ISUZU DIESEL ENGINE 4HK1 TIER 4STAGE 4 EXHAUST EMISSION STANDARDS WORKSHOP MANUAL PDF

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ISUZU DIESEL ENGINE 4HK1 TIER 4STAGE 4 EXHAUST EMISSION STANDARDS WORKSHOP MANUAL – PDF DOWNLOAD

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ISUZU DIESEL ENGINE 4HK1 TIER 4STAGE 4 EXHAUST EMISSION STANDARDS WORKSHOP MANUAL – PDF DOWNLOAD

Language : English
Pages :1212
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

ISUZU DIESEL ENGINE 4HK1 TIER 4STAGE 4 EXHAUST EMISSION STANDARDS WORKSHOP MANUAL – PDF DOWNLOAD

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.

TABLE OF CONTENTS:

ISUZU DIESEL ENGINE 4HK1 TIER 4STAGE 4 EXHAUST EMISSION STANDARDS WORKSHOP MANUAL – PDF DOWNLOAD

IDE-2720 1
0 Introduction (All models) 4
Introduction 5
safety information 5
14A Service Information Guide (All models) 6
Contents included in service information 7
Plastic gauge 9
Recommended liquid gasket 11
Thread locking adhesive agent 13
Term 14
Abbreviations 15
Standard bolts 19
15B Maintenance Information (4HK1) 26
Maintenance precautions 27
Primary specifications 30
Function, Structure, Operation 33
Introduction to the trouble diagnosis 84
15C Functional Inspection (4HK1) 94
Engine compression pressure inspection 95
Fuel system check 97
Lubrication system check 98
Air intake system check 99
Exhaust system check 100
EGR control system check 101
Starting system check 102
Glow control system check 103
OBD system check 105
Inspection of the diagnostic light warning light illumination circuit system 106
Inspection of the diagnostic light warning light blinking circuit system 107
Inspection of the starter circuit system 108
15D Symptom (4HK1) 110
Engine start failure 111
Engine stalling 113
Engine hunching, rough idling 115
Excessive white smoke in the exhaust gas 116
Excessive black smoke in the exhaust gas 117
Abnormal noise 118
Large fuel consumption 119
Large oil consumption 121
Insufficient engine output 122
15E DTC Information (4HK1) 124
DTC P0016 (Flash Code 16) Crankshaft Position – CamshaftPosition Correlation Error 127
DTC P0045 (Flash Code 33) Turbocharger Boost Control VNT Error 128
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure – Too Low 129
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 130
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low 131
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 132
DTC P0097 (Flash Code 214) Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 133
DTC P0098 (Flash Code 214) Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 134
DTC P0102 (Flash Code 91) Mass Air Flow Sensor Circuit Low Input 135
DTC P0103 (Flash Code 91) Mass Air Flow Sensor Circuit High Input 136
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low 137
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High 138
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 139
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High 140
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 141
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High 142
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low 143
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High 144
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low 145
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 146
DTC P0201 (Flash Code 271) Injector Circuit Open – Cylinder 1 147
DTC P0202 (Flash Code 272) Injector Circuit Open – Cylinder 2 148
DTC P0203 (Flash Code 273) Injector Circuit Open – Cylinder 3 149
DTC P0204 (Flash Code 274) Injector Circuit Open – Cylinder 4 150
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition 151
DTC P0219 (Flash Code 543) Engine Overspeed Condition 152
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition 153
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low 154
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High 155
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit 156
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance 157
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 158
DTC P0380 (Flash Code 66) Glow Relay Circuit Error 159
DTC P0401 (Flash Code 93) EGR Flow Insufficient Detected 160
DTC P0404 (Flash Code 45) EGR Control Circuit Range/Performance 161
DTC P0409 (Flash Code 44) EGR Sensor Circuit 162
DTC P041C (Flash Code 27) EGR Cooler Outlet 1 Temp Sensor Circuit Low 163
DTC P041D (Flash Code 27) EGR Cooler Outlet 1 Temp Sensor Circuit High 164
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1 165
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 166
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 167
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 168
DTC P0522 (Flash Code 295) Engine Oil Pressure Sensor Circuit Low Input 169
DTC P0523 (Flash Code 295) Engine Oil Pressure Sensor Circuit High Input 170
DTC P0545 (Flash Code 39) EGR Cooler Inlet 1 Temp Sensor Circuit Low 171
DTC P0546 (Flash Code 39) EGR Cooler Inlet 1Temp Sensor Circuit High 172
DTC P0560 (Flash Code 155) 12Volt Circuit Error 173
DTC P0563 (Flash Code 35) System Voltage High 174
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error 175
DTC P0602 (Flash Code 154) Internal Control Module QR Code Error 176
DTC P0604 (Flash Code 153) Internal Control Module RAM Error 177
DTC P0606 (Flash Code 51) Internal Control Module CPU Error 178
DTC P060A (Flash Code 51) Internal Control Module CPU IC Error 179
DTC P060C (Flash Code 36) Internal Control Module A/D Processing Performance 180
DTC P0615 (Flash Code 19) Starter Relay Circuit Error 181
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance 182
DTC P0685 (Flash Code 416) ECM Power Relay Control Circuit Open 183
DTC P0687 (Flash Code 416) ECM Power Relay Control Circuit High 184
DTC P06A6 (Flash Code 55) Sensor Reference Voltage 1 Circuit 185
DTC P06A7 (Flash Code 56) Sensor Reference Voltage 2 Circuit 186
DTC P06A8 (Flash Code 57) Sensor Reference Voltage 3 Circuit 187
DTC P06A9 (Flash Code 59) Sensor Reference Voltage 4 Circuit 188
DTC P06AF (Flash Code 277) Torque Management System – Forced Engine Shutdown 189
DTC P06D5 (Flash Code 56) Sensor Reference Voltage 5 Circuit 190
DTC P1076 (Flash Code 313) Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 191
DTC P1077 (Flash Code 313) Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 192
DTC P1093 (Flash Code 227) Fuel Rail Pressure Too Low 193
DTC P1097 (Flash Code 213) Compressor Outlet Temperature Sensor Circuit High 194
DTC P1098 (Flash Code 213) Compressor Outlet Temperature Sensor Circuit High 195
DTC P1236 (Flash Code 315) Charge Air Cooler Performance Failure 196
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 197
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 198
DTC P1404 (Flash Code 45) EGR Position Fault 199
DTC P1606 (Flash Code 51) SW-IC Internal failure 200
DTC P160B (Flash Code 36) AD-IC Failure Error 201
DTC P160C (Flash Code 36) AD-IC2 Failure Error 202
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance 203
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 204
DTC P204F (Flash Code 611) SCR System Error (No Inducement) 205
DTC P207F (Flash Code 611) Urea Fluid Concentration Too Low 206
DTC P20C9 (Flash Code 611) SCR System Error 207
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input 208
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input 209
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input 210
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input 211
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 – 2 Voltage Correlation 212
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 213
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 214
DTC P2228 (Flash Code 71) Barometric Pressure Sensor Circuit Low 215
DTC P2229 (Flash Code 71) Barometric Pressure Sensor Circuit High 216
DTC P2457 (Flash Code 95) Exhaust Gas Recirculation (EGR) Cooling System Performance 217
DTC P2458 (Flash Code 139) Purge time Out Error 218
DTC P2BA7 (Flash Code 611) Urea Fluid Quantity Too Low 219
DTC P2BAA (Flash Code 611) SCR System Error (Inducement, No Purge) 220
DTC P3093 (Flash Code 227) Fuel Rail Pressure Too Low 221
DTC U0001 (Flash Code 84) CAN Bus Error (ISO-CAN) 222
DTC U0073 (Flash Code 84) Control Module Communication Bus Off 223
DTC U0101 (Flash Code 85) Lost Communication With CAN 224
DTC U010E (Flash Code 83) Lost Communications With Dosing Control Module 225
DTC U0110 (Flash Code 87) Lost Communication With VNT System 226
DTC U0411 (Flash Code 87) Lost CAN Communications With VNT Control Module 227
DTC U2106 (Flash Code 85) Lost CAN Communications With Wheel Loader Transmission Control System 228
DTC mapping table 229
1A Engine Control (4HK1) 234
DTC P0016 (Flash Code 16) Crankshaft Position – Camshaft Position Correlation Error 237
DTC P0045 (Flash Code 33) Turbocharger Boost Control VNT Error 238
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure – Too Low 240
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 243
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low 245
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 246
DTC P0097 (Flash Code 214) Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 247
DTC P0098 (Flash Code 214) Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 248
DTC P0102 (Flash Code 91) Mass Air Flow Sensor Circuit Low Input 249
DTC P0103 (Flash Code 91) Mass Air Flow Sensor Circuit High Input 250
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low 251
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High 252
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 253
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High 254
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 255
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High 256
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low 257
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High 258
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low 259
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 260
DTC P0201 (Flash Code 271) Injector Circuit Open – Cylinder 1 261
DTC P0202 (Flash Code 272) Injector Circuit Open – Cylinder 2 262
DTC P0203 (Flash Code 273) Injector Circuit Open – Cylinder 3 263
DTC P0204 (Flash Code 274) Injector Circuit Open – Cylinder 4 264
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition 265
DTC P0219 (Flash Code 543) Engine Overspeed Condition 266
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition 267
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low 268
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High 269
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit 270
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance 272
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 273
DTC P0380 (Flash Code 66) Glow Relay Circuit Error 275
DTC P0401 (Flash Code 93) EGR Flow Insufficient Detected 276
DTC P0404 (Flash Code 45) EGR Control Circuit Range/Performance 277
DTC P0409 (Flash Code 44) EGR Sensor Circuit 278
DTC P041C (Flash Code 27) EGR Cooler Outlet 1 Temp Sensor Circuit Low 280
DTC P041D (Flash Code 27) EGR Cooler Outlet 1 Temp Sensor Circuit High 281
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1 282
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 283
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 284
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 285
DTC P0522 (Flash Code 295) Engine Oil Pressure Sensor Circuit Low Input 287
DTC P0523 (Flash Code 295) Engine Oil Pressure Sensor Circuit High Input 288
DTC P0545 (Flash Code 39) EGR Cooler Inlet 1 Temp Sensor Circuit Low 289
DTC P0546 (Flash Code 39) EGR Cooler Inlet 1 Temp Sensor Circuit High 290
DTC P0560 (Flash Code 155) 12Volt Circuit Error 291
DTC P0563 (Flash Code 35) System Voltage High 292
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error 293
DTC P0602 (Flash Code 154) Internal Control Module QR Code Error 294
DTC P0604 (Flash Code 153) Internal Control Module RAM Error 295
DTC P0606 (Flash Code 51) Internal Control Module CPU Error 296
DTC P060A (Flash Code 51) Internal Control Module CPU IC Error 297
DTC P060C (Flash Code 36) Internal Control Module A/D Processing Performance 298
DTC P0615 (Flash Code 19) Starter Relay Circuit Error 299
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance 300
DTC P0685 (Flash Code 416) ECM Power Relay Control Circuit Open 301
DTC P0687 (Flash Code 416) ECM Power Relay Control Circuit High 302
DTC P06A6 (Flash Code 55) Sensor Reference Voltage 1 Circuit 303
DTC P06A7 (Flash Code 56) Sensor Reference Voltage 2 Circuit 304
DTC P06A8 (Flash Code 57) Sensor Reference Voltage 3 Circuit 305
DTC P06A9 (Flash Code 59) Sensor Reference Voltage 4 Circuit 306
DTC P06AF (Flash Code 277) Torque Management System- Forced Engine Shutdown 307
DTC P06D5 (Flash Code 56) Sensor Reference Voltage 5 Circuit 308
DTC P1076 (Flash Code 313) Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 309
DTC P1077 (Flash Code 313) Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 310
DTC P1093 (Flash Code 227) Fuel Rail Pressure Too Low 311
DTC P1097 (Flash Code 213) Compressor Outlet Temperature Sensor Circuit High 314
DTC P1098 (Flash Code 213) Compressor Outlet Temperature Sensor Circuit High 315
DTC P1236 (Flash Code 315) Charge Air Cooler Performance Failure 316
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 317
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 318
DTC P1404 (Flash Code 45) EGR Position Fault 319
DTC P1606 (Flash Code 51) SW-IC Internal failure 320
DTC P160B (Flash Code 36) AD-IC Failure Error 321
DTC P160C (Flash Code 36) AD-IC2 Failure Error 322
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance 323
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 324
DTC P204F (Flash Code 611) SCR System Error (No Inducement) 325
DTC P207F (Flash Code 611) Urea Fluid Concentration Too Low 326
DTC P20C9 (Flash Code 611) SCR System Error 327
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input 328
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input 329
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input 330
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input 331
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 – 2 Voltage Correlation 332
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 333
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 335
DTC P2228 (Flash Code 71) Barometric Pressure Sensor Circuit Low 337
DTC P2229 (Flash Code 71) Barometric Pressure Sensor Circuit High 338
DTC P2457 (Flash Code 95) Exhaust Gas Recirculation (EGR) Cooling System Performance 339
DTC P2458 (Flash Code 139) Purge time Out Error 340
DTC P2BA7 (Flash Code 611) Urea Fluid Quantity Too Low 341
DTC P2BAA (Flash Code 611) SCR System Error (Inducement, No Purge ) 342
DTC P3093 (Flash Code 227) Fuel Rail Pressure Too Low 343
DTC U0001 (Flash Code 84) CAN Bus Error (ISO-CAN) 346
DTC U0073 (Flash Code 84) Control Module Communication Bus Off 348
DTC U0101 (Flash Code 85) Lost Communication With CAN 350
DTC U010E (Flash Code 83) Lost Communications With Dosing Control Module 351
DTC U0110 (Flash Code 87) Lost Communication With VNT System 352
DTC U0411 (Flash Code 87) Lost CAN Communications With VNT Control Module 353
DTC U2106 (Flash Code 85) Lost CAN Communications With Wheel Loader Transmission Control System 354
1B Mechanical (4HK1) 356
Cylinder head cover 357
removal 357
installation 358
Cylinder head assembly 359
removal 359
disassembly 370
inspection 375
reassembly 382
installation 390
Idle gear 408
removal 408
inspection 422
installation 423
Inlet cover 449
removal 449
installation 455
Cylinder block 464
removal 464
inspection 483
installation 484
Exhaust manifold 521
removal 521
inspection 525
installation 526
Crankshaft 532
removal 532
disassembly 550
inspection 551
reassembly 555
installation 556
Piston 592
removal 592
disassembly 604
inspection 605
reassembly 612
installation 614
Camshaft 635
removal 635
disassembly 637
inspection 638
reassembly 640
installation 641
Flywheel 647
removal 647
inspection 649
installation 650
Crankshaft front oil seal 652
removal 652
installation 654
Crankshaft rear oil seal 657
removal 657
installation 659
Rocker arm shaft 662
removal 662
disassembly 664
inspection 665
reassembly 667
installation 669
Valve spring 673
removal 673
inspection 676
installation 677
Valve stem oil seal 684
removal 684
installation 687
CMP sensor 694
removal 694
inspection 695
installation 696
Front cover 697
removal 697
installation 700
Intake throttle valve 706
removal 706
installation 707
CKP sensor 708
removal 708
inspection 709
installation 710
Supplementary Information 711
1C Fuel System (4HK1) 738
Fuel supply pump 739
removal 739
installation 741
Common rail assembly 745
removal 745
installation 748
Injector 753
removal 753
installation 757
Suction control valve 763
removal 763
installation 764
Fuel filter 766
removal 766
installation 767
Relief valve 769
removal 769
installation 770
Fuel filter element 772
removal 772
installation 774
Fuel filter pressure sensor 777
removal 777
installation 778
Supplementary Information 779
1D Cooling (4HK1) 786
Water pump assembly 787
removal 787
inspection 789
installation 790
Thermostat 794
removal 794
inspection 795
installation 796
Cooling fan belt 798
inspection 798
Radiator 799
inspection 799
Overheat switch 800
removal 800
installation 801
Engine coolant temperature sensor 802
removal 802
inspection 803
installation 804
Coolant 805
inspection 805
Supplementary Information 810
1E Lubrication (4HK1) 816
Oil pan 817
removal 817
installation 818
Oil pump assembly 819
removal 819
disassembly 833
inspection 834
reassembly 836
installation 837
Oil level switch 862
removal 862
installation 863
Oil cooler assembly 864
removal 864
disassembly 869
reassembly 870
installation 871
Oil pressure sensor 880
removal 880
inspection 881
installation 882
Oil port cover 883
removal 883
installation 884
Engine oil 885
inspection 885
Supplementary Information 886
1F Induction (4HK1) 894
Turbocharger assembly 895
removal 895
inspection 898
installation 899
Intercooler 903
inspection 903
Air cleaner element 904
inspection 904
IMT sensor 905
removal 905
installation 906
Pressure sensor/boost temperature sensor 907
removal 907
inspection 908
installation 909
Charge air cooler temperature sensor 1 910
removal 910
inspection 911
installation 912
Supplementary Information 913
1G Exhaust (4HK1) 916
Exhaust gas temperature sensor 917
removal 917
inspection 918
installation 919
Oxidation catalyst assembly 920
removal 920
installation 922
Supplementary Information 924
1H Aux Emission Control Devices (4HK1) 926
EGR valve 927
removal 927
inspection 930
installation 931
Dosing module 935
removal 935
disassembly 936
reassembly 937
installation 938
DEF supply module 940
removal 940
disassembly 941
reassembly 942
installation 943
Coolant control valve 945
removal 945
installation 946
EGR gas temperature sensor 1 948
removal 948
inspection 949
installation 950
EGR gas temperature sensor 2 951
removal 951
inspection 952
installation 953
NOx sensor 954
removal 954
installation 955
DCU 956
removal 956
installation 957
Exhaust gas temperature sensor 3 958
removal 958
installation 959
DEF sensor 960
removal 960
installation 961
Silicon controlled rectifier catalyst 962
removal 962
disassembly 963
inspection 964
reassembly 965
installation 966
DEF supply module filter 967
removal 967
installation 968
Supplementary Information 969
1J Electrical (4HK1) 974
Glow plug 975
removal 975
inspection 976
installation 977
Generator 978
removal 978
disassembly 979
inspection 980
reassembly 984
installation 985
ECM 987
removal 987
installation 988
Starter assembly 989
removal 989
disassembly 990
inspection 992
reassembly 996
installation 998
Supplementary Information 999
38B Maintenance Information (Urea SCR System)1006
Function, structure, operation of emission control1007
Introduction to the trouble diagnosis of emission control1038
38C Functional Inspection (Urea SCR System)1042
Diagnostic system check-urea selective catalytic reduction system1043
38D Symptom (Urea SCR System)1044
Intermittent conditions of urea selective catalytic reduction system1045
Urea fluid consumption too high1048
Ammonia smell noticeable1049
White crystalline powder visible1050
38E DTC Information (Urea SCR System)1052
DTC P0607 Control Module Performance1054
DTC P060B Internal Control Module A/D Processing Performance1055
DTC P062F Control Module EEPROM Error1056
DTC P0641 Sensor Reference Voltage 1 Circuit1057
DTC P0658 Actuator Supply Voltage Circuit1058
DTC P0659 Actuator Supply Voltage Circuit1059
DTC P1462 Urea Fluid Quality Sensor Timeout Error1060
DTC P1464 Main Relay Performance1061
DTC P1468 DCU Overtemperature1062
DTC P1491 Urea Fluid Overpressure1063
DTC P1493 DCU Driver Overtemperature1064
DTC P149C Urea Fluid Pressure Reduction Malfunction1065
DTC P149D Urea Fluid Tank Overtemperature1066
DTC P203B Urea Fluid Tank Level Sensor Stuck1067
DTC P203C Urea Fluid Tank Level Sensor Low Voltage1068
DTC P203D Urea Fluid Tank Level Sensor High Voltage1069
DTC P2048 Urea Fluid Injector Circuit Low Voltage1070
DTC P2049 Urea Fluid Injector Circuit High Voltage1071
DTC P204B Urea Fluid Pressure Sensor Performance1072
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage1073
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage1074
DTC P205B Urea Fluid Tank Temperature Sensor Performance1075
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage1076
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage1077
DTC P206A Urea Fluid Quality Sensor Circuit1078
DTC P206B Urea Sensor Over Temperature Condition1079
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage1080
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage1081
DTC P207F Urea Fluid Concentration Too Low1082
DTC P208A Urea Fluid Pump Control Circuit1083
DTC P208B Usea Fluid Pump Performance1084
DTC P208C Urea Fluid Pump Control Circuit Low Voltage1085
DTC P208D Urea Fluid Pump Control Circuit High Voltage1086
DTC P208E Urea Fluid Injector Stuck1087
DTC P20A0 Urea Fluid Reverting Valve Circuit Open1088
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage1089
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage1090
DTC P20AC Urea Fluid Pump Temperature Sensor Performance1091
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance1092
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open1093
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage1094
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage1095
DTC P20E8 Urea Fluid Pressure Underpressure1096
DTC P20E9 Urea Fluid Overpressure1097
DTC P20EA Urea Fluid Pressure Reduction Malfunction1098
DTC P20FE Urea Fluid Pressure Build-Up Error1099
DTC P2201 Upstream Nox Sensor Performance1100
DTC P2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 11101
DTC P2207 NOx Sensor Heater Control Circuit High Voltage Sensor 11102
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance1103
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage1104
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage1105
DTC U0002 CAN Bus Off1106
DTC U0100 Lost Communication with Engine Control Module (ECM)1107
DTC U029D Lost Communication With NOx Sensor 11108
DTC mapping table1109
10M Emission Control (Urea SCR System)1112
DTC P0607 Control Module Performance1114
DTC P060B Internal Control Module A/D Processing Performance1115
DTC P062F Control Module EEPROM Error1116
DTC P0641 Sensor Reference Voltage 1 Circuit1117
DTC P0658 Actuator Supply Voltage Circuit1118
DTC P0659 Actuator Supply Voltage Circuit1120
DTC P1462 Urea Fluid Quality Sensor Timeout Error1122
DTC P1464 Main Relay Performance1123
DTC P1468 DCU Overtemperature1124
DTC P1491 Urea Fluid Overpressure1125
DTC P1493 DCU Driver Overtemperature1127
DTC P149C Urea Fluid Pressure Reduction Malfunction1128
DTC P149D Urea Fluid Tank Overtemperature1130
DTC P203B Urea Fluid Tank Level Sensor Stuck1131
DTC P203C Urea Fluid Tank Level Sensor Low Voltage1133
DTC P203D Urea Fluid Tank Level Sensor High Voltage1134
DTC P2048 Urea Fluid Injector Circuit Low Voltage1135
DTC P2049 Urea Fluid Injector Circuit High Voltage1136
DTC P204B Urea Fluid Pressure Sensor Performance1137
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage1138
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage1139
DTC P205B Urea Fluid Tank Temperature Sensor Performance1140
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage1141
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage1142
DTC P206A Urea Fluid Quality Sensor Circuit1143
DTC P206B Urea Sensor Over Temperature Condition1144
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage1145
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage1146
DTC P207F Urea Fluid Concentration Too Low1147
DTC P208A Urea Fluid Pump Control Circuit1148
DTC P208B Usea Fluid Pump Performance1149
DTC P208C Urea Fluid Pump Control Circuit Low Voltage1150
DTC P208D Urea Fluid Pump Control Circuit High Voltage1151
DTC P208E Urea Fluid Injector Stuck1152
DTC P20A0 Urea Fluid Reverting Valve Circuit Open1153
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage1154
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage1155
DTC P20AC Urea Fluid Pump Temperature Sensor Performance1156
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance1157
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open1158
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage1159
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage1160
DTC P20E8 Urea Fluid Pressure Underpressure1161
DTC P20E9 Urea Fluid Overpressure1163
DTC P20EA Urea Fluid Pressure Reduction Malfunction1165
DTC P20FE Urea Fluid Pressure Build-Up Error1166
DTC P2201 Upstream Nox Sensor Performance1168
DTC P2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 11169
DTC P2207 NOx Sensor Heater Control Circuit High Voltage Sensor 11170
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance1171
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage1172
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage1173
DTC U0002 CAN Bus Off1174
DTC U0100 Lost Communication With ECM1175
DTC U029D Lost Communication With NOx Sensor 11176
Wiring Diagram1178
Using the ETM1180
Structure and Content of This Document1181
1 Wiring Diagram1182
2 Location Diagram / 3 Connector Information /4 Terminal Name1185
5 Circuit Symbols1186
6 Abbreviations1187
Engine1188
Engine Control1189
Engine Control1189
Location Diagram1194
Connector Location Diagram1195
Connector List1198
H (Connector List)1199
S (Connector List)1200
T (Connector List)1202
Terminal Name1204
Terminal Name1205

S.M 3/1/25