in the pump control
DTC P208B
DCU.
If the DCU detects abnormal rotation speed of the urea
fluid pump motor, the DTC is set.
The DCU is ON.
The DCU detects that the difference between the actual
and desired urea fluid pump motor speeds is a
predetermined value or more.
light illuminates.
DTC P208C
DCU.
GND circuit
If the DCU detects a short to another GND circuit in the
pump control circuit, the DTC is set.
The DCU is ON.
The DCU detects a short to the GND circuit in the control
DTC P208D
DCU.
GND circuit
ignition power supply in the pump control circuit, the
DTC is set.
The DCU is ON.
ignition power supply circuit in the pump control circuit
DTC P208E
1. DTC P208E description of DTC
If the DCU detects that the dosing module is stuck open
or closed, the DTC is set.
2. DTC P208E condition for setting the DTC
The DCU is ON.
The DCU detects that the current in the dosing module
circuit is a predetermined value or less.
3. DTC P208E action taken when the DTC sets
light illuminates.
DTC P20A0
Control circuit
the DTC is set.
The DCU is ON.
The DCU detects an open circuit in the reverting valve
DTC P20A2
Control circuit
another ground, the DTC is set.
The DCU is ON.
The DCU detects a short to ground in the reverting valve
DTC P20A3
Control circuit
ignition power supply circuit in the control circuit, the
DTC is set.
The DCU is ON.
ignition power supply in the reverting valve control
DTC P20AC
1. DTC P20AC description of DTC
The supply module temperature sensor is installed inside
the urea fluid supply module, and monitors the urea fluid
supply module internal temperature.
The temperature sensor signal shares the urea fluid pump
control circuit, and is sent to the DCU by a PWM signal.
If the DCU detects a communication malfunction or an
abnormal signal in the supply module temperature sensor,
the DTC is set.
2. DTC P20AC condition for setting the DTC
The DCU is ON.
Note：
・ Communication malfunction
The DCU detects that no supply module temperature
sensor signal is received.
Note：
・ Signal malfunction
The DCU receives an abnormal supply module
temperature signal for several seconds or more.
3. DTC P20AC action taken when the DTC sets
DTC P20AD
1. DTC P20AD description of DTC
The DCU controls the coolant control valve relay by
supplying voltage based on temperature signals. In order
to remove frost and prevent the temperature from
dropping to the specified temperature or less, the coolant
control valve circulates engine coolant to the urea fluid
tank and supply module. The supply module temperature
sensor is installed inside the supply module, and monitors
the supply module internal temperature. When the
coolant control valve is ON, if the DCU detects that the
temperature inside the supply module has not risen within
the specified time, the DTC is set.
2. DTC P20AD condition for setting the DTC
The DCU is ON.
The urea SCR system heater control is ON.
A urea fluid pump module temperature increase of 3°C
{5°F} or less over a period of 500 seconds is detected.
3. DTC P20AD action taken when the DTC sets
failure history.
DTC P20B1
from the DCU.
Control circuit
the DTC is set.
The DCU is ON.
The DCU detects an open circuit in the control circuit for
3 seconds or more.
DTC P20B3
from the DCU.
Control circuit
another GND circuit, the DTC is set.
The DCU is ON.
The DCU detects a short to ground in the control circuit
DTC P20B4
from the DCU.
Control circuit
ignition power supply in the control circuit, the DTC is
set.
The DCU is ON.
ignition power supply in the control circuit for 3 seconds
or more.
DTC P20E8
The DCU maintains pressure by controlling the urea fluid
supply module, using the signals from the urea fluid
pressure sensor built into the urea fluid supply module as
feedback.
If the DCU detects a urea fluid pressure lower than the
The DCU is ON.
psi} or less for 240 seconds or more.
light illuminates.
DTC P20E9
The DCU maintains pressure by controlling the urea fluid
supply module, using the signals from the urea fluid
pressure sensor built into the urea fluid supply module as
feedback.
If the DCU detects a urea fluid pressure higher than the
The DCU is ON.
light illuminates.
DTC P20EA
1. DTC P20EA description of DTC
module pump motor. Then, the urea fluid passes the main
filter and pressure line and is sent to the dosing module.
the one-way valve.
2. DTC P20EA condition for setting the DTC
The DCU is ON.
decrease to the predetermined value or less within the
specified amount of time during urea fluid pressure-
reducing control.
3. DTC P20EA action taken when the DTC sets
failure history.
DTC P20FE
1. DTC P20FE description of DTC
startup control and the injection control. The DCU
maintains pressure by controlling the urea fluid supply
module, using the signals from the urea fluid pressure
sensor built into the urea fluid supply module as
feedback.
If the DCU detects that the urea fluid pressure has not
increased to the specified pressure within a predetermined
2. DTC P20FE condition for setting the DTC
The DCU is ON.
It is detected that the urea fluid pressure does not rise to
650 kPa {94 psi} for 250 seconds or more during startup
control.
3. DTC P20FE action taken when the DTC sets
indicated in the monitor on the machine, or the diagnosis
light illuminates.
DTC P2201
NOx sensor 1 is installed onto the mixer chamber, and
upstream of the SCR catalyst. NOx sensor 1 is equipped
with heater to maintain it in an active condition. If NOx
sensor 1 is valid, measurement of NOx concentration in
the exhaust gases begins, and the DCU changes to the
urea fluid injection control based on the actual measured
values from NOx sensor 1. Before NOx sensor 1 becomes
valid, the NOx concentration calculated from the engine
start conditions is used for control. NOx sensor 1 signals
are sent to the DCU via the CAN circuit. The DCU
calculates the required urea fluid injection quantity based
on the signals from NOx sensor 1. When the DCU
compares the concentration from NOx sensor 1 with the
concentration that was calculated from the engine start
conditions and detects that the former is much lower or
higher than the latter, the DTC is set.
The DCU is ON.
The SCR catalyst upstream temperature is 190 to 400°C
{374 to 752°F}.
The engine speed is 1400 to 2200 rpm.
The desired fuel injection quantity is 80 mm3/st or more.
The EGR valve position is 3 to 100%.
Ｉ t is detected that the NOx concentration measured by
NOx sensor 1 is extremely low or high compared to the
NOx concentration that was calculated based on
operating conditions for 70 seconds or more.
light illuminates.
DTC P2206
NOx sensor 1 is installed upstream of the SCR catalyst,
and measures the NOx concentration in the exhaust gases
before passing through the SCR catalyst.
NOx sensor 1 has the following circuits.
GND circuit
CAN High circuit
CAN Low circuit
open circuit from the NOx sensor, the DTC is set.
DTC U029D is not set.
circuit from NOx sensor 1 for 9 seconds or more.
DTC P2207
NOx sensor 1 is installed upstream of the SCR catalyst,
and measures the NOx concentration in the exhaust gases
before passing through the SCR catalyst.
GND circuit
CAN High circuit
CAN Low circuit
circuit from NOx sensor 1, the DTC is set.
DTC U029D is not set.
DTC P2210
Reading the error(open) information detected by Rr NOx sensor
NOx sensor 2 is installed downstream of the SCR
exhaust gases after passing through the SCR catalyst.
GND circuit
CAN High circuit
CAN Low circuit
open circuit from NOx sensor 2, the DTC is set.
DTC U029E is not set.
DTC P2211
Reading the error(short) information detected by Rr NOx sensor
NOx sensor 2 is installed downstream of the SCR
exhaust gases after passing through the SCR catalyst.
GND circuit
CAN High circuit
CAN Low circuit
circuit from NOx sensor 2, the DTC is set.
DTC U029E is not set.
DTC P242B
EGT sensor 3 is installed in the SCR front chamber. EGT
SCR catalyst. EGT sensor 1 is installed in the catalyst
catalyst 2. The DCU continually monitors both
temperatures. If the DCU detects that the difference
between the temperature measured by EGT sensor 3 and
the calculated temperature is not within the specified
temperature range, the DTC is set.
The DCU is ON.
The exhaust gas temperature in front of oxidation catalyst
2 is 230 to 250°C {446 to 482°F}.
It is detected that the EGT sensor 3 temperature is higher
than the EGT sensor 1 temperature by 200°C {392°F} or
indicated in the monitor on the machine, or the diagnosis
light illuminates.
DTC P242C
SCR catalyst.
The DCU is ON.
DTC P242D
SCR catalyst.
The DCU is ON.
DTC U0002
CAN Bus Off
If the DCU detects that no communication data can be
sent to the ECM for a predetermined length of time, the
DTC is set.
The DCU detects that the CAN Bus messages are not sent
to the ECM for 8 seconds or more.
DTC U0100
If the DCU detects interruption in communication from
the ECM, the DTC is set.
the ECM for 9 seconds or more.
DTC U029D
1. DTC U029D description of DTC
communication. If the DCU detects a CAN
communication interruption error or that no
communication data can be received from NOx sensor 1
for a predetermined length of time, the DTC is set.
2. DTC U029D condition for setting the DTC
Note：
・ CAN bus open circuit
NOx sensor 1 for 8 seconds or more.
Note：
・ CAN communication malfunction
received from NOx sensor 1 for 10 seconds or more.
3. DTC U029D action taken when the DTC sets
DTC U029E
CAN communication error between DCU and Rr NOx sensor
communication. If the DCU detects that no
communication data can be received from NOx sensor 2
for a predetermined length of time, the DTC is set.
received from NOx sensor 2 for 10 seconds or more.
DTC mapping table

SPN-FMI Failure code

10044-1 10514-12 P0607 Control Module Performance
10044-1 10514-12 P060B Internal Control Module A/D Processing Performance
10044-1 10514-12 P062F Control Module EEPROM Error
10514-12
10044-1 P0641 Sensor Reference Voltage Circuit
10515-12
10044-1 10526-12 P1462 Urea Fluid Quality Sensor Timeout Error
- 10534-12 Main Relay Performance
P1464
10043-2 10528-12 Main Relay Performance
- 10517-12 P1468 Urea Dosing Control Module (DCM) Overtemperature
- 10518-12 P1491 Urea Fluid Overpressure
- 10517-12 P1493 Urea Dosing Control Module (DCM) Driver Overtemperature
- 10519-12 P149C Urea Fluid Pressure Reduction Malfunction
10043-2 10521-12 P149D Urea Fluid Tank Overtemperature
10044-1 10542-12 P2000 Monitoring the NOx Efficiency
10044-1 10522-12 P203B Urea Fluid Tank Level Sensor Stuck
10044-1 10531-12 P203C Urea Fluid Tank Level Sensor Low Voltage
10044-1 10531-12 P203D Urea Fluid Tank Level Sensor High Voltage
10044-1 10500-12 P2048 Urea Fluid Injector Circuit Low Voltage
10044-1 10500-12 P2049 Urea Fluid Injector Circuit High Voltage
10044-1 10512-12 P204B Urea Fluid Pressure Sensor Performance
10044-1 10511-12 P204C Urea Fluid Pressure Sensor Circuit Low Voltage
10044-1 10511-12 P204D Urea Fluid Pressure Sensor Circuit High Voltage
- 10506-12 P205B Urea Fluid Tank Temperature Sensor Performance
10044-1 10532-12 P205C Urea Fluid Tank Temperature Sensor Low Voltage
10044-1 10532-12 P205D Urea Fluid Tank Temperature Sensor High Voltage
10044-1 10529-12 P206A Urea Fluid Quality Sensor Circuit
- 10535-12 P206B Urea Sensor Over Temperature Condition
10044-1 10529-12 P206C Urea Fluid Quality Sensor Circuit Open
10044-1 10529-12 P206D Urea Fluid Quality Sensor Circuit Open
4332-12 10523-12 P207F Urea Fluid Concentration Too Low
10044-1 10508-12 P208A Urea Fluid Pump Control Circuit
10044-1 10509-12 P208B Urea Fluid Pump Performance
10044-1 10508-12 P208C Urea Fluid Pump Control Circuit Low Voltage
10044-1 10508-12 P208D Urea Fluid Pump Control Circuit High Voltage
10044-1 10501-12 P208E Urea Fluid Injector Stuck
10043-2 10510-12 P20A0 Urea Fluid Reverting Valve Circuit Open
10044-1 10536-12 P20A2 Urea Fluid Reverting Valve Circuit Low Voltage
10043-2 10510-12 P20A3 Urea Fluid Reverting Valve Circuit High Voltage
10513-12
10044-1 P20AC Urea Fluid Pump Temperature Sensor Performance
10508-12
- 10516-12 P20AD Urea Fluid Pump Module Temperature Sensor Performance
10044-1 10507-12 P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open
10044-1 10507-12 P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage
10044-1 10507-12 P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage
10044-1 10533-12 P20E8 Urea Fluid Pressure Underpressure
10044-1 10530-12 P20E9 Urea Fluid Overpressure
- 10534-12 P20EA Urea Fluid Pressure Reduction Malfunction
10044-1 10520-12 P20FE Urea Fluid Pressure Build-Up Error
10044-1 10505-12 P2201 Upstream NOx Sensor Performance
10044-1 10504-12 P2206 Reading the error (open) information detected by Ft NOx sensor
10044-1 10504-12 P2207 Reading the error (short) information detected by Ft NOx sensor
10044-1 10540-12 P2210 Reading the error (open) information detected by Rr NOx sensor
10044-1 10540-12 P2211 Reading the error (short) information detected by Rr NOx sensor
10044-1 10503-12 P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance
10044-1 10502-12 P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage
10044-1 10502-12 P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage
10044-1 10527-12 U0002 CAN Bus Off
10044-1 10525-12 U0100 Lost Communication with Engine Control Module (ECM)
10044-1 U029D
10044-1 10541-12 U029E CAN communication error between DCU and Rr NOx sensor
Emission Control (Urea SCR System (Generator 12V)) 10M-1
Emission Control
Emission Control
(Urea SCR System (Generator 12V))
Table of Contents
DTC P0607 Control Module Performance...................10M-3 DTC P206D Urea Fluid Quality Sensor Circuit Short
DTC P060B Internal Control Module A/D Processing ....................................................................................10M-33
Performance..................................................................10M-4 DTC P207F Urea Fluid Concentration Too Low.......10M-34
DTC P062F Control Module EEPROM Error.............10M-5 DTC P208A Urea Fluid Pump Control Circuit..........10M-35
DTC P0641 Sensor Reference Voltage Circuit............10M-6 DTC P208B Urea Fluid Pump Performance..............10M-36
DTC P0658 Actuator Supply Voltage Circuit..............10M-7 DTC P208C Urea Fluid Pump Control Circuit Low Voltage
DTC P0659 Actuator Supply Voltage Circuit..............10M-9 ....................................................................................10M-37
DTC P1462 Urea Fluid Quality Sensor Timeout Error DTC P208D Urea Fluid Pump Control Circuit High Voltage
....................................................................................10M-11 ....................................................................................10M-38
DTC P1464 Main Relay Performance........................10M-12 DTC P208E Urea Fluid Injector Stuck.......................10M-39
DTC P1468 Urea Dosing Control Module (DCM) DTC P20A0 Urea Fluid Reverting Valve Circuit Open
Overtemperature.........................................................10M-13 ....................................................................................10M-40
DTC P1491 Urea Fluid Overpressure........................10M-14 DTC P20A2 Urea Fluid Reverting Valve Circuit Low
Voltage.......................................................................10M-41
Overtemperature.........................................................10M-16 DTC P20A3 Urea Fluid Reverting Valve Circuit High
Voltage.......................................................................10M-42
DTC P149C Urea Fluid Pressure Reduction Malfunction
....................................................................................10M-17 DTC P20AC Urea Fluid Pump Temperature Sensor
Performance................................................................10M-43
DTC P149D Urea Fluid Tank Overtemperature........10M-19
DTC P203B Urea Fluid Tank Level Sensor Stuck.....10M-20
Performance................................................................10M-44
....................................................................................10M-22
Circuit Open...............................................................10M-45
....................................................................................10M-23
Circuit Low Voltage...................................................10M-46
....................................................................................10M-24
Circuit High Voltage..................................................10M-47
DTC P20E8 Urea Fluid Pressure Underpressure.......10M-48
....................................................................................10M-25
DTC P20E9 Urea Fluid Overpressure........................10M-50
Voltage.......................................................................10M-26 DTC P20EA Urea Fluid Pressure Reduction Malfunction
....................................................................................10M-52
Voltage.......................................................................10M-27 DTC P20FE Urea Fluid Pressure Build-Up Error......10M-53
DTC P205B Urea Fluid Tank Temperature Sensor DTC P2201 Upstream Nox Sensor Performance.......10M-55
Performance................................................................10M-28 DTC P2206 Reading the error(open) information detected
DTC P205D Urea Fluid Tank Temperature Sensor High by Ft NOx sensor........................................................10M-56
Voltage.......................................................................10M-29 DTC P2207 Reading the error(short) information detected
DTC P206A Urea Fluid Quality Sensor Circuit.........10M-30 by Ft NOx sensor........................................................10M-57
DTC P206B Urea Sensor Over Temperature Condition DTC P242B Exhaust Gas Temperature (EGT) Sensor 3
....................................................................................10M-31 Performance................................................................10M-58
DTC P206C Urea Fluid Quality Sensor Circuit Open DTC P242C Exhaust Gas Temperature (EGT) Sensor 3
....................................................................................10M-32 Circuit Low Voltage...................................................10M-59
10M-2 Emission Control (Urea SCR System (Generator 12V))

DTC U0002 CAN Bus Off.........................................10M-61
Module (ECM)...........................................................10M-62
Ft NOx sensor.............................................................10M-63
DTC P0607
1. Inspect the DCU harness GND connection terminal
for intermittent conditions, improper tightening, or
corrosion.
2. If a problem is found, repair the mounting of the
DCU harness GND connection terminal.
4. Disconnect the DCU harness connector.
5. Inspect the DCU harness connector.
Note：
・ There should be no intermittent conditions,
poor connections, or corrosion.
・ There should be no water intrusion or adhering
foreign material.
7. Inspect the battery power supply circuit between the
urea SCR fuse and the DCU for an open circuit or
high resistance.
8. If a problem is found, repair the battery power
supply circuit or connector.
9. Inspect the DCU GND circuit for an open circuit or
high resistance.
10. If a problem is found, repair the GND circuit or
connector.
Note：
・ After clearing the DCU DTC, observe whether
ECM DTC P20C9 is set.
・ If DTC P20C9 is set, clear it.
2. Turn OFF the ignition switch until communication
with the trouble diagnosis scan tool is discontinued.
engine.
DTC P060B
engine.
3. Check whether the DTC is a current failure with the
4. If the DTC is a past failure, perform the urea SCR
system intermittent diagnosis.
5. If the DTC is a current failure, replace the DCU.
Note：
engine.
DTC P062F
1. DTC P062F diagnostics If DTC P1464 is set as a current failure or past
failure at the same time, treat that first.
Note：
・ If an applicable DTC is set after the following 14. If the DTC is a past failure, perform the urea SCR
conditions occur, the DCU is normal, and the system intermittent diagnosis.
DTC should simply be cleared. 15. If the DTC is a current failure, replace the DCU.
The battery enters a low voltage condition.
If the battery enters a low voltage condition Refer to "1.Engine 1H.Aux. Emission Control
due to cranking or operation of the machine's Devices(4HK1) DCU removal".
electronic components, the DCU will Refer to "1.Engine 1H.Aux. Emission Control
temporarily turn OFF. Devices(4HK1) DCU installation".
The battery or urea SCR fuse is removed
before turning the DCU power supply OFF 2. DTC P062F confirm resolution
after turning OFF the ignition switch (during 1. Clear the DTC with the trouble diagnosis scan tool.
after-run control or within 3 minutes of turning
OFF the ignition switch). Note：
1. Turn OFF the ignition switch until communication ECM DTC P20C9 is set.
for intermittent conditions, improper tightening, or 2. Turn OFF the ignition switch until communication
corrosion. with the trouble diagnosis scan tool is discontinued.
3. If a problem is found, repair the mounting of the 3. Turn ON the ignition switch without starting the
DCU harness GND connection terminal. engine.
Note：
foreign material.
high resistance.
high resistance.
connector.
engine.
DTC P0641
1. DTC P0641 diagnostics ・ There should be no short to metallic parts such
1. Turn OFF the ignition switch. as the frame.
2. Disconnect the urea fluid supply module harness 11. If a problem is found, repair the 5 V power supply
connector. circuit.
Note： 12. Disconnect the DCU harness connector.

・ The urea fluid pump, reverting valve, and urea 13. Inspect the DCU harness connector.
fluid pressure sensor are built in.
Note：
3. Inspect the urea fluid supply module harness ・ There should be no intermittent conditions,
connector. poor connections, or corrosion.
Note：・ There should be no water intrusion or adhering
・ There should be no intermittent conditions, foreign material.
poor connections, or corrosion. 14. If a problem is found, repair the connector.
foreign material.
engine.
circuit and the DCU harness GND connection.
values： 4.8 to 5.2 V
Note：
7. If the reading is within the specified range, replace
the urea fluid supply module. ・ After clearing the DCU DTC, observe whether
Devices(4HK1) DEF supply module removal".
Devices(4HK1) DEF supply module installation".
engine.
value, inspect the 5 V power supply circuit between
the DCU and the urea fluid pressure sensor. 4. Observe the DTC information with the trouble
Note：
・ There should be no short to the battery or
・ There should be no short to other power
supply circuits.
circuit.
the DCU and the urea fluid pressure sensor.
Note：
・ There should be no short to the GND circuit.
・ There should be no short to other GND
circuits.
DTC P0658
1. DTC P0658 diagnostics Refer to "1.Engine 1H.Aux. Emission Control
2. Disconnect the coolant control valve harness
connector.
15. Inspect the battery voltage supply circuit between the
3. Inspect the coolant control valve harness connector.
DCU and the coolant control valve for a short to any
Note： metallic components, such as the frame.
・ There should be no intermittent conditions, 16. If a problem is found, repair the battery voltage
poor connections, or corrosion. supply circuit.
foreign material.
DCU and the urea fluid supply module.
Note：
5. Turn ON the ignition switch without starting the ・ There should be no short to other GND
engine. circuits.
6. Observe the DTC information with a trouble ・ There should be no short to other power
diagnosis scan tool. supply circuits.
7. If DTC P20B1 is set but P0658 is not set, replace the 18. If a problem is found, repair the battery voltage
coolant control valve. supply circuit.
Refer to "1.Engine 1H.Aux. Emission Control 19. Turn OFF the ignition switch.
Devices(4HK1) Coolant control valve removal".
Devices(4HK1) Coolant control valve installation".
Note：
9. Disconnect the urea fluid supply module harness poor connections, or corrosion.
connector.
Note： foreign material.
・ The urea fluid pump, reverting valve, and urea 22. If a problem is found, repair the connector.
10. Inspect the urea fluid supply module harness
connector. Refer to "1.Engine 1H.Aux. Emission Control
Note：
・ There should be no water intrusion or adhering 2. DTC P0658 confirm resolution
foreign material. 1. Clear the DTC with the trouble diagnosis scan tool.
11. If a problem is found, repair the connector. Note：
12. Turn ON the ignition switch without starting the ・ After clearing the DCU DTC, observe whether
engine. ECM DTC P20C9 is set.
13. Observe the DTC information with a trouble ・ If DTC P20C9 is set, clear it.
diagnosis scan tool. 2. Turn OFF the ignition switch until communication
14. If DTC P20A0 and P20B1 are set but P0658 is not with the trouble diagnosis scan tool is discontinued.
set, replace the urea fluid supply module. 3. Turn ON the ignition switch without starting the
engine.
DTC P0659
1. DTC P0659 priority DTC 13. Observe the DTC information with a trouble
DTC P208D
14. If DTC P20A0 and P20B1 are set but P0659 is not
DTC P20A3
set, replace the urea fluid supply module.
DTC P20B4
2. DTC P0659 diagnostics Devices(4HK1) DEF supply module removal".
1. Turn OFF the ignition switch. Refer to "1.Engine 1H.Aux. Emission Control
connector. 15. If P0659 is detected, inspect the battery voltage
supply circuit between the DCU and the coolant
control valve for a short to the battery or a short to
Note： the ignition power supply.
foreign material.
DCU and the urea fluid supply module for a short to
4. If a problem is found, repair the connector. the battery or a short to the ignition power supply.
5. Turn ON the ignition switch without starting the 18. If a problem is found, repair the battery voltage
engine. supply circuit.
6. Observe the DTC information with a trouble 19. Turn OFF the ignition switch.
7. If DTC P20B1 is set but P0659 is not set, replace the
coolant control valve.
Refer to "1.Engine 1H.Aux. Emission Control Note：
Devices(4HK1) Coolant control valve removal". ・ There should be no intermittent conditions,
Devices(4HK1) Coolant control valve installation". ・ There should be no water intrusion or adhering
foreign material.
9. Disconnect the urea fluid supply module harness
connector.
Note：
・ The urea fluid pump, reverting valve, and urea
fluid pressure sensor are built in. Refer to "1.Engine 1H.Aux. Emission Control
connector. 3. DTC P0659 confirm resolution
Note： 1. Clear the DTC with the trouble diagnosis scan tool.
・ There should be no water intrusion or adhering Note：
foreign material. ・ After clearing the DCU DTC, observe whether
・ There should be no intermittent conditions, ECM DTC P20C9 is set.
poor connections, or corrosion. ・ If DTC P20C9 is set, clear it.
11. If a problem is found, repair the connector. 2. Turn OFF the ignition switch until communication
12. Turn ON the ignition switch without starting the with the trouble diagnosis scan tool is discontinued.
engine.
engine.
DTC P1462
Devices(4HK1) DEF sensor removal".
DTC U029D
Devices(4HK1) DEF sensor installation".
2. Disconnect the urea fluid sensor harness connector.
3. Inspect the urea fluid sensor harness connector.
Note：
Note：・ After clearing the DCU DTC, observe whether
foreign material.
5. Turn ON the ignition switch. engine.
6. Connect a test lamp between the urea fluid sensor 4. Observe the DTC information with the trouble
power supply circuit and the DCU harness GND diagnosis scan tool. A DTC should not be set.
connection.
7. If the test lamp does not illuminate, repair the open
circuit or high resistance in the urea fluid sensor
8. Connect a test lamp between the power supply
circuit and the GND circuit.
GND circuit.
11. Measure the voltage between the CAN Low circuit
and the DCU harness GND connection, and between
the CAN High circuit and the DCU harness GND
connection.
the CAN Low circuit and CAN High circuit between
the urea fluid sensor and the DCU.
Note：
resistance in the CAN High circuit.
resistance in the CAN Low circuit.
resistance in the termination resistor.
13. If a problem is found, repair the CAN circuit or
14. Replace the urea fluid sensor.
DTC P1464
1. DTC P1464 diagnostics 1. Clear the DTC with the trouble diagnosis scan tool.
Note： Note：
・ If an applicable DTC is set after the following ・ After clearing the DCU DTC, observe whether
conditions occur, the DCU is normal, and the ECM DTC P20C9 is set.
DTC should simply be cleared. ・ If DTC P20C9 is set, clear it.
If the battery enters a low voltage condition 2. Turn OFF the ignition switch for 3 minutes or more.
due to cranking or operation of the machine's 3. Turn ON the ignition switch without starting the
electronic components, the DCU will engine.
temporarily turn OFF.
The battery or urea SCR fuse is removed 4. Observe the DTC information with the trouble
before turning the DCU power supply OFF diagnosis scan tool. A DTC should not be set.
after turning OFF the ignition switch (during Note：
after-run control or within 3 minutes of turning ・ Repeat Step 2 and Step 3 several times, and
OFF the ignition switch). check if a DTC is not set.
corrosion.
Note：
foreign material.
high resistance.
high resistance.
connector.
DTC P1468
All the DTCs that were set at the same time
1. If there are DTCs that were set at the same time, treat
those first.
2. Check whether any equipment which could cause
abnormally high temperature is installed in the area
around the DCU.
3. If a problem is found, take countermeasures to
prevent abnormally high temperature.
4. Ask the operator whether or not there were any
external factors in the past which could have caused
abnormally high temperature close to the DCU.
5. If there is the possibility that abnormally high
temperature occurred in the past, inspect the
corresponding location.
Note：
・ This DTC is set for the purpose of recording
information. It is not a malfunction of the DCU.
Replacement of the DCU is not necessary.
3. Without starting the engine, observe the DTC
information with the trouble diagnosis scan tool. A
DTC should not be set. Turn ON the switch.
DTC P1491
1. DTC P1491 priority DTC 6. If a problem is found, replace the backflow
connector.
DTC P204B
DTC P204C
Devices(4HK1) DEF supply module disassembly".
DTC P204D
DTC P208B Devices(4HK1) DEF supply module reassembly".
2. DTC P1491 diagnostics 7. Turn OFF the ignition switch.
Note： 8. Disconnect the urea fluid supply module harness
・ If DTC P20E9 is set as a current failure or past connector.
failure at the same time, treat that first. 9. Inspect the urea fluid supply module harness
1. Inspect the backflow piping between the urea fluid connector.
supply module and the urea fluid tank. Note：
Note：・ There should be no intermittent conditions,
・ There should be no clogging caused by poor connections, or corrosion.
twisting or bending. ・ There should be no water intrusion or adhering
・ There should be no clogging caused by foreign foreign material.
material. 10. If a problem is found, repair the connector.
・ There should be no clogging caused by urea
fluid freezing.
・ There should be no layout changes in the urea 12. Inspect each circuit between the DCU and the urea
fluid piping that differ from the specified layout. fluid supply module.
Caution： Note：
・ Do not blow air onto the urea fluid connector ・ There should be no open circuit, breakage, or
on the urea fluid supply module. high resistance.
・ There should be no short circuit or improper
2. If a problem is found, repair or replace.
modification.
3. Inspect the urea fluid sensor backflow line.
Note：
・ There should be no clogging caused by
twisting or bending. Note：
・ There should be no clogging caused by urea ・ There should be no intermittent conditions,
fluid freezing. poor connections, or corrosion.
4. If a problem is found, replace the urea fluid sensor.
foreign material.
16. Replace the urea fluid supply module.
Devices(4HK1) DEF sensor installation". Refer to "1.Engine 1H.Aux. Emission Control
5. Inspect the backflow connector of the urea fluid
supply module. Refer to "1.Engine 1H.Aux. Emission Control
Note：
・ The check valve should not be clogged or 3. DTC P1491 confirm resolution
stuck closed. 1. Clear the DTC with the trouble diagnosis scan tool.
deformation of the connector.
engine.
4. Perform the leak test with the trouble diagnosis scan
tool.
Caution：
・ Do not perform the leak test when the urea
fluid is frozen.
Note：
・ Verify that the urea fluid tank temperature and
outside air temperature are 5°C or more when
the leak test is performed.
5. Check whether the urea fluid pressure is less than or
equal to the specified value with the trouble
values： less than 1250 kPa { less than 181 psi }
DTC P1493
those first.
around the DCU.
Note：
engine.
DTC P149C
1. DTC P149C priority DTC 6. If a problem is found, replace the urea fluid sensor.
DTC P204B Refer to "1.Engine 1H.Aux. Emission Control
DTC P204C
DTC P204D
DTC P208B
DTC P20A0
DTC P20A2 connector.
DTC P20A3 9. Inspect the urea fluid supply module harness
connector.
1. There should be no damage to or clogging of the Note：
supply module filter. ・ There should be no intermittent conditions,
2. If a problem is found, replace the supply module
filter. ・ There should be no water intrusion or adhering
foreign material.
Devices(4HK1) DEF supply module filter removal".
Devices(4HK1) DEF supply module filter installation". 12. Inspect each circuit between the DCU and the urea
fluid supply module.
Caution：
・ Do not blow air onto the urea fluid connector Note：
on the urea fluid supply module. ・ There should be no open circuit, breakage, or
3. Inspect the suction piping between the urea fluid high resistance.
supply module and the urea fluid tank. ・ There should be no short circuit or improper
modification.
Note：
twisting or bending. 14. Inspect the DCU harness connector.
・ There should be no clogging caused by foreign Note：
material.
・ There should be no clogging caused by urea poor connections, or corrosion.
fluid freezing.
・ There should be no layout changes in the urea foreign material.
fluid piping that differ from the specified layout.
Caution：
・ Do not blow air onto the urea fluid connector
on the urea fluid supply module. 17. Perform Urea Fluid Reverting Valve on the trouble
diagnosis scan tool and inspect for sticking of the
reverting valve.
5. Inspect the urea fluid sensor suction line.
18. If a problem is found, replace the urea fluid supply
Note： module.
・ There should be no clogging caused by Refer to "1.Engine 1H.Aux. Emission Control
twisting or bending. Devices(4HK1) DEF supply module removal".
fluid freezing.
engine.
tool.
Caution：
fluid is frozen.
Note：
engine.
DTC P149D
1. DTC P149D diagnostics b. Put the urea fluid sensor in a container with water or
warm water at 60°C {140°F} or less.
1. Perform Urea fluid tank heater coolant control valve
on the trouble diagnosis scan tool and inspect the Note：
operation of the coolant control valve. ・ The temperature sensing element on the
Note： bottom end of the urea fluid sensor should be
submerged in the water.
・ There should be no sticking of the coolant
control valve. ・ Do not use warm water at 70°C {158°F} or
more. This may cause the DTC to be set.
・ There should be no circuit malfunction in the
coolant control valve. c. Measure the temperature of the water or warm water in
the container using an engine coolant temperature gauge.
d. Turn ON the ignition switch.
Devices(4HK1) Coolant control valve removal". e. Compare the urea fluid tank temperature display on the
trouble diagnosis scan tool with the value of the engine
coolant temperature gauge, and check whether the
difference is less than or equal to the specified value.
Note：
4. Disconnect the urea fluid sensor harness connector. ・ It takes time for the Temperature display on
5. Inspect the urea fluid sensor harness connector. the trouble diagnosis scan tool to stabilize.
Determine after the temperature display is
Note： stable.
Specified value: 5°C {9°F} or less (Temperature
difference)
foreign material. f. Measure 2 to 3 times at different temperatures and
check whether the temperature difference is less than or
6. If a problem is found, repair the connector. equal to the specified value.
7. Inspect the urea fluid sensor in the urea fluid tank for 10. If the temperature difference is more than or equal to
engine coolant leakage. the specified value, replace the urea fluid sensor.
a. Drain the urea fluid from the drain plug of the urea Refer to "1.Engine 1H.Aux. Emission Control
fluid tank. Devices(4HK1) DEF sensor removal".
b. Check the color of the drained urea fluid, and inspect Refer to "1.Engine 1H.Aux. Emission Control
for an intrusion of engine coolant. Devices(4HK1) DEF sensor installation".
c. If an intrusion of engine coolant is found, remove the 2. DTC P149D confirm resolution
urea fluid sensor and visually inspect for engine coolant
leakage from the engine coolant pipe and pipe installation 1. Clear the DTC with the trouble diagnosis scan tool.
section. Note：
8. If a problem is found, replace the urea fluid sensor. ・ After clearing the DCU DTC, observe whether
Refer to "1.Engine 1H.Aux. Emission Control ECM DTC P20C9 is set.
Devices(4HK1) DEF sensor removal". ・ If DTC P20C9 is set, clear it.
Refer to "1.Engine 1H.Aux. Emission Control 2. Turn OFF the ignition switch until communication
Devices(4HK1) DEF sensor installation". with the trouble diagnosis scan tool is discontinued.
9. Inspect the urea fluid temperature sensor for 3. Turn ON the ignition switch without starting the
characteristic malfunctions. engine.
a. Connect the urea fluid sensor harness connector to the 4. Observe the DTC information with the trouble
removed urea fluid sensor. diagnosis scan tool. A DTC should not be set.
DTC P203B
1. DTC P203B priority DTC 9. Turn ON the ignition switch.
DTC P203C 10. Connect a test lamp between the urea fluid sensor
power supply circuit and the DCU harness GND
DTC P203D
connection.
Note： circuit or high resistance in the urea fluid sensor
・ Check the frequency with which urea fluid is power supply circuit.
added, because this DTC may be set if urea 12. Connect a test lamp between the power supply
fluid is repeatedly added with a high amount of circuit and the GND circuit.
urea fluid remaining in the urea fluid tank.
1. Remove the urea fluid tank level sensor. circuit or high resistance in the urea fluid sensor
2. Inspect the urea fluid tank level sensor. GND circuit.
Note： 14. Disconnect the harness connector from the DCU.
・ There should be no bending of the level 15. Inspect the DCU harness connector.
sensor tube.
Note：
・ The float should not be stuck and there should
be no foreign material that restricts the
movement of the float.
・ There should be no leaning or delayed
foreign material.
response of the level sensor.
・ The urea fluid tank should not be deformed or 16. Inspect each circuit for high resistance.
broken. 17. If a problem is found, repair the harness connector or
3. If a problem is found, repair or replace the urea fluid circuit.
tank level sensor. 18. Replace the urea fluid tank level sensor.
4. Turn ON the ignition switch. 3. DTC P203B confirm resolution
5. Observe the urea fluid tank level display on the 1. Clear the DTC with the trouble diagnosis scan tool.
trouble diagnosis scan tool while slowly moving the
float. Note：
Note：
・ The display changes gradually between 18
and 90% in accordance with the float
movement. 2. Turn OFF the ignition switch until communication
・ It may take some time for the scan tool display with the trouble diagnosis scan tool is discontinued.
to change in accordance with the float 3. Turn ON the ignition switch without starting the
movement. engine.
6. If a problem is found, turn OFF the ignition switch. 4. Observe the urea fluid tank level display on the
7. Disconnect the harness connector from the urea fluid trouble diagnosis scan tool while slowly pouring
sensor. urea fluid into the urea fluid tank.
8. Inspect the urea fluid sensor harness connector. ・The display should change depending on the urea fluid
quantity.
Note：
Note：
poor connections, or corrosion. ・ Wait for approx. 30 seconds after adding the
urea fluid, and then observe the remaining oil
level.
foreign material.
DTC P203D
2. Disconnect the harness connector from the urea fluid
sensor.
Note：
foreign material.
6. Connect a test lamp between the urea fluid sensor
connection.
GND circuit.
2. DTC P203D confirm resolution
Note：
engine.
DTC P2048
1. DTC P2048 diagnostics values： 11 to 15 Ω
1. Turn OFF the ignition switch. 13. If the measured value is outside the specified range,
replace the dosing module.
2. Disconnect the dosing module harness connector.
Devices(4HK1) Dosing module removal".
engine.
4. Measure the voltage between the injector drive
Devices(4HK1) Dosing module installation".
circuit (High) and the DCU harness GND
connection. Note：
values： 5.5 V ・ When the dosing module is replaced, perform
Dosing module data reset with the trouble
5. If the reading is less than or equal to the specified diagnosis scan tool.
value, inspect the injector drive circuit (High)
between the DCU and the dosing module. 14. Turn OFF the ignition switch.

・ There should be no open circuits. 16. Inspect the DCU harness connector.
・ There should be no short to metallic parts such Note：
as the frame.
・ There should be no short to the injector drive poor connections, or corrosion.
circuit (Low).
・ There should be no high resistance. foreign material.
6. If a problem is found, repair the injector drive circuit 17. If a problem is found, repair the connector.
(High).
circuit (High) and the injector drive circuit (Low). Refer to "1.Engine 1H.Aux. Emission Control
values： 5.5 V
8. If the reading is less than or equal to the specified Devices(4HK1) DCU installation".
value, inspect the injector drive circuit (Low)
between the DCU and the dosing module. 2. DTC P2048 confirm resolution
・ There should be no open circuits. Note：
・ There should be no short to metallic parts such ・ After clearing the DCU DTC, observe whether
as the frame. ECM DTC P20C9 is set.
・ There should be no high resistance. ・ If DTC P20C9 is set, clear it.
9. If a problem is found, repair the injector drive circuit 2. Turn OFF the ignition switch until communication
(Low). with the trouble diagnosis scan tool is discontinued.
10. Inspect the dosing module harness connector. 3. Turn ON the ignition switch without starting the
engine.
Note：
・ There should be no intermittent conditions, 4. Observe the DTC information with the trouble
poor connections, or corrosion. diagnosis scan tool. A DTC should not be set.
foreign material.
12. Measure the internal resistance between the dosing
module connector terminals.
DTC P2049
1. DTC P2049 diagnostics 2. DTC P2049 confirm resolution
1. Inspect the injector drive circuit (High) and the 1. Clear the DTC with the trouble diagnosis scan tool.
injector drive circuit (Low) between the DCU and
Note：
the dosing module for a short to the battery or a short
to the ignition power supply. ・ After clearing the DCU DTC, observe whether
2. If a problem is found, repair the injector drive circuit
(High) or (Low).
5. Inspect the dosing module harness connector. engine.
Note： 4. Observe the DTC information with the trouble
・ There should be no intermittent conditions, diagnosis scan tool. A DTC should not be set.
foreign material.
values： 11 to 15 Ω
8. If the measured value is outside the specified range,
Note：
・ When the dosing module is replaced, perform
Note：
foreign material.
DTC P204B
1. DTC P204B priority DTC 12. Replace the urea fluid supply module.
DTC P204C Refer to "1.Engine 1H.Aux. Emission Control
DTC P204D
connector.
Note：
3. Inspect each circuit of the urea fluid pressure sensor
between the DCU and the urea fluid supply module. ・ After clearing the DCU DTC, observe whether
Note：
・ There should be no open circuit, breakage, or
high resistance. 2. Turn OFF the ignition switch until communication
modification. 3. Turn ON the ignition switch without starting the
engine.
connector.
Note：
foreign material.
Note：
foreign material.
Note：
・ Perform the following inspection only when it is
cold, such as in winter.
10. Turn ON the Urea Fluid Tank Heater Coolant
Control Valve under Actuator Test on the trouble
Note：
・ The engine coolant should flow into the supply
module.
11. If a problem is found, repair or replace the urea fluid
heater control system.
DTC P204C
1. DTC P204C diagnostics 2. DTC P204C confirm resolution
2. Disconnect the urea fluid supply module harness Note：
connector. ・ After clearing the DCU DTC, observe whether
3. Inspect the urea fluid supply module harness ECM DTC P20C9 is set.
connector. ・ If DTC P20C9 is set, clear it.
Note： 2. Turn OFF the ignition switch until communication
・ There should be no intermittent conditions, with the trouble diagnosis scan tool is discontinued.
poor connections, or corrosion. 3. Turn ON the ignition switch without starting the
・ There should be no water intrusion or adhering engine.
foreign material.
4. If a problem is found, repair the connector. diagnosis scan tool. A DTC should not be set.
engine.
7. If DTC P204D is set but P204C is not set, replace the
urea fluid supply module.
8. Inspect the signal circuit between the DCU and the
urea fluid pressure sensor.
Note：
・ There should be no short to metallic parts such
as the frame.
Note：
foreign material.
DTC P204D
1. DTC P204D priority DTC 15. Inspect the urea fluid supply module harness
connector.
DTC P0641
Note：
1. Turn OFF the ignition switch. poor connections, or corrosion.
2. Disconnect the urea fluid supply module harness ・ There should be no water intrusion or adhering
connector. foreign material.
3. Turn ON the ignition switch without starting the 16. If a problem is found, repair the connector.
engine.
the DCU harness GND connection.
values： 5.5 V
5. If the reading is more than or equal to the specified Devices(4HK1) DEF supply module installation".
value, inspect the signal circuit between the DCU
and the urea fluid pressure sensor for a short to the
battery power supply or a short to the ignition power 19. Disconnect the DCU harness connector.
supply circuit.
Caution：
Note：
・ The urea fluid pressure sensor may be
damaged if the sensor signal circuit is shorted
to the power supply.
6. If a problem is found, repair the signal circuit. foreign material.
7. If the reading is less than or equal to the specified 21. If a problem is found, repair the connector.
and the urea fluid pressure sensor for an open circuit 22. Replace the DCU.
or a short to the 5 V power supply circuit. Refer to "1.Engine 1H.Aux. Emission Control
8. If a problem is found, repair the signal circuit. Devices(4HK1) DCU removal".
9. Measure the voltage between the 5 V power supply Refer to "1.Engine 1H.Aux. Emission Control
circuit and the DCU harness GND connection. Devices(4HK1) DCU installation".
values： 4.8 V 3. DTC P204D confirm resolution
10. If the reading is less than or equal to the specified 1. Clear the DTC with the trouble diagnosis scan tool.
value, inspect the 5 V power supply circuit between Note：
the DCU and the urea fluid pressure sensor for an
open circuit or high resistance.
11. If a problem is found, repair the 5 V power supply ・ If DTC P20C9 is set, clear it.
circuit.
12. Measure the voltage between the 5 V power supply with the trouble diagnosis scan tool is discontinued.
values： 4.8 V engine.
13. If the reading is less than or equal to the specified 4. Observe the DTC information with the trouble
value, inspect the GND circuit between the DCU and diagnosis scan tool. A DTC should not be set.
the urea fluid pressure sensor for an open circuit or
high resistance.
DTC P205B
1. DTC P205B priority DTC temperature are all the specified value or less, and
start the engine.
5°C {9°F} or less (Temperature difference)
Note：
those first. ・ If the reading is not within the specified
requirements, soak until it is.
abnormally high temperature is installed in the area 4. Observe the DTC information with the trouble
around the urea fluid tank. diagnosis scan tool. A DTC should not be set.

abnormally high temperature close to the urea fluid
tank.
sensor.
Note：
foreign material.
Note：
3. Confirm that the differences between the engine
coolant temperature, intake air temperature, and fuel
DTC P205D
sensor.
Note：
foreign material.
connection.
GND circuit.
Note：
engine.
DTC P206A
3. Inspect the urea fluid sensor power supply circuit
between the ignition switch and the urea fluid sensor
for an open circuit or high resistance.
4. If a problem is found, repair the urea fluid sensor
Note：
foreign material.
Note：
engine.
4. Check if the following parameters change to "No" on
・Urea fluid concentration sensor error
・Urea fluid conductivity sensor error
・Urea fluid tank temperature sensor error
・Urea fluid sensor error
DTC P206B
1. DTC P206B priority DTC Refer to "1.Engine 1H.Aux. Emission Control
those first. Note：
2. Turn OFF the ignition switch. ・ After clearing the DCU DTC, observe whether
sensor.
Note：
・ There should be no intermittent conditions, coolant temperature, intake air temperature, and fuel
poor connections, or corrosion. temperature are all the specified value or less, and
・ There should be no water intrusion or adhering start the engine.
foreign material.
Note：
6. Turn ON the ignition switch. ・ If the reading is not within the specified
7. Connect a test lamp between the urea fluid sensor requirements, soak until it is.
power supply circuit and the DCU harness GND 4. Observe the DTC information with the trouble
connection. diagnosis scan tool. A DTC should not be set.
GND circuit.
around the urea fluid tank.
tank.
DTC P206C
1. DTC P206C diagnostics 4. Check if the following parameters change to "No" on
・ Urea fluid concentration sensor error
・ Urea fluid conductivity sensor error
sensor.
・ Urea fluid tank temperature sensor error
3. Inspect the urea fluid sensor harness connector. ・ Urea fluid sensor error
foreign material.
connection.
GND circuit.
connector.
13. Inspect each circuit between the DCU and the urea
fluid quality sensor for a short circuit.
engine.
DTC P206D
sensor.
3. Inspect the power supply circuit of the urea fluid
sensor for an open circuit.
4. If a problem is found, repair the power supply
circuit.
5. Inspect for poor connections at the urea fluid sensor
harness connector.
engine.
・ Urea fluid sensor error
DTC P207F
1. Inspect the concentration of the urea fluid.
2. If a problem is found, add the specified urea fluid
after cleaning the inside of the urea fluid tank.
3. Inspect the urea fluid tank.
・There should be no water intrusion caused by cracking
or damage.
4. If a problem is found, replace the urea fluid tank.
5. Inspect the urea fluid sensor.
・There should be no coolant intrusion caused by
cracking or damage of the coolant passages.
・There should be no water intrusion from the urea fluid
sensor installation area or seal area.
engine.
diagnosis scan tool. DTC P207F should not be set.
10. If DTC P207F is set, replace the urea fluid sensor.
engine.
DTC P208A
1. DTC P208A diagnostics Refer to "1.Engine 1H.Aux. Emission Control
Note：
・ There should be no intermittent conditions, 2. DTC P208A confirm resolution
poor connections, or corrosion for any of the 1. Clear the DTC with the trouble diagnosis scan tool.
terminals.
Note：
・ There should be no open circuit, high
resistance, or short to any of the circuits. ・ After clearing the DCU DTC, observe whether
foreign material. ・ If DTC P20C9 is set, clear it.
6. Disconnect the DCU harness connector. engine.
7. Inspect the DCU harness connector. 4. Observe the DTC information with the trouble
Note： diagnosis scan tool. A DTC should not be set.
foreign material.
9. Inspect the urea fluid pump power supply circuit
between the DCU and the urea fluid supply module
harness connector for an open circuit or high
resistance.
10. If a problem is found, repair the pump power supply
circuit.
11. Inspect the GND circuit between the DCU and the
urea fluid supply module harness connector for an
13. Inspect the pump control circuit between the DCU
and the urea fluid supply module harness connector
for an open circuit.
14. If a problem is found, repair the pump control
circuit.
DTC P208B
1. DTC P208B priority DTC Note：
DTC P208A ・ The engine coolant should flow into the supply
module.
DTC P208C
DTC P208D heater control system.
2. DTC P208B diagnostics 14. Replace the urea fluid supply module.
2. Disconnect the urea fluid supply module harness Devices(4HK1) DEF supply module removal".
3. Inspect the urea fluid supply module harness Devices(4HK1) DEF supply module installation".
connector. 3. DTC P208B confirm resolution
Note：
poor connections, or corrosion for any of the
terminals. ・ After clearing the DCU DTC, observe whether
resistance, or short to any of the circuits. ・ If DTC P20C9 is set, clear it.
・ There should be no water intrusion or adhering 2. Turn OFF the ignition switch until communication
foreign material. with the trouble diagnosis scan tool is discontinued.
4. If a problem is found, repair the connector. 3. Start the engine.
5. Disconnect the DCU harness connector. 4. Test run at the specified speed or higher while
observing the exhaust gas temperature 3 value with
Note：
values： 190 ℃ { 374 °F }
poor connections, or corrosion. 5. Observe the DTC information with the trouble
foreign material.
circuit.
Note：
DTC P208C
1. DTC P208C diagnostics 16. Inspect the urea fluid pump control circuit between
the DCU and the urea fluid supply module.
Note：
connector. ・ There should be no short to the GND circuit.
as the frame.
connector.
17. If a problem is found, repair the urea fluid pump
Note：
control circuit.
poor connections, or corrosion for any of the 18. Replace the DCU.
terminals. Refer to "1.Engine 1H.Aux. Emission Control
・ There should be no open circuit, high Devices(4HK1) DCU removal".
resistance, or short to any of the circuits.
・ There should be no water intrusion or adhering Devices(4HK1) DCU installation".
foreign material.
Note：
Note： ECM DTC P20C9 is set.
・ There should be no intermittent conditions, ・ If DTC P20C9 is set, clear it.
・ There should be no water intrusion or adhering with the trouble diagnosis scan tool is discontinued.
foreign material.
7. If a problem is found, repair the connector. engine.
8. Inspect the urea fluid pump power supply circuit 4. Observe the DTC information with the trouble
between the DCU and the urea fluid supply module diagnosis scan tool. A DTC should not be set.
circuit.
engine.
14. If DTC P208A is set but P208C is not set, replace the
DTC P208D
1. DTC P208D diagnostics 16. Inspect the urea fluid pump control circuit between
Note：
connector. ・ There should be no short to the battery or
short to the ignition power supply circuit.
・ There should be no short to the battery voltage
connector.
supply circuit.
Note：
・ There should be no intermittent conditions, control circuit.
terminals. 18. Replace the DCU.
・ There should be no open circuit, high Refer to "1.Engine 1H.Aux. Emission Control
resistance, or short to any of the circuits. Devices(4HK1) DCU removal".
・ There should be no water intrusion or adhering Refer to "1.Engine 1H.Aux. Emission Control
foreign material. Devices(4HK1) DCU installation".
4. If a problem is found, repair the connector. 2. DTC P208D confirm resolution
5. Disconnect the DCU harness connector. 1. Clear the DTC with the trouble diagnosis scan tool.
6. Inspect the DCU harness connector. Note：
7. If a problem is found, repair the connector. 3. Turn ON the ignition switch without starting the
8. Inspect the urea fluid pump power supply circuit engine.
between the DCU and the urea fluid supply module 4. Observe the DTC information with the trouble
for an open circuit or high resistance. diagnosis scan tool. A DTC should not be set.
circuit.
engine.
14. If DTC P208A is set but P208D is not set, replace
the urea fluid supply module.
DTC P208E
1. DTC P208E priority DTC Note：
DTC P2048 ・ When the dosing module is replaced, perform
DTC P2049 diagnosis scan tool.
2. DTC P208E diagnostics 14. Clear the DTC with the trouble diagnosis scan tool.
1. Turn OFF the ignition switch. 15. Turn OFF the ignition switch until communication
2. Disconnect the dosing module harness connector. with the trouble diagnosis scan tool is discontinued.
3. Inspect the dosing module harness connector. 16. Start the engine.
Note： 17. Test run at the specified speed or higher while
・ There should be no water intrusion or adhering values： 190 ℃ { 374 °F }
foreign material. 18. Observe the DTC information with a trouble
4. If a problem is found, repair the connector. diagnosis scan tool.
5. Disconnect the DCU harness connector. 19. If the applicable DTC is set as a current failure,
replace the DCU.
Note： Devices(4HK1) DCU removal".
foreign material. 3. DTC P208E confirm resolution
7. If a problem is found, repair the connector. 1. Clear the DTC with the trouble diagnosis scan tool.
8. Inspect the injector drive circuit (High) and injector Note：
drive circuit (Low) between the DCU and the dosing ・ After clearing the DCU DTC, observe whether
module for high resistance. ECM DTC P20C9 is set.
9. If a problem is found, repair the injector drive circuit ・ If DTC P20C9 is set, clear it.
(High) or (Low). 2. Turn OFF the ignition switch until communication
10. Remove the dosing module. with the trouble diagnosis scan tool is discontinued.
Devices(4HK1) Dosing module removal". 4. Test run at the specified speed or higher while
11. Inspect the dosing module. observing the exhaust gas temperature 3 value with
Note：
values： 190 ℃ { 374 °F }
・ The dosing module should not be clogged by
crystals adhering to its end. 5. Observe the DTC information with the trouble
・ There should be no damage to or deformation diagnosis scan tool. A DTC should not be set.
of the dosing module unit.
13. Clean or replace the dosing module.
DTC P20A0
1. DTC P20A0 diagnostics Refer to "1.Engine 1H.Aux. Emission Control
connector.
Note：
・ There should be no intermittent conditions, Refer to "1.Engine 1H.Aux. Emission Control
poor connections, or corrosion for any of the Devices(4HK1) DCU installation".
terminals. 2. DTC P20A0 confirm resolution
6. Inspect the DCU harness connector. with the trouble diagnosis scan tool is discontinued.
Note： 3. Turn ON the ignition switch without starting the
・ There should be no intermittent conditions, engine.
・ There should be no water intrusion or adhering diagnosis scan tool. A DTC should not be set.
foreign material.
8. Inspect the urea fluid reverting valve power supply
circuit between the DCU and the urea fluid supply
module for an open circuit or high resistance.
9. If a problem is found, repair the urea fluid reverting
valve power supply circuit.
urea fluid supply module for an open circuit or high
resistance.
13. Inspect the urea fluid reverting valve control circuit
between the DCU and the urea fluid supply module.
Note：
as the frame.
control circuit.
DTC P20A2
1. DTC P20A2 diagnostics 16. Inspect the control circuit between the DCU and the
reverting valve.
Note：
connector. ・ There should be no short to other GND
circuits.
connector.
as the frame.
Note：
foreign material.
Note：
foreign material.
8. Inspect the urea fluid reverting valve power supply 4. Observe the DTC information with the trouble
circuit between the DCU and the urea fluid supply diagnosis scan tool. A DTC should not be set.
resistance.
engine.
14. If DTC P20A0 is set but P20A2 is not set, replace
DTC P20A3
1. DTC P20A3 diagnostics 16. Inspect the control circuit between the DCU and the
reverting valve.
Note：
・ There should be no short to the power supply
connector.
circuit.
Note：
foreign material.
Note：
foreign material.
8. Inspect the urea fluid reverting valve power supply 4. Observe the DTC information with a trouble
resistance.
engine.
DTC P20AC
1. DTC P20AC priority DTC 13. If a problem is found, repair the urea fluid pump
control circuit.
DTC P208A
14. If the control circuit is normal, replace the urea fluid
DTC P208C
supply module.
DTC P208D
2. DTC P20AC diagnostics Devices(4HK1) DEF supply module removal".
connector. 15. Clear the DTC with the trouble diagnosis scan tool.
3. Inspect the urea fluid supply module harness 16. Turn OFF the ignition switch until communication
connector. with the trouble diagnosis scan tool is discontinued.
poor connections, or corrosion for any of the 18. Observe the DTC information with a trouble
terminals. diagnosis scan tool.
19. If the DTC is set, turn OFF the ignition switch.
・ There should be no water intrusion or adhering 20. Replace the DCU.
foreign material. Refer to "1.Engine 1H.Aux. Emission Control
4. If a problem is found, repair the connector. Devices(4HK1) DCU removal".
5. Disconnect the DCU harness connector. Refer to "1.Engine 1H.Aux. Emission Control
3. DTC P20AC confirm resolution
Note：
poor connections, or corrosion. Note：
・ There should be no water intrusion or adhering ・ After clearing the DCU DTC, observe whether
foreign material. ECM DTC P20C9 is set.
7. If a problem is found, repair the connector. ・ If DTC P20C9 is set, clear it.
8. Inspect the urea fluid pump power supply circuit 2. Turn OFF the ignition switch until communication
between the DCU and the urea fluid supply module with the trouble diagnosis scan tool is discontinued.
for an open circuit or high resistance. 3. Turn ON the ignition switch without starting the
9. If a problem is found, repair the pump power supply engine.
circuit. 4. Observe the DTC information with the trouble
10. Inspect the GND circuit between the DCU and the diagnosis scan tool. A DTC should not be set.
12. Inspect the urea fluid pump control circuit between
the DCU and the urea fluid supply module for
abnormal harness appearances.
Note：
・ There should be no damage, deformation, etc.
DTC P20AD
1. DTC P20AD priority DTC Refer to "1.Engine 1H.Aux. Emission Control
3. DTC P20AD confirm resolution
2. DTC P20AD diagnostics
supply module.
connector.
Note：
・ There should be no intermittent conditions, temperature are all the specified value or less, and
poor connections, or corrosion. start the engine.
foreign material.
Note：
・ If the reading is not within the specified
6. Turn ON the ignition switch. requirements, soak until it is.
7. Connect a test lamp between the urea fluid supply 4. Observe the DTC information with the trouble
module power supply circuit and the DCU harness diagnosis scan tool. A DTC should not be set.
GND connection.
circuit or high resistance in the urea fluid supply
module GND circuit.
around the urea fluid supply module.
supply module.
DTC P20B1
1. DTC P20B1 diagnostics Refer to "1.Engine 1H.Aux. Emission Control
connector.
15. If the test lamp does not illuminate or turn OFF in
accordance with the urea fluid tank heater coolant
Note： control valve being turned ON or OFF with the
・ There should be no intermittent conditions, Actuator Test, replace the DCU.
poor connections, or corrosion for any of the Refer to "1.Engine 1H.Aux. Emission Control
terminals. Devices(4HK1) DCU removal".
foreign material. 2. DTC P20B1 confirm resolution
5. Disconnect the DCU harness connector. Note：

Note：・ If DTC P20C9 is set, clear it.
foreign material. 3. Turn ON the ignition switch without starting the
engine.
8. Inspect the power supply circuit between the DCU diagnosis scan tool. A DTC should not be set.
and the coolant control valve for an open circuit or
high resistance.
circuit.
10. Inspect the control circuit between the DCU and the
Note：
as the frame.
resistance.
12. Connect a test lamp between the coolant control
valve power supply circuit and the control circuit.
13. Perform Urea Fluid Tank Heater Coolant Control
Valve under Actuator Test.
14. If the test lamp illuminates/turns OFF in accordance
with the ON/OFF commands, replace the coolant
control valve.
DTC P20B3
connector. 16. Replace the DCU.
3. Inspect the coolant control valve harness connector. Refer to "1.Engine 1H.Aux. Emission Control
Note：
terminals. 2. DTC P20B3 confirm resolution
foreign material.
8. Inspect the power supply circuit between the DCU
high resistance.
circuit.
Note：
as the frame.
engine.
14. If DTC P20B1 is set but P20B3 is not set, replace the
DTC P20B4
1. DTC P20B4 diagnostics Note：
connector.
Note：
foreign material.
engine.
coolant control valve for a short to the battery or a
Note：
foreign material.
2. DTC P20B4 confirm resolution
DTC P20E8
1. DTC P20E8 priority DTC Refer to "1.Engine 1H.Aux. Emission Control
DTC P204B
DTC P204C
Devices(4HK1) DEF supply module filter installation".
DTC P204D
5. Inspect the suction piping between the urea fluid
DTC P208B supply module and the urea fluid tank.
DTC P208E Note：
DTC P20A0 ・ There should be no clogging caused by
twisting or bending.
DTC P20A2
・ There should be no clogging caused by foreign
DTC P20A3 material.
2. DTC P20E8 diagnostics ・ There should be no clogging caused by urea
fluid freezing.
1. Inspect for urea fluid leakage.
・ There should be no layout changes in the urea
Note： fluid piping that differ from the specified layout.
・ There should be no leakage from the urea fluid 6. If a problem is found, repair or replace.
piping between the urea fluid supply module
and the dosing module. 7. Inspect the urea fluid sensor.
・ There should be no leakage from the urea fluid Note：
piping between the urea fluid tank and the ・ There should be no clogging caused by
urea fluid supply module. bending of the breather hose or foreign
・ There should be no leakage from the urea fluid material.
piping connection. ・ There should be no clogging caused by
・ There should be no leakage from the urea fluid bending of the suction line or foreign material.
supply module unit. ・ There should be no clogging caused by urea
・ There should be no leakage from the dosing fluid freezing.
module unit.
8. If a problem is found, clean or replace the urea fluid
2. If a problem is found, repair or replace. sensor.
Refer to "1.Engine 1H.Aux. Emission Control Refer to "1.Engine 1H.Aux. Emission Control
Devices(4HK1) DEF supply module removal". Devices(4HK1) DEF sensor removal".
Devices(4HK1) DEF supply module installation". Devices(4HK1) DEF sensor installation".
Refer to "1.Engine 1H.Aux. Emission Control 9. Inspect for floating substances such as foreign
Devices(4HK1) Dosing module removal". material in the urea fluid tank which may cause
Refer to "1.Engine 1H.Aux. Emission Control clogging of the filter.
Devices(4HK1) Dosing module installation". 10. If a problem is found, clean the inside of the urea
Note： fluid tank and replace the urea fluid.
・ When the dosing module is replaced, perform 11. Turn OFF the ignition switch.
Dosing module data reset with the trouble 12. Disconnect the urea fluid supply module harness
diagnosis scan tool. connector.
3. There should be no clogging of the supply module 13. Inspect the urea fluid supply module harness
filter. connector.
4. If a problem is found, replace the supply module Note：
filter.

foreign material.
Note：
foreign material.
for high resistance.
3. DTC P20E8 confirm resolution
Note：
engine.
tool.
5. Check whether the urea fluid pressure is more than
or equal to the specified value with the trouble
values： 750 kPa { 109 psi }
DTC P20E9
DTC P204B
DTC P204C
Devices(4HK1) DEF supply module reassembly".
DTC P204D
DTC P208B
2. DTC P20E9 diagnostics connector.
1. Inspect the backflow piping between the urea fluid 9. Inspect the urea fluid supply module harness
supply module and the urea fluid tank. connector.
Note： Note：
・ There should be no clogging caused by ・ There should be no intermittent conditions,
twisting or bending. poor connections, or corrosion.
・ There should be no clogging caused by foreign ・ There should be no water intrusion or adhering
material. foreign material.
・ There should be no clogging caused by urea 10. If a problem is found, repair the connector.
fluid freezing.
fluid piping that differ from the specified layout. 12. Inspect each circuit between the DCU and the urea
Caution：
high resistance.
3. Inspect the urea fluid sensor backflow line. modification.
Note： 13. If a problem is found, repair the applicable circuit.
・ There should be no clogging caused by urea Note：
fluid freezing. ・ There should be no intermittent conditions,
Refer to "1.Engine 1H.Aux. Emission Control foreign material.
Devices(4HK1) DEF sensor installation". 16. Replace the urea fluid supply module.
5. Inspect the backflow connector of the urea fluid Refer to "1.Engine 1H.Aux. Emission Control
supply module. Devices(4HK1) DEF supply module removal".
Note： Refer to "1.Engine 1H.Aux. Emission Control

・ The check valve should not be clogged or
stuck closed. 3. DTC P20E9 confirm resolution
・ There should be no clogging caused by 1. Clear the DTC with the trouble diagnosis scan tool.
Note：
6. If a problem is found, replace the backflow
connector.
engine.
tool.
DTC P20EA
1. DTC P20EA priority DTC 9. Inspect each circuit between the DCU and the urea
DTC P204B
・There should be no open circuit, breakage, or high
DTC P204C
resistance.
DTC P204D ・There should be no short circuit.
DTC P208B 10. If a problem is found, repair the applicable circuit.
DTC P20A0 11. Perform Reverting Valve under Actuator Test with
the trouble diagnosis scan tool to check if the
DTC P20A2
reverting valve is stuck.
DTC P20A3
2. DTC P20EA diagnostics
1. If there are DTCs that were set at the same time, treat Devices(4HK1) DEF supply module removal".
those first.
Note： Devices(4HK1) DEF supply module installation".
・ If a DTC other than DTC P20EA is not set, 3. DTC P20EA confirm resolution
perform the diagnosis for DTC P1464 first.
2. There should be no damage to or clogging of the
supply module filter. 2. Turn OFF the ignition switch until communication
filter. 3. Turn ON the ignition switch without starting the
engine.
Devices(4HK1) DEF supply module filter removal". 4. Observe the DTC information with the trouble
Caution：
on the urea fluid supply module.
supply module and the urea fluid tank.
・There should be no clogging caused by twisting or
bending.
・There should be no clogging caused by foreign
material.
・There should be no layout in the urea fluid piping that
differs from the specified layout.
・There should be no clogging caused by urea fluid
freezing.
supply module.
7. Inspect for poor connections at the urea fluid supply
module harness connector.
DTC P20FE
1. DTC P20FE priority DTC 7. Replace the suction hose between the urea fluid
supply module and the urea fluid tank with a clear
DTC P204B
hose.
DTC P204C
Caution：
DTC P204D ・ The clamp should be installed to the hose.
DTC P208B 8. Clear the DTC with the trouble diagnosis scan tool.
DTC P208E 9. Turn OFF the ignition switch until communication
DTC P20A0 with the trouble diagnosis scan tool is discontinued.
DTC P20A2 10. Start the engine.
DTC P20A3 11. Check for the intrusion of air.
2. DTC P20FE diagnostics 12. If air intrusion is found, replace the urea fluid sensor.
1. There should be no damage to or clogging of the Refer to "1.Engine 1H.Aux. Emission Control
supply module filter. Devices(4HK1) DEF sensor removal".
2. If a problem is found, replace the supply module Refer to "1.Engine 1H.Aux. Emission Control
filter. Devices(4HK1) DEF sensor installation".
Refer to "1.Engine 1H.Aux. Emission Control 13. Inspect the DCU system.
Devices(4HK1) DEF supply module filter removal". ・There should be no clogging caused by bending of the
Refer to "1.Engine 1H.Aux. Emission Control sensor tube of the urea fluid tank level sensor in the tank,
Devices(4HK1) DEF supply module filter installation". and no malfunctions caused by the float being at an angle.
・There should be no layout of the urea fluid tank and
Caution： urea fluid supply module which differs from the specified
・ Do not blow air onto the urea fluid connector layout.
on the urea fluid supply module. ・There should be no damage to or clogging of the supply
3. Inspect the suction piping between the urea fluid module filter.
supply module and the urea fluid tank. ・There should be no clogging of the urea fluid quality
sensor strainer.
・There should be no clogging caused by twisting or ・There should be no freezing of the urea fluid suction
bending. line, pressure line, inside the tank, or in the coolant
・There should be no clogging caused by foreign piping.
material. ・There should be no clogging of the urea fluid tank vent
・There should be no layout in the urea fluid piping that hose.
differs from the specified layout. ・The reverting valve should not be stuck in the normal
・There should be no clogging caused by urea fluid position.
freezing. ・The dosing module should not remain open.
・There should be no poor connections at the urea fluid ・There should be no leakage from the urea fluid piping,
supply module inlet connector section. urea fluid supply module, or dosing module.
4. If a problem is found, repair or replace. ・There should be no damage to or clogging caused by
twisting of the pressure line between the urea fluid supply
5. Check whether or not the urea fluid supply module module and the dosing module, and no layout which
inlet connector remains closed. differs from the specified layout.
6. If a problem is found, replace the urea fluid supply ・There should be no damage to or clogging caused by
module. twisting of the suction line between the urea fluid supply
module and the tank, and no layout which differs from
Refer to "1.Engine 1H.Aux. Emission Control the specified layout.
Devices(4HK1) DEF supply module removal". ・There should be no damage to or clogging caused by
Refer to "1.Engine 1H.Aux. Emission Control twisting of the urea fluid sensor suction piping, and no
Devices(4HK1) DEF supply module installation". layout that differs from the specified layout.
・The one-way valve of the backflow connector should
not remain open.
・There should be no clogging of the urea fluid supply
module suction connector.
Caution：
・ Do not blow air onto the urea fluid supply
module.
14. If a problem is found, repair or replace the applicable
area.
connector.
fluid supply module for high resistance.
3. DTC P20FE confirm resolution
Note：
4. Observe the Urea Fluid Pressure display on the
values： 860 to 940 kPa { 125 to 136 psi }
DTC P2201
DTC P2206
DTC P2207
1. Inspect the NOx sensor.
・There should be no improper installation of the NOx
sensor.
・There should be no damage to or clogging of the NOx
sensor.
・There should be no exhaust gas leakage from the
exhaust pipe.
・There should be no damage caused by crushing of the
exhaust system.
2. If a problem is found, replace the NOx sensor.
Devices(4HK1) NOx sensor removal".
Devices(4HK1) NOx sensor installation".
Note：
engine.
DTC P2206
1. Replace the NOx sensor.
Note：
3. Start the engine and warm up until the NOx Sensor 1
NOx Detection display changes to Enabled on the
・NOx sensor 1 heater system malfunction
・NOx sensor 1 NOx detection system malfunction
・NOx sensor 1 O2 detection system malfunction
DTC P2207
1. Replace the NOx sensor.
Note：
DTC P242B
1. DTC P242B priority DTC
DTC P242C
DTC P242D
2. Inspect the installation status of EGT sensor 3.
3. If a problem is found, repair the installation status of
EGT sensor 3.
4. Disconnect the harness connector from EGT sensor
3.
5. Inspect for poor connections at the EGT sensor 3
harness connector.
connector.
8. Inspect each circuit between the DCU and EGT
sensor 3 for high resistance.
9. If a problem is found, repair the circuit or
connections.
10. Replace EGT sensor 3.
Devices(4HK1) Exhaust gas temperature sensor
3 removal".
3 installation".
Note：
engine.
DTC P242C
1. DTC P242C diagnostics 14. Replace the DCU.
2. Disconnect the EGT sensor 3 harness connector.
3. Inspect the EGT sensor 3 harness connector.
Note：
poor connections, or corrosion. 1. Clear the DTC with the trouble diagnosis scan tool.
4. If a problem is found, repair the connector. ECM DTC P20C9 is set.
engine. 2. Turn OFF the ignition switch until communication
diagnosis scan tool. 3. Turn ON the ignition switch without starting the
engine.
7. If DTC P242D is set but P242C is not set, replace
EGT sensor 3. 4. Observe the DTC information with the trouble
3 removal".
3 installation".
8. Inspect the signal circuit between the DCU and EGT
sensor 3.
Note：
as the frame.
Note：
foreign material.
DTC P242D
1. DTC P242D diagnostics 15. Turn OFF the ignition switch.
1. Turn OFF the ignition switch. 16. Disconnect the DCU harness connector.
2. Disconnect the EGT sensor 3 harness connector. 17. Inspect the DCU harness connector.
4. Measure the voltage between the signal circuit and ・ There should be no intermittent conditions,
the DCU harness GND connection. poor connections, or corrosion.
values： 5.2 V
foreign material.
and EGT sensor 3 for a short to the battery or a short 19. Replace the DCU.
to the ignition power supply.
・ EGT sensor 3 may be damaged if the sensor Refer to "1.Engine 1H.Aux. Emission Control
signal circuit is shorted to the power supply. Devices(4HK1) DCU installation".
6. If a problem is found, repair the signal circuit. 2. DTC P242D confirm resolution
and EGT sensor 3 for an open circuit or high Note：
resistance. ・ After clearing the DCU DTC, observe whether
the GND circuit. 2. Turn OFF the ignition switch until communication
values： 4.6 V
10. If the reading is less than or equal to the specified engine.
value, inspect the GND circuit between the DCU and
EGT sensor 3 for an open circuit or high resistance. 4. Observe the DTC information with the trouble
Note：
foreign material.
3 removal".
3 installation".
DTC U0002
CAN Bus Off
1. DTC U0002 diagnostics 22. If the resistance of the termination resistor exceeds
the specified range, replace the termination resistor.
Note：
・ The applicable DTC may be set after CPS 23. If a DTC is set, inspect the CAN Low and CAN
work. If the applicable DTC is set after CSP High circuits.
work, simply clear the DTC because it is not a Note：
malfunction of the machine.
・ There should be no short to the battery power
1. Disconnect the harness connector from the ECM. supply or ignition power supply circuit.
2. Inspect the ECM harness connector. ・ There should be no high resistance.
・ There should be no short together between
CAN circuits.
4. Observe the DTC information with a trouble ・ There should be no short to the GND circuit.
5. If a DTC is not set, replace the ECM. as the frame.
Refer to "1.Engine 1J.Electrical(4HK1) 24. If a problem is found, repair the CAN circuit.
ECM removal".
25. If the CAN circuit is normal, inspect the DCU
Refer to "1.Engine 1J.Electrical(4HK1) harness connector.
ECM installation".
Note：
6. Set the Injector ID Code, fuel delivery rate, and ・ There should be no intermittent conditions,
engine No. for the ECM. poor connections, or corrosion.
7. Perform SCR purging with a trouble diagnosis scan ・ There should be no water intrusion or adhering
tool. foreign material.
8. Turn OFF the ignition switch. 26. Replace the DCU.
9. Connect the harness connector to the ECM. Refer to "1.Engine 1H.Aux. Emission Control
10. Disconnect the harness connector from the control
unit of the machine. Refer to "1.Engine 1H.Aux. Emission Control
11. Inspect the machine control unit harness connector.
diagnosis scan tool. Note：
14. If a DTC is not set, replace the control unit of the ・ After clearing the DCU DTC, observe whether
machine. ECM DTC P20C9 is set.
15. Connect the harness connector to the control unit of ・ If DTC P20C9 is set, clear it.
the machine. 2. Turn OFF the ignition switch until communication
termination resistor if a DTC is set.
20. Inspect the terminal resistor harness connector.
DTC U0100
1. DTC U0100 diagnostics Note：
Note：・ There should be no short to the battery power
supply or ignition power supply circuit.
・ The applicable DTC may be set after CPS
work. If the applicable DTC is set after CSP ・ There should be no high resistance.
work, simply clear the DTC because it is not a ・ There should be no short together between
malfunction of the machine. CAN circuits.
1. Turn OFF the ignition switch. ・ There should be no short to the GND circuit.
2. Disconnect the ECM harness connector.
as the frame.
16. If a problem is found, repair the CAN circuit.
4. Inspect the CAN High circuit between the DCU and
the ECM for an open circuit, short circuit, or
breakage. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
6. Inspect the CAN Low circuit between the DCU and
ECM installation".
breakage. 18. Set the Injector ID Code on the ECM.
7. If a problem is found, repair the CAN Low circuit. 19. Perform the unit difference learning of fuel supply
pumps on the ECM.
8. Inspect the ECM harness connector.
Note：
poor connections, or corrosion. Devices(4HK1) DCU removal".
9. If a problem is found, repair the connector. 2. DTC U0100 confirm resolution
10. Inspect the DCU harness connector. 1. Clear the DTC with the trouble diagnosis scan tool.
Note： Note：
・ There should be no intermittent conditions, ・ After clearing the DCU DTC, observe whether
poor connections, or corrosion. ECM DTC P20C9 is set.
・ There should be no water intrusion or adhering ・ If DTC P20C9 is set, clear it.
foreign material.
11. If a problem is found, repair the connector. with the trouble diagnosis scan tool is discontinued.
12. Observe the DTC information with the trouble 3. Start the engine.
diagnosis scan tool. If a DTC is set, disconnect the
harness connector from the termination resistor.
14. If the resistance of the termination resistor exceeds
diagnosis scan tool. If a DTC is set, inspect the CAN
High and CAN Low circuits.
DTC U029D
1. DTC U029D diagnostics Diagnosis when DTC P1462 and U029D are set at the
same time.
1. Check if DTC P1462 is set at the same time, and go
to each diagnosis. 14. Inspect the NOx sensor 1 power supply circuit.
Diagnosis when DTC U029D is set independently. Note：
2. Turn OFF the ignition switch. ・ There should be no open circuit, breakage, or
high resistance.
3. Disconnect the NOx sensor 1 harness connector.
4. Inspect the NOx sensor 1 harness connector. ・ There should be no short to metallic parts such
Note： as the frame.
・ There should be no intermittent conditions, 15. If a problem is found, repair the NOx sensor 1 power
・ There should be no water intrusion or adhering 16. Inspect the NOx sensor 1 GND circuit between the
foreign material. NOx sensor 1 and the DCU harness GND
5. If a problem is found, repair the connector. connection.
6. Inspect the NOx sensor 1 power supply circuit for an Note：
open circuit or breakage. ・ There should be no open circuit, breakage, or
7. If a problem is found, repair the NOx sensor 1 power high resistance.
supply circuit. 17. If a problem is found, repair the NOx sensor 1 GND
circuit.
circuit and the GND circuit. 18. Inspect the urea fluid sensor power supply circuit.
9. If the test lamp does not illuminate, repair the open Note：
circuit or high resistance in the NOx sensor 1 GND ・ There should be no open circuit, breakage, or
circuit. high resistance.
10. Turn ON the ignition switch without starting the ・ There should be no short to the GND circuit.
engine. ・ There should be no short to metallic parts such
11. Measure the voltage between the CAN Low circuit as the frame.
and the DCU harness GND connection, and between 19. If a problem is found, repair the urea fluid sensor
the CAN High circuit and the DCU harness GND power supply circuit.
connection.
20. Inspect the urea fluid sensor GND circuit between
values： 1.5 to 3.5 V the urea fluid sensor and the DCU harness GND
12. If the voltage is outside the specified range, repair connection.
the open circuit or high resistance between the CAN Note：
High terminal and the CAN Low terminal on NOx
sensor 1 and in the joint connector.
high resistance.
13. Replace NOx sensor 1.
Refer to "1.Engine 1H.Aux. Emission Control GND circuit.
Note：
・ If NOx sensor 1 is replaced, perform NOx
sensor 1 data reset with the trouble diagnosis 25. If DTC P1462 is set but U029D is not set, inspect the
scan tool. urea fluid sensor harness connector.
Note： Refer to "1.Engine 1H.Aux. Emission Control
・ There should be no intermittent conditions, Devices(4HK1) NOx sensor installation".
・ There should be no water intrusion or adhering ・ If NOx sensor 1 is replaced, perform NOx
foreign material. sensor 1 data reset with the trouble diagnosis
26. If a problem is found, repair the connector. scan tool.
27. Replace the urea fluid sensor. 38. If the resistance is outside the specified range,
disconnect the DCU harness connector and check the
Refer to "1.Engine 1H.Aux. Emission Control resistance of the DMM.
Devices(4HK1) DEF sensor installation". 39. If the resistance is outside the specified range, repair
the short together in the CAN circuits between the
28. If DTC P1462 and U029D are both set, turn the DCU, NOx sensor 1, urea fluid sensor, and
ignition switch OFF until communication with the termination resistors.
trouble diagnostic scan tool is discontinued.
40. If the resistance is within the specified range, inspect
29. Measure the resistance between the CAN Low and the DCU harness connector.
CAN High circuits.
Note：
30. If the resistance between the CAN Low and High poor connections, or corrosion.
circuits is more than or equal to the specified value, ・ There should be no water intrusion or adhering
measure the resistance of the termination resistor. foreign material.
values： 115 to 125 Ω 41. If a problem is found, repair the connector.
31. If the resistance of the termination resistor is outside 42. Replace the DCU.
32. If the resistance of the termination resistor is within Devices(4HK1) DCU removal".
the specified range, inspect the DCU, joint
connector, CAN circuit between the termination Refer to "1.Engine 1H.Aux. Emission Control
resistors, and CAN jumper wire for an open circuit Devices(4HK1) DCU installation".
or high resistance. 2. DTC U029D confirm resolution
33. If a problem is found, repair the CAN circuit. 1. Clear the DTC with the trouble diagnosis scan tool.
34. If the resistance between the CAN Low and High Note：
circuits is less than or equal to the specified value,
disconnect the NOx sensor 1 harness connector and
check the resistance.
35. If the resistance is within the specified range, inspect with the trouble diagnosis scan tool is discontinued.
the NOx sensor 1 harness connector.
Note：
foreign material.
Emission Control (Urea SCR System (24V)) 10M-1
Emission Control
Emission Control
(Urea SCR System (24V))
Table of Contents
DTC P0607 Control Module Performance...................10M-3 DTC P206A Urea Fluid Quality Sensor Circuit.........10M-34
DTC P060B Internal Control Module A/D Processing DTC P206B Urea Sensor Over Temperature Condition
Performance..................................................................10M-4 ....................................................................................10M-35
DTC P062F Control Module EEPROM Error.............10M-5 DTC P206C Urea Fluid Quality Sensor Circuit Open
DTC P0641 Sensor Reference Voltage Circuit............10M-6 ....................................................................................10M-36
DTC P0658 Actuator Supply Voltage Circuit..............10M-7 DTC P206D Urea Fluid Quality Sensor Circuit Short
....................................................................................10M-37
DTC P0659 Actuator Supply Voltage Circuit..............10M-9
DTC P207F Urea Fluid Concentration Too Low.......10M-38
DTC P1462 Urea Fluid Quality Sensor Timeout Error
....................................................................................10M-11 DTC P208A Urea Fluid Pump Control Circuit..........10M-39
DTC P1464 Main Relay Performance........................10M-12 DTC P208B Urea Fluid Pump Performance..............10M-40
DTC P1468 Urea Dosing Control Module (DCM) DTC P208C Urea Fluid Pump Control Circuit Low Voltage
Overtemperature.........................................................10M-13 ....................................................................................10M-41
DTC P1491 Urea Fluid Overpressure........................10M-14 DTC P208D Urea Fluid Pump Control Circuit High Voltage
....................................................................................10M-42
Overtemperature.........................................................10M-16 DTC P208E Urea Fluid Injector Stuck.......................10M-43
DTC P149C Urea Fluid Pressure Reduction Malfunction DTC P20A0 Urea Fluid Reverting Valve Circuit Open
....................................................................................10M-17 ....................................................................................10M-44
DTC P149D Urea Fluid Tank Overtemperature........10M-19 DTC P20A2 Urea Fluid Reverting Valve Circuit Low
Voltage.......................................................................10M-45
DTC P2000 Monitoring the NOx Efficiency.............10M-20
DTC P20A3 Urea Fluid Reverting Valve Circuit High
DTC P203B Urea Fluid Tank Level Sensor Stuck.....10M-22
Voltage.......................................................................10M-46
DTC P203C Urea Fluid Tank Level Sensor Low Voltage
DTC P20AC Urea Fluid Pump Temperature Sensor
....................................................................................10M-24
Performance................................................................10M-47
....................................................................................10M-25
Performance................................................................10M-48
....................................................................................10M-26
Circuit Open...............................................................10M-49
....................................................................................10M-27
....................................................................................10M-28
DTC P20E8 Urea Fluid Pressure Underpressure.......10M-52
Voltage.......................................................................10M-29
DTC P20E9 Urea Fluid Overpressure........................10M-54
Voltage.......................................................................10M-30 DTC P20EA Urea Fluid Pressure Reduction Malfunction
....................................................................................10M-56
DTC P205B Urea Fluid Tank Temperature Sensor
Performance................................................................10M-31 DTC P20FE Urea Fluid Pressure Build-Up Error......10M-57
DTC P205C Urea Fluid Tank Temperature Sensor Low DTC P2201 Upstream Nox Sensor Performance.......10M-59
Voltage.......................................................................10M-32 DTC P2206 Reading the error(open) information detected
DTC P205D Urea Fluid Tank Temperature Sensor High by Ft NOx sensor........................................................10M-60
Voltage.......................................................................10M-33 DTC P2207 Reading the error(short) information detected
by Ft NOx sensor........................................................10M-61
10M-2 Emission Control (Urea SCR System (24V))
DTC P2210 Reading the error(open) information detected

by Rr NOx sensor.......................................................10M-62
DTC P2211 Reading the error(short) information detected
by Rr NOx sensor.......................................................10M-63
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3
Performance................................................................10M-64
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3
DTC U0002 CAN Bus Off.........................................10M-67
Module (ECM)...........................................................10M-68
Ft NOx sensor.............................................................10M-69
DTC U029E CAN communication error between DCU and
Rr NOx sensor............................................................10M-72
DTC P0607
corrosion.
Note：
foreign material.
high resistance.
high resistance.
connector.
Note：
engine.
DTC P060B
engine.
4. If the DTC is a past failure, perform the urea SCR
system intermittent diagnosis.
5. If the DTC is a current failure, replace the DCU.
Note：
engine.
DTC P062F
1. DTC P062F diagnostics If DTC P1464 is set as a current failure or past
failure at the same time, treat that first.
Note：
・ If a relevant DTC is set after the following 14. If the DTC is a past failure, perform the urea SCR
conditions occur, the DCU is normal, and the system intermittent diagnosis.
DTC should simply be cleared. 15. If the DTC is a current failure, replace the DCU.
If the battery enters a low voltage condition Refer to "1.Engine 1H.Aux. Emission Control
due to cranking or operation of the machine's Devices(4HK1) DCU removal".
electronic components, the DCU will Refer to "1.Engine 1H.Aux. Emission Control
temporarily turn OFF. Devices(4HK1) DCU installation".
The battery or urea SCR fuse is removed
before turning the DCU power supply OFF 2. DTC P062F confirm resolution
after turning OFF the ignition switch (during 1. Clear the DTC with the trouble diagnosis scan tool.
after-run control or within 3 minutes of turning
OFF the ignition switch). Note：
1. Turn OFF the ignition switch until communication ECM DTC P20C9 is set.
for intermittent conditions, improper tightening, or 2. Turn OFF the ignition switch until communication
corrosion. with the trouble diagnosis scan tool is discontinued.
3. If a problem is found, repair the mounting of the 3. Turn ON the ignition switch without starting the
DCU harness GND connection terminal. engine.
Note：
foreign material.
high resistance.
high resistance.
connector.
engine.
DTC P0641
1. DTC P0641 diagnostics ・ There should be no short to metallic parts such
1. Turn OFF the ignition switch. as the frame.
2. Disconnect the urea fluid supply module harness 11. If a problem is found, repair the 5 V power supply
connector. circuit.

・ The urea fluid pump, reverting valve, and urea 13. Inspect the DCU harness connector.
Note：
3. Inspect the urea fluid supply module harness ・ There should be no intermittent conditions,
connector. poor connections, or corrosion.
Note：・ There should be no water intrusion or adhering
・ There should be no intermittent conditions, foreign material.
poor connections, or corrosion. 14. If a problem is found, repair the connector.
foreign material.
engine.
circuit and the DCU harness GND connection.
Note：
7. If the reading is within the specified range, replace
the urea fluid supply module. ・ After clearing the DCU DTC, observe whether
engine.
the DCU and the urea fluid pressure sensor. 4. Observe the DTC information with the trouble
Note：
・ There should be no short to the battery or
・ There should be no short to other power
supply circuits.
circuit.
the DCU and the urea fluid pressure sensor.
Note：
・ There should be no short to other GND
circuits.
DTC P0658
1. DTC P0658 diagnostics Refer to "1.Engine 1H.Aux. Emission Control
connector.
DCU and the coolant control valve for a short to any
Note： metallic components, such as the frame.
foreign material.
DCU and the urea fluid supply module.
Note：
5. Turn ON the ignition switch without starting the ・ There should be no short to other GND
engine. circuits.
6. Observe the DTC information with a trouble ・ There should be no short to other power
diagnosis scan tool. supply circuits.
7. If DTC P20B1 is set but P0658 is not set, replace the 18. If a problem is found, repair the battery voltage
coolant control valve. supply circuit.
Refer to "1.Engine 1H.Aux. Emission Control 19. Turn OFF the ignition switch.
Note：
9. Disconnect the urea fluid supply module harness poor connections, or corrosion.
connector.
Note： foreign material.
・ The urea fluid pump, reverting valve, and urea 22. If a problem is found, repair the connector.
Note：
・ There should be no water intrusion or adhering 2. DTC P0658 confirm resolution
foreign material. 1. Clear the DTC with the trouble diagnosis scan tool.
11. If a problem is found, repair the connector. Note：
12. Turn ON the ignition switch without starting the ・ After clearing the DCU DTC, observe whether
engine. ECM DTC P20C9 is set.
13. Observe the DTC information with a trouble ・ If DTC P20C9 is set, clear it.
diagnosis scan tool. 2. Turn OFF the ignition switch until communication
14. If DTC P20A0 and P20B1 are set but P0658 is not with the trouble diagnosis scan tool is discontinued.
set, replace the urea fluid supply module. 3. Turn ON the ignition switch without starting the
engine.
DTC P0659
1. DTC P0659 priority DTC 13. Observe the DTC information with a trouble
DTC P208D
14. If DTC P20A0 and P20B1 are set but P0659 is not
DTC P20A3
set, replace the urea fluid supply module.
DTC P20B4
2. DTC P0659 diagnostics Devices(4HK1) DEF supply module removal".
connector. 15. If P0659 is detected, inspect the battery voltage
supply circuit between the DCU and the coolant
control valve for a short to the battery or a short to
Note： the ignition power supply.
foreign material.
DCU and the urea fluid supply module for a short to
4. If a problem is found, repair the connector. the battery or a short to the ignition power supply.
5. Turn ON the ignition switch without starting the 18. If a problem is found, repair the battery voltage
engine. supply circuit.
6. Observe the DTC information with a trouble 19. Turn OFF the ignition switch.
7. If DTC P20B1 is set but P0659 is not set, replace the
Refer to "1.Engine 1H.Aux. Emission Control Note：
Devices(4HK1) Coolant control valve removal". ・ There should be no intermittent conditions,
Devices(4HK1) Coolant control valve installation". ・ There should be no water intrusion or adhering
foreign material.
connector.
Note：
・ The urea fluid pump, reverting valve, and urea
fluid pressure sensor are built in. Refer to "1.Engine 1H.Aux. Emission Control
connector. 3. DTC P0659 confirm resolution
12. Turn ON the ignition switch without starting the with the trouble diagnosis scan tool is discontinued.
engine.
engine.
DTC P1462
DTC U029D
Note：
foreign material.
5. Turn ON the ignition switch. engine.
6. Connect a test lamp between the urea fluid sensor 4. Observe the DTC information with the trouble
power supply circuit and the DCU harness GND diagnosis scan tool. A DTC should not be set.
connection.
GND circuit.
connection.
the CAN Low circuit and the CAN High circuit
between the urea fluid sensor and the DCU.
Note：
resistance in the CAN High circuit.
resistance in the CAN Low circuit.
resistance in the termination resistor.
13. If a problem is found, repair the CAN circuit or
DTC P1464
1. DTC P1464 diagnostics 1. Clear the DTC with the trouble diagnosis scan tool.
Note： Note：
・ If a relevant DTC is set after the following ・ After clearing the DCU DTC, observe whether
conditions occur, the DCU is normal, and the ECM DTC P20C9 is set.
DTC should simply be cleared. ・ If DTC P20C9 is set, clear it.
If the battery enters a low voltage condition 2. Turn OFF the ignition switch for 3 minutes or more.
due to cranking or operation of the machine's 3. Turn ON the ignition switch without starting the
electronic components, the DCU will engine.
temporarily turn OFF.
The battery or urea SCR fuse is removed 4. Observe the DTC information with the trouble
before turning the DCU power supply OFF diagnosis scan tool. A DTC should not be set.
after turning OFF the ignition switch (during Note：
after-run control or within 3 minutes of turning ・ Repeat Step 2 and Step 3 several times, and
OFF the ignition switch). check if a DTC is set.
corrosion.
Note：
foreign material.
high resistance.
high resistance.
connector.
DTC P1468
those first.
around the DCU.
Note：
3. Without starting the engine, observe the DTC
information with the trouble diagnosis scan tool. A
DTC should not be set. Turn ON the switch.
DTC P1491
1. DTC P1491 priority DTC 6. If a problem is found, repair the backflow connector.
DTC P204C
DTC P204D
DTC P208B
Note： connector.
・ If DTC P20E9 is set as a current failure or past 9. Inspect the urea fluid supply module harness
failure at the same time, treat that first. connector.
1. Inspect the backflow piping between the urea fluid Note：
Note： poor connections, or corrosion.
・ There should be no clogging caused by ・ There should be no water intrusion or adhering
twisting or bending. foreign material.
・ There should be no clogging caused by foreign 10. If a problem is found, repair the connector.
material.
fluid freezing. 12. Inspect each circuit between the DCU and the urea
・ There should be no layout changes in the urea fluid supply module.
fluid piping that differ from the specified layout. Note：
Caution：・ There should be no open circuit, breakage, or
・ Do not blow air onto the urea fluid connector high resistance.
on the urea fluid supply module. ・ There should be no short circuit or improper
modification.
Note：
・ There should be no clogging caused by Note：
twisting or bending. ・ There should be no intermittent conditions,
fluid freezing. ・ There should be no water intrusion or adhering
foreign material.
Devices(4HK1) DEF sensor removal". 16. Replace the urea fluid supply module.
Devices(4HK1) DEF sensor installation". Devices(4HK1) DEF supply module removal".
supply module. Devices(4HK1) DEF supply module installation".
Note： 3. DTC P1491 confirm resolution
・ The check valve should not be clogged or 1. Clear the DTC with the trouble diagnosis scan tool.
stuck closed.
engine.
tool.
Caution：
fluid is frozen.
Note：
values： less than 1250 kPa { less than 181 psi }
DTC P1493
those first.
around the DCU.
Note：
engine.
DTC P149C
1. DTC P149C priority DTC 6. If a problem is found, replace the urea fluid sensor.
DTC P204C
DTC P204D
DTC P208B
DTC P20A0
DTC P20A2 connector.
DTC P20A3 9. Inspect the urea fluid supply module harness
connector.
1. There should be no damage to or clogging of the Note：
supply module filter. ・ There should be no intermittent conditions,
filter. ・ There should be no water intrusion or adhering
foreign material.
Devices(4HK1) DEF supply module filter installation". 12. Inspect each circuit between the DCU and the urea
Caution：
3. Inspect the suction piping between the urea fluid high resistance.
supply module and the urea fluid tank. ・ There should be no short circuit or improper
modification.
Note：
twisting or bending. 14. Inspect the DCU harness connector.
・ There should be no clogging caused by foreign Note：
material.
fluid freezing.
・ There should be no layout changes in the urea foreign material.
fluid piping that differ from the specified layout.
Caution：
on the urea fluid supply module. 17. Perform Urea Fluid Reverting Valve on the trouble
diagnosis scan tool and inspect for sticking of the
reverting valve.
5. Inspect the urea fluid sensor suction line.
18. If a problem is found, replace the urea fluid supply
Note： module.
・ There should be no clogging caused by Refer to "1.Engine 1H.Aux. Emission Control
twisting or bending. Devices(4HK1) DEF supply module removal".
fluid freezing.
engine.
tool.
Caution：
fluid is frozen.
Note：
engine.
DTC P149D
1. DTC P149D diagnostics Note：
1. Perform Urea fluid tank heater coolant control valve ・ The temperature sensing element on the
on the trouble diagnosis scan tool and inspect the bottom end of the urea fluid sensor should be
operation of the coolant control valve. submerged in the water.
・ Do not use warm water at 70 °C {158 °F} or
Note：
more. This may cause the DTC to be set.
・ There should be no sticking of the coolant
control valve. c. Measure the temperature of the water or warm water in
the container using an engine coolant temperature gauge.
・ There should be no circuit malfunction in the
coolant control valve. d. Turn ON the ignition switch.
2. If a problem is found, repair or replace. e. Compare the urea fluid tank temperature display on the
trouble diagnosis scan tool with the value of the engine
coolant temperature gauge, and check whether the
difference is less than or equal to the specified value.
Note：
・ It takes time for the temperature display on the
3. Turn OFF the ignition switch. trouble diagnosis scan tool to stabilize.
4. Disconnect the urea fluid sensor harness connector. Determine after the temperature display is
stable.
Specified value: 5 °C {9°F} or less (Temperature
Note： difference)
f. Measure 2 to 3 times at different temperatures and
check whether the temperature difference is less than or
・ There should be no water intrusion or adhering equal to the specified value.
foreign material.
10. If the temperature difference is more than or equal to
6. If a problem is found, repair the connector. the specified value, replace the urea fluid sensor.
7. Inspect the urea fluid sensor in the urea fluid tank for 2. DTC P149D confirm resolution
engine coolant leakage.
a. Drain the urea fluid from the drain plug of the urea
fluid tank. Note：
b. Check the color of the drained urea fluid, and inspect ・ After clearing the DCU DTC, observe whether
for an intrusion of engine coolant. ECM DTC P20C9 is set.
c. If an intrusion of engine coolant is found, remove the
urea fluid sensor and visually inspect for engine coolant 2. Turn OFF the ignition switch until communication
leakage from the engine coolant pipe and pipe installation with the trouble diagnosis scan tool is discontinued.
section. 3. Turn ON the ignition switch without starting the
8. If a problem is found, replace the urea fluid sensor. engine.
9. Inspect the urea fluid temperature sensor for 4. Observe the DTC information with the trouble
characteristic malfunctions. diagnosis scan tool. A DTC should not be set.
a. Connect the urea fluid sensor harness connector to the
removed urea fluid sensor.
b. Put the urea fluid sensor in a container with water or
warm water at 60°C {140 °F} or less.
DTC P2000
Monitoring the NOx Efficiency
1. DTC P2000 diagnostics 3. Inspect NOx sensor 1 and NOx sensor 2.
1. If there are DTCs that were set at the same time, treat Note：
those first. ・ Inspect NOx sensor 1 and NOx sensor 2 for
2. Inspect the DCU system. improper installation, damage, or clogging due
to adhering foreign material.
・There should be no clogging caused by bending of the
sensor tube of the urea fluid tank level sensor in the tank, 4. Repair or replace as necessary.
and no malfunctions caused by the float being at an angle. Refer to "1.Engine 1H.Aux. Emission Control
・There should be no layout of the urea fluid tank and Devices(4HK1) NOx sensor removal".
urea fluid supply module which differs from the specified
layout. Refer to "1.Engine 1H.Aux. Emission Control
・There should be no damage to or clogging of the supply Devices(4HK1) NOx sensor installation".
module filter. Note：
・There should be no clogging of the urea fluid quality
・ If the NOx sensor is replaced, perform NOx
sensor strainer.
sensor data reset with the trouble diagnosis
・There should be no freezing of the urea fluid suction
scan tool.
line, pressure line, inside the tank, or in the coolant
piping. 5. Inspect the air intake system.
・There should be no clogging of the urea fluid tank vent ・There should be no clogging of the air cleaner and inlet
hose. cover.
・The reverting valve should not be stuck in the normal ・There should be no changes to the air intake system.
position. ・There should be no air leakage.
・The dosing module should not remain open. ・Is the MAF and IAT sensor value appropriate?
・There should be no leakage from the urea fluid piping,
urea fluid supply module, or dosing module. 6. Repair or replace as necessary.
・There should be no damage to or clogging caused by 7. Inspect the exhaust system.
module and the dosing module, and no layout which ・There should be no exhaust gas leakage from the
differs from the specified layout. exhaust pipe, gasket, NOx sensor, EGT sensor, and SCR
・There should be no damage to or clogging caused by catalyst pressure hose.
twisting of the suction line between the urea fluid supply ・There should be no layout which differs from the
module and the tank, and no layout which differs from specified layout in the exhaust system.
the specified layout. ・There should be no damage or cracking of the mixer
・There should be no damage to or clogging caused by chamber.
twisting of the urea fluid sensor suction piping, and no ・There should be no accumulation of white crystallized
layout that differs from the specified layout. urea fluid in the SCR catalyst of the mixer chamber.
・The one-way valve of the backflow connector should ・There should be no damage, cracking, or melting of the
not remain open. SCR catalyst (front and rear).
・There should be no clogging of the urea fluid supply 8. Repair or replace as necessary.
Note：
Caution：
・ If the SCR catalyst is replaced, perform SCR
・ Do not blow air onto the urea fluid supply catalyst data reset with the trouble diagnosis
module. scan tool.
Note： 2. DTC P2000 confirm resolution
・ Clean with warm water if there is any white
crystallized urea fluid adhering to the end of
the dosing module. Note：
・ If the dosing module is replaced, perform urea ・ After clearing the DCU DTC, observe whether
fluid injector data reset with the trouble ECM DTC P20C9 is set.
diagnosis scan tool. ・ If DTC P20C9 is set, clear it.
DTC P203B
1. DTC P203B priority DTC 9. Turn ON the ignition switch.
DTC P203C 10. Connect a test lamp between the urea fluid sensor
DTC P203D
connection.
Note： circuit or high resistance in the urea fluid sensor
・ Check the frequency with which urea fluid is power supply circuit.
added, because this DTC may be set if urea 12. Connect a test lamp between the power supply
fluid is repeatedly added with a high amount of circuit and the GND circuit.
urea fluid remaining in the urea fluid tank.
1. Remove the urea fluid tank level sensor. circuit or high resistance in the urea fluid sensor
2. Inspect the urea fluid tank level sensor. GND circuit.
Note： 14. Disconnect the harness connector from the DCU.
・ There should be no bending of the level 15. Inspect the DCU harness connector.
sensor tube.
Note：
・ The float should not be stuck and there should
be no foreign material that restricts the
movement of the float.
・ There should be no leaning or delayed
foreign material.
response of the level sensor.
・ The urea fluid tank should not be deformed or 16. Inspect each circuit for high resistance.
broken. 17. If a problem is found, repair the harness connector or
3. If a problem is found, repair or replace the urea fluid circuit.
tank level sensor. 18. Replace the urea fluid tank level sensor.
4. Turn ON the ignition switch. 3. DTC P203B confirm resolution
5. Observe the urea fluid tank level display on the 1. Clear the DTC with the trouble diagnosis scan tool.
trouble diagnosis scan tool while slowly moving the
float. Note：
Note：
・ The display changes gradually between 18
and 90% in accordance with the float
movement. 2. Turn OFF the ignition switch until communication
・ It may take some time for the scan tool display with the trouble diagnosis scan tool is discontinued.
to change in accordance with the float 3. Turn ON the ignition switch without starting the
movement. engine.
6. If a problem is found, turn OFF the ignition switch. 4. Observe the urea fluid tank level display on the
7. Disconnect the harness connector from the urea fluid trouble diagnosis scan tool while slowly pouring
sensor. urea fluid into the urea fluid tank.
8. Inspect the urea fluid sensor harness connector. ・The display should change depending on the urea fluid
quantity.
Note：
Note：
poor connections, or corrosion. ・ Wait for approx. 30 seconds after adding the
urea fluid, and then observe the remaining oil
level.
foreign material.
DTC P203C
Urea Fluid Tank Level Sensor Low Voltage
1. DTC P203C diagnostics Refer to "1.Engine 1H.Aux. Emission Control
sensor. 1. Clear the DTC with the trouble diagnosis scan tool.
3. Inspect the urea fluid sensor harness connector. Note：
4. Turn ON the ignition switch. 3. Turn ON the ignition switch without starting the
engine.
GND circuit.
9. Inspect the signal side circuit between the DCU and
urea fluid tank level sensor.
Note：
・ There should be no short to ground.
Note：
DTC P203D
1. DTC P203D diagnostics 17. Inspect for poor connections at the DCU harness
connector.
sensor. 19. Replace the DCU.
3. Connect the DMM between the urea fluid tank level Refer to "1.Engine 1H.Aux. Emission Control
sensor signal circuit and a known good GND. Devices(4HK1) DCU removal".
4. Turn ON the ignition switch. Refer to "1.Engine 1H.Aux. Emission Control
5. Observe the DMM voltage display.
value, inspect the signal circuit between the DCU Note：
and the urea fluid tank level sensor for a short to the ・ After clearing the DCU DTC, observe whether
battery or a short to the ignition power supply. ECM DTC P20C9 is set.
7. If a problem is found, repair the signal circuit. ・ If DTC P20C9 is set, clear it.
8. If the reading is less than or equal to the specified 2. Turn OFF the ignition switch until communication
value, inspect the signal circuit between the DCU with the trouble diagnosis scan tool is discontinued.
and the urea fluid tank level sensor for an open
engine.
10. If the reading is within the specified range, connect diagnosis scan tool. A DTC should not be set.
the DMM between the urea fluid tank level sensor
signal circuit and the GND circuit.
voltage： 4.6 V
the urea fluid tank level sensor for an open circuit or
high resistance.
Note：
・ The urea fluid tank level sensor shares the
set.
harness connector.
DTC P2048
1. DTC P2048 diagnostics values： 11 to 15 Ω
1. Turn OFF the ignition switch. 13. If the measured value is outside the specified range,
engine.
circuit (High) and the DCU harness GND
connection. Note：
values： 5.5 V ・ When the dosing module is replaced, perform
5. If the reading is less than or equal to the specified diagnosis scan tool.
value, inspect the injector drive circuit (High)
between the DCU and dosing module. 14. Turn OFF the ignition switch.

・ There should be no open circuits. 16. Inspect the DCU harness connector.
・ There should be no short to metallic parts such Note：
as the frame.
・ There should be no short to the injector drive poor connections, or corrosion.
circuit (Low).
・ There should be no high resistance. foreign material.
6. If a problem is found, repair the injector drive circuit 17. If a problem is found, repair the connector.
(High).
circuit (High) and the injector drive circuit (Low). Refer to "1.Engine 1H.Aux. Emission Control
values： 5.5 V
8. If the reading is less than or equal to the specified Devices(4HK1) DCU installation".
value, inspect the injector drive circuit (Low)
between the DCU and dosing module. 2. DTC P2048 confirm resolution
・ There should be no open circuits. Note：
・ There should be no short to metallic parts such ・ After clearing the DCU DTC, observe whether
as the frame. ECM DTC P20C9 is set.
・ There should be no high resistance. ・ If DTC P20C9 is set, clear it.
9. If a problem is found, repair the injector drive circuit 2. Turn OFF the ignition switch until communication
(Low). with the trouble diagnosis scan tool is discontinued.
10. Inspect the dosing module harness connector. 3. Turn ON the ignition switch without starting the
engine.
Note：
・ There should be no intermittent conditions, 4. Observe the DTC information with the trouble
foreign material.
DTC P2049
1. DTC P2049 diagnostics 2. DTC P2049 confirm resolution
1. Inspect the injector drive circuit (High) and the 1. Clear the DTC with the trouble diagnosis scan tool.
injector drive circuit (Low) between the DCU and
Note：
the dosing module for a short to the battery or a short
to the ignition power supply. ・ After clearing the DCU DTC, observe whether
2. If a problem is found, repair the injector drive circuit
(High) or (Low).
5. Inspect the dosing module harness connector. engine.
foreign material.
8. If the measured value is outside the specified range,
Note：
・ When the dosing module is replaced, perform
Note：
foreign material.
DTC P204B
1. DTC P204B priority DTC 12. Replace the urea fluid supply module.
DTC P204C Refer to "1.Engine 1H.Aux. Emission Control
DTC P204D
connector.
Note：
between the DCU and the urea fluid supply module. ・ After clearing the DCU DTC, observe whether
Note：
high resistance. 2. Turn OFF the ignition switch until communication
modification. 3. Turn ON the ignition switch without starting the
engine.
connector.
Note：
foreign material.
Note：
foreign material.
Note：
Note：
・ The engine coolant should flow into the supply
module.
heater control system.
DTC P204C
1. DTC P204C diagnostics 2. DTC P204C confirm resolution
2. Disconnect the urea fluid supply module harness Note：
connector. ・ After clearing the DCU DTC, observe whether
3. Inspect the urea fluid supply module harness ECM DTC P20C9 is set.
connector. ・ If DTC P20C9 is set, clear it.
Note： 2. Turn OFF the ignition switch until communication
・ There should be no intermittent conditions, with the trouble diagnosis scan tool is discontinued.
poor connections, or corrosion. 3. Turn ON the ignition switch without starting the
・ There should be no water intrusion or adhering engine.
foreign material.
4. If a problem is found, repair the connector. diagnosis scan tool. A DTC should not be set.
engine.
7. If DTC P204D is set but DTC P204C is not set,
replace the urea fluid supply module.
8. Inspect the signal circuit between the DCU and the
urea fluid pressure sensor.
Note：
as the frame.
Note：
foreign material.
DTC P204D
1. DTC P204D priority DTC 15. Inspect the urea fluid supply module harness
connector.
DTC P0641
Note：
1. Turn OFF the ignition switch. poor connections, or corrosion.
2. Disconnect the urea fluid supply module harness ・ There should be no water intrusion or adhering
connector. foreign material.
3. Turn ON the ignition switch without starting the 16. If a problem is found, repair the connector.
engine.
the DCU harness GND connection.
values： 5.5 V
5. If the reading is more than or equal to the specified Devices(4HK1) DEF supply module installation".
and the urea fluid pressure sensor for a short to the
battery power supply or a short to the ignition power 19. Disconnect the DCU harness connector.
supply circuit.
Caution：
Note：
・ The urea fluid pressure sensor may be
damaged if the sensor signal circuit is shorted
to the power supply.
6. If a problem is found, repair the signal circuit. foreign material.
7. If the reading is less than or equal to the specified 21. If a problem is found, repair the connector.
and the urea fluid pressure sensor for an open circuit 22. Replace the DCU.
or a short to the 5 V power supply circuit. Refer to "1.Engine 1H.Aux. Emission Control
8. If a problem is found, repair the signal circuit. Devices(4HK1) DCU removal".
9. Measure the voltage between the 5 V power supply Refer to "1.Engine 1H.Aux. Emission Control
circuit and the DCU harness GND connection. Devices(4HK1) DCU installation".
values： 4.8 V 3. DTC P204D confirm resolution
value, inspect the 5 V power supply circuit between Note：
the DCU and the urea fluid pressure sensor for an
11. If a problem is found, repair the 5 V power supply ・ If DTC P20C9 is set, clear it.
circuit.
12. Measure the voltage between the 5 V power supply with the trouble diagnosis scan tool is discontinued.
values： 4.8 V engine.
value, inspect the GND circuit between the DCU and diagnosis scan tool. A DTC should not be set.
the urea fluid pressure sensor for an open circuit or
high resistance.
DTC P205B
1. DTC P205B priority DTC temperature are all the specified value or less, and
start the engine.
5 °C {9°F} or less (Temperature difference)
Note：
those first. ・ If the reading is not within the specified
requirements, soak until it is.
abnormally high temperature is installed in the area 4. Observe the DTC information with the trouble
around the urea fluid tank. diagnosis scan tool. A DTC should not be set.

tank.
sensor.
Note：
foreign material.
Note：
DTC P205C
Urea Fluid Tank Temperature Sensor Low Voltage
1. DTC P205C diagnostics Note：
sensor.
Note：
foreign material.
connection.
GND circuit.
10. Inspect the signal side circuit between the DCU and
urea fluid tank temperature sensor.
・There should be no short to ground.
・There should be no short to the ground circuit.
・There should be no intermittent conditions, poor
connections, or corrosion.
DTC P205D
1. DTC P205D diagnostics 19. Replace the DCU.
tank temperature sensor. Refer to "1.Engine 1H.Aux. Emission Control
3. Connect the DMM between the urea fluid tank
temperature sensor signal circuit and a known good 2. DTC P205D confirm resolution
GND.
Note：
5. Observe the DMM voltage display. ・ After clearing the DCU DTC, observe whether
voltage： 4.6 to 5.2 V ECM DTC P20C9 is set.
value, inspect the signal circuit between the DCU 2. Turn OFF the ignition switch until communication
and the urea fluid tank temperature sensor for a short with the trouble diagnosis scan tool is discontinued.
7. If a problem is found, repair the signal circuit. engine.
value, inspect the signal circuit between the DCU diagnosis scan tool. A DTC should not be set.
and the urea fluid tank temperature sensor for an
10. If the reading is within the specified range, connect
the DMM between the urea fluid tank temperature
sensor signal circuit and the GND circuit.
voltage： 4.6 V
the urea fluid tank temperature sensor for an open
Note：
・ The urea fluid tank temperature sensor shares
set.
14. Inspect for poor connections at the urea fluid tank
temperature sensor harness connector.
16. Replace the urea fluid tank temperature sensor.
connector.
DTC P206A
3. Inspect the urea fluid sensor power supply circuit
between the ignition switch and the urea fluid sensor
Note：
foreign material.
Note：
engine.
・Urea fluid concentration sensor error
・Urea fluid conductivity sensor error
・Urea fluid tank temperature sensor error
・Urea fluid sensor error
DTC P206B
1. DTC P206B priority DTC Refer to "1.Engine 1H.Aux. Emission Control
sensor.
Note：
・ There should be no intermittent conditions, coolant temperature, intake air temperature, and fuel
poor connections, or corrosion. temperature are all the specified value or less, and
・ There should be no water intrusion or adhering start the engine.
foreign material.
Note：
6. Turn ON the ignition switch. ・ If the reading is not within the specified
7. Connect a test lamp between the urea fluid sensor requirements, soak until it is.
GND circuit.
tank.
DTC P206C
1. DTC P206C diagnostics 4. Check if the following parameters change to "No" on
sensor.
3. Inspect the urea fluid sensor harness connector. ・ Urea fluid sensor error
foreign material.
connection.
GND circuit.
connector.
fluid quality sensor for a short circuit.
engine.
DTC P206D
sensor.
3. Inspect the power supply circuit of the urea fluid
sensor for an open circuit.
circuit.
harness connector.
engine.
・ Urea fluid sensor error
DTC P207F
1. Inspect the concentration of the urea fluid.
2. If a problem is found, add the specified urea fluid
after cleaning the inside of the urea fluid tank.
3. Inspect the urea fluid tank.
・There should be no water intrusion caused by cracking
or damage.
4. If a problem is found, replace the urea fluid tank.
5. Inspect the urea fluid sensor.
・There should be no coolant intrusion caused by
cracking or damage of the coolant passages.
・There should be no water intrusion from the urea fluid
sensor installation area or seal area.
engine.
diagnosis scan tool. DTC P207F should not be set.
10. If DTC P207F is set, replace the urea fluid sensor.
engine.
DTC P208A
1. DTC P208A diagnostics 15. Replace the DCU.
connector. 2. DTC P208A confirm resolution
・ There should be no intermittent conditions, Note：
terminals.
engine.
6. Inspect the DCU harness connector. diagnosis scan tool. A DTC should not be set.
Note：
foreign material.
harness connector for an open circuit or high
resistance.
circuit.
12. Inspect the pump control circuit between the DCU
and the urea fluid supply module harness connector
for an open circuit.
13. If a problem is found, repair the pump control
circuit.
DTC P208B
1. DTC P208B priority DTC Note：
DTC P208A ・ The engine coolant should flow into the supply
module.
DTC P208C
DTC P208D heater control system.
2. DTC P208B diagnostics 14. Replace the urea fluid supply module.
2. Disconnect the urea fluid supply module harness Devices(4HK1) DEF supply module removal".
3. Inspect the urea fluid supply module harness Devices(4HK1) DEF supply module installation".
connector. 3. DTC P208B confirm resolution
Note：
terminals. ・ After clearing the DCU DTC, observe whether
resistance, or short to any of the circuits. ・ If DTC P20C9 is set, clear it.
4. If a problem is found, repair the connector. 3. Start the engine.
5. Disconnect the DCU harness connector. 4. Test run at the specified speed or higher while
Note：
Specified value： 190 ℃
poor connections, or corrosion. 5. Observe the DTC information with the trouble
foreign material.
circuit.
Note：
DTC P208C
1. DTC P208C diagnostics 16. Inspect the urea fluid pump control circuit between
Note：
connector. ・ There should be no short to the GND circuit.
as the frame.
connector.
Note：
control circuit.
foreign material.
Note：
foreign material.
8. Inspect the urea fluid pump power supply circuit 4. Observe the DTC information with the trouble
between the DCU and the urea fluid supply module diagnosis scan tool. A DTC should not be set.
circuit.
engine.
14. If DTC P208A is set but P208C is not set, replace the
DTC P208D
1. DTC P208D diagnostics 16. Inspect the urea fluid pump control circuit between
Note：
short to the ignition power supply circuit.
・ There should be no short to the battery voltage
connector.
supply circuit.
Note：
・ There should be no intermittent conditions, control circuit.
terminals. 18. Replace the DCU.
・ There should be no open circuit, high Refer to "1.Engine 1H.Aux. Emission Control
resistance, or short to any of the circuits. Devices(4HK1) DCU removal".
4. If a problem is found, repair the connector. 2. DTC P208D confirm resolution
5. Disconnect the DCU harness connector. 1. Clear the DTC with the trouble diagnosis scan tool.
6. Inspect the DCU harness connector. Note：
8. Inspect the urea fluid pump power supply circuit engine.
between the DCU and the urea fluid supply module 4. Observe the DTC information with the trouble
for an open circuit or high resistance. diagnosis scan tool. A DTC should not be set.
circuit.
engine.
14. If DTC P208A is set but P208D is not set, replace
DTC P208E
1. DTC P208E priority DTC Note：
DTC P2048 ・ When the dosing module is replaced, perform
DTC P2049 diagnosis scan tool.
2. DTC P208E diagnostics 14. Clear the DTC with the trouble diagnosis scan tool.
1. Turn OFF the ignition switch. 15. Turn OFF the ignition switch until communication
2. Disconnect the dosing module harness connector. with the trouble diagnosis scan tool is discontinued.
3. Inspect the dosing module harness connector. 16. Start the engine.
Note： 17. Test run at the specified speed or higher while
・ There should be no water intrusion or adhering Specified value： 190 ℃
foreign material. 18. Observe the DTC information with a trouble
4. If a problem is found, repair the connector. diagnosis scan tool.
5. Disconnect the DCU harness connector. 19. If the applicable DTC is set as a current failure,
replace the DCU.
foreign material. 3. DTC P208E confirm resolution
8. Inspect the injector drive circuit (High) and injector Note：
drive circuit (Low) between the DCU and the dosing ・ After clearing the DCU DTC, observe whether
module for high resistance. ECM DTC P20C9 is set.
9. If a problem is found, repair the injector drive circuit ・ If DTC P20C9 is set, clear it.
(High) or (Low). 2. Turn OFF the ignition switch until communication
10. Remove the dosing module. with the trouble diagnosis scan tool is discontinued.
Devices(4HK1) Dosing module removal". 4. Test run at the specified speed or higher while
11. Inspect the dosing module. observing the exhaust gas temperature 3 value with
Note：
values： 190 ℃ { 374 °F }
・ The dosing module should not be clogged by
crystals adhering to its end. 5. Observe the DTC information with the trouble
・ There should be no damage to or deformation diagnosis scan tool. A DTC should not be set.
of the dosing module unit.
13. Clean or replace the dosing module.
DTC P20A0
1. DTC P20A0 diagnostics Refer to "1.Engine 1H.Aux. Emission Control
connector.
Note：
terminals. 2. DTC P20A0 confirm resolution
foreign material.
8. Inspect the urea fluid reverting valve power supply
circuit between the DCU and the urea fluid supply
resistance.
13. Inspect the urea fluid reverting valve control circuit
between the DCU and the urea fluid supply module.
Note：
as the frame.
control circuit.
DTC P20A2
1. DTC P20A2 diagnostics 16. Inspect the control circuit between the DCU and
reverting valve.
Note：
connector. ・ There should be no short to other GND
circuits.
connector.
as the frame.
Note：
foreign material.
Note：
foreign material.
8. Inspect the urea fluid reverting valve power supply 4. Observe the DTC information with the trouble
resistance.
engine.
DTC P20A3
1. DTC P20A3 diagnostics 16. Inspect the control circuit between the DCU and
reverting valve.
Note：
・ There should be no short to the power supply
connector.
circuit.
Note：
foreign material.
Note：
foreign material.
8. Inspect the urea fluid reverting valve power supply 4. Observe the DTC information with a trouble
resistance.
engine.
DTC P20AC
1. DTC P20AC priority DTC 13. If a problem is found, repair the urea fluid pump
control circuit.
DTC P208A
14. If the control circuit is normal, replace the urea fluid
DTC P208C
supply module.
DTC P208D
2. DTC P20AC diagnostics Devices(4HK1) DEF supply module removal".
connector. 15. Clear the DTC with the trouble diagnosis scan tool.
3. Inspect the urea fluid supply module harness 16. Turn OFF the ignition switch until communication
connector. with the trouble diagnosis scan tool is discontinued.
poor connections, or corrosion for any of the 18. Observe the DTC information with a trouble
terminals. diagnosis scan tool.
19. If the DTC is set, turn OFF the ignition switch.
・ There should be no water intrusion or adhering 20. Replace the DCU.
4. If a problem is found, repair the connector. Devices(4HK1) DCU removal".
5. Disconnect the DCU harness connector. Refer to "1.Engine 1H.Aux. Emission Control
3. DTC P20AC confirm resolution
Note：
・ There should be no water intrusion or adhering ・ After clearing the DCU DTC, observe whether
foreign material. ECM DTC P20C9 is set.
7. If a problem is found, repair the connector. ・ If DTC P20C9 is set, clear it.
8. Inspect the urea fluid pump power supply circuit 2. Turn OFF the ignition switch until communication
between the DCU and the urea fluid supply module with the trouble diagnosis scan tool is discontinued.
for an open circuit or high resistance. 3. Turn ON the ignition switch without starting the
9. If a problem is found, repair the pump power supply engine.
circuit. 4. Observe the DTC information with the trouble
10. Inspect the GND circuit between the DCU and the diagnosis scan tool. A DTC should not be set.
12. Inspect the urea fluid pump control circuit between
the DCU and the urea fluid supply module for
abnormal harness appearances.
Note：
・ There should be no damage, deformation, etc.
DTC P20AD
1. DTC P20AD priority DTC Refer to "1.Engine 1H.Aux. Emission Control
3. DTC P20AD confirm resolution
2. DTC P20AD diagnostics
supply module.
connector.
Note：
・ There should be no intermittent conditions, temperature are all the specified value or less, and
poor connections, or corrosion. start the engine.
foreign material.
Note：
・ If the reading is not within the specified
6. Turn ON the ignition switch. requirements, soak until it is.
7. Connect a test lamp between the urea fluid supply 4. Observe the DTC information with the trouble
module power supply circuit and the DCU harness diagnosis scan tool. A DTC should not be set.
GND connection.
module power supply circuit.
module GND circuit.
supply module.
DTC P20B1
connector.
15. If the test lamp does not illuminate or turn OFF in
accordance with the urea fluid tank heater coolant
Note： control valve being turned ON or OFF with the
・ There should be no intermittent conditions, Actuator Test, replace the DCU.
poor connections, or corrosion for any of the Refer to "1.Engine 1H.Aux. Emission Control
terminals. Devices(4HK1) DCU removal".
foreign material. 2. DTC P20B1 confirm resolution
5. Disconnect the DCU harness connector. Note：

Note：・ If DTC P20C9 is set, clear it.
foreign material. 3. Turn ON the ignition switch without starting the
engine.
8. Inspect the power supply circuit between the DCU diagnosis scan tool. A DTC should not be set.
high resistance.
circuit.
Note：
as the frame.
resistance.
12. Connect a test lamp between the coolant control
valve power supply circuit and the control circuit.
13. Perform Urea Fluid Tank Heater Coolant Control
Valve under Actuator Test.
14. If the test lamp illuminates/turns OFF in accordance
with the ON/OFF commands, replace the coolant
control valve.
DTC P20B3
connector. 16. Replace the DCU.
3. Inspect the coolant control valve harness connector. Refer to "1.Engine 1H.Aux. Emission Control
Note：
terminals. 2. DTC P20B3 confirm resolution
foreign material.
8. Inspect the power supply circuit between the DCU
high resistance.
circuit.
Note：
as the frame.
engine.
DTC P20B4
1. DTC P20B4 diagnostics Note：
connector.
Note：
foreign material.
engine.
coolant control valve for a short to the battery or a
Note：
foreign material.
2. DTC P20B4 confirm resolution
DTC P20E8
DTC P204B
DTC P204C
DTC P204D
DTC P208B supply module and the urea fluid tank.
DTC P208E Note：
DTC P20A0 ・ There should be no clogging caused by
DTC P20A2
・ There should be no clogging caused by foreign
DTC P20A3 material.
2. DTC P20E8 diagnostics ・ There should be no clogging caused by urea
fluid freezing.
1. Inspect for urea fluid leakage.
Note： fluid piping that differ from the specified layout.
・ There should be no leakage from the urea fluid 6. If a problem is found, repair or replace.
piping between the urea fluid supply module
and dosing module. 7. Inspect the urea fluid sensor.
・ There should be no leakage from the urea fluid Note：
piping between the urea fluid tank and urea ・ There should be no clogging caused by
fluid supply module. bending of the breather hose or foreign
・ There should be no leakage from the urea fluid material.
piping connection. ・ There should be no clogging caused by
・ There should be no leakage from the urea fluid bending of the suction line or foreign material.
supply module unit. ・ There should be no clogging caused by urea
・ There should be no leakage from the dosing fluid freezing.
module unit.
8. If a problem is found, clean or replace the urea fluid
2. If a problem is found, repair or replace. sensor.
Devices(4HK1) DEF supply module removal". Devices(4HK1) DEF sensor removal".
Devices(4HK1) DEF supply module installation". Devices(4HK1) DEF sensor installation".
Refer to "1.Engine 1H.Aux. Emission Control 9. Inspect for floating substances such as foreign
Devices(4HK1) Dosing module removal". material in the urea fluid tank which may cause
Refer to "1.Engine 1H.Aux. Emission Control clogging of the filter.
Devices(4HK1) Dosing module installation". 10. If a problem is found, clean the inside of the urea
Note： fluid tank and replace the urea fluid.
・ When the dosing module is replaced, perform 11. Turn OFF the ignition switch.
Dosing module data reset with the trouble 12. Disconnect the urea fluid supply module harness
diagnosis scan tool. connector.
3. There should be no clogging of the supply module 13. Inspect the urea fluid supply module harness
filter. connector.
4. If a problem is found, replace the supply module Note：
filter.

foreign material.
Note：
foreign material.
for high resistance.
3. DTC P20E8 confirm resolution
Note：
engine.
tool.
5. Check whether the urea fluid pressure is more than
or equal to the specified value with the trouble
DTC P20E9
DTC P204B
DTC P204C
DTC P204D
connector.
DTC P208B
2. DTC P20E9 diagnostics connector.
1. Inspect the backflow piping between the urea fluid Note：
supply module and the urea fluid tank. ・ There should be no intermittent conditions,
Note： poor connections, or corrosion.
・ There should be no clogging caused by ・ There should be no water intrusion or adhering
twisting or bending. foreign material.
・ There should be no clogging caused by foreign 10. If a problem is found, repair the connector.
material.
fluid freezing. 12. Inspect each circuit between the DCU and the urea
fluid piping that differ from the specified layout. Note：
Caution：・ There should be no open circuit, breakage, or
high resistance.
on the urea fluid supply module. ・ There should be no short circuit or improper
modification.
Note：
Note：
twisting or bending. ・ There should be no intermittent conditions,
fluid freezing. ・ There should be no water intrusion or adhering
foreign material.
Devices(4HK1) DEF sensor removal". 16. Replace the urea fluid supply module.
Devices(4HK1) DEF sensor installation". Devices(4HK1) DEF supply module removal".
supply module. Devices(4HK1) DEF supply module installation".
Note： 3. DTC P20E9 confirm resolution

・ The check valve should not be clogged or 1. Clear the DTC with the trouble diagnosis scan tool.
stuck closed.
Note：
6. If a problem is found, repair the backflow connector. ・ If DTC P20C9 is set, clear it.
Refer to "1.Engine 1H.Aux. Emission Control 2. Turn OFF the ignition switch until communication
Devices(4HK1) DEF supply module disassembly". with the trouble diagnosis scan tool is discontinued.
engine.
tool.
DTC P20EA
1. DTC P20EA priority DTC 9. Inspect each circuit between the DCU and the urea
DTC P204B
・There should be no open circuit, breakage, or high
DTC P204C
resistance.
DTC P204D ・There should be no short circuit.
DTC P208B 10. If a problem is found, repair the applicable circuit.
DTC P20A0 11. Perform Reverting Valve under Actuator Test with
the trouble diagnosis scan tool to check if the
DTC P20A2
reverting valve is stuck.
DTC P20A3
2. DTC P20EA diagnostics
1. If there are DTCs that were set at the same time, treat Devices(4HK1) DEF supply module removal".
those first.
Note： Devices(4HK1) DEF supply module installation".
・ If a DTC other than DTC P20EA is not set, 3. DTC P20EA confirm resolution
perform the diagnosis for DTC P1464 first.
2. There should be no damage to or clogging of the
supply module filter. 2. Turn OFF the ignition switch until communication
filter. 3. Turn ON the ignition switch without starting the
engine.
Devices(4HK1) DEF supply module filter removal". 4. Observe the DTC information with the trouble
Caution：
on the urea fluid supply module.
・There should be no clogging caused by twisting or
bending.
・There should be no clogging caused by foreign
material.
・There should be no layout in the urea fluid piping that
differs from the specified layout.
・There should be no clogging caused by urea fluid
freezing.
supply module.
DTC P20FE
1. DTC P20FE priority DTC 7. Replace the suction hose between the urea fluid
supply module and the urea fluid tank with a clear
DTC P204B
hose.
DTC P204C
Caution：
DTC P204D ・ The clamp should be installed to the hose.
DTC P208B 8. Clear the DTC with the trouble diagnosis scan tool.
DTC P208E 9. Turn OFF the ignition switch until communication
DTC P20A0 with the trouble diagnosis scan tool is discontinued.
DTC P20A2 10. Start the engine.
DTC P20A3 11. Check for the intrusion of air.
2. DTC P20FE diagnostics 12. If air intrusion is found, replace the urea fluid sensor.
1. There should be no damage to or clogging of the Refer to "1.Engine 1H.Aux. Emission Control
supply module filter. Devices(4HK1) DEF sensor removal".
2. If a problem is found, replace the supply module Refer to "1.Engine 1H.Aux. Emission Control
filter. Devices(4HK1) DEF sensor installation".
Refer to "1.Engine 1H.Aux. Emission Control 13. Inspect the DCU system.
Devices(4HK1) DEF supply module filter removal". ・There should be no clogging caused by bending of the
Refer to "1.Engine 1H.Aux. Emission Control sensor tube of the urea fluid tank level sensor in the tank,
Devices(4HK1) DEF supply module filter installation". and no malfunctions caused by the float being at an angle.
・There should be no layout of the urea fluid tank and
Caution： urea fluid supply module which differs from the specified
・ Do not blow air onto the urea fluid connector layout.
on the urea fluid supply module. ・There should be no damage to or clogging of the supply
3. Inspect the suction piping between the urea fluid module filter.
supply module and the urea fluid tank. ・There should be no clogging of the urea fluid quality
sensor strainer.
・There should be no clogging caused by twisting or ・There should be no freezing of the urea fluid suction
bending. line, pressure line, inside the tank, or in the coolant
・There should be no clogging caused by foreign piping.
material. ・There should be no clogging of the urea fluid tank vent
・There should be no layout in the urea fluid piping that hose.
differs from the specified layout. ・The reverting valve should not be stuck in the normal
・There should be no clogging caused by urea fluid position.
freezing. ・The dosing module should not remain open.
・There should be no poor connections at the urea fluid ・There should be no leakage from the urea fluid piping,
supply module inlet connector section. urea fluid supply module, or dosing module.
4. If a problem is found, repair or replace. ・There should be no damage to or clogging caused by
5. Check whether or not the urea fluid supply module module and the dosing module, and no layout which
inlet connector remains closed. differs from the specified layout.
6. If a problem is found, replace the urea fluid supply ・There should be no damage to or clogging caused by
module. twisting of the suction line between the urea fluid supply
module and the tank, and no layout which differs from
Refer to "1.Engine 1H.Aux. Emission Control the specified layout.
Devices(4HK1) DEF supply module removal". ・There should be no damage to or clogging caused by
Refer to "1.Engine 1H.Aux. Emission Control twisting of the urea fluid sensor suction piping, and no
Devices(4HK1) DEF supply module installation". layout that differs from the specified layout.
・The one-way valve of the backflow connector should
not remain open.
・There should be no clogging of the urea fluid supply
Caution：
・ Do not blow air onto the urea fluid supply
module.
14. If a problem is found, repair or replace the applicable
area.
connector.
fluid supply module for high resistance.
3. DTC P20FE confirm resolution
Note：
4. Observe the urea fluid pressure display on the
values： 860 to 940 kPa { 125 to 136 psi }
DTC P2201
DTC P2206
DTC P2207
1. Inspect NOx sensor 1.
・There should be no improper installation of NOx sensor
1.
・There should be no damage to or clogging of the NOx
sensor 1.
・There should be no exhaust gas leakage from the
exhaust pipe.
・There should be no damage caused by crushing of the
exhaust system.
2. If a problem is found, replace NOx sensor 1.
Note：
sensor 1 data reset with the trouble diagnosis
scan tool.
Note：
engine.
DTC P2206
Note：
scan tool.
Note：
DTC P2207
Note：
scan tool.
Note：
DTC P2210
Reading the error(open) information detected by Rr NOx sensor
Note：
scan tool.
Note：
DTC P2211
Reading the error(short) information detected by Rr NOx sensor
Note：
scan tool.
Note：
DTC P242B
1. DTC P242B priority DTC
DTC P242C
DTC P242D
2. Inspect the installation status of EGT sensor 3.
3. If a problem is found, repair the installation status of
EGT sensor 3.
4. Disconnect the harness connector from EGT sensor
3.
5. Inspect for poor connections at the EGT sensor 3
harness connector.
connector.
8. Inspect each circuit between the DCU and EGT
sensor 3 for high resistance.
9. If a problem is found, repair the circuit or
connections.
3 removal".
3 installation".
Note：
engine.
DTC P242C
1. DTC P242C diagnostics 14. Replace the DCU.
2. Disconnect the EGT sensor 3 harness connector.
Note：
poor connections, or corrosion. 1. Clear the DTC with the trouble diagnosis scan tool.
4. If a problem is found, repair the connector. ECM DTC P20C9 is set.
engine. 2. Turn OFF the ignition switch until communication
diagnosis scan tool. 3. Turn ON the ignition switch without starting the
engine.
7. If DTC P242D is set but P242C is not set, replace
EGT sensor 3. 4. Observe the DTC information with the trouble
3 removal".
3 installation".
8. Inspect the signal circuit between the DCU and EGT
sensor 3.
Note：
as the frame.
Note：
foreign material.
DTC P242D
1. DTC P242D diagnostics 15. Turn OFF the ignition switch.
1. Turn OFF the ignition switch. 16. Disconnect the DCU harness connector.
2. Disconnect the EGT sensor 3 harness connector. 17. Inspect the DCU harness connector.
4. Measure the voltage between the signal circuit and ・ There should be no intermittent conditions,
the DCU harness GND connection. poor connections, or corrosion.
values： 5.2 V
foreign material.
and EGT sensor 3 for a short to the battery or a short 19. Replace the DCU.
to the ignition power supply.
・ EGT sensor 3 may be damaged if the sensor Refer to "1.Engine 1H.Aux. Emission Control
signal circuit is shorted to the power supply. Devices(4HK1) DCU installation".
6. If a problem is found, repair the signal circuit. 2. DTC P242D confirm resolution
and EGT sensor 3 for an open circuit or high Note：
resistance. ・ After clearing the DCU DTC, observe whether
the GND circuit. 2. Turn OFF the ignition switch until communication
values： 4.6 V
10. If the reading is less than or equal to the specified engine.
EGT sensor 3 for an open circuit or high resistance. 4. Observe the DTC information with the trouble
Note：
foreign material.
3 removal".
3 installation".
DTC U0002
CAN Bus Off
1. DTC U0002 diagnostics 22. If the resistance of the termination resistor exceeds
Note：
・ The applicable DTC may be set after CSP 23. If a DTC is set, inspect the CAN Low and CAN
work. If the applicable DTC is set after CSP High circuits.
work, simply clear the DTC because it is not a Note：
malfunction of the machine.
・ There should be no short to the battery power
1. Disconnect the harness connector from the ECM. supply or ignition power supply circuit.
2. Inspect the ECM harness connector. ・ There should be no high resistance.
・ There should be no short together between
CAN circuits.
4. Observe the DTC information with the trouble ・ There should be no short to the GND circuit.
・ There should be no short to a metal
5. If a DTC is not set, replace the ECM. component, such as the frame.
Refer to "1.Engine 1J.Electrical(4HK1) 24. If a problem is found, repair the CAN circuit.
ECM removal".
25. If the CAN circuit is normal, inspect the DCU
Refer to "1.Engine 1J.Electrical(4HK1) harness connector.
ECM installation".
Note：
6. Set the Injector ID Code and engine No. for the ・ There should be no intermittent conditions,
ECM. poor connections, or corrosion.
7. Perform SCR purging with a trouble diagnosis scan ・ There should be no water intrusion or adhering
tool. foreign material.
8. Turn OFF the ignition switch. 26. Replace the DCU.
9. Connect the harness connector to the ECM. Refer to "1.Engine 1H.Aux. Emission Control
10. Disconnect the harness connector from the control
unit of the machine. Refer to "1.Engine 1H.Aux. Emission Control
11. Inspect the machine control unit harness connector.
diagnosis scan tool. Note：
14. If a DTC is not set, replace the control unit of the ・ After clearing the DCU DTC, observe whether
machine. ECM DTC P20C9 is set.
15. Connect the harness connector to the control unit of ・ If DTC P20C9 is set, clear it.
the machine. 2. Turn OFF the ignition switch until communication
termination resistor if a DTC is set.
20. Inspect the terminal resistor harness connector.
DTC U0100
1. DTC U0100 diagnostics Note：
Note：・ There should be no short to the battery power
supply or ignition power supply circuit.
・ The applicable DTC may be set after CSP
work. If the applicable DTC is set after CSP ・ There should be no high resistance.
work, simply clear the DTC because it is not a ・ There should be no short together between
malfunction of the machine. CAN circuits.
1. Turn OFF the ignition switch. ・ There should be no short to the GND circuit.
・ There should be no short to a metal
2. Disconnect the ECM harness connector.
component, such as the frame.
4. Inspect the CAN High circuit between the DCU and
breakage. Refer to "1.Engine 1J.Electrical(4HK1)
ECM removal".
6. Inspect the CAN Low circuit between the DCU and
ECM installation".
breakage. 18. Set the Injector ID Code and engine No. on the
ECM.
8. Inspect the ECM harness connector.
tool.
Note：
poor connections, or corrosion. Refer to "1.Engine 1H.Aux. Emission Control
Note：
・ There should be no intermittent conditions, Note：
poor connections, or corrosion. ・ After clearing the DCU DTC, observe whether
・ There should be no water intrusion or adhering ECM DTC P20C9 is set.
foreign material. ・ If DTC P20C9 is set, clear it.
diagnosis scan tool. If a DTC is set, disconnect the 3. Start the engine.
harness connector from the termination resistor.
13. Measure the resistance of the termination resistor. diagnosis scan tool. A DTC should not be set.
14. If the resistance of the termination resistor exceeds
diagnosis scan tool. If a DTC is set, inspect the CAN
High and CAN Low circuits.
DTC U029D
1. DTC U029D diagnostics Diagnosis when DTCs P1462, U029D, and U029E are set
at the same time
1. Check if DTCs P1462, U029D, and U029E are set at
the same time, and go to each diagnosis. 14. Inspect NOx sensor 1 and NOx sensor 2 power
supply circuits.
Diagnosis when DTC U029D is set independently.
Note：
3. Disconnect the NOx sensor 1 harness connector. high resistance.
4. Inspect the NOx sensor 1 harness connector. ・ There should be no short to the GND circuit.
Note：・ There should be no short to a metal
component, such as the frame.
poor connections, or corrosion. 15. If a problem is found, repair the NOx sensor 1 or
・ There should be no water intrusion or adhering NOx sensor 2 power supply circuit.
foreign material. 16. Inspect the following NOx sensor GND circuit.
5. If a problem is found, repair the connector. ・Between the NOx sensor 1 and the DCU harness GND
6. Inspect the NOx sensor 1 power supply circuit for an connection
open circuit or breakage. ・Between the NOx sensor 2 and the DCU harness GND
connection
7. If a problem is found, repair the NOx sensor 1 power
supply circuit. Note：
8. Connect a test lamp between the power supply ・ There should be no open circuit, breakage, or
circuit and the GND circuit. high resistance.
17. If a problem is found, repair the NOx sensor 1 or
NOx sensor 2 GND circuit.
circuit or high resistance in the NOx sensor 1 GND
circuit. 18. Inspect the urea fluid sensor power supply circuit.
10. Turn ON the ignition switch without starting the Note：
engine. ・ There should be no open circuit, breakage, or
11. Measure the voltage between the CAN Low circuit high resistance.
and the DCU harness GND connection, and between ・ There should be no short to the GND circuit.
the CAN High circuit and the DCU harness GND ・ There should be no short to a metal
connection. component, such as the frame.
values： 1.5 to 3.5 V 19. If a problem is found, repair the urea fluid sensor
12. If the voltage is outside the specified range, repair power supply circuit.
the open circuit or high resistance between the CAN 20. Inspect the urea fluid sensor GND circuit between
High terminal and the CAN Low terminal on NOx the urea fluid sensor and the DCU harness GND
sensor 1 and in the joint connector. connection.
13. Replace NOx sensor 1. Note：
Refer to "1.Engine 1H.Aux. Emission Control ・ There should be no open circuit, breakage, or
Devices(4HK1) NOx sensor removal". high resistance.
Refer to "1.Engine 1H.Aux. Emission Control 21. If a problem is found, repair the urea fluid sensor
Devices(4HK1) NOx sensor installation". GND circuit.
Note： 22. Turn OFF the ignition switch.
・ If NOx sensor 1 is replaced, perform NOx 23. Disconnect the urea fluid sensor harness connector.
scan tool. 24. Observe the DTC information with a trouble
25. If DTC P1462 is set but U029D and U092E are not 37. If the resistance of the termination resistor is within
set, inspect the urea fluid sensor harness connector. the specified range, inspect the DCU, joint
connector, CAN circuit between the termination
Note：
resistors, and CAN jumper wire for an open circuit
・ There should be no intermittent conditions, or high resistance.
foreign material. 39. If the resistance between the CAN Low and High
circuits is less than or equal to the specified value,
disconnect the NOx sensor 1 and NOx sensor 2
27. Replace the urea fluid sensor. harness connectors and check the resistance.
Refer to "1.Engine 1H.Aux. Emission Control values： 55 to 65 Ω
Refer to "1.Engine 1H.Aux. Emission Control the NOx sensor 1 and NOx sensor 2 harness
Devices(4HK1) DEF sensor installation". connectors.
28. Disconnect the NOx sensor 2 harness connector. Note：
29. Observe the DTC information with a trouble ・ There should be no intermittent conditions,
diagnosis scan tool. poor connections, or corrosion.
30. If DTC U029E is set but P1462 and U029D are not ・ There should be no water intrusion or adhering
set, inspect the NOx sensor 2 harness connector. foreign material.
Note：
・ There should be no intermittent conditions, 42. Replace NOx sensor 1.
poor connections, or corrosion. Refer to "1.Engine 1H.Aux. Emission Control
・ There should be no water intrusion or adhering Devices(4HK1) NOx sensor removal".
foreign material.
31. If a problem is found, repair the connector. Devices(4HK1) NOx sensor installation".
32. Replace NOx sensor 2. Note：
Refer to "1.Engine 1H.Aux. Emission Control ・ If NOx sensor 1 is replaced, perform NOx
Devices(4HK1) NOx sensor removal". sensor 1 data reset with the trouble diagnosis
scan tool.
Devices(4HK1) NOx sensor installation". 43. If the resistance is outside the specified range,
disconnect the DCU harness connector and check the
Note： resistance of the DMM.
scan tool. 44. If the resistance is outside the specified range, repair
the short together in the CAN circuits between the
33. If DTCs P1462, U029D, and U029E are set, turn the
DCU, NOx sensor, urea fluid sensor, and termination
ignition switch OFF until communication with the
resistors.
trouble diagnostic scan tool is discontinued.
34. Measure the resistance between the CAN Low and
the DCU harness connector.
CAN High circuits.
values： 55 to 65 Ω Note：
35. If the resistance between the CAN Low and High poor connections, or corrosion.
circuits is more than or equal to the specified value,
measure the resistance of the termination resistor. ・ There should be no water intrusion or adhering
foreign material.
36. If the resistance of the termination resistor is outside
2. DTC U029D confirm resolution
Note：
DTC U029E
CAN communication error between DCU and Rr NOx sensor
1. DTC U029E priority DTC 3. DTC U029E confirm resolution
DTC P1462 1. Clear the DTC with a trouble diagnosis scan tool.
DTC U029D Note：
2. DTC U029E diagnostics ・ After clearing the DCU DTC, observe whether
2. Disconnect the NOx sensor 2 harness connector.
3. Inspect the NOx sensor 2 harness connector. with the trouble diagnosis scan tool is discontinued.
Note： 3. Start the engine.
・ There should be no intermittent conditions, 4. Observe the DTC information with a trouble
foreign material.
5. Inspect the NOx sensor 2 power supply circuit for an
open circuit or breakage.
6. If a problem is found, repair the NOx sensor 2 power
supply circuit.
circuit or high resistance in the NOx sensor 2 GND
circuit.
engine.
connection.
11. If the voltage is outside the specified range, repair
the open circuit or high resistance between the CAN
High terminal and the CAN Low terminal on NOx
sensor 2 and in the joint connector.
Note：
scan tool.
Wiring Diagram 1
Wiring Diagram
Table of Contents
Using the ETM...................................................................... 3
Engine ................................................................................. 11
Location Diagram ............................................................... 17
Connector List..................................................................... 21
Terminal Name.................................................................... 27
Using the ETM
Structure and Content of This Document ············································ 4
1. Wiring Diagram ··························································································· 5
2. Location Diagram / 3. Connector Information /
4. Terminal Name ······················································································· 8
5. Circuit Symbols ·························································································· 9
6. Abbreviations ··························································································· 10
3
Using the ETM…Structure and Content of This Document
Using the ETM

Structure and Content of This Document
1. Wiring Diagram…………………Includes from the parts installed on the engine to the connectors used for inputting
and outputting control signals.
2. Location Diagram………………Includes the positions of connectors used at each part of the engine.
3. Connector Information…………The connector information includes connector shape, terminal position and connector color, if it is other
than milky white color.
4. Terminal Name…………………Includes the circuits that correlate to each terminal of the parts.
5. Circuit Symbols
6. Abbreviations
4
Using the ETM…1. Wiring Diagram
1. Wiring Diagram Example:
When 2 colors such as “Y/B” are indicated,
(1) Wiring information
it means wiring of yellow base with black line.
The wire size and wiring colors are described.
The wiring colors are described using color indications
and color symbols.
Symbol Color Symbol Color Y / B
B Black BR Brown (Yellow) (Black)
W White LG Light green
R Red GY Gray
G Green P Pink B 13 A 31 B 5
Y Yellow SB Sky blue
Color
L Blue V Violet
display
O Orange T Tan Wire size
1.25
BR/W
0.5 Y/B
Wire Size Table
0.85 O/L
Symbol
Nominal size Calculated area Outside diameter
(mm2) (mm)
0.3 0.372 1.8 (2) Connection symbols between pages
0.5 0.563 2.0 The symbols indicate that the wiring with the same symbol
is connecting from the previous page to the next page.
0.85 0.885 2.2
1.25 1.287 2.5 Previous page Next page
2 2.091 2.9
0.5 V/W 0.5 V/W
3 3.296 3.6 A A
5 5.227 4.4
8 7.952 5.5 0.3 Y 0.3 Y
B B
15 13.36 7.0
20 20.61 8.2
(3) Connection symbols within a page
The symbol indicates that it is connecting to the same symbol
within the page.
Within a page
0.3 LG 0.3 LG
1 1
5
(4) Connector
(a) Connector number (b) Inline connector
When multiple wires which are connected to equipment Connectors that are connecting wires are indicated.
(a component) exist within the same connector, “ ” indicates the female connector, and “ ”
the connector number is indicated either inside or indicates the male connector.
outside the equipment, and the corresponding terminal On the wiring diagram, when connectors are linked with
position is indicated next to each wire. a dashed line ( ), it means that they are the same
Connector number
connector.
Barometric pressure
sensor B121
0.5 LG/R
0.5 LG/R
3 2 1 H23 12 1
Terminal position
0.5 G
0.5 L
0.5 W/R
0.5 LG/R
0.5 LG/R
When multiple connectors are connected to a component,

each connector number is expressed on the wiring diagram
with a replacing simplified symbol. (c) Connector shape and terminal shape
• Female connector
Example:
…indicates that the terminals are female.
“A: J14” means that J14 connector is described using the
simplified symbol of “A”. • Male connector
…indicates that the terminals are male.
Housing
0.5 G
0.5 O/G
0.5 G/O
A 35 A 28 B 21
Simplified symbol
Terminal position
㸿㸸㹈14
㹀㸸㹃12 ECM
Female terminal Male terminal

Connector number replacement indication Female connector Male connector
6
(d) Joint connector (6) Wiring not described
A connector in which multiple terminals are collectively This document describes connections between engine wire
connected using joint terminals is indicated. harness and each component.
Alphabets indicate jointed groups (collectively connected Therefore, connections made between components without
terminals). mediating the engine wire harness are not described.
A
Engine wire harness
0.5 LG
A A A A B B
J/C
C C C D D B
B388
A
0.5 LG
The connection between components A and B
is not described.
(5) Component
A component is represented as a frame (yellow inside), and the
name of component is indicated either inside or outside the frame.
0.5B
0.5R
1 2
J35
Water temperature sensor
7
Using the ETM…2. Location Diagram / 3. Connector Information / 4. Terminal Name
2. Location Diagram 4. Terminal Name
The positional information of connectors is displayed. Includes the circuits that correlate to each terminal of the parts.
T3
T19 H6
T18 H7 Pin No. Pin name
T17
T9 1 Engine coolant temperature sensor GND
T16
T7 2 Engine coolant temperature sensor signal
T10
T1 3 Engine coolant temperature sensor OEM meter
T11 T5
T3
T8 Pin No. Pin name
T6 1 Oil pressure sensor GND
T4
T13 2 Oil pressure sensor signal
3 Oil pressure sensor power source
T14
T5
3. Connector Information
The information for connector shape, terminal position
and connector color (except for milky white color) is displayed.
1 2 3 4
5 6 7 8 9 10
Brown
8
Using the ETM…5. Circuit Symbols
5. Circuit Symbols
Meaning of symbol Symbol Meaning of symbol Symbol Meaning of symbol Symbol
Battery Resistor Shield
Fuse Buzzer Ground
Slow blow M
Connection
Motor A A
fuse between pages
Fusible link Pressure Connection

1 1
(wire) sensor, etc. within a page
Circuit Temperature
breaker sensor
Relay Pulse sensor
Other sensors,
Switch
etc.
Inline
Reed switch connector
Joint
connector,
Diode
junction
block
Light emitting Joint

diode
joint no joint
Single filament Pair

bulb
Solenoid valve,
Magnetic valve, Twisted pair
etc.
9
Using the ETM…6. Abbreviations
6. Abbreviations
The following abbreviations are used in this wiring diagram.
Abbreviations Explanation
# Cylinder or number indication
C/B Circuit Breaker
Fr Front
INJ Injector
J/C Joint Connector
L/H Left Hand
R/H Right Hand
Rr Rear
SW Switch
VSV Vacuum Switching Valve
10
Engine
Engine Control ······························································································ 12
Engine Control ·································································································12
* Refer to the sections of the workshop manual for emission

control.
11
12V
Battery
Battery Battery
24V Glow relay
H5
5 B/W
1
1
Glow plug
T1
Engine Control…Engine Control
Starter
Starter relay
V74
Starter cut relay
V91
H4
H7
H6
0.75 W 1.25 B/W

E43 V76
8
5
INJ#1
0.75 G 1.25 L
E23 V82
4
1
2
5
T16
0.75 W INJ#4 0.75 B 1.25 W/B
E24
2
3
1
T19
ON
ST
ACC
0.75 W 1.25 R
7 E02
8
Ignition switch
0.75 R 1.25 B
E04 V1
OFF
3
5
7
S2 ECM
S1
INJ#3
0.75 Y 1.25 W/L
E44 V3
1
2
7
1
T18
INJ#2
0.75 R 0.75 L 1.25 B/R
E45 V5
2
6
1
12
T17
Main relay
0.75 R 1.25 L/R
E03 V72
6
2
16
Hour meter relay
V40
V57
A
( Specifications vary depending on each machine. Refer to the machine’s manual.)
12
A
H4
0.75 B/W
E71
14
E84
0.5 Y
E69
H4
0.75 R/B
3
20
E105
17
1
0.5 T
E99
1
19
E42
CMP sensor
T14
0.5 O/B
Suction control valve
E49
0.75 R/W
2
18
E63
13
T12
H1
0.5 BR
1
17
Engine stop switch

0.5 L/W V50
E16
2
10
Idling selector switch
Fuel pressure sensor

0.5 L V87
3
5
T6
Idle up switch
0.75 B/W V71
E73
14
Idle down switch

V47
ECM
V37
1
S2
S1
Mode map switch 0

V65
V88
3
Mode map switch 1
V70
V36
2
Mode map switch 2
MAF sensor/IAT sensor

V61
V29
4
Reguration mode switch
V68
5
S6
Air cleaner switch
V46
H2
0.75 R
V21
2
16
Load advance switch
V86
0.75 B
V11
Charge air cooler

1
temprerature sensor
15
T24
Exhaust gas
V18
temperature sensor 1
S3
13
B
H2
0.75 W/R
E93
8
8
Diagnosis lamp
V39
0.75 W/B
M
E92
7
7
Oil pressure lamp

V55
0.75 W/L
E91
6
6
Glow lamp
V89
0.75 L
E26
1
1
Reduced engine power indicator light

V54
0.75 G/B
E53
4
4
Over heat lamp

V90
0.75 G/W
EGR DC motor/EGR position sensor
E54
3
3
Engine over run lamp

V38
0.75 G/Y
E55
2
2
DEF injection system warning light

E75
0.75 L/W
E59
5
5
DEF warning light (REFILL DEF)
T10
E76
ECM
H1
0.75 W/B
S2
S1
Exhaust system warning light
3
30 E80
0.75 L/Y
E17
2
Abnormal DEF quality warning light (EXH. SYSTEM)
25
E94
Oil pressure sensor

0.75 B/Y
1
20
T5
0.75 Y/G
E20
2
31
0.75 R/L
1
13

T13
V27
V30
0.5 V/W
E5
3
1
V9
0.5 GY/B
E78
CKP sensor
0.5 W/B V15

E48
2
15
T15
V58
0.75 B
E74
11
14
Exhaust gas
Fuel filter pressure sensor temperature sensor 2
S9 S4
1 3 2
V16
V17
V35
V19
S1
ECM S2
E12
E68
E11
E50
E10
E90
E89
E39
E18
E15
E14
meter
Engine
coolant
temprerature
H1 9 29 24 19 H1 16 3 8 7 2
H3 8 14 11 13 12 H2 12 11 9 10
0.75 B/Y
0.75 R/B
0.75 R
0.5 L
0.5 V/W
0.5 L/W
0.5 R/W
0.5 G
0.75 B/R
0.75 R/W
0.75 L
0.75 R/L
0.75 W/R
0.75 G/Y
0.75 B/R
0.75 L/R
0.75 R/W
0.75 B/W
1 2 3
T3
4 3 1 2 2 4 3 5 6 2 1 2 1 2 1
T7 T8 Engine coolant T9 T23 T22
M temperature sensor
Boost temperature sensor/Boost pressure sensor Intake throttle position sensor/Intake throttle motor IMT sensor EGR gas EGR gas
temperature sensor 2 temperature sensor 1
15
GND
POWER
13 14 Turbo control unit 16 15
S8
4 8 1 2 3 5 10 11 12
H3 9 10 6 5 4 7 3 2 1
0.5 L/W
0.5 BR
0.5 L
0.75 B
0.75 R
0.75 B/W
0.75 G/R
0.75 Y/R
0.75 L/R
DCU
5 1 4 3 2 8 7 6
T2
M
Turbo actuator
V64
V81
S1
ECM S2
V60
V77
V52
V75
V41
V42
V2
V4
V6
V23
V7
V44
lamp
Tacho
meter
Overheat
Machine
control unit
Diagnosis switch
H1 4
7
3
6
12
11
14
4
5
0.75 G
DLC
1
T4
Overheat switch
16
Location Diagram
Connector Location Diagram ·································································· 18
17
Location Diagram…Connector Location Diagram
T19
T18 T9
T17 T23
H6
T16 H7
T10
T1
T7
T3
T8
T6
T4
T13
T14
T5
18
Location Diagram…Connector Location Diagram
T24
T22
T12
T15
T2
H1
H2
H3
H4
H5
19
MEMO
Connector List
H（Connector List） ···················································································· 22
S（Connector List） ···················································································· 23
T（Connector List）····················································································· 25
21
H…（Connector List）
H1 H2 H3 H4
1 2 3 4 5 5 4 3 2 1 3 2 1
1 2 3 4 4 3 2 1 1 2 3
6 7 8 9 10 10 9 8 7 6 1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5 7 6 5 4
4 5 6 7
11 12 13 14 14 13 12 11 10 9 8 5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9 8 9 10
15 16 17 17 16 15 14 13 12 11 9 10 11 12 12 11 10 9
13 14 15 16 16 15 14 13 11 12 13 14
18 19 20 21 22 22 21 20 19 18 13 14 15 16 16 15 14 13
23 24 25 26 27 27 26 25 24 23
17 18 19 20 20 19 18 17
28 29 30 31 32 32 31 30 29 28 Gray Gray
Gray
Gray
H5 H6 H7
1 1 1 2 3 4 4 3 2 1
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5 5 6 7 8 8 7 6 5
Gray
Dark Gray Gray Dark Gray
Gray
22
S…（Connector List）
S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
Black
23
S…（Connector List）
S2 S3 S4 S6
2 1
2 1 1 2 3 4 5
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Black
1 2
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
S8 S9
3 4 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 1 2 3 4
5 6
75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 5 6 7 8
9 10 11 12 1 2
13 14 15 16 3
Black
Black
24
T…（Connector List）
T1 T2 T3 T4 T5 T6
1 2 3 4 1 2 1 2 3 1 2 3
5 6 7 8 3
Black
Dark Brown Gray Black
T7 T8 T9 T10 T12 T13
1 2 3 4
1 2 1 2 3 4 1 2 3 1 2
5 6 7 8
Black
Dark Gray
1 2 3 4 5 6 Light Gray
Dark Brown Dark Green
Black
T14 T15 T16 T17 T18 T19
1 2
1 2 3
Gray
Light Gray
1 2 1 2 1 2 1 2
25
T…（Connector List）
T22 T23 T24
1 2 1 2 1 2
Gray Gray Dark Gray
26
Terminal Name
Terminal Name······························································································· 28
27
Terminal Name
T1 T8 T15
Pin No. Pin name Pin No. Pin name Pin No. Pin name
1 Glow plug power source 1 㸫 1 CKP sensor signal
2 Intake throttle position sensor power supply 2 CKP sensor GND
T2 3 Intake throttle position sensor GND 3 CKP sensor power supply
Pin No. Pin name 4 Intake throttle position sensor signal
1 Turbocharger actuator power source 5 Intake throttle motor drive High T16
2 Turbocharger actuator signal W 6 Intake throttle motor drive Low Pin No. Pin name
3 Turbocharger actuator signal V 1 Injector power source 1, No.1 cylinder
4 Turbocharger actuator signal U T9 2 Injector 1 control, No.1 cylinder
5 Turbocharger actuator GND Pin No. Pin name
6 Turbocharger actuator motor drive W 1 IMT sensor GND T17
7 Turbocharger actuator motor drive V 2 IMT sensor signal Pin No. Pin name
8 Turbocharger actuator motor drive U 1 Injector power source 2, No.2 cylinder
T10 2 Injector 2 control, No.2 cylinder
T3 Pin No. Pin name
Pin No. Pin name 1 EGR position sensor power supply T18
1 Engine coolant temperature sensor GND 2 EGR position sensor signal W Pin No. Pin name
2 Engine coolant temperature sensor signal 3 EGR position sensor signal V 1 Injector power source 2, No.3 cylinder
3 Engine coolant temperature sensor OEM meter 4 EGR position sensor signal U 2 Injector 3 control, No.3 cylinder
5 EGR position sensor GND
T4 6 EGR valve DC servo motor drive W T19
Pin No. Pin name 7 EGR valve DC servo motor drive V Pin No. Pin name
1 Overheat switch signal 8 EGR valve DC servo motor drive U 1 Injector power source 1, No.4 cylinder
2 Injector 4 control, No.4 cylinder
T5 T12
Pin No. Pin name Pin No. Pin name T22
1 Oil pressure sensor GND 1 CMP sensor signal Pin No. Pin name
2 Oil pressure sensor signal 2 CMP sensor GND 1 EGR gas temperature sensor 1 GND
3 Oil pressure sensor power source 3 CMP sensor power source 2 EGR gas temperature sensor 1 signal
T6 T13 T23
Pin No. Pin name Pin No. Pin name Pin No. Pin name
1 FRP sensor GND 1 Fuel temperature sensor GND 1 EGR gas temperature sensor 2 GND
2 FRP sensor signal 2 Fuel temperature sensor signal 2 EGR gas temperature sensor 2 signal
3 FRP sensor power supply
T14 T24
Pin No. Pin name Pin No. Pin name
T7
1 SCV-HI drive 1 Charge air cooler temperature sensor 1 GND
Pin No. Pin name
2 SCV-HI drive 2 Charge air cooler temperature sensor 1 signal
1 Boost pressure sensor signal
2 Boost sensor GND
3 Boost pressure sensor
4 Boost temperature sensor signal
28
Terminal Name
( Speciﬁcations vary depending on each machine. Refer to the machine’s manual.)
S1 S1

1 No. 2 cylinder injector control 34 -
2 No. 3 cylinder injector control 35 -
3 - 36 -
4 - 37 -
5 CKP sensor power supply 38 -
6 - 39 Engine coolant temperature sensor signal
7 - 40 -
8 - 41 -
9 - 42 SCV-LO drive
10 Intake throttle position sensor signal 43 No. 1 cylinder injector control
11 Boost pressure sensor signal 44 -
12 Boost temperature sensor signal 45 -
13 - 46 Injector power supply 2 (No. 4 cylinder )
14 EGR gas temperature sensor 1 signal 47 -
15 EGR gas temperature sensor 2 signal 48 CKP sensor GND
16 FRP sensor signal 49 CMP sensor, FRP sensor GND
17 Oil pressure sensor signal Boost pressure sensor, intake throttle position sensor, engine coolant temperature
50 sensor, IMT sensor, EGR gas temperature sensor 1, EGR gas temperature
18 IMT sensor signal sensor2, boost temperature sensor GND
19 - 51 -
20 Fuel temperature sensor signal 52 -
21 - 53 EGR position sensor signal U
22 - 54 EGR position sensor signal V
23 Injector power supply 1 (Cylinder No. 1) 55 EGR position sensor signal W
24 Injector power supply 1 (No. 3 cylinder ) 56 -
25 Injector power supply 1 (No. 2 cylinder ) 57 -
26 EGR position sensor, oil pressure sensor power supply 58 -
27 - 59 EGR position sensor, oil pressure sensor, fuel temperature sensor GND
28 - 60 -
29 - 61 -
30 - 62 -
31 - 63 SCV-LO drive
32 - 64 -
33 - 65 -
29
Terminal Name
S1 S1

66 - 99 CMP sensor signal
67 - 100 -
68 Boost pressure sensor, intake throttle position sensor power supply 101 -
69 CMP sensor, FRP sensor power supply 102 -
70 - 103 -
71 CMP sensor shield 104 -
72 - 105 SCV-HI drive
73 FRP sensor shield
74 CKP sensor shield
75 Abnormal urea fluid injection warning light
76 Refill urea fluid warning light
77 -
78 CKP sensor signal
79 -
80 Restart prohibited warning light
81 -
82 -
83 -
84 SCV-HI drive
85 No. 4 cylinder injector control
86 -
87 -
88 -
89 Intake throttle motor drive Low
90 Intake throttle motor drive High
91 EGR valve DC servo motor drive W
92 EGR valve DC servo motor drive V
93 EGR valve DC servo motor drive U
94 Abnormal urea fluid quality warning light
95 -
96 -
97 -
98 -
30
Terminal Name
S2 S2

1 Battery power supply 34 -
2 ECM power supply GND 35 Fuel filter pressure sensor, EGT sensor 2 GND
3 Battery power supply 36 MAF sensor GND
4 ECM power supply GND 37 MAF sensor power supply
5 Battery power supply 38 Engine overrun light
6 ECM power supply GND 39 Diagnosis light
7 Data link connector 40 ECM main relay control
8 - 41 Signal GND
9 Accelerator position sensor GND 42 Signal GND
10 - 43 -
11 IAT sensor, charge air cooler temperature sensor 1, EGT sensor 1 GND 44 Diagnostic switch signal
12 - 45 -
13 - 46 Air cleaner switch signal
14 - 47 Idling control switch Down signal
15 Accelerator position sensor power supply 48 -
16 Fuel filter pressure sensor power supply 49 -
17 Fuel filter pressure sensor signal 50 Engine stop switch signal
18 EGT sensor 1 signal 51 -
19 EGT sensor 2 signal 52 -
20 - 53 -
21 Charge air cooler temperature sensor 1 signal 54 Output restricted warning light
22 - 55 Engine hydraulic light
23 Tachometer 56 -
24 - 57 ECM main relay control
25 - 58 Accelerator position sensor shield
26 - 59 -
27 Accelerator position sensor 2 signal 60 CAN-High
28 - 61 Mode map switch 2 signal
29 IAT sensor signal 62 -
30 Accelerator position sensor 1 signal 63 -
31 - 64 ISO CAN-High
32 - 65 Mode map switch 0 signal
33 - 66 -
31
Terminal Name
S2 S4
67 - 1 Exhaust gas temperature sensor 2 signal
68 Regulation mode switch signal 2 Exhaust gas temperature sensor 2 GND
69 -
S6
70 Mode map switch 1 signal
Pin No. Pin name
71 Idling control switch Up signal
1 MAF sensor power source
72 Hour meter relay
2 MAF sensor GND
73 -
3 MAF sensor signal
74 Starter cut relay
4 IAT sensor signal
75 ECM case GND
5 IAT sensor GND
76 Ignition switch ON signal
S8
77 CAN-Low
78 - Pin No. Pin name
79 - 1 Turbocharger actuator signal U
80 - 2 Turbocharger actuator signal V
81 ISO CAN-Low 3 Turbocharger actuator signal W
82 Ignition switch start signal 4 Turbocharger actuator GND
83 - 5 Turbocharger actuator shield
84 - 6 -
85 - 7 -
86 Load advance switch signal 8 Turbocharger actuator power supply
87 Idling control change switch signal 9 -
88 MAF sensor signal 10 Turbocharger actuator motor drive U
89 Glow light 11 Turbocharger actuator motor drive V
90 Overheat light 12 Turbocharger actuator motor drive W
91 Glow relay 13 Turbocharger control Unit power supply

14 Turbocharger control Unit GND
S3
15 ISO CAN-High
Pin No. Pin name
16 ISO CAN-Low
1 Exhaust gas temperature sensor 1 signal
S9
2 Exhaust gas temperature sensor 1 GND
Pin No. Pin name
1 Fuel filter pressure sensor power source
2 Fuel filter pressure sensor GND
3 Fuel filter pressure sensor signal
32
Terminal Name
H1 H2 H4
Terminal No. Terminal name Terminal No. Terminal name Terminal No. Terminal name
1 CKP sensor power supply 1 EGR position sensor power supply 1 Injector 3 control, No.3 cylinder
2 IMT sensor GND 2 EGR position sensor signal W 2 -
3 Engine coolant temperature sensor signal 3 EGR position sensor signal V 3 Injector 4 control, No.4 cylinder
4 Overheat switch signal 4 EGR position sensor signal U 4 Injector 1 control, No.1 cylinder
5 FRP sensor power supply 5 EGR position sensor GND 5 Injector power source 2, No.3 cylinder
6 CKP sensor signal 6 EGR valve DC servo motor drive W 6 -
7 IMT sensor signal 7 EGR valve DC servo motor drive V 7 Injector power source 1, No.4 cylinder
8 Engine coolant temperature sensor OEM meter 8 EGR valve DC servo motor drive U 8 Injector power source 1, No.1 cylinder
9 Boost temperature sensor signal 9 EGR gas temperature sensor 1 signal 9 -
10 FRP sensor signal 10 EGR gas temperature sensor 1 GND 10 -
11 CKP sensor shield 11 EGR gas temperature sensor 2 GND 11 -
12 - 12 EGR gas temperature sensor 2 signal 12 Injector 2 control, No.2 cylinder
13 Fuel temperature sensor GND 13 - 13 SCV-LO drive
14 FRP sensor shield 14 - 14 CMP sensor shield
15 CKP sensor GND 15 Charge air cooler temperature sensor GND 15 -
16 Engine coolant temperature sensor GND 16 Charge air cooler temperature sensor signal 16 Injector power source 2, No.2 cylinder
17 FRP sensor GND H3 17 SCV-HI drive
18 - 18 CMP sensor GND
Terminal No. Terminal name
19 Boost pressure sensor GND 19 CMP sensor signal
1 Turbocharger actuator motor drive W
20 Oil pressure sensor GND 20 CMP sensor power supply
2 Turbocharger actuator motor drive V
21 - H5
3 Turbocharger actuator motor drive U
22 -
4 Turbocharger actuator signal W Terminal No. Terminal name
23 -
5 Turbocharger actuator signal V 1 Glow plug power supply
24 Boost pressure sensor signal
6 Turbocharger actuator signal U
25 Oil pressure sensor signal
7 Turbocharger actuator shield
26 -
8 Intake throttle position sensor power supply
27 -
9 Turbocharger actuator GND
28 -
10 Turbocharger actuator power source
29 Boost pressure sensor power supply
11 Intake throttle position sensor GND
30 Oil pressure sensor power supply
12 Intake throttle motor drive Low
31 Fuel temperature sensor signal
13 Intake throttle motor drive High
32 -
14 Intake throttle position sensor signal
33
MEMO
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: [email protected]
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
(Located at the bottom center in the page. If two or more revisions
FAX:
are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

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PART NO.

ENGINE MANUAL TECHNICAL MANUAL

Service Manual consists of the following sections.

This manual consists of the following sub-sections.

safety information 9. Be sure to check that there is no fuel leaks when

10. When handling volatile materials, be extremely

Description General Information

Contents included in service information

1. Vehicle front 9. Gas or warm air

Recommended liquid gasket

Thread locking adhesive agent

： 358.9 to 539.4 N・m ： 430.5 to 711.0 N・m

： 490.8 to 810.5 N・m ： 554.1 to 830.6 N・m

1. Hex bolt, 4.8, 4 T 10. Hex bolt, non-thermal refining 8.8

Tightening torque for large/medium sizeFlare nut width across flat

Tapered thread for connectors and brass products

Item Engine model 4HK1

Function, Structure, Operation

1. Engine number stamping

2. Function, Structure, Operation 1. Engine structural diagram

2. Description of functions and operations Crankshaft

1. Electromagnetic pump 6. Fuel tank

Fuel system diagram (Type 2)

1. Electromagnetic pump 5. Supply pump

Caution： Common rail

1. Pressure sensor 3. Common rail (Fuel rail)

Fuel supply pump (Type 1)

1. Fuel temperature sensor 5. Camshaft nut

Fuel supply pump (Type 2)

1. Camshaft key 4. FRP regulator

Fuel filter (Element replacement type specification)

Fuel filter (Cartridge type specification)

1. Water jacket 10. Radiator reserve tank

Water pump The water pump is a centrifugal-impeller-type pump and

1. Fan guide 4. Seal unit

Thermostat housing unit and allow for specific temperature

1. Jiggle valve 4. Gasket

5. Lubrication system A full-flow bypass integrated filter element, water

Oil pump structural diagram

1. Driven gear 6. Drive gear

6. Induction system Turbocharger structural diagram

1. Connector 6. Coolant inlet

7. Exhaust system cleans exhaust gases by purifying NOx in the exhaust

1. Front chamber 7. NOx sensor 1

1. EGR position sensor 9. IMT sensor

1. Lever assembly 6. Internal gear

Fuel injection correction

Control during overheat

Electronic control fuel injection system Injection quantity control

Injection pressure control second injection is performed when ignition is made.

1. Electromagnetic pump 6. Fuel tank

EGR The ECM controls the EGR valve lift amount by

1. EGR position sensor 2. EGR valve

Turbocharger control 1. Turbine wheel

Engine operation control

CAN communication Mode map switch

When CAN controller exists on the machine side

1. Engine 2. MAF/IAT sensor