COMMON RAIL SYSTEM (CRS) SERVICE MANUAL: Operation
Contents
1. Multi Hole Filter JO5D gt Solenoid Valve Control Chamber Mutli Hole Filter Command Piston Nozzle Spring Pressure Pin QR Code on the Injector Connector Injection Quantity Q Correction Points Using QR Codes Actuating Pulse Width TQ lt JO8E gt Q002392E Pressure Parameter Q002393E Operation Section 1 17 3 2010 model ID Codes QR Codes Solenoid Valve Control Chamber Mutli Hole Filter Command Piston Nozzle Spring Pressure Pin Q004784E 70 MPa Correction 35 MPa 12 Points Injection Quantity Q Actuating Pulse Width TQ Q004785E Correction Points Using QR Codes Operation Section 1 18 6 CONTROL SYSTEM 6 1 Engine ECU 2004 2007 model e The construction and operational characteristics of the engine ECU equipped with the JO5D JO8E engines are identical to the conventional engine ECU The engine ECU determines engine status based on signals from each sensor The engine ECU then controls various actuators so that the engine runs under optimal conditions Q002394E Operation Section 1 19 2010 model e The 2010 model y2. Twisted Pair Wires etc Injector JO5D 4 injectors JO8E 6 injectors Q002520E Operation Section 1 47 Sensor 1 Q Rail Pressure IL Q 120 O fai Press E r bani u Sensor 2 TT Fuel Temperature 0 l Mu a Intake Manifold O Q Temperature Sensor Starter Cut Relay Manifold Absolute Pressure MAP Sensor Diesel Throttle O O Temperature Sensor Mass Air Flow MAF Meter Intercooler Outlet i Frequency Type Intake Air Temperature Sensor O Coolant Temperature Sensor EGR Cooler Outlet Temperature Sensor Q004788E 2010 Model 1 Operation Section 1 48 Crankshaft Position Senso NE Sensor Camshaft Position Sensor G Sensor Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 EDO 6 O VNT is Post Processing fz System NE NE NE SLD G VCC G G GND COM 1 COM 1 TWV 1 TWV 3 TWV 5 COM 2 COM 2 TWV 2 TWV 6 TWV 4 INJ SLD SCV HI SCV HI SCV LO SCV LO Switches CAN3H CAN3L CAN1H CAN1L KWP A VCC10 ADV1 A GND10 A VCC11 ADV2 A GND11 A GND12 ADV4 Switches Actuators OUTV5 CAN2H CAN2L POUT1 PIM5 VS TAC1 Lights Relay Valve 2010 Model 2 Vehicle Control ECU Diagnostic Connector Accelerator Position Sensor 1 Accelerator Position Sensor 2 VVork Use Accelerator Position
3. 5TDC 3TDC 6TDC 2TDC 4TDC 1TDC 1 1 1 1 1 1 NE 1112114151617 18 192021 22 23 24 252827 2829 3091329 M 353837 339 4041 42 344 4348 7 4B 40 051 5253 51 56 12345678 9 101121914151817 18 192021222324 282827 ZB 2 3031 32 99343536 7 38394041 4243444548 47 48495051 53 545556 12345678 onga NE Standard 4th Missing Tooth G G GND Standard Extra Tooth Q002396E Pulse Chart Operation Section 1 22 2 Accelerator position sensor built in accelerator pedal module The accelerator position sensor is a conventional hall element type sensor lt Connector Pin Layout gt GND1 VC1 VPA2 Sensor Hall Elements 2 iy O m gt 5 ag O gio Ee 5 5 10 16 26 20 Accelerator 0 29 Pedal Fully Closed Fully Open Position Full Stroke lt Wiring Diagram gt lt Linear Output Characteristics Graph gt Q002306E Operation Section 1 23 3 Manifold Absolute Pressure MAP sensor The construction and operational characteristics of the MAP sensor equipped with the JO5D JO8E engines are identical to the conventional sensor The MAP sensor uses the Piezoelectric Resistance Effect to detect air pressure inside the intake manifold Under the Piezoelectric Resistance Effect changes in electrical resistance accompany changes in voltage applied to the silicon element inside the sensor lt External View Diagram gt 2004 2007 Model 2010 Model
4. Q004758E 3 Flow damper 2010 model The specifications for the 2010 model year flow damper are compliant with a pressure of 200 MPa Stopper Spring Q004792E Operation Section 1 14 5 INJECTOR 5 1 Outline e The 2004 and 2007 model year CRSs use G2 injectors The construction and operational characteristics of the G2 injectors are identical to the conventional injector The G2 injector injects fuel into the engine combustion chamber in accordance with signals from the engine ECU e As ofthe 2007 model year CRS the injectors use a mutli hole filter e The 2010 model year CRS uses G3 injectors G3 injectors are compliant with a pressure of 200 MPa and show improved responsiveness as well as an increased resistance to foreign material adherence Operation Section 1 13 1 2004 model ID Codes Solenoid Valve Control Chamber Bar Filter Bar Filter Command Piston Nozzle Spring Pressure Pin JO5D gt lt JO8E gt Q002391E Roe Code on the Injector Connector Injection Quantity Q Pressure Parameter Actuating Pulse Width TQ Q000260E Correction Points Using QR Codes Operation Section 1 16 2 2007 model ID Codes
5. 1630 d N PB GND Ve PB lt Pressure Characteristics gt 2004 2007 Model 2010 Model o o y y gt gt 2 a 2 o 200 370 40 100 300 Boost Pressure Boost Pressure kPa lt Conceptual Diagram gt lt Wiring Diagram gt Engine ECU Boost Pressure Sensor Engine ECU Intake Manifold Q004787E Operation Section 1 24 4 Coolant temperature sensor 2004 model only The construction and operational characteristics of the coolant temperature sensor equipped with the JO5D JO8E engines are identical to the conventional sensor Sensor resistance values in relation to coolant temperature are provided below Resistance Value Characteristics Temperature C Resistance Value KQ 25 4 15 04 129 9 16 Thermistor 5 74 Engine Side Control Terminals 3 70 2 45 19 18 1 66 1 15 0 811 0 584 0 428 0 318 0 008 Coolant Temperature 0 240 Measurement r Terminal 0 1836 0 1417 0 0018 0 1108 Reference values are shown in brackets 0000406 Operation Section 1 25 5 Mass Air Flow MAF meter 2004 model only The MAF sensor detects the intake air flow mass flow rate in the hot wire type air flow meter The intake air flow is converted to a voltage value and this signal is then transmitted to the ECU E2 THA
6. Cranking P246F Exhaust Gas Catalyst Temperature 2 Sensor Performance Malfunction Driving 7 77 77 IEEE pass si Pan argo 077 IC CEEI END 5 CAN Bus Line Open From After Treatment 1 Inlet NOx U029D Sensor CAN Bus Line Open From After Treatment 1 Outlet NOx U029E Sensor Operation Section 1 45 9 ATTACHED MATERIALS 9 1 Engine ECU External Wiring Diagrams Power 4 Relay For CAN Wire Twisted Pair Wires etc Crankshaft Position Injector JO5D 4 injectors JO8E 6 injectors 4 Sensor 4 J oH COMMON EER E Cylinder Recognition Sensor as Coolant Temperature Sensor Accelerator Position Fre Sensor 2 COMMON2O EE gt ER oo Accelerator Position Sensor II Specially Equipped Vehicles Rail Pressure Sensor Idle Controller Boost Pressure Sensor Q000441E 2004 Model Operation Section 1 46 Power 4 Relay Main Relay 5 Starter Relay Crankshaft Position F u Sensor a EED 4 Cylinder Recognition 807777 Sensor 2 O Accelerator Position Coolant Temperature Sensor ae Accelerator Position Sensor Specially Equipped Vehicles Fuel Temperature Sensor VVv idle Controller LS EE A O Boost Pressure Sensor 252 2007 Model
7. AD22 EGR valve lift sensor 2 A VCC5 Sensor power supply 5 Operation Section 1 51 NO ee ATT E s T n rasa NA CN IS AA ss swe CTC HEM EN 2 CCT A ees AA Tie feo engine zona T ono engine gra va foom eng Een man ay rs foume eng 200 mam ay 0 lk be re MENA lek A T CUCA EYE MEM CUCA ETE AA slee son IS OCS pH WET CEI BE fsm TI ee 8 z swe ous mnr s on loan ECN COP r sw roca presse s l m 180 slae or lewes eweseer CTN s fr cor ae grat y r rw ETE Operation Section 1 52 NO se ATT Romane foomo iar eoumont eer geeet ioe our II lee z fours susin foua ET a forms E o S le we pH ICI OTTO CN SSCS v l y r ao eken heme as aves sensor JCC OSS res avoe series s avocr v r CC ESTE v s CO to nis TWV2 Injector drive signal 2 TWV4 Injector drive signal 4 TWV6 Injector drive signal 6 Operation Section 1 53 Oe ee ALT Romane ma sono wms 2 s 8 v s som EST CT v r son ser CT el IS A EN EN IS AA slee fr TI Bee TR slee ele IS AA ves T r osganmyssiesn sl ko I EET NN
8. Check the sensor voltage Possible short circuit to B P1211 Injector Common 1 GND Possible short circuit to ground Check the injector Short and wiring Possible open or short circuit to B Check the P1212 Injector Common 1 B Short m iniector and vviring Possible open or short circuit to B Check the P1212 Injector Common 1 Open 55 injector and vviring Operation Section 1 35 DTC Detection Item DTC Description Remarks Code P1214 Injector Common 2 GND Possible short circuit to ground Check the injector Short and wiring Possible open or short circuit to B Check the P1215 Injector Common 2 B Short injector and wiring Possible open or short circuit to B Check the P1215 Injector Common 2 Open Er a injector and vviring ssued when the differential pressure sensor cannot Differential Pressure Sensor be correctly detected Possible causes include Malfunction Abnormal Sensor Characteristics clogging in the pressure piping leaks a sensor malfunction a wiring harness open short circuit and or poor terminal contact in the connector Issued when exhaust pressure cannot be correctly Differential Pressure Sensor detected Possible causes include a sensor Malfunction Lo malfunction or an open short circuit to ground in the wiring harness Issued when exhaust pressure cannot be correctly Differential Pressure Sensor detected Possible causes include a sensor
9. Installed Vehicles with DPF Installed Vehicles with DPF Installed Vehicles with DPF Installed Vehicles with DPF Installed Operation Section 1 36 DTC Detection Item DTC Description Remarks Code P2032 P2033 P2080 P2084 P2100 P2101 P2103 P2120 P2122 P2123 P2127 Exhaust Gas Temperature Sensor 2 Malfunction Lo Exhaust Gas Temperature Sensor 2 Malfunction Hi Exhaust Gas Temperature Sensor 1 Malfunction Abnormal Sensor Characteristics Exhaust Gas Temperature Sensor 2 Malfunction Abnormal Sensor Characteristics Electronic Control Throttle Ground Short Diagnosis Cannot be Performed on the Circuit Electronic Control Throttle Seizure Electronic Control Throttle Open Circuit Accelerator Position Sensor 1 and 2 Malfunction Accelerator Position Sensor 1 Malfunction Lo Accelerator Position Sensor 1 Malfunction Hi Accelerator Position Sensor 2 Malfunction Lo ssued when temperature cannot be correctly Vehic ehicles detected Possible causes include a sensor with DPF malfunction and or a short circuit to ground in the E Installed wiring harness Issued when temperature cannot be correctly Vehicl ehicles detected Possible causes include a sensor 250 with DPF malfunction or an open short circuit to B in the Installed wiring harness Issued when the temperature from exhaust gas temperature sensor 1 cannot be correctly detected
10. Malfunction Hi malfunction and or a short circuit to B in the wiring harness P1458 EGR Actuator Malfunction 1 Issued when the EGR controller is malfunctioning P1459 EGR Actuator Malfunction 2 Issued when the EGR controller is malfunctioning Issued when the engine stop switch is Engine Stop Switch Closing malfunctioning or there is short circuit in the wiring Malfunction Monitor switch status and check the ON OFF judgment QR Code Unreadable QR Code Malfunction Issued when there is an error in the QR code Check QR Code Malfunction Out of Issued when there is an error in the QR code Check Issued when the exhaust brake solenoid valve is Exhaust Brake Solenoid Valve malfunctioning Possible causes include a solenoid valve malfunction and or an open short circuit to P1601 P1601 P1601 Malfunction Open Ground Short ground in the wiring harness Issued when the exhaust brake solenoid valve is Exhaust Brake Solenoid Valve Malfunction B Short malfunctioning Possible causes include a solenoid valve malfunction and or a short to B in the wiring harness Issued when the DPF system is malfunctioning Diesel Particulate Filter DPF Possible causes include melt down and clogging System Malfunction Perform the DPF system check Malfunction Issued when there is an error in the QR code Check the QR code Vehicles with DPF Installed Vehicles with DPF
11. Possible causes include a sensor malfunction Vehicles short open circuit in the wiring harness and or a with DPF faulty connector DPF inlet temperature and coolant Installed temperature sensor abnormalities may also cause this code to be issued Check both of these items Issued when the temperature from exhaust gas temperature sensor 2 cannot be correctly detected Possible causes include a sensor malfunction Vehicles short open circuit in the wiring harness and or a with DPF faulty connector DPF inlet temperature and coolant Installed temperature sensor abnormalities may also cause this code to be issued Check both of these items A possible ground short in the wiring harness connecting the engine ECU and electronic control throttle Issued when seizure in the electronic control throttle is detected Possible causes include an open circuit in the wiring between the engine ECU and SCV a ground short and or a malfunction in the electronic control throttle driver Issued when both accelerator position sensors 1 and 2 are malfunctioning Possible causes include sensor and or harness malfunctions Issued when accelerator position sensor 1 cannot be correctly detected Check the sensor voltage Issued when accelerator position sensor 1 cannot be correctly detected Check the sensor voltage Possible short circuit to B Issued when accelerator position sensor 2 cannot be correctly detected Check the sensor volt
12. Switch Open Load Short to GND U P1681 OUTE7 Output Open Short to GND P1682 OUTE7 Output Open Short to Battery P200C Diesel Particulate Filter DPF Meltdown 1 Urea Level Low 1 P203F Urea Level Low 2 Operation Section 1 43 CTE T ETE T FT ETE T T ETE T oe Bey Seen ER TP 5 7T CTE T ETE EE ETE EE Urea Selective Catalytic Reduction SCR Catalyst P20EE x Deterioration P2100 Diesel Throttle Control DC Motor Output 1 Open Load Output 2 Open Load Motor Open Load P2101 Diesel Throttle Open Close Stuck U P2103 Diesel Throttle Control DC Motor Out 1 Short to Battery GND Out 2 Short to Battery GND Motor Short P2120 Both Accelerator Pedal Sensor Signals Invalid U 0 P2122 Accelerator Pedal Sensor No 1 Signal Too Lovv d P2123 Accelerator Pedal Sensor No 1 Signal Too High NY0 4 P2127 Accelerator Pedal Sensor No 2 Signal Too Lovv U 0 P2128 Accelerator Pedal Sensor No 2 Signal Too High P2135 Intake Throttle Position Sensor Performance P2138 Accelerator Pedal Sensor Performance Invalid P2214 NOx Sensor SCR Catalyst Downstream Performance Failure Operation Section 1 44 DTC Code Detection Item Exhaust Gas Catalyst Temperature 0 Sensor Performance Malfunction Cranking P242B Exhaust Gas Catalyst Temperature 0 Sensor Performance Malfunction Driving ik P244B Exhaust Gas Catalyst Temperature 2 Sensor Performance Malfunction
13. VG E2G B Airflow Sensor Intake Air Temperature Sensor Q000280E The MAF meter is installed to the rear of the air cleaner and consists of a heater thermometer intake air temperature sensor and control circuit base The MAF meter diverts a portion of the air from the cleaner and measures the intake air flow at the hot wire measuring section Outline Diagram of Hot Wire Type MAF Meter Temperature Compensating Resistor Hot Wire i i Intake Air from Heating Resistor Hot VVire Air Cleaner Q000285E 6 Intake air temperature sensor 2010 model only e The intake air temperature sensor detects the temperature of the intake air after passing through the turbocharger Resistance Value Q 50 100 150 Exhaust Gas Temperature C Q004791E Operation Section 1 26 7 EXHAUST GAS CONTROL SYSTEM 7 1 Exhaust Gas Recirculation EGR System 2004 Model Only 1 Control system Engine ECU EGR Target Opening Final EGR Target Processing Duty Ratio i EF Opening Calculation Calculation Compensation Control Feedback EGR Valve Lift Sensor waton Detects Actual Position ROR AUTO EGR Valve Assembly Q002399E 2 Related sensors Air volume sensor Detects the volume of air flowing into the engine Coolant tem
14. materials Urea is added to the exhaust gas via injection causing NOx decomposition The resulting non hazardous water H20 and nitrogen gas N2 are then discharged Operation Section 1 30 8 ENGINE ECU DIAGNOSTIC TROUBLE CODES DTC 8 1 DTC Table 1 2004 2007 Model DTC Detection Item DTC Description Remarks Code P0045 Variable Nozzle Turbo VNT Issued when the VNT actuator is malfunctioning Malfunction Issued when actual rail pressure in relation to the Rail Pressure Control 1 command rail pressure is continuously low Check Abnormality Continuously Below f the fuel filter for clogging the supply of fuel to the the Standard Value pump as well as for any foreign matter intrusion Rail High Pressure Control Issued when rail fuel pressure is abnormally high or Abnormality Pressure is when actual rail pressure in relation to the command Continuously Above the rail pressure is continuously high Possible causes Standard Value or Pressure include faulty contacts in the rail pressure sensor Momentarily Becomes line noise lack of injection and or a supply pump Abnormally High malfunction Issued when the MAF meter is malfunctioning Mass Air Flow MAF Meter Possible causes include a sensor malfunction or an Malfunction Lo ro open short circuit to ground in the wiring harness Issued when the MAF meter is malfunctioning MAF Meter Malfunction Hi Possible causes incl
15. vviring harness and or a ground short ssued when the signal from the electronic control P0123 Electronic Control Throttle throttle position sensor cannot be correctly detected Malfunction Hi Possible causes include a malfunction within the sensor and or a Vcc short within the wiring harness ssued when temperature cannot be correctly P0182 Fuel Temperature Sensor detected Possible causes include a sensor Malfunction Lo malfunction and or a short circuit to ground in the wiring harness Issued when temperature cannot be correctly P0183 Fuel Temperature Sensor detected Possible causes include a sensor Malfunction Hi malfunction or an open short circuit to B in the wiring harness Issued when rail pressure cannot be correctly P0192 Rail Pressure Sensor detected Possible causes include a sensor Malfunction Lo malfunction and or a short circuit to ground in the wiring harness Issued when rail pressure cannot be correctly P0193 Rail Pressure Sensor detected Possible causes include a sensor Malfunction Hi malfunction or an open short circuit to B in the wiring harness o a Engine ECU Charge Issued when the injector activation voltage is too 2222 Hi high Replace the ECU Possible causes include an injector 1 malfunction P0201 Injector 1 Open Circuit and or an open circuit in the wiring harness Possible causes include an injector 2 malfunction P0202 Injector 2 Open Circuit and or an open circ
16. 0 plus one irregularly placed pulsar As a result five pulses are output for every two revolutions of the engine or one revolution of the pump Top dead center of compression for the first cylinder occurs after the irregular pulse at 96 CA refer to the chart on the following page v On the JOBE engine driveshaft gear there is one pulsar every 60 plus one irregularly placed pulsar As a result seven pulses are output for every two revolutions of the engine or one revolution of the pump Top dead center of compression for the first cylinder occurs after the irregular pulse at 78 CA refer to the chart on the following page Operation Section 1 21 lt J05D Engine gt Engine ECU i Input Circuit lt JO8E Engine gt Engine ECU VCC Input Circuit OUT GND Vcc Q002395E JO5D Engine OCA 180 CA 360 CA 540 CA OCA I T 1TDG I 1 3TDC I 1 4TDC I 1 2TDC I HHTDC 1 1 1 1 N E 1112 13 14151617 18 19 2021 22 23 24 25 26 27 28 29 3031 32 33 4 35 36 37 38 39 4041 42 43 44 4546 47 48 49 5051 5253 54 55 56 12345678 9 10111213 14 1516 17 18 19 202122 23 24 25 26 27 28 29 30 31 32 3334 35 36 37 38 39 40 41 42 4344 45 46 47 48495051 52 53545556 12345678 9101112131415 NE Standard 4th Missing Tooth G G Standard 3 CA Extra Tooth JO8E Engine 0 CA 120 CA 240 CA 360 CA 480 CA 600 CA 720 CA
17. 83E e In the DPF system regeneration mode a post injection is added to the normal injection pattern pilot injection main injection after injection After injection causes exhaust temperature to increase promoting PM oxidation Catalyst temperature is increased to the self ignition temperature for PM by the post injection causing the PM accumulated in the filter to combust Top Dead Center TDC Top Dead Center TDC Main Injection Main Injection After Injection Post Injection 1 Pilot Injection After Injection Pilot Injection 1 lt Normal Mode gt lt DPF Regeneration Mode gt Q002384E Operation Section 1 28 2 Exhaust gas temperature sensor 2007 model only The construction and operational characteristics of the exhaust gas temperature sensor equipped with the JO5D JO8E engines are identical to the conventional sensor The exhaust gas temperature sensor detects the temperature of the exhaust gas both before and after the DPF o X Nu on NO ci gt o s 2 YN o az 50 650 700 Exhaust Gas Temperature C Q002398E 3 Differential pressure sensor The construction and operational characteristics of the differential pressure sensor equipped with the JO5D JO8E engines are identical to the conventional sensor The differential pressure sensor detects the difference in exhaust gas pressure across the DPF Output Voltage 4 65 100 P
18. ECU P0606 Engine ECU Malfunction Issued when there is a malfunction internal to the Detected in the Hardware engine ECU Replace the engine ECU P0607 Engine ECU Monitor IC Issued when there is a malfunction internal to the Abnormality engine ECU Replace the engine ECU Circuit Lo Replace the engine ECU Issued when there is a short in the starter switch P0617 Starter Switch Malfunction circuit Monitor switch status and check the ON OFF judgment Possible causes include an open circuit in the wiring Suction Control Valve SCV 0628 harness connecting the engine ECU and SCV or a GND Short ground short m Possible causes include a B short in the vviring P0629 1 SCV B Short harness connecting the engine ECU and SCV Issued when the main relay cannot be turned OFF P0686 Main Relay Malfunction Check the relay Issued when the clutch switch cannot be correctly P0704 Clutch Switch Malfunction detected Monitor switch status and check the ON OFF judgment Issued when the neutral switch cannot be correctly P0850 Neutral Switch Malfunction detected Monitor switch status and check the ON OFF judgment Hi the sensor voltage Possible short circuit to B Vehicle External Accelerator Issued when the vehicle external accelerator P1133 Position Sensor Malfunction position sensor cannot be correctly detected Check ssued when the idle volume cannot be correctly P1143 Idle Volume Hi detected
19. JO5D JO8E Engine COMMON RAIL SYSTEM CRS SERVICE MANUAL Operation Issued September 2007 Revised May 2010 DENSO CORPORATION Revision History 2007 09 e Basic CRS content omitted March 2007 model CRS content added Items added are as per the following Y Applicable Vehicles and Product Information v Main Components and Sensors Y Exhaust Gas Control System DPF System v Engine ECU Diagnostic Trouble Codes DTC v Engine ECU External Wiring Diagram and Connector Terminal Layout 2010 05 e March 2010 model CRS content added Items added are as per the following v Applicable Vehicles and Product Information Y CRS Outline Diagram Supply Pump Rail Injector Engine ECU Selective Catalytic Reduction SCR System Engine ECU Diagnostic Trouble Codes DTC Engine ECU External Wiring Diagrams and Connector Terminal Layout O 2010 DENSO CORPORATION All rights reserved This material may not be reproduced or copied in whole or in part without the written permission of DENSO Corporation Table of Contents Operation Section 1 APPLICABLE VEHICLE AND PRODUCT INFORMATION 1 1 Introduction alii A A A AA ae ah RARAS Een 1 1 12 Applicable Vehicles saza ob a ii Der Te REL a ida RE AR De 1 1 1 3 Appli dbleProductsList cz aa b d aie aaa n 1 2 2 COMMON RAIL SYSTEM CRS OUTLINE 2 1 GRSOutline Diagraim EE A HERE A DIL DIE Eh 1 4 3 SUPPLY PUMP 3 1 OUTI
20. NG es ee a A a Be te de AL ds 1 6 3 2 Suction Control Valve 22 een 1 8 3 3 Fuel Temperature Sensor ou A ad 1 10 4 RAIL 4 1 A EN oe 1 11 5 INJECTOR Sk OUE RE RE 000000 0 0 ieh 1 14 6 CONTROL SYSTEM 6 1 ENGINS EC Ui od bucal lodo te oa eg yab Dela ante Oren m sin Ra IR a 1 18 6 2 SENSONS ea Pinel OR EK Satan EER GEE EE EE 1 20 7 EXHAUST GAS CONTROL SYSTEM 7 1 Exhaust Gas Recirculation EGR System 2004 Model Only 1 26 72 Diesel Particulate Filter DPF System 2007 2010 Model 1 27 7 3 Selective Catalytic Reduction SCR System 2010 Model Only 1 29 8 ENGINE ECU DIAGNOSTIC TROUBLE CODES DTC 8 1 DIE Table iio ni ee ee an ad dll hee da boda dy o 1 30 9 ATTACHED MATERIALS 9 1 Engine ECU External Wiring Diagrams eee 1 45 9 2 Connector Terminal layout RS EER GE ate aad cca La RR A ER DER IR an 1 49 Operation Section 1 1 1 APPLICABLE VEHICLE AND PRODUCT INFORMATION 1 1 Introduction e This manual describes the Common Rail System CRS equipped with JO5D JO8E engines used in the HINO Medium Truck For information on items common to all CRSs refer to the previously published CRS general addition manual Doc ID 00400076E Items common to all CRSs CRS development process system control construction and operation of m
21. Sensor Exhaust Gas Temperature Sensor 2 Exhaust Gas Temperature Sensor 3 Exhaust Gas Temperature Sensor 4 Differential Pressure Sensor GCU L6 Battery Q004789E Operation Section 1 49 9 2 Connector Terminal Layout 1 2004 2007 model 1112 131141 5 16 177 Bilal ey ME 819 10111213141516 7 mul 771879808182 kostice frofit pels Jets ft a is Jrs a Js sn felis AAA AA 057 596960161 ELENA A NP fei STNG 6829 Gob 826364 EE 46 Bot 6755 inn ini inin AG aa Q000442E Connector terminal layout e race ETE IC AA mpo IS 1 ele AE re fm AA slim AA pH fem 1 ONES Case wand AA fan leek am IS AE r Ca a azot on Tes aoo ann anne Operation Section 1 50 HO Gade We LEC as easton lese ae N E s fo PT ae imee ar temperature sensor Giro te MA meen 7 refer E EA l Ser f ours esnasis tossnusse 00 aee O O O O slae MEM ESC ETA e Tai Ne elk SR s fours ea 05 s ours 00 s fsm fernen A leek AA ss fa ICM CEI TEC AA s FN l A aw s ssn an o ECC o A fsm erea 8 sa ET r 0 1
22. age Operation Section 1 37 DTC Detection Item DTC Description Remarks Code m Issued when accelerator position sensor 2 cannot Accelerator Position Sensor 2 P2128 be correctly detected Check the sensor voltage Malfunction Hi Possible short circuit to B Issued when the atmospheric pressure sensor built P2228 Atmospheric Pressure Sensor into the engine ECU is malfunctioning If the Malfunction Lo malfunction occurs frequently it is necessary to repair or replace the engine ECU Issued when the atmospheric pressure sensor built P2229 Atmospheric Pressure Sensor into the engine ECU is malfunctioning If the Malfunction Hi malfunction occurs frequently it is necessary to repair or replace the engine ECU Possible causes include an open circuit in the wiring P2635 SCV Seizure between the engine ECU and SCV and or an SCV internal malfunction seizure Possible causes include an open circuit in the wiring P2635 Pump Replacement between the engine ECU and SCV and or an SCV internal malfunction seizure einen U0073 CAN 1 Abnormality Engine with the VNT Automatic Transmission ECU is lost Transmission ECU is lost Cruise lost ABS lost Air Suspension ECU is lost Meter lost U1001 2 Abnormality Vehicle with other computers equipped in the vehicle EE N EGR abnormality vvith the EGR actuation ECU Possible c
23. ain components supply pump rail injectors sensors and actuators Minor changes have been made to the HINO medium truck as of June 2010 With this minor change the CRS equipped with the JO8E engine has also changed and now this engine uses the Selective Catalytic Reduction SCR system The SCR system dramatically reduces the quantity of NOx exhaust and achieves superior environmental protection functionality suited to the stringent emission standards stipulated in the US10 regulations Changes to the CRS are shown below e Maximum injection pressure increased to 200 MPa e Fuel path related with the supply pump changed e Rail is compliant with a pressure of 200 MPa Engine ECU changed to a direct mount type e CRS now equipped with G3 type injectors The JO8E engine now uses the Selective Catalytic Reduction SCR system 1 2 Applicable Vehicles 2004 model Engine Vehicle Type Vehicle Model Engine Model Release Date Displacement HINO145 HINO165 JO5D 4 73L HINO185 Medium Truck HINO238 April 2004 HINO268 JO8E 7 68 L HINO308 HINO338 Operation Section 2007 model HINO145 HINO165 HINO185 Medium Truck HINO238 March 2007 HINO258 JO8E 7 68 L HINO268 HINO338 2010 model HINO238 HINO258 Medium Truck JOSE 7 68 L June 2010 HINO268 HINO338 1 3 Applicable Products List 2004 model Manufacturer Part Name DENSO Part Number Remarks Part Number 294000 025 S2273 01321 JO5D HP3 Supp
24. ation Section 1 40 EI P0275 ETE T Er T P0278 ETA P IO mae sme 600 yas sme Ra lees Re sme vas sme 6 AN ES P0335 EXE EN rs Poston ero Sa ma ro posta see ewe ICO EEE ee 4 P0381 EET EE IN ESE 5 P0402 s nr s sra T EE mm EE NE OESTE We ees ter Wat Gee IG EEC 07 poset posse Vere Sion poses erie Seen GET F Operation Section 1 41 CET WEEN end 00 P0610 EOLP Data Error Log EOLP Data is Not Written MA Capacitor Charge up Circuit Malfunction Insufficient Charge Starter Switch Short to Battery 2 2 1 SCV Output Open Load Short to GND SCV 757 Open Load Short to GND m SCV Coil Open SCV Coil Short SCV Output Short to BATT 27 SCV Output Short to BATT Battery 5 V Reference 1 Circuit Lovv Battery 5 V Reference 1 Circuit High U Glovv Control Unit Malfunction 50 Battery 5 V Reference 2 Circuit Lovv B ul Battery 5 V Reference 2 Circuit High 5 Glow Plug 1 Open Short Failure N Glow Plug 2 Open Short Failure Glow Plug 3 Open Short Failure N Glow Plug 4 Open Short Failure 20 Glovv Control Unit Communication Error Main Relay Diagnostics Main Relay Stuck Clo
25. auses include a malfunction in the VNT U1123 Communication Disruption control unit or a short open circuit in the VNT communication line between the control unit and engine ECU Operation Section 1 38 2 2010 Model DTC Code Detection Item P0016 Crank Cam Signal Synchronization Error N j DIAG Information 1 from Variable Nozzle Turbo VNT P0045 Controller DIAG Information 2 from VNT Controller xl ntercooler Temperature Sensor Performance nvalid Cranking Intercooler Temperature Sensor Performance Invalid Low P007B A Driving ntercooler Temperature Sensor Performance Invalid High Driving P007C Intercooler Temperature Sensor Signal Too Low P007D ntercooler Temperature Sensor Signal Too High Rail Pressure Falls Belovv the Control Limit of the Target P0087 Pressure Rail Pressure Exceeds Upper Limit Rail Pressure Exceeds High Upper Limit P0088 Rail Pressure Exceeds the Control Limit of the Target Pressure Intake Air Temperature Sensor Performance Invalid Cranking P0096 Intake Air Temperature Sensor Performance Invalid Low Driving P0097 Intake Air Temperature Sensor Signal Too Low P0098 Intake Air Temperature Sensor Signal Too High DIAG Information 1 Controller From VNT Controller POOAF DIAG Information 2 Controller From VNT Controller P0101 Mass Air Flow MAF Meter Performance Invalid MAF Meter Signal Frequency Too Low P0104 Intake Manifold Temperature Sensor Performa
26. cted Possible causes include sensor and or harness malfunctions Issued when the brake switch cannot be correctly detected Monitor brake switch status and verify ON OFF judgments ssued when the idle switch is malfunctioning Monitor switch status and check the ON OFF judgment Engine Oil Pressure Issued when engine oil pressure is too low Abnormality Preheat Device Malfunction Ground Short B Short Open Exhaust Gas Temperature Sensor 1 Malfunction Lo Issued when the intake heater relay is malfunctioning Possible causes include relay and or wiring harness malfunctions Issued when the EGR rate is insufficient in relation to the intake quantity Possible causes include a malfunction in the MAF meter EGR valve EGR actuation ECU and or an open or short circuit in the wiring harness Issued when temperature cannot be correctly Vehicles with DPF Installed detected Possible causes include a sensor malfunction and or a short circuit to ground in the wiring harness Operation Section 1 34 DTC Detection Item DTC Description Remarks Code ssued when temperature cannot be correctly Vehicles with DPF Installed Exhaust Gas Temperature detected Possible causes include a sensor Sensor 1 Malfunction Hi malfunction or an open short circuit to B in the wiring harness f Issued when there is a malfunction internal to the P0605 Flash ROM Malfunction engine ECU Replace the engine
27. e crankshaft position sensor cannot be detected Possible causes include sensor and or harness malfunctions Operation Section 1 33 DTC Detection Item DTC Description Remarks Code P0336 P0340 P0341 P0400 P0400 P0500 P0501 P0504 P0510 P0524 P0540 P0545 Crankshaft Position Sensor Pulse Number Abnormality Camshaft Position Sensor Malfunction Camshaft Position Sensor Pulse Number Abnormality Excessive Exhaust Gas Recirculation EGR Rate nsufficient EGR Rate Vehicle Speed Sensor Malfunction Lo Vehicle Speed Sensor Malfunction Hi Brake Switch Malfunction Idle Switch Stuck ON Possible causes include the use of an incorrect pulsar and or an abnormality in the wiring harness intermittent open circuits etc Issued when the pulse from the engine speed sensor cannot be detected Possible causes include sensor and or harness malfunctions Possible causes include the use of an incorrect pulsar and or an abnormality in the wiring harness open circuit modifications etc Issued when the EGR rate is excessive in relation to the intake quantity Possible causes include a malfunction in the MAF meter EGR valve EGR actuation ECU and or an open or short circuit in the wiring harness Issued when the pulse from the vehicle speed sensor cannot be detected Possible causes include sensor and or harness malfunctions Issued when the pulse from the vehicle speed sensor cannot be dete
28. ear engine ECU mounts directly to the engine direct mount type Q004786E Operation Section 1 20 6 2 Sensors 1 Crankshaft position sensor and camshaft position sensor The construction and operational characteristics of both the crankshaft position sensor and camshaft position sensor equipped with the JO5D JO8E engines are identical to the conventional sensors Crankshaft position sensor v A Magnetic Pick Up MPU type sensor is attached to the flywheel housing Pulses are detected when the signal holes established on the side of the flywheel pass the sensor v Signal holes are established every 6 on the side of the flywheel However there are no signal holes in four locations As a result there are 56 signal holes on the outer diameter of the flywheel resulting in the detection of 112 pulses for every two revolutions of the flywheel Engine ECU Input Circuit Q002441E Camshaft position sensor 2004 2007 model v A Magnetic Resistance Element MRE type sensor is attached to the back end of the driveshaft housing When the pulsar attached to the driveshaft gear passes the sensor the MRE internal resistance value changes due to a change in magnetic flux density As a result the voltage passing through the sensor also changes This change in voltage is amplified by the IC circuit within the sensor and then outputted to the engine ECU v On the JO5D engine driveshaft gear there is one pulsar every 9
29. ensor Q002389E JO8E Engine 095440 048 124 156 Operation Section 1 12 1 Rail pressure sensor The construction and operational characteristics of the rail pressure sensor equipped with the JO5D JO8E engines are identical to the conventional sensor The rail pressure sensor detects fuel pressure inside the rail The 2010 model year CRS has redundant rail pressure sensors 2004 2007 Model Output Voltage Engine ECU Volt Vcc Ve Vout GND Rall Pressure Sensor 0 200 Rail Pressure MPa 2010 Model Engine ECU Output Voltage 1 Output Voltage 2 GND2 Vout2 Vc2 Volt Vcc _ Volt Vec Rail Pressure Sensor Rail Pressure MPa Rail Pressure 1 Sensor Q004757E Operation Section 1 13 2 Pressure limiter The construction and operational characteristics of the pressure limiter equipped with the JO5D JO8E engines are identical to the conventional limiter In the event that pressure inside the rail becomes abnormally high the valve inside the pressure limiter opens to discharge a portion of the fuel Pressure limiter characteristics are as per the chart below Housing Spring Valve Guide Valve Body MIS Closed Valve Open Valve Pressure Pressure Abnormally High Pressure EE EEE valve Open 095420 019 Approx 2004 model 200 MPa 095420 020 Approx Approx 2007 model 50 MPa 221 MPa Valve Close 2010 model 241 MPa Rail Pressure
30. fs ves lew ann A pe EEE pH O O o Os lesse EST A ele ko I yes a ri m nus n 5 el II os en 0 ESC lege 0 A ran Atmosphere pressure sensor bun ne erge EU Operation Section 1 54 2 2010 model Engine Side arcana anno a Pr spree aes sz l n er oh Pc oo erfand en one Q004790E Connector terminal layout Service Department DENSO CORPORATION 1 1 Showa cho Kariya shi Aichi ken 448 8661 Japan
31. ly Pump 294050 001 S2273 01311 JOSE HPA 095440 053 S2276 01221 JO5D 095440 048 S2276 01181 JOSE 095000 539 S2391 01311 JO5D G2 Injector 095000 528 S2391 01361 JOSE G2 Engine ECU 102758 301 S8956 06540 Ka Accelerator Position Sensor 198800 316 S7801 E0010 Coolant Temperature Sensor 071560 011 S8342 01250 7 Crankshaft Position Sensor 029600 057 8941 11280 N 949979 136 S8941 01590 JOSE Camshaft Position Sensor 949979 949979 131 58941 01570 JO5D Manifold Absolute Pressure 079800 589 S8939 01080 MAP Sensor JO5D 2004 Model 135000 707 S1735 01210 Exhaust Gas Recirculation Only EGR Valve JOSE 2004 Model 135000 709 S1735 01220 Onl y Mass Air Flow MAF Meter 197400 200 22204 21010 For EGR Control Operation Section 2007 model Manufacturer Part Name DENSO Part Number Remarks Part Number JO5D 095000 692 23670 E0231 Four Injectors Injector JO8E G2 095000 681 23670 E0201 Six Injectors 275800 422 89661 E0030 Without Bracket Der Der 102758 422 98660 E0100 With Bracket Accelerator Pedal Module 198800 316 S7801 E0010 MN 949979 131 S8941 01570 JO5D Crankshaft Position Sensor 949979 136 S8941 01590 JOSE Camshaft Position Sensor Position Sensor 029600 057 8941 11280 E 7U Absolute Pressure 079800 589 8939 01080 MAP Sensor Differential Pressure Sensor 104990 104990 106 58939 01090 01090 Exhaust Gas Temperature 5 265600 060 S8944 16511 Two DPF Sensors e
32. mperature Sensor Bubble Separator Q004793E Operation Section 3 SUPPLY PUMP 3 1 Outline e The HP3 and HP4 supply pumps have the same construction and operational characteristics as the conventional supply pumps Supply pumps place fuel suctioned from the fuel tank under high pressure for delivery to the rail O A feed pump outlet and pump inlet have been added to the 2010 model supply pump to inhibit air mixing As a result of this change the fuel flow has been altered to travel through the following path main filter feed pump bubble separator pump unit 1 2004 model Fuel Temperature Sensor Q000252E Fuel Temperature Sensor Q000253E HP4 294050 001 Operation Section 2 2007 model Fuel Temperature Sensor Q002386E Q002387E 3 2010 model Fuel Temperature Sensor a Y Fuel Inlet SAA ME from Bubble Separator Fuel Inlet from Main Filter ad Fuel Outlet to Bubble Separator Q004756E HP4 294050 036 Operation Section 1 8 3 2 Suction Control Valve SCV 1 2004 2010 model The 2004 and 2010 model SCV is a normally open type valve lt External View gt Short Duty ON gt Large Valve Opening gt Maximum Intake Quantity AER Large Opening Cross Section gt Q002339E ITZA Long Duty ON gt Small Valve Opening gt Minimum Intake Quantity 4 Small Opening Cylinder Q004794E Operati
33. nce Invalid High Driving MAF Meter Signal Frequency Too High P0106 Manifold Absolute Pressure MAP Sensor Performance Invalid P0108 MAP Sensor Signal Too High P0112 ntake Air Temperature Sensor Signal Too Lovv P0113 ntake Air Temperature Sensor Signal Too High Operation Section 1 39 Gosen Temperature Sensor Paromanos maa 1 onr OooloniTempertureSensorSgraimolen roma Coote temperature Sensor Sra Too gh Pomo tano pr Temperature Sensor Perormarce mad Poz nate trono Postion Sensors siora feto Poz make mt Poston Sensor Sra Tee Me Pos memes _ Poz Trans Pump Sensor Sarat Tootw NET ELI IE iN EEN O O OO O poise TEE O Pon _ RairessuesersorSignaimone O F zu apactor Charge cin Malina Excessve Charge Trt open Load ester genoee _ rws tut open Load ester eek Geen _ rezos rvsout Open Load n r cars rozas open Load sterol Geen rozas toad sterol Geen _ rezos ouput Load Coote tempera Exceeds Unperim MON gesoen rozz2 tano mt Postion Sersor2SigalTeotow rozas nike trono Poston Bere era fe Me NEE I P0234 MAP Sensor ErnadsUpperim Per a Senso Sinarm t v ras ee EE P0263 Oinder1Fuisystemran em I P0266 865 P0269 2 Flow Damper 2 Activated P0272 Cylinder 2 Fuel System Failure Oper
34. nsor 2010 model Manufacturer Part Name DENSO Part Number Remarks Part Number Ri sonr Accelerator Pedal Module 198800 316 78010 E0010 Crankshaft Position Sensor 029600 057 S8941 11280 A Manifold Absolute Pressure 079800 941 89421 E0050 MAP Sensor Differential Pressure Sensor 104990 106 S8939 01090 B U Intake Air Temperature Sensor 072800 040 89424 E0030 U Operation Section 2 COMMON RAIL SYSTEM CRS OUTLINE 2 1 CRS Outline Diagram 2004 2007 model e The CRS consists primarily of a supply pump rail injectors and engine ECU Fuel Temperature Sensor Vehicle Speed Accelerator Opening Boost Pressure Intake Air Temperature Engine ECU Coolant Temperature Crankshaft Position Cylinder Recognition Sensor Intake Airflow Rate Injector Rail Pressure Sensor Supply Pum Suction Control b p Valve SCV Fuel Tank Q002385E Operation Section 1 5 2010 model e The fuel flow path in the 2010 model year CRS has changed as per the figure below to inhibit air mixing Fuel Temperature Sensor Vehicle Speed Accelerator Opening Injector Boost Pressure ntake Air Temperature Engine ECU Coolant Temperature Rail Pressure Crankshaft Position Y gt Sensor Camshaft Position gt Pressure Limiter Intake Airflow Rate Suction Control Valve SCV Fuel Tank Suction Discharge Feed Return Fuel Te
35. on Concept Diagram Operation Section 2 2007 model The 2007 model SCV is a compact normally open type valve Valve Body Return Spring Needle Valve Q001113E Supply Pump Needle Valve 22 Short Duty ON Long Duty ON gt Large Valve Opening Small Valve Opening gt Maximum Intake Quantity Minimum Intake Quantity Needle Valve Large Opening Needle Valve Small Opening Q002366E Operation Concept Diagram Operation Section 1 10 3 3 Fuel Temperature Sensor O The fuel temperature sensor is a conventional type sensor Sensor resistance values in relation to fuel temperature are provided below Resistance Value Characteristics Temperature C Resistance Value KO Thermistor Fuel Temperature Reference values are shown in brackets Q002380E Operation Section 1 11 4 RAIL 4 1 Outline e The construction and operational characteristics of the rail equipped with the JO5D JO8E engines are identical to the conventional rail The rail distributes fuel delivered from the supply pump to each injector e The rail detailed herein is equipped with both a pressure limiter and pressure sensor In the 2010 model CRS the rail pressure sensor and flow damper have changed Pressure Limiter Rail Pressure Sensor Q002390E Pressure Limiter Rail Pressure S
36. perature sensor Detects the engine coolant temperature Atmospheric pressure sensor Detects the atmospheric pressure around the engine built into the ECU 3 EGR valve An EGR valve is used as the system actuator for the Electric Exhaust Gas Recirculation E EGR system The EGR valve consists of an upper section and a lower section The upper section receives output signals from the engine ECU and contains a solenoid that generates electromagnetic force The lower section is constructed of a nozzle that moves up and down in response to the electromagnetic force and a valve with an opening that changes in response to the nozzle position to les EE HOE Q002442E Operation Section 1 27 4 Control operation Operation Start Conditions During engine warm up other than start up when not overheating etc EGR Operating Range During medium engine load EN 7 2 Diesel Particulate Filter DPF System 2007 2010 Model Q000269E e A DPF system has been installed in the North American HINO JO5D JO8E engines to comply with North American exhaust gas regulations for 2007 and 2010 model vehicles While the DPF itself is made by another manufacturer both the exhaust gas temperature and differential pressure sensors are DENSO products DPF Built In Oxidation Catalyst from Exhaust Manifold D gt to Muffler Differential Pressure Sensor Engine ECU 1 Control Exhaust Temperature Sensor Q0023
37. ressure kPa Q002277E Operation Section 1 29 7 3 Selective Catalytic Reduction SCR System 2010 Model Only Outline e The SCR system is an exhaust gas cleaning system that injects an aqueous solution of urea known as AdBlue into the exhaust pipe just before the catalyst to create a chemical reaction with the exhaust gas As a result approximately 40 of the NOx contained in the exhaust gas is converted into non hazardous nitrogen Until now the SCR system was large and was therefore only equipped in heavy duty vehicles SCR System System components are made by Engine ECU manufacturers other than DENSO gUERBEBEREEBEBEEER EB EB EBENE RE BB BR BE HET BER EBENE m Meter Display L DCM dis Urea Pump wette SS CAN Communication 7 Urea Temperature Sensor Urea 1 from Engine gt YY Differential A H Pressure Sensor a a a n n a m n n u m a u a a a a a 0 to Tailpipe tunnan Exhaust Gas Temperature A SCR NOx Sensor DOC Sensor 1 Exha st Gas Exhaust Gas LEE SE ES U SD U DE ES u ES u u a SE Su u a EEN u u a a a u u u zu u u mi Temperature DOC DPF Temperature A F Sensor Sensor 2 Sensor 3 Q004518E SCR e The SCR is a urea selective type reduction catalyst Urea is used to chemically decompose and convert the NOx contained in the exhaust gas into non hazardous
38. sed U MAF Sensor Power Supply Failure Short to GND 5 MAF Sensor Power Supply Failure Short to Battery U 0 Clutch Svvitch Circuit Malfunction Manual Transmission Only Transmission Malfunction AT or AMT Transmission Only Starter Block Relay Output Short to GND Starter Block Relay Output Open Short to Battery Neutral Switch Circuit Malfunction Manual Transmission P0850 Only niy P1133 ASC PTO Accelerator Pedal Sensor Signal Too High P1197 Rail Pressure Sub Sensor Signal Too Lovv P1198 Rail Pressure Sub Sensor Signal Too High Operation Section 1 42 DTC Code Detection Item P119F Rail Pressure Sensor Signal Rationality Check PE P1211 COM1 Output Short to GND TWV1 3 or 5 Output Short to GND COM1 Output Short to Battery TWV1 3 or 5 Output Short to P1212 Battery COM1 Output Open Load TWV1 3 and 5 Open Load 1 1 1214 COM2 Output Short to GND TWV2 4 or 6 Output Short to GND COM2 Output Short to Battery TWV2 4 or 6 Output Short to P1215 Battery COM1 Output Open Load TVVV2 4 and 6 Open Load N Thermal Regenerator BCU Failure 1 N Thermal Regenerator BCU Failure 2 U 0 P141F Thermal Regenerator BCU Failure 3 B Thermal Regenerator BCU Failure 4 1 11 P1426 Exhaust Gas Pressure Sensor 1 Signal Performance Invalid 7 1 AECE Fras EE Engine Stop Svvitch Stuck Closed QR Data is Not Written 2 P1601 QR Definition Error Definition Concerning QR Correction is Incorrect P1676 MEIIR
39. tuation Cylinder Comparative Correction Error 4 Cylinder Injection Quantity Rotational Fluctuation Cylinder Comparative Correction Error 5 Cylinder Injection Quantity Rotational Fluctuation Cylinder Comparative Correction Error 6 Cylinder Injection Quantity Rotational Fluctuation Crankshaft Position Sensor Camshaft Sensor Malfunction and Position Issued when the intake air pressure cannot be correctly detected Possible causes include a sensor malfunction or an open short circuit in the wiring harness Issued when the rotational fluctuation in cylinder 1 is larger than the other cylinders There is a possibility that the flow damper is operating Issued when the rotational fluctuation in cylinder 2 is larger than the other cylinders There is a possibility that the flow damper is operating Issued when the rotational fluctuation in cylinder 3 is larger than the other cylinders There is a possibility that the flow damper is operating Issued when the rotation fluctuation in cylinder 4 is larger than the other cylinders There is a possibility that the flow damper is operating Issued when the rotational fluctuation in cylinder 5 is larger than the other cylinders There is a possibility that the flow damper is operating Issued when the rotational fluctuation in cylinder 6 is larger than the other cylinders There is a possibility that the flow damper is operating Issued when the pulse from th
40. ude a sensor malfunction and or a short circuit to B in the wiring harness Issued when boost pressure cannot be correctly 1 detected Possible causes include a sensor Boost Pressure Abnormality x BES a malfunction and or a short circuit in the wiring harness Issued when temperature cannot be correctly Intake Air Temperature detected Possible causes include a sensor Sensor Malfunction Lo malfunction and or a short circuit to ground in the wiring harness Issued when temperature cannot be correctly Intake Air Temperature detected Possible causes include a sensor Sensor Malfunction Hi malfunction or an open short circuit to B in the wiring harness Issued when temperature cannot be correctly Coolant Temperature Sensor detected Possible causes include a sensor Malfunction Lo malfunction and or a short circuit to ground in the wiring harness Operation Section 1 31 Detection Item DTC Description Remarks BER lssued when temperature cannot be correctly when temperature cannot be correcty P0118 Coolant Temperature Sensor detected Possible causes include a sensor Malfunction Hi malfunction or an open short circuit to B in the wiring harness Issued when the signal from the electronic control Electronic Control Throttle m throttle position sensor cannot be correctly detected P0122 1 Position Sensor Malfunction Lo Possible causes include an open circuit vvithin the o sensor or
41. uit in the wiring harness Possible causes include an injector 3 malfunction P0203 Injector 3 Open Circuit and or an open circuit in the wiring harness Possible causes include an injector 4 malfunction P0204 Injector 4 Open Circuit and or an open circuit in the wiring harness Rail Pressure Sensor Malfunction Issued when rail pressure cannot be correctly P0191 Abnormal Sensor detected Possibility of a sensor malfunction Characteristics Operation Section 1 32 DTC Detection Item DTC Description Remarks Code 2 7 Possible causes include an injector 5 malfunction P0205 Injector 5 Open Circuit ye Fh 5 and or an open circuit in the wiring harness AT Possible causes include an injector 6 malfunction PO206 Injector 6 Open Circuit des and or an open circuit in the wiring harness Issued when an over temperature condition is P0217 Overheat detected Check the cooling system Issued when the engine speed exceeds the rated P0219 Engine Overrun value Issued when the boost pressure is higher than the P0234 Turbo Overboost is specified value P0278 PO335 Manifold Absolute Pressure MAP Sensor Lo Malfunction Cylinder Comparative Correction Error 1 Cylinder Injection Quantity Rotational Fluctuation Cylinder Comparative Correction Error 2 Cylinder Injection Quantity Rotational Fluctuation Cylinder Comparative Correction Error 43 Cylinder Injection Quantity Rotational Fluc
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