Hino Motors HINO 155 series Workshop Manual

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This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.

Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.

As for maintenance items, refer to the Owner

All information and specifications in this manual are based upon the latest product information available at the time of printing.

Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.

Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys-

tems in these vehicles.

Chassis Workshop Manual

J05E Engine Workshop Manual

Trouble shooting Workshop Manual

FOREWORD

s Manual.

Manual Name

Pub. No.

S1-LXJE05A

S1-LXJE05A EWD

S5-LJ05E07A

S7-LXJE05A 2/5

S7-LXJE05A 3/5

S7-LXJE05A 4/5

S7-LXJE05A 5/5

Table of Contents

Troubleshooting

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Summary of Contents for Hino Motors HINO 155 series

Page 1 All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice. Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys- tems in these vehicles.
Page 2 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL No. S7-LXJE05A 1/5 (U.S.A.), S7-LXJE06A 1/5 (CANADA) MODELS HINO 155, 155h, 195, 195h CHAPTER Production Code XFC710, XFC720, XFC730, XFC740, XJC700, XJC710, XJC720,XJC730, XJC740 GENERAL INTRODUCTION 1-001...
Page 3: Heater And Air Conditioner
BODY CONSTRUCTION BODY INSIDE ACCESSORY BODY OUTSIDE ACCESSORY AIR BAG AND SEAT BELT All rights reserved. This manual may not be reproduced or copied in whole in part, with- HEATER AND AIR CONDITIONER out the written consent of Hino Motors, Ltd.
Page 4 INDEX: TROUBLE SHOOTING GROUP 2/2 ELECTRICAL CONTROL SYSTEM...
Page 5: Table Of Contents
GENERAL INTRODUCTION 1–1 GENERAL INTRODUCTION 1-001 HOW TO IDENTIFY VEHICLE TYPE ....1-2 HOW TO IDENTIFY VEHICLE TYPE ......1-2 VEHICLE TYPE ............1-2 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE ............1-3 APPEARANCE OF VEHICLE ......1-4 APPEARANCE.............1-4 APPEARANCE OF VEHICLE .........1-4 SAFETY INSTRUCTIONS AND READINESS TO WORK ........
Page 6: How To Identify Vehicle Type
1–2 GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE HOW TO IDENTIFY VEHICLE TYPE HOW TO IDENTIFY VEHICLE TYPE VEHICLE TYPE EN01H01ZZZ010102001001 REPORTED MODEL CLASSIFICATION ENGINE MODEL VEHICLE MODEL DECK HEIGHT HEAVY DUTY TRACK J05E-UG (HV) K HIGH FLOOR CAB J05E-TP (Diesel) CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE TRANSMISSION CAB WIDTH DRIVE...
Page 7: Structure
GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE 1–3 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE EN01H01ZZZ010102001002 SHTS01ZZZ0100002...
Page 8: Appearance Of Vehicle
1–4 GENERAL INTRODUCTION/APPEARANCE OF VEHICLE APPEARANCE OF VEHICLE APPEARANCE APPEARANCE OF VEHICLE EN01H01ZZZ020101003001 SHTS01ZZZ0200001...
Page 9: General Precautions
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–5 SAFETY INSTRUCTIONS AND READINESS TO WORK WARNING GENERAL PRECAUTIONS EN01H01ZZZ030101001001 Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a mal- function of the vehicle which may result in personal injury and/or property damage.
Page 10 1–6 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK PRECAUTIONS IN TILTING AND LOWERING THE CAB ! WARNING Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage. •...
Page 11 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–7 DEFINITION OF SAFETY TERMS Indicates an extremely hazardous situation if proper procedures are not followed and could result in death or serious injury. Indicates a potential hazardous situation if proper procedures are not followed and could result in death or serious injury.
Page 12 1–8 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK TOWING • When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No.
Page 13 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–9 CLEAN AIR ACT Heavy-duty engine rebuilding practices. § 86.004-40 • The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reas- sembly, and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine.
Page 14: Identification Information
1–10 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK IDENTIFICATION INFORMATION EN01H01ZZZ030101001002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number (VIN) is stamped on the right frame, as shown in the illustration. This number has also been stamped on the manufacture's plate. A: Vehicle Identification Number (VIN) B: Manufacturer's Plate See VEHICLE IDENTIFICATION NUMBER (VIN) STRUC-...
Page 15 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–11 VEHICLE NOISE EMISSION CONTROL INFORMATION • The Vehicle Noise Emission Control Information is affixed to the left pillar of the cab. The name of manufacturer, production year FOR ALL MODELS and month, and noise emission applicable to medium and heavy trucks in conformity with U.S.
Page 16 1–12 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK VEHICLE EMISSION CONTROL INFORMATION • The Vehicle Emission Control Information is affixed to the side of the right door. The name of manufacturer, production year and month, and emission applicable to medium and heavy trucks in conformity with U.S.
Page 17: Safety Instructions For Work
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–13 SAFETY INSTRUCTIONS FOR WORK PRECAUTIONS EN01H01ZZZ030101004001 SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS Removing the battery cable ! WARNING • Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you disconnect the battery terminals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the exhaust gas after treatment after the starter key is turned to "LOCK"...
Page 18 1–14 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK Handling of electronic parts Never give an impact to electronic parts of a computer or relay. Keep electronic parts away from high temperatures and humidity. Never splash water onto electronic parts in washing the vehicle. Do not remove the harness connector, electric component box, and cover except for repair and inspection.
Page 19 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–15 Handling of connectors When removing a connector, hold a connector (area shown in an arrow in the figure) and then pull it off. Do not pull wire harnesses. Pull off a lockable connector after unlocking. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound.
Page 20 1–16 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc.
Page 21: Introduction To Workshop Manual
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–17 GENERAL INFORMATION INTRODUCTION TO WORKSHOP MANUAL GENERAL EN01H01ZZZ030102002001 SCOPE OF REPAIR DESCRIPTIONS There are three major processes in repair work: i.e. "trouble shooting", "removal/installation, replacement, over- haul, assembly, inspection and adjustment" and "final inspection". This document covers only the first process (trouble shooting) and the second process (removal/installation, replacement, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).
Page 22: Introduction To Descriptions
1–18 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK INTRODUCTION TO DESCRIPTIONS EN01H01ZZZ030102002002 TROUBLE SHOOTING FOR EACH TROUBLE SYMPTOM WITH REFERENCE TO THE CHART A possible cause and remedy/prevention are indicated for every item, respectively. SHTS01ZZZ0300019...
Page 23 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–19 INTRODUCTION TO TROUBLE SHOOTING This document covers the trouble shooting steps 2 and 3 listed below. Identify a fact through adequate hearings on the situation (1) Hearing "Step 1" and environment where a trouble has occurred. Conduct a diagnosis inspection, a symptom check, a func- (2) Prior check tional inspection and a basic inspection to identify a symp-...
Page 24 1–20 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK INTRODUCTION TO TROUBLE SHOOTING FOR EACH DIAGNOSIS MONITOR CODE The "diagnosis code list" and the "trouble shooting for each code" are contained in this document to address each system for which a diagnosis monitor code will be output. If a diagnosis monitor code is already identified, it is possible to immediately proceed with a trouble shooting process based on the code list.
Page 25: Definition Of Term
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–21 DEFINITION OF TERM EN01H01ZZZ030102002003 DEFINITION OF TERM Terms used in this document are defined as follows. DIRECTION CHASSIS RELATED Longitudinal direction The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the installed position in a vehicle.
Page 26: Trouble Shooting
1–22 GENERAL INTRODUCTION/TROUBLE SHOOTING TROUBLE SHOOTING TROUBLESHOOTING WITH DIAGNOSIS MONITOR TROUBLESHOOTING PROCEDURE EN01H01ZZZ040301002001 NOTICE • Before reading the diagnosis code, turn the starter key to "ON" and check that the check engine warning light comes on. • Inspection is not available in check mode. CONNECTION OF DIAGNOSIS CHECK WIRE Turn the starter key to the "LOCK"...
Page 27 GENERAL INTRODUCTION/TROUBLE SHOOTING 1–23 INDICATION OF DIAGNOSIS MONITOR CODE A diagnosis monitor code can be identified by viewing the diagnosis monitor and the check engine light. The example shown below represents how to identify diagnosis monitor codes 32 and 21. Intervals between light flashings will iden- tify a diagnosis monitor code.
Page 28: Apparatus For Trouble Shooting
1–24 GENERAL INTRODUCTION/TROUBLE SHOOTING • If the check engine warning light is lit and no code is output at 1,000 r/min or more, once turn the starter key to "LOCK" and then recheck. Release DLC3 12(TS) or 13(TS)  14(CG) terminals. APPARATUS FOR TROUBLE SHOOTING EN01H01ZZZ040301002002 TAG CODE AND SYSTEM NAME LIST FOR DEDICATED HARNESS...
Page 29: Step Of Trouble Diagnosis
GENERAL INTRODUCTION/TROUBLE SHOOTING 1–25 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DX Ⅱ ) STEP OF TROUBLE DIAGNOSIS EN01H01ZZZ040301003001 PREPARATION FOR CONNECTING HINO DX Ⅱ The "HINO DX Ⅱ " is a failure diagnosis tool for the common rail fuel injection system and the chassis system. For con- necting the computer to a vehicle, the "DST-i"...
Page 30: Apparatus For Trouble Diagnosis
1–26 GENERAL INTRODUCTION/TROUBLE SHOOTING APPARATUS FOR TROUBLE DIAGNOSIS EN01H01ZZZ040301003002 APPARATUS FOR TROUBLE DIAGNOSIS Part name Part No. Illustration of appearance Outline/function Laptop computer* The following specifications are nec- essary for operation of HINO DX Ⅱ . • Operating system (OS): Windows7 Professional 32 bit.
Page 31: Glossary
GENERAL INTRODUCTION/GLOSSARY 1–27 GLOSSARY DEFINITION OF ABBREVIATION LIST OF ABBREVIATION EN01H01ZZZ060102001001 Abbreviations Meaning, or Official Name Air Conditioner Anti-lock Brake System Accessory Auto Clutch Unit Automated Manual Transmission After Turbo Catalyst Automatic Transmission Fluid Crank Angle Controller Area Network CD-ROM Compact Disc Read Only Memory Central Processing Unit Decibel...
Page 32 1–28 GENERAL INTRODUCTION/GLOSSARY Abbreviations Meaning, or Official Name FF shift Feather touch & Finger shift Fusible link Front Fiber Reinforced Plastic Front Underrun Protector Glow Control Unit Ground Gross Vehicle Weight High HINO DX Hino Diagnostic eXplorer Hybrid Vehicle HVAC Heating, Ventilating and Air-Conditioning unit I.S.C.
Page 33 GENERAL INTRODUCTION/GLOSSARY 1–29 Abbreviations Meaning, or Official Name Pump Control Valve PCV valve Positive Crankcase Ventilation valve Particulate Matter Glass-fiber-reinforced Polypropylene Parts Per Million Power Steering Power Take-Off Physical Vapor Deposit Power QR code Quick Response Code Rear Axle Right Hand Selective Catalytic Reduction Suction Control Valve Special Service Tool...
Page 34: Glossary Of Sae And Hino Terms
1–30 GENERAL INTRODUCTION/GLOSSARY GLOSSARY OF SAE AND HINO TERMS EN01H01ZZZ060102001002 This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents. SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS AUTOMATIC TRANSMISSION Automatic transmission AMBIENT AIR TEMPERATURE...
Page 35 GENERAL INTRODUCTION/GLOSSARY 1–31 SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS ENGINE CONTROL Engine control ENGINE COOLANT TEMPERATURE Coolant Temperature ENGINE COOLANT TEMPERATURE Water Temperature ENGINE FUEL TEMPERATURE Fuel temperature EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor EXHAUST GAS RECIRCULATION EGR Valve EXHAUST GAS RECIRCULATION Valve EGR valve...
Page 36 1–32 GENERAL INTRODUCTION/GLOSSARY SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve PARK/NEUTRAL POSITION Neutral position PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch RAIL FUEL PRESSURE Common rail Pressure RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor SPARK PLUG SPARK PLUG...
Page 37 ENGINE (J05E) 2–1 ENGINE (J05E) 2-001 TROUBLESHOOTING ........2-4 DTC: P0027 ............2-116 DTC: P003A ............2-121 ENGINE ECU (J05E)............2-4 DTC: P0045 ............2-126 PRECAUTIONS FOR DIAGNOSIS ......2-4 DTC: P0047 ............2-130 ELECTRICAL ............2-6 DTC: P0048 ............2-134 PRECAUTIONS ............2-7 DTC: P006E ............2-138 COMPUTER (ECU) PIN ASSIGNMENT....2-11 DTC: P006F ............2-142 ENGINE ECU CONNECTOR........2-15 DTC: P007B ............2-146...
Page 38 2–2 ENGINE (J05E) DTC: P0341............2-453 DTC: P1427............2-755 DTC: P0381............2-461 DTC: P1428............2-762 DTC: P0401............2-467 DTC: P1458............2-770 DTC: P0402............2-483 DTC: P1459............2-775 DTC: P0404............2-494 DTC: P14B0 ............2-780 DTC: P0405 and P0406 ........2-499 DTC: P14B2 ............2-784 DTC: P041B ............2-505 DTC: P14B3 and P14B4 ........2-788 DTC: P041C and P041D ........2-518 DTC: P14B7 and P14B8 ........2-794 DTC: P0420............2-526...
Page 39 ENGINE (J05E) 2–3 DTC: P2458 ............2-1115 DTC: P2458 ............2-1115 DTC: P2459 ............2-1125 DTC: P2459 ............2-1125 DTC: P2463 ............2-1128 DTC: P2463 ............2-1128 DTC: P246F ............2-1136 DTC: P246F ............2-1136 DTC: P2470 and P2471 ........2-1144 DTC: P2470 and P2471 ........
Page 40: Troubleshooting
2–4 ENGINE (J05E)/TROUBLESHOOTING TROUBLESHOOTING ENGINE ECU (J05E) PRECAUTIONS FOR DIAGNOSIS EN01H02127030602016001 • Ensure that individual connectors are certainly connected before start of checking works. • Make sure to set the starter key to the "LOCK" position before disconnecting a connector. •...
Page 41 ENGINE (J05E)/TROUBLESHOOTING 2–5 ILLUSTRATION OF CONNECTOR AND MEASUREMENT ON TERMINAL LOCK ILLUSTRATION OF CONNECTOR The illustration of a connector contained in this document represents an image of a connector with its lock positioned on top as viewed from the connecting face. TO BE CONNECTED MALE FEMALE...
Page 42 2–6 ENGINE (J05E)/TROUBLESHOOTING ELECTRICAL EN01H02127030602016002 ACTUATOR RELAY FUSE POWER SOURCE FUSE KEY SWITCH STARTER SWITCH MAIN RELAY ACCELERATOR PEDAL BATTERY POSITION SENSOR 1, 2 CAN COMMUNICATION (VARIABLE NOZZLE TURBO CHARGER, EGR VALVE DEF DOSING SYSTEM) PTO ACCELERATOR SENSOR OTHERS VEHICLE SPEED SENSOR CAN COMMUNICATION (DIAGNOSIS,VEHICLE CONTROL ECU) VEHICLE CONTROL ECU ENGINE STOP SWITCH...
Page 43 ENGINE (J05E)/TROUBLESHOOTING 2–7 PRECAUTIONS EN01H02127030602016003 ! WARNING Approximately 110V is generated for the injector drive actuation system. For this reason, electrical shock may result if the injector drive circuit is touched directly by hand. Set the starter key to the LOCK position if it is necessary to check or repair the computer, harnesses, or connectors.
Page 44 2–8 ENGINE (J05E)/TROUBLESHOOTING AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE THE MALFUNCTION MEMORY STORED IN THE PAST. OTHER- WISE, THE MALFUNCTION LIGHT IN THE DISPLAY WILL REMAIN LIT. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING LEAD FROM THE BACKSIDE.
Page 45 ENGINE (J05E)/TROUBLESHOOTING 2–9 CONNECT THE SIGNAL CHECK HARNESS. Set the starter key to the "LOCK" position and disconnect the connectors from the engine ECU. Connect a signal check harness to the engine sub harness and the engine ECU. SST: 09843-E4050 Signal check harness Computer (engine ECU) Connector...
Page 46 2–10 ENGINE (J05E)/TROUBLESHOOTING RADIO INSTALLATION • There is a danger that the control unit might malfunction if a high output radio transmitter (over 50W) is installed in the vehicle. 10. USING A QUICK CHARGER • Disconnect both battery terminals before using a quick charger. 11.
Page 47 ENGINE (J05E)/TROUBLESHOOTING 2–11 COMPUTER (ECU) PIN ASSIGNMENT EN01H02127030602016004 SHTS021270300006...
Page 48 2–12 ENGINE (J05E)/TROUBLESHOOTING SHTS021270300007...
Page 49 ENGINE (J05E)/TROUBLESHOOTING 2–13 SHTS021270300008...
Page 50 2–14 ENGINE (J05E)/TROUBLESHOOTING SHTS021270300009...
Page 51 ENGINE (J05E)/TROUBLESHOOTING 2–15 ENGINE ECU CONNECTOR EN01H02127030602016005 REMOVING THE ENGINE ECU CONNECTOR NOTICE Before replacement, wait until the engine cools down as you may get burned. (Set the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.) CLEANING THE ENGINE ECU CONNECTOR Check that the engine ECU connector is completely con- nected to the engine ECU.
Page 52 2–16 ENGINE (J05E)/TROUBLESHOOTING While pushing the primary latch of the connector, move the lever in the direction of the arrow as shown in the figure until a "click" is heard and then detach the connector. Primary latch Lever SHTS021270300012 Pull out the connector straight. NOTICE •...
Page 53 ENGINE (J05E)/TROUBLESHOOTING 2–17 MOUNTING THE ENGINE ECU CONNECTOR ATTACHING THE ENGINE ECU CONNECTOR Check that the harness side connector lever is fully open and place it straight on the engine ECU side connector. NOTICE At this time, check that the lever is fully open. Lever SHTS021270300016 HINT...
Page 54 2–18 ENGINE (J05E)/TROUBLESHOOTING Move the lever in the direction of the arrow as shown in the figure until a "click" is heard and attach the connector. NOTICE If the lever cannot move smoothly, repeat steps (1) and (2). Also drop a few drops of water to the sliding portion to make it smooth. Sliding Lever portion...
Page 55 ENGINE (J05E)/TROUBLESHOOTING 2–19 INSPECTION EN01H02127030602016006 PRIOR CHECK Set the starter key to the "ON" position (do not start the engine) and confirm that the SVS (Service Vehicle Soon) light in the indicator area lights up. HINT • If the MIL (Malfunction Indicator Light) is lit, perform a system check to see if the malfunction is of the past or present.
Page 56 2–20 ENGINE (J05E)/TROUBLESHOOTING TROUBLE DIAGNOSIS USING THE COM- PUTER (HINO DX Ⅱ ) EN01H02127030602016007 PREPARATION FOR CONNECTING HINO DX Ⅱ The "HINO DX Ⅱ " is a failure diagnosis tool for the common rail fuel injection system and the chassis system. For con- necting the computer to a vehicle, the "DST-i"...
Page 57 ENGINE (J05E)/TROUBLESHOOTING 2–21 DIAGNOSTIC TROUBLE CODE (DTC) TABLE EN01H02127030602016008 NOTICE A: Torque limit DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light — Light No Light P0005 Fuel Cut Valve stuck closed • Fuel cut valve • Fuel cut valve Malfunction of fuel cutoff valve - —...
Page 58 2–22 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Intercooler outlet temperature sensor Intake air temperature sensor — • ECU (ECU connector) Light No Light P007C (intercooler outlet) - out of range (Out of range low) •...
Page 59 ENGINE (J05E)/TROUBLESHOOTING 2–23 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Air cleaner element • Intake system • Air flow sensor • ECU (ECU connector) — Light No Light P0101 Air flow sensor - rationality • Wire harness •...
Page 60 2–24 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Intake throttle valve position sensor 1 Intake throttle valve position sen- — • ECU (ECU connector) Light No Light P0122 sor 1 - out of range (Out of range low) •...
Page 61 ENGINE (J05E)/TROUBLESHOOTING 2–25 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Engine • Supply pump • SCV • Engine ECU • Pre fuel filter • Fuel pipe • Breather hose • Fuel tank feed pipe Fuel system pressure control - Light No Light P016F...
Page 62 2–26 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Common rail pressure sensor Fuel rail pressure sensor (sub) — • Wire harness Light No Light P01A5 - out of range (Out of range low) •...
Page 63 ENGINE (J05E)/TROUBLESHOOTING 2–27 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Boost pressure sensor Boost pressure sensor - out of • ECU (ECU connector) Light No Light P0237 range (Out of range low) • Wire harness •...
Page 64 2–28 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Fuel injection pipe — Light No Light P0303 #3 Misfire • Injector • Fuel injection pipe — Light No Light P0304 #4 Misfire • Injector •...
Page 65 ENGINE (J05E)/TROUBLESHOOTING 2–29 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light EGR valve controller position sensor signal too low (EGR actu- Light No Light P0405 • EGR valve ator position sensor signal too low) Valve position sensor magnet Light No Light P0406...
Page 66 2–30 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light — — Light No Light P04DA EGR feedback failure • Combination meter — Light No Light P0500 Vehicle speed sensor - low • Wire harness • ECU (ECU connector) •...
Page 67 ENGINE (J05E)/TROUBLESHOOTING 2–31 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Fuse • Fusible link • Battery cable Battery voltage - out of range — Light P0563 Light (Out of range high) • Alternator • Wire harness •...
Page 68 2–32 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Common rail pressure sensor 1 • Accelerator sensor 2 • Wire harness • Boost pressure sensor ECU sensor power supply 1 fail- — No Light P0643 •...
Page 69 ENGINE (J05E)/TROUBLESHOOTING 2–33 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light Glow controller - Battery for glow • Glow control unit controller open, GND short Glow — • Wire harness Light No Light P0683 controller - Glow control signal Glow controller - Diagnosis sig- •...
Page 70 2–34 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light Valve position control failure - DC motor out of range, functional No Light P1458 • EGR valve Light (EGR actuator over temp warn- ing level) Controller high temperature Light No Light P1459...
Page 71 ENGINE (J05E)/TROUBLESHOOTING 2–35 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Engine stop switch — • Wire harness No Light P1530 Engine stop switch malfunction Light • ECU (ECU connector) Fuel injector adjustment data — • Injector Light No Light P1601...
Page 72 2–36 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Fuel dosing valve Malfunction of fuel addition valve — • Wire harness Light No Light P20CD [Short-circuit] • ECU (ECU connector) Malfunction of fuel addition valve —...
Page 73 ENGINE (J05E)/TROUBLESHOOTING 2–37 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light Throttle/Pedal Position Sensor/ — — Light P2120 Light Switch "D" Circuit • Accelerator sensor Accelerator pedal position sen- — • Wire harness Light No Light P2122 sor 1 - out of range (Out of range low) •...
Page 74 2–38 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • DEF • Exhaust pipe • Air flow sensor • Exhaust gas temperature sensor NOx sensor (SCR downstream) (SCR inlet) — Light No Light P2214 - Performance and Monitoring •...
Page 75 ENGINE (J05E)/TROUBLESHOOTING 2–39 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Exhaust gas temperature sensor (DPF inlet) Exhaust gas temperature sensor — Light No Light P242B (DOC inlet) - rationality • Wire harness • ECU (ECU connector) •...
Page 76 2–40 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Exhaust pipe • Exhaust brake valve • Exhaust gas temperature sensor (DPF inlet) — • Exhaust gas temperature sensor Light P2458 DPR manual regeneration failure Light (DOC1 inlet) •...
Page 77 ENGINE (J05E)/TROUBLESHOOTING 2–41 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light Nozzle position sensor failure • VNT controller range (High level) (VNT actuator Light No Light P2562 position sensor performance • VNT actuator invalid) Nozzle operating range failure - •...
Page 78 2–42 ENGINE (J05E)/TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM Light • Connector Engine ECU CAN communica- — • Wire harness Light No Light U010E tion (DeNOx ECU) • DCU • Connector — • Wire harness Light No Light U0293 CAN Bus-Line Open From HV...
Page 79 ENGINE (J05E)/TROUBLESHOOTING 2–43 GROUP SHARING THE SENSOR SUPPLY TERMINAL EN01H02127030602016009 • If one of the sensor power supplies fails, more than one malfunction codes will occur for the sensors sharing the sensor supply terminal. Check the sensors for short circuits and whether the sensor supply circuit is in normal condition. ECU terminal Sensor Intake throttle valve position sensor 1...
Page 80 2–44 ENGINE (J05E)/TROUBLESHOOTING GROUP SHARING THE SENSOR GND TERMINAL EN01H02127030602016010 ECU terminal Sensor Fuel temperature sensor Intake air temperature sensor (intake manifold) Common rail pressure sensor (Main) Boost sensor Exhaust gas temperature sensor 1 Engine coolant temperature sensor Intake air temperature sensor Exhaust gas temperature sensor 2 Exhaust gas temperature sensor 3 Exhaust gas temperature sensor 4...
Page 81 ENGINE (J05E)/TROUBLESHOOTING 2–45 MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION EN01H02127030602016011 Since the CAN communication line is configured as described below, more than one malfunction code may occur depend- ing on the faulty area of the circuit. For single failure •...
Page 82 2–46 ENGINE (J05E)/TROUBLESHOOTING CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ENGINE ECU) Malfunction Part Case U010A U010C U029E U029D U02A2 6-12 U010A, U010C, U029D, U029E, U0073, U010E, U02A2 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (DCU) Malfunction Part Case U029E U029D U02A2 6-12...
Page 83 ENGINE (J05E)/TROUBLESHOOTING 2–47 ENGINE CONTROL/DIAGNOSIS CAN LINE (500 k) <Diesel> Engine control/ Diagnosis CAN Line CAN-TMN2 CAN-TMN2 J/C_CAN2 (22P) J/C_CAN2 (22P) J/C_CAN2 J/C_CAN2 J/C_CAN1 (10P) J/C_CAN1 (10P) J/C_CAN5 J/C_CAN5 (Terminator) (Terminator) (Terminator) (Terminator) Engine Engine ATM ECU VCS ECU VCS ECU ABS ECU <Hybrid>...
Page 84 2–48 ENGINE (J05E)/TROUBLESHOOTING PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k) EN01H02127030602016012 Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Check that the any DTC other than CAN communication system DTC (U****) has been detected.
Page 85 ENGINE (J05E)/TROUBLESHOOTING 2–49 Check for +B/GND short-circuit in CAN H-line Set the starter key to the "LOCK" position. GND4 GND1 +24V CAN- Disconnect the following sensors and controllers connected to the GND5 GND2 Engine peripherals and after-treatment CAN line. ISOK CAN+ SGND CGFR...
Page 86 2–50 ENGINE (J05E)/TROUBLESHOOTING Check for +B/GND short-circuit in CAN L-line Use the electrical tester to check the continuity between the follow- ing terminals. GND4 GND1 +24V CAN- (1) Between the CAL0 terminal in the DCU (53P) vehicle side GND5 GND2 ISOK CAN+ SGND...
Page 87 ENGINE (J05E)/TROUBLESHOOTING 2–51 Check the terminating resistance Use the electrical tester to check the continuity between the follow- ing terminals. (1) Between the CAH0 terminal and CAL0 terminal in the DCU (53P). (2) Between the CANP terminal and CANN terminal in CAN- TMN2.
Page 88 2–52 ENGINE (J05E)/TROUBLESHOOTING Check the resistance Use the electrical tester to check the continuity between the follow- ing terminals. (1) Between the CAH0 terminal and CAL0 terminal in the DCU (53P). Measurement Tester ISGW Standard values conditions connections CAH0 DCU (53P): 45 –...
Page 89 ENGINE (J05E)/TROUBLESHOOTING 2–53 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL] EN01H02127030602016013 Check harness in CAN bus line between J/C DEF SSR and DCU (Failure Site 11) Set the starter key to the "LOCK" position. Disconnect the following sensors and controllers connected to the Engine peripherals and aftertreatment CAN line.
Page 90 2–54 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between J/C_CAN_Diesel and J/C DEF SSR (Failure Site 10) Disconnect the J/C_CAN_Diesel connector. Use electrical tester to measure the resistance between No.5 (CANH) terminal No.8 (CANL) terminal C_CAN_Diesel connector. Measurement Tester Standard values conditions connections...
Page 91 ENGINE (J05E)/TROUBLESHOOTING 2–55 Check harness in CAN bus line between J/C_ENG_CAN and J/C_CAN_Diesel (Failure Site 9) Disconnect the J/C_ENG_CAN connector. Use electrical tester to measure the resistance between No.6 (CANH) terminal and No.8 (CANL) terminal at the J/C_ENG_CAN connector. Measurement Tester Standard values conditions...
Page 92 2–56 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between J/C_ENG_CAN2 and J/C_ENG_CAN (Failure Site 8) Disconnect the J/C_ENG_CAN2 connector. Use electrical tester to measure the resistance between No.5 (CANH) terminal No.8 (CANL) terminal C_ENG_CAN2 connector. Measurement Tester Standard values conditions connections J/C_ENG_CAN2...
Page 93 ENGINE (J05E)/TROUBLESHOOTING 2–57 Check harness in CAN bus line between engine ECU and J/C_ENG_CAN2 (Failure Site 7) Disconnect the engine ECU connector (both 2 connectors). Connect the signal check harness to the engine ECU vehicle-side connector. (Do not connect harness to the ECU) Use electrical tester to measure the resistance between (CANH) terminal and (CANL) terminal at the ECU check harness.
Page 94 2–58 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between engine ECU and CAN-TMN2 (terminating resistance) (Failure Site 6) Use electrical tester to measure the resistance between (CANN) terminal and (CANH) terminal at the ECU check harness. These circuits are identified as terminal V17 and terminal V37 on the ECU check harness A.
Page 95 ENGINE (J05E)/TROUBLESHOOTING 2–59 Inspect the EGR controller [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the connector of the engine ECU. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Erase the malfunction history and set the starter key to the "LOCK"...
Page 96 2–60 ENGINE (J05E)/TROUBLESHOOTING Inspect the VNT controller [HINO DX Ⅱ ] Erase the trouble history and set the starter key to the "LOCK" position. Connect the VNT controller connector. Set the starter key to the "ON" position. Check that the VNT controller communication failure (U010C) is not detected.
Page 97 ENGINE (J05E)/TROUBLESHOOTING 2–61 Inspect the NOx sensor 2 [HINO DX Ⅱ ] Erase the trouble history and set the starter key to the "LOCK" position. Connect the NOx sensor 2 connector. Set the starter key to the "ON" position. Check that the NOx sensor 2 communication failure (U029E) is not detected.
Page 98 2–62 ENGINE (J05E)/TROUBLESHOOTING DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID] EN01H02127030602016014 Check harness in CAN bus line between J/C DEF SSR and DCU (Failure Site 12) Set the starter key to the "LOCK" position. Disconnect the following sensors and controllers connected to the Engine peripherals and after-treatment CAN line.
Page 99 ENGINE (J05E)/TROUBLESHOOTING 2–63 Check harness in CAN bus line between J/C_HV1 and J/C DEF SSR (Failure Site 11) Disconnect the J/C_HV1 connector. Use electrical tester to measure the resistance between No.4 (CANH) terminal and No.9 (CANL) terminal at the J/C_HV1 con- nector.
Page 100 2–64 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between J/C_HV2 and J/C_HV1 (Failure Site 10) Disconnect the J/C_HV2 connector. Use electrical tester to measure the resistance between No.3 (CANH) terminal and No.8 (CANL) terminal at the J/C_HV2 con- nector. Measurement Tester Standard values...
Page 101 ENGINE (J05E)/TROUBLESHOOTING 2–65 Check harness in CAN bus line between J/C_ENG_CAN and J/C_HV2 (Failure Site 9) Disconnect the J/C_ENG_CAN connector. Use electrical tester to measure the resistance between No.6 (CANH) terminal and No.8 (CANL) terminal at the CAN_J/C1 con- nector. Measurement Tester Standard values...
Page 102 2–66 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between J/C_ENG_CAN2 and J/C_ENG_CAN (Failure Site 8) Disconnect the J/C_ENG_CAN2 connector. Use electrical tester to measure the resistance between No.5 (CANH) terminal No.8 (CANL) terminal C_ENG_CAN2 connector. Measurement Tester Standard values conditions connections J/C_ENG_CAN2...
Page 103 ENGINE (J05E)/TROUBLESHOOTING 2–67 Check harness in CAN bus line between engine ECU and J/C_ENG_CAN2 (Failure Site 7) Disconnect the engine ECU connector (both 2 connectors). Connect the signal check harness to the engine ECU vehicle-side connector. (Do not connect harness to the ECU) HINT Refer to "PRECAUTIONS".
Page 104 2–68 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between engine ECU and CAN-TMN2 (terminating resistance) (Failure Site 6) Use electrical tester to measure the resistance between (CANP) terminal and (CANH) terminal at the ECU check harness. These circuits are identified as terminal V17 and terminal V37 on the ECU check harness A.
Page 105 ENGINE (J05E)/TROUBLESHOOTING 2–69 Inspect the EGR controller [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the connector of the engine ECU. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Erase the malfunction history and set the starter key to the "LOCK"...
Page 106 2–70 ENGINE (J05E)/TROUBLESHOOTING Inspect the VNT controller [HINO DX Ⅱ ] Erase the trouble history and set the starter key to the "LOCK" position. Connect the VNT controller connector. Set the starter key to the "ON" position. Check that the VNT controller communication failure (U010C) is not detected.
Page 107 ENGINE (J05E)/TROUBLESHOOTING 2–71 Inspect the NOx sensor 2 [HINO DX Ⅱ ] Erase the trouble history and set the starter key to the "LOCK" position. Connect the NOx sensor 2 connector. Set the starter key to the "ON" position. Check that the NOx sensor 2 communication failure (U029E) is not detected.
Page 108 2–72 ENGINE (J05E)/TROUBLESHOOTING PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL] EN01H02127030602016015 Check the DTC detected Engine ECU Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Check that any DTC other than CAN communication system DTC (U****) has been detected.
Page 109 ENGINE (J05E)/TROUBLESHOOTING 2–73 Check for +B/GND short-circuit in CAN H-line Set the starter key to the "LOCK" position. GND4 GND1 +24V CAN- Disconnect the following sensors and controllers connected to the GND5 GND2 Engine_control/Diagnosis_CAN line. ISOK CAN+ SGND CGFR GND3 •...
Page 110 2–74 ENGINE (J05E)/TROUBLESHOOTING Check for +B/GND short-circuit in CAN L-line Use the electrical tester to check the continuity between the CAL1 terminal in the DCU vehicle-side connector (53P) and the 4th ter- GND4 GND1 minal and 16th terminal in the diagnostic connector (16P). +24V CAN- GND5...
Page 111 ENGINE (J05E)/TROUBLESHOOTING 2–75 Check the terminating resistance Use the electrical tester to check the continuity between the follow- ing terminals. (1) Between the CAH1 terminal and CAL1 terminal in the DCU (53P). (2) Between the 1st terminal and 2nd terminal in the CAN_TMN. ISGW Measurement Tester...
Page 112 2–76 ENGINE (J05E)/TROUBLESHOOTING Check the resistance Connect the DCU (53P) connector and CAN-TMN connector. Use the electrical tester to measure the terminating resistance of DCU (53P). ISGW Measurement Tester Standard values conditions connections TE2A DCU (53P): 45 – 75  Starter key: ON TE2B CAL0...
Page 113 ENGINE (J05E)/TROUBLESHOOTING 2–77 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID] EN01H02127030602016016 Check the DTC detected Engine ECU Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Check that any DTC other than CAN communication system DTC (U****) has been detected.
Page 114 2–78 ENGINE (J05E)/TROUBLESHOOTING Check for +B/GND short-circuit in CAN H-line Set the starter key to the "LOCK" position. GND4 GND1 +24V CAN- Disconnect the following sensors and controllers connected to the GND5 GND2 Engine_control/Diagnosis_CAN line. ISOK CAN+ SGND CGFR GND3 •...
Page 115 ENGINE (J05E)/TROUBLESHOOTING 2–79 Check for +B/GND short-circuit in CAN L-line Use the electrical tester to check the continuity between the CAL1 terminal in the DCU vehicle-side connector (53P) and the 4th ter- GND4 GND1 minal and 16th terminal in the diagnostic connector (16P). +24V CAN- GND5...
Page 116 2–80 ENGINE (J05E)/TROUBLESHOOTING Check the DCU (terminating resistance) Use the electrical tester to measure the terminating resistance of DCU (53P). Measurement Tester Standard values conditions connections ISGW DCU (53P): 120  10  Starter key: ON CAH1 – CAL1 TE2A TE2B CAL0 CAL1...
Page 117 ENGINE (J05E)/TROUBLESHOOTING 2–81 Check the HV ECU (terminating resistance) Use the electrical tester to measure the terminating resistance of the HV ECU. Measurement Tester Standard values conditions connections HV ECU 120  10  Starter key: ON 21st – 22nd SHTS021270300064 Do the measurements meet the standard value? Go to step 6.
Page 118 2–82 ENGINE (J05E)/TROUBLESHOOTING Check the resistance Connect the DCU (53P) connector and HV PCU connector. Use the electrical tester to measure the terminating resistance of DCU (53P). ISGW Measurement Tester Standard values conditions connections TE2A DCU (53P): 45 – 75  Starter key: ON TE2B CAL0...
Page 119 ENGINE (J05E)/TROUBLESHOOTING 2–83 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL] EN01H02127030602016017 Check harness in CAN bus line between J/C_CAN5 and DCU (Failure Site 8) Set the starter key to the "LOCK" position. Disconnect the following controller connectors connected to the Engine_control/Diagnosis_CAN line.
Page 120 2–84 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between J/C_CAN1 (10P) and J/C_CAN5 (Failure Site 7) Disconnect the J/C_CAN1 (10P) connector. Use the electrical tester to measure the resistance between the terminals in the CAN H-line and L-line on the J/C_CAN5 side, viewed from J/C_CAN1 (10P).
Page 121 ENGINE (J05E)/TROUBLESHOOTING 2–85 Check harness in CAN bus line between J/C_CAN1 (22P) and J/C_CAN2 (Failure Site 5) Disconnect the J/C_CAN1 (22P) connector. Use the electrical tester to measure the resistance between the terminals in the CAN H-line and L-line on the J/C_CAN2 side, viewed from J/C_CAN1 (22P).
Page 122 2–86 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between DLC and J/C_CAN1 (22P) (Failure Site 1) Use the electrical tester to measure the resistance between the DLC CAN H line terminal and L line terminal. +24V CAN- Measurement Tester Standard values ISOK CAN+...
Page 123 ENGINE (J05E)/TROUBLESHOOTING 2–87 Check harness in CAN bus line between engine ECU and J/C_CAN5 (Failure Site 3) Disconnect the J/C_CAN1 (10P) connector. Connect the signal check harness to the engine ECU vehicle-side connector. (Do not connect harness to the ECU) Use electrical tester to measure the resistance between (CANL) terminal and (CANH) terminal at the ECU check harness.
Page 124 2–88 ENGINE (J05E)/TROUBLESHOOTING DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID] EN01H02127030602016018 Check harness in CAN bus line between J/C_CAN5 and DCU (Failure Site 8) Set the starter key to the "LOCK" position. Disconnect the following controller connectors connected to the Engine_control/Diagnosis_CAN line.
Page 125 ENGINE (J05E)/TROUBLESHOOTING 2–89 Check harness in CAN bus line between J/C_CAN2 and J/C_CAN5 (Failure Site 7) Disconnect the J/C_CAN2 connector. Use the electrical tester to measure the resistance between the terminals in the CAN H-line and L-line on the J/C_CAN5 side, viewed from J/C_CAN2.
Page 126 2–90 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between J/C_CAN1 (10P) and J/C_CAN1 (22P) (Failure Site 5) Use the electrical tester to measure the resistance between the terminals in the CAN H-line and L-line on J/C_CAN1 (22P) side, viewed from J/C_CAN1 (10P). Measurement Tester Standard values...
Page 127 ENGINE (J05E)/TROUBLESHOOTING 2–91 Check harness in CAN bus line between DLC and J/C_CAN1 (22P) (Failure Site 1) Use the electrical tester to measure the resistance between the DLC CAN H line terminal and L line terminal. +24V CAN- Measurement Tester ISOK CAN+ SGND...
Page 128 2–92 ENGINE (J05E)/TROUBLESHOOTING Check harness in CAN bus line between engine ECU and J/C_CAN5 (Failure Site 3) Disconnect the J/C_CAN2 connector. Connect the signal check harness to the engine ECU vehicle-side connector. (Do not connect harness to the ECU) Use electrical tester to measure the resistance between (CANL) terminal and (CANH) terminal at the ECU check harness.
Page 129 ENGINE (J05E)/TROUBLESHOOTING 2–93 MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY EN01H02127030602016019 Since the following actuators and switches are connected in the downstream of the actuator power relay, more than one malfunction code or functional failure can occur. Check the supply circuit from the actuator power relay. Sensor Case Brake switch...
Page 130 2–94 ENGINE (J05E)/TROUBLESHOOTING ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET) EN01H02127030602016020 * After inspection, indicate a check mark in the boxes below. Inspec- tion steps Exhaust Fuel Air intake Inspec- Engine/ Sensor system/ VN turbo- Supply tank, system valve/ Injector tion area system...
Page 131 ENGINE (J05E)/TROUBLESHOOTING 2–95 Inspec- tion steps Exhaust Fuel Air intake Inspec- Engine/ Sensor system/ VN turbo- Supply tank, system valve/ Injector tion area system exhaust charger pump filter parts cooler brake Injection Inspect Engine Inspect quantity the boost coolant the fuel compen- Check sensor.
Page 132 2–96 ENGINE (J05E)/TROUBLESHOOTING Inspec- tion steps Exhaust Fuel Air intake Inspec- Engine/ Sensor system/ VN turbo- Supply tank, system valve/ Injector tion area system exhaust charger pump filter parts cooler brake -Remove contami- Retighte - Check - Re-fit nants - Inspect - Clean parts - Check...
Page 133 ENGINE (J05E)/TROUBLESHOOTING 2–97 Standard injection quantity J05E r/min Idling (normal) 7 – 16 Injection quantity (mm /st) r/min 1,500 Mid-speed inspection point Injection quantity (mm /st) 10 or more (AT) r/min 2,800 Standard DPR filter differential pressure Differential pressure 1.5 kPa or under...
Page 134 2–98 ENGINE (J05E)/TROUBLESHOOTING NO DTC EN01H02127030602016021 ENGINE LOW POWER, MISS-FIRE, HESITATION, KNOCKING, RUNNING ROUGH Check Parts Check contents Judgement If fail (Pass/Fail) Injection quantity at 1,500r/min No load 10 (mm /st) or Injector Injector Coolant temp. more than 80 C {176 F} more Replace Cylinder cut-off test...
Page 135 ENGINE (J05E)/TROUBLESHOOTING 2–99 Cylinder cut-off test 1. Park vehicle with parking brake set, Engine  and chock whiles. Data monitor and Active test 2. Set engine speed at 1,500r/min by  cruse control switch. Active test Setting 3. Check each cylinder for decreased ...
Page 136 2–100 ENGINE (J05E)/TROUBLESHOOTING Intake throttle Visually check No excessive dirt inside of throttle body and no movement between but- terfly valve and shaft Intake throttle activation test 1. Park vehicle with parking brake set, Engine and chock whiles.  2. When click [UP/DOWN] button, the Inspection Menu directed Intake throttle valve posi- ...
Page 137 ENGINE (J05E)/TROUBLESHOOTING 2–101 DPR NORMAL MANUAL REGENERATION IS NOT COMPLETE Check Parts Check contents Judgement If fail (Pass/Fail) Check carbon of fuel addition valve nozzle No carbon Cleaning Fuel addition valve and folder deposited carbon...
Page 138 2–102 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE FOR WHEN THE DEF MIXED INTO THE ENGINE COOLANT EN01H02127030602016022 Inspect the DEF in the DEF tank Check the color of the DEF in the tank. (check if the fluid is trans- parent or not.) Is the DFE transparent? Go to step 3.
Page 139 ENGINE (J05E)/TROUBLESHOOTING 2–103 Inspect if engine coolant is mixed into the DEF injector Remove the DEF injector from the muffler and perform a HINO DX Ⅱ activation test to check the DEF injection. Set the starter switch to the "Lock" position and connect the vehi- cle to HINO DX Ⅱ...
Page 140 2–104 ENGINE (J05E)/TROUBLESHOOTING DTC: P0005 EN01H02127030602016023 P0005: Fuel Cut Valve stuck closed INFORMATION Engine ECU Fuel cut valve TYP 0.7A (FCV) (FCV) SHTS021270300096 Technical description • The engine ECU monitors the pressure in the fuel pipe based on the value of the fuel pressure sensor. <Description of malfunction>...
Page 141 ENGINE (J05E)/TROUBLESHOOTING 2–105 INSPECTION PROCEDURE: P0005 Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle. Set the starter key to the "ON" position. On the screen of the diagnostic system, select [Engine], and check any DTC listed below other than P0005.
Page 142 2–106 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel cut valve downstream pipe 1 Check if any of the following defects is found in the pipe between the fuel cut valve and the fuel dosing valve. • Fuel leakage (loose joint bolt) • Crush •...
Page 143 ENGINE (J05E)/TROUBLESHOOTING 2–107 Inspect the fuel cut valve upstream pipe 1 Check if any of the following defects is found in the pipe between the fuel pump and the fuel cut valve. (1) Fuel leakage (loose joint bolt) (2) Crush (3) Wrong assembly Was any failure found? Repair or replace the defective part.After...
Page 144 2–108 ENGINE (J05E)/TROUBLESHOOTING DTC: P0006 and P0007 EN01H02127030602016024 P0006: Malfunction of fuel cut valve (Low) INFORMATION Engine ECU Fuel cut valve TYP 0.7A (FCV) (FCV) SHTS021270300099 Technical description • – <Description of malfunction> • Fuel cut valve is not working properly. •...
Page 145 ENGINE (J05E)/TROUBLESHOOTING 2–109 P0007: Malfunction of fuel cut valve (High) INFORMATION Engine ECU Fuel cut valve TYP 0.7A (FCV) (FCV) SHTS021270300100 Technical description • – <Description of malfunction> • Fuel cut valve is not working properly. • Possible magnetic valve failure or +B short-circuit or disconnection DTC set condition DTC detection condition •...
Page 146 2–110 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0006 and P0007 Inspect the fuel cut valve connector Check the connection of the fuel cut valve connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 147 ENGINE (J05E)/TROUBLESHOOTING 2–111 Inspect the fuel cut valve unit Set the starter key to the "LOCK" position. Disconnect the fuel cut valve connector. BODY GND Use the electrical tester to measure the resistance between the terminals of the fuel cut valve FCV and ground. Measurement Tester Standard values...
Page 148 2–112 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the fuel cut valve harness Use the electrical tester to measure the resistance between the terminals of the fuel cut valve vehicle side connector and the engine ECU. Measurement Tester Standard values conditions connections Fuel cut valve vehicle side con- nector –...
Page 149 ENGINE (J05E)/TROUBLESHOOTING 2–113 DTC: P0016 EN01H02127030602016025 P0016: Crankshaft position sensor and Camshaft position sensor - rationality INFORMATION No pulse section Crankshaft position sensor pulse Extra pulse 112 pulses per 2 revolutions Camshaft position sensor pulse 5 pulses per 2 revolutions Monitor location SHTS021270300105 Technical description...
Page 150 2–114 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 151 ENGINE (J05E)/TROUBLESHOOTING 2–115 INSPECTION PROCEDURE: P0016 Inspect the camshaft gear Check that the camshaft gear is properly assembled. Was any failure found? Assemble the camshaft gear properly. Go to step 2. Inspect the flywheel Check that the flywheel is properly assembled. Was any failure found? Assemble the flywheel normally.
Page 152 2–116 ENGINE (J05E)/TROUBLESHOOTING DTC: P0027 EN01H02127030602016026 P0027: Exhaust Brake Performance INFORMATION Technical description <Description of malfunction> • The engine ECU detected sticking of the exhaust brake valve. DTC set condition DTC detection condition • DPR regeneration is in process. • The vehicle speed is 0 km/h. •...
Page 153 ENGINE (J05E)/TROUBLESHOOTING 2–117 INSPECTION PROCEDURE: P0027 Check the DTC detected 1 [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. On the screen of the diagnostic system, select [Engine], and check any DTC listed below other than P0027.
Page 154 2–118 ENGINE (J05E)/TROUBLESHOOTING Inspect the exhaust brake valve Check the exhaust brake valve for unease and sticking. SHTS021270300107 Was any failure found? Clean the exhaust brake valve.Replace if Go to step 5. necessary.After clearing or replacement, go to Step 4. Check the DTC detected 2 [HINO DX Ⅱ...
Page 155 ENGINE (J05E)/TROUBLESHOOTING 2–119 Inspect the exhaust brake valve Warm up the engine. (Coolant temperature: 80 C {176 F} or more) Turn OFF the devices that place load on the engine, such as the air conditioner and PTO. <Inspection procedure> - Adjust the engine revolution to 980 r/min by using the idling volume. (For vehicles without the idling volume, adjust the engine revolution to 980 r/min by using [Data monitor and Active test] for the diagnostic system.)
Page 156 2–120 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected [HINO DX Ⅱ ] Perform a DPR forced regeneration. After regeneration, on the screen of the diagnostic system, select [Engine] and check the detected DTCs. SHTS021270300110 Has DTC P0027 been detected? Replace the engine ECU. Procedure completed.
Page 157 ENGINE (J05E)/TROUBLESHOOTING 2–121 DTC: P003A EN01H02127030602016027 P003A: Initialization failure (VNT actuator initialize error) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V) CAN-H Micro CAN I/F MOTOR (W) CAN-L computer block...
Page 158 2–122 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 159 ENGINE (J05E)/TROUBLESHOOTING 2–123 INSPECTION PROCEDURE: P003A Check the DTC detected 1 [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P003A (for exam- ple, U010C) has been detected.
Page 160 2–124 ENGINE (J05E)/TROUBLESHOOTING Inspect the operation of the VNT controller [HINO DX Ⅱ ] Set the starter key to the "ON" position. Erase the trouble history using HINO DX Ⅱ . Set the starter key to the "LOCK" position. Set the starter key to the "ON" position again. Select [Engine] and check if P003A has been detected.
Page 161 ENGINE (J05E)/TROUBLESHOOTING 2–125 Check the response delay of the VNT controller Select [Inspection Menu] [VNT inspection] from the menu, and inspect the response delay at the Target VNT position and Actual VNT position. ! CAUTION Perform the inspection while the engine is stopped to avoid engine damages.
Page 162 2–126 ENGINE (J05E)/TROUBLESHOOTING DTC: P0045 EN01H02127030602016028 P0045: DC motor terminal open circuit or DC motor coil open circuit INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V) CAN-H Micro CAN I/F...
Page 163 ENGINE (J05E)/TROUBLESHOOTING 2–127 Reset condition • After restoration to normal condition and starter key "LOCK" Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Engine output is restricted. Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)>...
Page 164 2–128 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0045 Check the DTC detected 1 [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0045 (for exam- ple U010C) has been detected.
Page 165 ENGINE (J05E)/TROUBLESHOOTING 2–129 Check the connector connection [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Disconnect the VNT actuator and VNT controller connector and connect properly again. Set the starter key to the "ON" position. Select [Engine] and check if P0045 has been detected. VNT controller SHTS021270300119 Has DTC P0045 been detected?
Page 166 2–130 ENGINE (J05E)/TROUBLESHOOTING DTC: P0047 EN01H02127030602016029 P0047: DC motor terminal short circuit, DC motor short circuit (Short to Battery) (VNT actuator motor short to BATT) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V)
Page 167 ENGINE (J05E)/TROUBLESHOOTING 2–131 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 168 2–132 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0047 Check the DTC detected (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0047 (for exam- ple U010C) has been detected.
Page 169 ENGINE (J05E)/TROUBLESHOOTING 2–133 Check the connector connection [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Disconnect the VNT actuator and VNT controller connector and connect properly again. Set the starter key to the "ON" position. Select [Engine] and check if P0047 has been detected. Has DTC P0047 been detected? Go to step 4.
Page 170 2–134 ENGINE (J05E)/TROUBLESHOOTING DTC: P0048 EN01H02127030602016030 P0048: DC motor terminal short circuit, DC motor short circuit (Short to GND) (VNT actuator motor short to GND) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V)
Page 171 ENGINE (J05E)/TROUBLESHOOTING 2–135 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 172 2–136 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0048 Check the DTC detected (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0048 (for exam- ple U010C) has been detected.
Page 173 ENGINE (J05E)/TROUBLESHOOTING 2–137 Check the connector connection [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Disconnect the VNT actuator and VNT controller connector and connect properly again. Set the starter key to the "ON" position. Select [Engine] and check if P0048 has been detected. Has DTC P0048 been detected? Go to step 4.
Page 174 2–138 ENGINE (J05E)/TROUBLESHOOTING DTC: P006E EN01H02127030602016031 P006E: Power supply failure (Out of range low) (VNT actuator power supply too low) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V) CAN-H Micro...
Page 175 ENGINE (J05E)/TROUBLESHOOTING 2–139 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 176 2–140 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P006E Check the DTC detected 1 (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P006E (U010C) has been detected.
Page 177 ENGINE (J05E)/TROUBLESHOOTING 2–141 Check the VNT controller power supply circuit Set the starter key to the "LOCK" position. Disconnect the VNT controller connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the VNT controller vehicle side connector.
Page 178 2–142 ENGINE (J05E)/TROUBLESHOOTING DTC: P006F EN01H02127030602016032 P006F: Power supply voltage failure (Out of range high) (VNT actuator power supply too high) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V) CAN-H Micro...
Page 179 ENGINE (J05E)/TROUBLESHOOTING 2–143 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 180 2–144 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P006F Check the DTC detected 1 (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P006F (U010C) has been detected.
Page 181 ENGINE (J05E)/TROUBLESHOOTING 2–145 Check the VNT controller power supply circuit Set the starter key to the "LOCK" position. Disconnect the VNT controller connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the VNT controller vehicle side connector.
Page 182 2–146 ENGINE (J05E)/TROUBLESHOOTING DTC: P007B EN01H02127030602016033 P007B: Intake air temperature sensor (intercooler outlet) - rationality INFORMATION [at Engine Startup] Engine ECU Coolant temperature sensor 10mA (THW) X28 (THW) Body earth 10mA (E5) (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2)
Page 183 ENGINE (J05E)/TROUBLESHOOTING 2–147 DTC set condition DTC detection condition • Starter key "ON". • The engine speed is 1000 r/min or less. • Engine coolant temperature is in the range of -30 to 55 C {-22 to 131 F}. • The battery voltage is in the range of 10 V to 16 V. •...
Page 184 2–148 ENGINE (J05E)/TROUBLESHOOTING P007B: Intake air temperature sensor (intercooler outlet) - rationality INFORMATION [while Driving (1)] Engine ECU Coolant temperature sensor 10mA (THW) X28 (THW) Body earth 10mA (E5) (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2)
Page 185 ENGINE (J05E)/TROUBLESHOOTING 2–149 DTC set condition DTC detection condition The conditions described below remain for 11 seconds or more. • The battery voltage is in the range of 10 V to 16 V. • The engine speed remains at 500 r/min or more for 5 seconds or more. The conditions described below remain for 40 seconds or more.
Page 186 2–150 ENGINE (J05E)/TROUBLESHOOTING P007B: Intake air temperature sensor (intercooler outlet) - rationality INFORMATION [while Driving (2)] Engine ECU Coolant temperature sensor 10mA (THW) X28 (THW) Body earth 10mA (E5) (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2)
Page 187 ENGINE (J05E)/TROUBLESHOOTING 2–151 DTC set condition DTC detection condition The conditions described below remain for 11 seconds or more. • The battery voltage is in the range of 10 V to 16 V. • The engine speed remains at 500 r/min or more for 5 seconds or more. The conditions described below remain for 40 seconds or more.
Page 188 2–152 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Intercooler outlet temperature sensor malfunction • Failure of intake air temperature sensor (with built-in air flow sensor) • Intake manifold temperature sensor malfunction • Boost pressure sensor - Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.) - Faulty resistance (due to sticking) •...
Page 189 ENGINE (J05E)/TROUBLESHOOTING 2–153 INSPECTION PROCEDURE: P007B Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] from the menu, and check if any DTC other than P007B (for example, P0401, P0402, P0404, P0234, P0299, P22D3, or turbocharger/EGR system DTC) has been detected.
Page 190 2–154 ENGINE (J05E)/TROUBLESHOOTING Inspect the intercooler outlet temperature sensor Check the installation of the intercooler outlet temperature sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the intercooler outlet temperature sensor. Was any failure found? Clean the sensing unit and install it properly.
Page 191 ENGINE (J05E)/TROUBLESHOOTING 2–155 Inspect the intercooler outlet temperature sensor power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the intercooler outlet temperature sensor vehicle side con- nector.
Page 192 2–156 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnection in wire harness of intercooler outlet temperature sensor Connect the intercooler outlet temperature sensor connector. Measure the resistance between the terminals of engine ECU (sig- nal check harness) using the electrical tester. Measurement Tester Standard values conditions connections...
Page 193 ENGINE (J05E)/TROUBLESHOOTING 2–157 Inspect the intake air temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (air flow sensor) con- nector. Measure the resistance between the terminals of the intake tem- perature sensor using the electrical tester. Measurement Tester Standard values...
Page 194 2–158 ENGINE (J05E)/TROUBLESHOOTING Inspect the boost pressure sensor power supply system Set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Measure the voltage between the terminals of the boost pressure sensor vehicle side connector using the electrical tester.
Page 195 ENGINE (J05E)/TROUBLESHOOTING 2–159 Inspect the intake manifold temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the intake manifold temperature sensor connector. Measure the resistance between the terminals of the sensor using the electrical tester. Measurement Tester Standard values conditions connections...
Page 196 2–160 ENGINE (J05E)/TROUBLESHOOTING DTC: P007C and P007D EN01H02127030602016034 P007C: Intake air temperature sensor (intercooler outlet) - out of range (Out of range low) INFORMATION Engine ECU (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2) 15mA (VC2)
Page 197 ENGINE (J05E)/TROUBLESHOOTING 2–161 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 198 2–162 ENGINE (J05E)/TROUBLESHOOTING P007D: Intake air temperature sensor (intercooler outlet) - out of range (Out of range high) INFORMATION Engine ECU (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2) 15mA (VC2) (PC2S) 10mA Exhaust gas (THG) (THG)
Page 199 ENGINE (J05E)/TROUBLESHOOTING 2–163 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 200 2–164 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P007C and P007D Inspect the intercooler outlet temperature sensor connector Check the connection of the intercooler outlet temperature sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 201 ENGINE (J05E)/TROUBLESHOOTING 2–165 Inspect the intercooler outlet temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the intercooler outlet temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the intercooler outlet temperature sensor. Measurement Tester Standard values...
Page 202 2–166 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit in wire harness of intercooler outlet temperature sensor Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between the engine ECU (signal check harness) terminals and ground.
Page 203 ENGINE (J05E)/TROUBLESHOOTING 2–167 Inspect the intercooler outlet temperature sensor power supply Disconnect the intercooler outlet temperature sensor connector. Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the engine ECU (signal check harness) terminals.
Page 204 2–168 ENGINE (J05E)/TROUBLESHOOTING DTC: P0088 EN01H02127030602016035 P0088: Fuel system pressure - High INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe Supply pump Overflow valve Fuel tank Pre fuel filter Fuel filter SHTS021270300156 Technical description...
Page 205 ENGINE (J05E)/TROUBLESHOOTING 2–169 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Cruise control does not work. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work •...
Page 206 2–170 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0088 Inspect the start of the engine Inspect the start of the engine. Does the engine start? Go to step 4. Go to step 2. Inspect the supply pump Check if fuel is leaking or seeping out of the supply pump. SUPPLY PUMP SHTS021270300157 Was any failure found?
Page 207 ENGINE (J05E)/TROUBLESHOOTING 2–171 Function check of supply pump [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Actual common rail pressure Specified common rail pressure Set the starter key to the "ON" position. 222MP The pressure limiter is Select [Engine].
Page 208 2–172 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel pipe Check if the fuel pipe and hose between the fuel tank and pre fuel filter are clogged, punctured, or bent. Make sure the fuel pipe joint bolts are not loose. Was any failure found? Repair or replace the faulty part, and go to Go to step 6.
Page 209 ENGINE (J05E)/TROUBLESHOOTING 2–173 Inspect the fuel tank Drain fuel out of the fuel tank and check if there are foreign objects inside the tank. Was any failure found? Remove the foreign object and clean the fuel Go to step 9. tank.
Page 210 2–174 ENGINE (J05E)/TROUBLESHOOTING Inspect the SCV connector Check the connection of the SCV connector (looseness and poor contact). Was any failure found? Repair or replace the faulty part, and go to Go to step 13. step 13. Inspect the common rail pressure sensor connector Check the connection of the common rail pressure sensor connec- tor (looseness and poor contact).
Page 211 ENGINE (J05E)/TROUBLESHOOTING 2–175 Inspect the engine speed main sensor (crankshaft position sensor) Set the starter key to the "ON" position. Select [Engine]. Select [NE active identification], [G active identification] in [Data monitor and Active test]. Start the engine and confirm that the engine main speed sensor (NE) and sub speed sensor (G) operate (stay ON) continuously.
Page 212 2–176 ENGINE (J05E)/TROUBLESHOOTING DTC: P0096 EN01H02127030602016036 P0096: Intake air temperature sensor (intake manifold) - rationality INFORMATION [at engine start] Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) (PC1S) 15mA (E1) (PCR1) PCR1 15mA (VC) Common rail 15mA pressure sensor (E2)
Page 213 ENGINE (J05E)/TROUBLESHOOTING 2–177 DTC set condition DTC detection condition The conditions described below remain for 20 seconds or more. • Starter key "ON". • The engine speed is 1000 r/min or less. • Fuel injection quantity is 35 mm /st. cyl or less. •...
Page 214 2–178 ENGINE (J05E)/TROUBLESHOOTING P0096: Intake air temperature sensor (intake manifold) - rationality INFORMATION [at engine running] Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2)
Page 215 ENGINE (J05E)/TROUBLESHOOTING 2–179 DTC set condition DTC detection condition The conditions described below remain for 11 seconds or more. • The battery voltage is in the range of 10 to 16 V. • The condition that the engine speed remains at 500 r/min or more for 5 seconds or more. The conditions described below remain for 40 seconds or more.
Page 216 2–180 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0096 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0096 (for exam- ple, P0401, P0402, P0404, P0234, P0299, P22D3, turbo, EGR DTC) has been detected.
Page 217 ENGINE (J05E)/TROUBLESHOOTING 2–181 Inspect the intake air temperature sensor (intake manifold) Check the installation of the intake air temperature sensor (intake manifold). Make sure there is no dirt, damage or clogging in the sensing unit of the intake air temperature sensor (intake manifold). Was any failure found? Clean the sensing unit and install it properly.
Page 218 2–182 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor (intake manifold) power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the intake air temperature sensor (intake manifold) vehicle side connector.
Page 219 ENGINE (J05E)/TROUBLESHOOTING 2–183 Inspect disconnection of the intake air temperature sensor (intake manifold) harness Connect the intake air temperature sensor (intake manifold) con- nector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 220 2–184 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor (air flow sensor built-in) unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (air flow sensor built- in) connector. Use the electrical tester to measure the resistance between the terminals of the intake air temperature sensor (air flow sensor built-in).
Page 221 ENGINE (J05E)/TROUBLESHOOTING 2–185 Inspect the intake air temperature sensor (intercooler outlet) unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (intercooler outlet) connector. Use the electrical tester to measure the resistance between the terminals of the intake air temperature sensor (intercooler outlet). Measurement Tester Standard values...
Page 222 2–186 ENGINE (J05E)/TROUBLESHOOTING Inspect the boost pressure sensor power supply system Set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor vehicle side connector.
Page 223 ENGINE (J05E)/TROUBLESHOOTING 2–187 DTC: P0097 and P0098 EN01H02127030602016037 P0097: Intake air temperature sensor (intake manifold) - out of range (Out of range low) INFORMATION Engine ECU (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2) 15mA (VC2)
Page 224 2–188 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Disconnection or short-circuit in sensor harness • Poor connector contact or faulty connector fit. • Intake air temperature sensor (intake manifold): - Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage) - Abnormality in resistance of sensor •...
Page 225 ENGINE (J05E)/TROUBLESHOOTING 2–189 P0098: Intake air temperature sensor (intake manifold) - out of range (Out of range high) INFORMATION Engine ECU (PC1S) 15mA (E1) PCR1 (PCR1) 15mA (VC) Common rail 15mA pressure sensor (E2) PCR2 (PCR2) 15mA (VC2) (PC2S) 10mA (E2) Intake manifold 10mA...
Page 226 2–190 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Disconnection or short-circuit in sensor harness • Irregular contact, improper engagement • Intake air temperature sensor (intake manifold): - Abnormality in resistance of sensor - Internal short-circuit •...
Page 227 ENGINE (J05E)/TROUBLESHOOTING 2–191 INSPECTION PROCEDURE: P0097 and P0098 Inspect the intake air temperature sensor (intake manifold) connector Check the connection of the intake air temperature sensor (intake manifold) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 228 2–192 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor (intake manifold) unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (intake manifold) connector. Use the electrical tester to measure the resistance between the terminals of the intake air temperature sensor (intake manifold). Measurement Tester Standard values...
Page 229 ENGINE (J05E)/TROUBLESHOOTING 2–193 Inspect for short-circuit of the intake air temperature sensor (intake manifold) harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 230 2–194 ENGINE (J05E)/TROUBLESHOOTING Inspect the sensor power supply Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 231 ENGINE (J05E)/TROUBLESHOOTING 2–195 DTC: P00AF EN01H02127030602016038 P00AF: Controller error (VNT actuator CPU malfunction) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V) CAN-H Micro CAN I/F MOTOR (W) CAN-L computer block...
Page 232 2–196 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 233 ENGINE (J05E)/TROUBLESHOOTING 2–197 INSPECTION PROCEDURE: P00AF Check the DTC detected (Engine ECU) 1 Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if P00AF (for example, U010C) has been detected. SHTS021270300181 Has a DTC other than P00AF been detected? Go to the diagnostic procedure of a related...
Page 234 2–198 ENGINE (J05E)/TROUBLESHOOTING Check the operation of the VNT controller [HINO DX Ⅱ ] Set the starter key to the "ON" position. Erase the trouble history using HINO DX Ⅱ . Set the starter key to the "OFF" position. Set the starter key to the "ON" position again. Select [Engine] and check if P00AF has been detected.
Page 235 ENGINE (J05E)/TROUBLESHOOTING 2–199 DTC: P0101 EN01H02127030602016039 P0101: Air flow sensor - rationality INFORMATION Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) 200mA (EVG) Intake air (E2G) (VAF) 200mA temperature sensor (+B) (air flow sensor built in) 10mA (E2)
Page 236 2–200 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • EGR valve is fully closed. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work •...
Page 237 ENGINE (J05E)/TROUBLESHOOTING 2–201 INSPECTION PROCEDURE: P0101 Inspect the air cleaner element Check the air cleaner element is dirty, clogged or damaged. Make sure the element is a Hino genuine part. Was any failure found? Clean or replace the air cleaner element. Go to step 2.
Page 238 2–202 ENGINE (J05E)/TROUBLESHOOTING Inspect the air flow sensor Check the installation of the air flow sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the air flow sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 4.
Page 239 ENGINE (J05E)/TROUBLESHOOTING 2–203 Inspect for disconnection in wire harness of air flow sensor Use the electrical tester to measure the resistance between the engine ECU (signal check harness) terminal and the air flow sen- sor vehicle side connector terminal. Measurement Tester Standard values conditions...
Page 240 2–204 ENGINE (J05E)/TROUBLESHOOTING Inspect the EGR valve Check the EGR valve for damage due to foreign substances. Check if there is soot obstructing the exhaust gas passageway inlet or outlet. Was any failure found? Remove foreign substances and clean the Go to step 7.
Page 241 ENGINE (J05E)/TROUBLESHOOTING 2–205 Check the response delay of the EGR valve Set the starter key to the "ON" position. Check the time lag (following characteristics) of the target EGR valve opening and actual EGR valve opening. ! CAUTION Perform the inspection while the engine is stopped to avoid engine damages.
Page 242 2–206 ENGINE (J05E)/TROUBLESHOOTING Inspect the diesel throttle valve Stop the engine. Check the operating status of the diesel throttle valve (for incorrect opening or sticky valve). Was any failure found? Replace the diesel throttle valve. Go to step 10. Perform "After-inspection work" of INFOR- MATION section.
Page 243 ENGINE (J05E)/TROUBLESHOOTING 2–207 Check the DTC detected Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if P0101 has been detected. SHTS021270300189 Has DTC P0101 been detected? Replace the engine ECU.
Page 244 2–208 ENGINE (J05E)/TROUBLESHOOTING DTC: P0104 EN01H02127030602016040 P0104: Air flow sensor - out of range INFORMATION Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) (EVG) 200mA Intake air (E2G) (VAF) 200mA temperature sensor (+B) (air flow sensor built in) 10mA...
Page 245 ENGINE (J05E)/TROUBLESHOOTING 2–209 Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Sensor disconnected from the measured part or sensing unit malfunctioning (due to dirt, clogging, damage, etc. •...
Page 246 2–210 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0104 Check the DTC detected (Engine ECU) 1 Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if P0104 (for example, P0642, P0643, P0652, P0653) has been detected.
Page 247 ENGINE (J05E)/TROUBLESHOOTING 2–211 Inspect the air flow sensor Check the installation of the air flow sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the air flow sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 4.
Page 248 2–212 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the air flow sensor harness Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and air flow sensor vehicle side connector. Measurement Tester Standard values conditions connections Engine ECU (sig-...
Page 249 ENGINE (J05E)/TROUBLESHOOTING 2–213 Inspect the air flow sensor power supply Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the air flow sensor vehicle side connector. Measurement Tester Standard values...
Page 250 2–214 ENGINE (J05E)/TROUBLESHOOTING Inspect the air flow sensor signal Set the starter key to the "LOCK" position. Connect the air flow sensor connector. Start the engine. Use the oscilloscope to measure the signal voltage between the terminals in the engine ECU (signal check harness). Measurement Tester Standard values...
Page 251 ENGINE (J05E)/TROUBLESHOOTING 2–215 DTC: P0106 EN01H02127030602016041 P0106: Boost pressure sensor - rationality INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S) 15mA (VC) X0G (PIM) (PIM) Boost pressure sensor...
Page 252 2–216 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. • EGR valve is fully closed. • DPR filter auto regeneration control is stopped. <Symptoms on the vehicle due to malfunction>...
Page 253 ENGINE (J05E)/TROUBLESHOOTING 2–217 INSPECTION PROCEDURE: P0106 Inspect the boost pressure sensor connector Check the connection of the boost pressure sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 254 2–218 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuits in wire harness of boost pressure sensor Set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between each terminal in the engine ECU (signal check harness) and ground.
Page 255 ENGINE (J05E)/TROUBLESHOOTING 2–219 Inspect for disconnection in wire harness of boost pressure sensor Use the electrical tester to measure the resistance between the engine ECU (signal check harness) and boost pressure sensor vehicle side connector terminals. Measurement Tester Standard values conditions connections Engine ECU (sig-...
Page 256 2–220 ENGINE (J05E)/TROUBLESHOOTING Inspect the boost pressure sensor power supply Connect the engine ECU vehicle side harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor vehicle side connector.
Page 257 ENGINE (J05E)/TROUBLESHOOTING 2–221 DTC: P0108 EN01H02127030602016042 P0108: Boost pressure sensor - out of range (Out of range high) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S)
Page 258 2–222 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Abnormality in resistance of sensor • Failure in engine ECU sensor power supply • Disconnection or short-circuit in sensor harness •...
Page 259 ENGINE (J05E)/TROUBLESHOOTING 2–223 INSPECTION PROCEDURE: P0108 Inspect the boost pressure sensor connector Check the connection of the boost pressure sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 260 2–224 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the boost pressure sensor harness Set the starter key to the "LOCK" position. Disconnect the boost pressure connector. Connect the signal check harness to the engine ECU vehicle side connector. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 261 ENGINE (J05E)/TROUBLESHOOTING 2–225 Inspect disconnection of the boost pressure sensor harness Connect the boost pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU and the boost pressure sensor vehi- cle side connector (signal check harness). Measurement Tester Standard values...
Page 262 2–226 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Set the starter key to the "ON" position. Select [Engine] and check if P0108 has been detected.
Page 263 ENGINE (J05E)/TROUBLESHOOTING 2–227 DTC: P0112 and P0113 EN01H02127030602016043 P0112: Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range low) INFORMATION Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) 200mA...
Page 264 2–228 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage) • Abnormality in resistance of sensor •...
Page 265 ENGINE (J05E)/TROUBLESHOOTING 2–229 P0113: Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range high) INFORMATION Engine ECU Coolant temperature sensor 10mA (THW) X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) (EVG) 200mA Intake air (E2G) (VAF)
Page 266 2–230 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Abnormality in resistance of sensor • Failure in engine ECU sensor power supply • Disconnection or short-circuit in sensor harness •...
Page 267 ENGINE (J05E)/TROUBLESHOOTING 2–231 INSPECTION PROCEDURE: P0112 and P0113 Inspect the intake air temperature sensor connector Check the connection of the intake air temperature sensor (air flow sensor) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 268 2–232 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the connector of intake air temperature sensor (air flow sensor built-in). Measure the resistance between the terminals of the intake air temperature sensor (built-in air flow sensor).
Page 269 ENGINE (J05E)/TROUBLESHOOTING 2–233 Inspect for short-circuit in wire harness of intake air temperature sensor Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between each terminal in the engine ECU (signal check harness) and ground.
Page 270 2–234 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnection in wire harness of intake air temperature sensor Connect the intake air temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values conditions...
Page 271 ENGINE (J05E)/TROUBLESHOOTING 2–235 DTC: P0115 EN01H02127030602016044 P0115: Malfunction of coolant temperature sensor and intake air temperature sensor INFORMATION Coolant temperature sensor Engine ECU 10mA (THW) X28 (THW) Body earth 10mA ZJQ (E5) Coolant temperature sensor 2 X3Q (SL) (THW2) 10mA XDN (THWO) Body earth 10mA...
Page 272 2–236 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. • EGR valve is fully closed. • VNT is fully open. <Symptoms on the vehicle due to malfunction> •...
Page 273 ENGINE (J05E)/TROUBLESHOOTING 2–237 INSPECTION PROCEDURE: P0115 Inspect the engine coolant temperature sensor 1 connector Check the connection of the engine coolant temperature sensor 1 connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 274 2–238 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine coolant temperature sensor 1 unit Set the starter key to the "LOCK" position. Disconnect the engine coolant temperature sensor 1. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor 1. Measurement Tester Standard values...
Page 275 ENGINE (J05E)/TROUBLESHOOTING 2–239 Check for short-circuit in wire harness of engine coolant temperature sensor 1 Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between each terminal in the engine ECU (signal check harness) and ground.
Page 276 2–240 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine coolant temperature sensor 2 connector Check the connection of the engine coolant temperature sensor 2 connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 8. Perform "After-inspection work" of INFOR- MATION section.
Page 277 ENGINE (J05E)/TROUBLESHOOTING 2–241 Inspect the engine coolant temperature sensor 2 unit Set the starter key to the "LOCK" position. THW2 Disconnect the engine coolant temperature sensor 2 connector. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor 2. Measurement Tester Standard values...
Page 278 2–242 ENGINE (J05E)/TROUBLESHOOTING Check for short-circuit in wire harness of engine coolant temperature sensor 2 Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between each terminal in the engine ECU (signal check harness) and ground.
Page 279 ENGINE (J05E)/TROUBLESHOOTING 2–243 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 280 2–244 ENGINE (J05E)/TROUBLESHOOTING DTC: P0117 and P0118 EN01H02127030602016045 P0117: Engine coolant temperature sensor 1 - out of range (Out of range low) INFORMATION Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) (EVG) 200mA Intake air...
Page 281 ENGINE (J05E)/TROUBLESHOOTING 2–245 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors Engine coolant temperature sensor: • Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage) • Abnormal resistance of the engine coolant temperature sensor •...
Page 282 2–246 ENGINE (J05E)/TROUBLESHOOTING P0118: Engine coolant temperature sensor 1 - out of range (Out of range high) INFORMATION Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) (EVG) 200mA Intake air (E2G) (VAF) 200mA temperature sensor...
Page 283 ENGINE (J05E)/TROUBLESHOOTING 2–247 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors Engine coolant temperature sensor: • Short-circuit in the sensor • Abnormal resistance of sensor • Failure in engine ECU sensor power supply •...
Page 284 2–248 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0117 and P0118 Inspect the engine coolant temperature sensor connector Check the connection of the engine coolant temperature sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 285 ENGINE (J05E)/TROUBLESHOOTING 2–249 Inspect the engine coolant temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the engine coolant temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor. Measurement Tester Standard values...
Page 286 2–250 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the engine coolant temperature sensor harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. (Do not con- nect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 287 ENGINE (J05E)/TROUBLESHOOTING 2–251 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 288 2–252 ENGINE (J05E)/TROUBLESHOOTING DTC: P011A EN01H02127030602016046 P011A: Engine coolant temperature sensor - rationality INFORMATION Coolant temperature sensor Engine ECU (THW) 10mA X28 (THW) Body earth 10mA ZJQ (E5) Coolant temperature sensor 2 X3Q (SL) (THW2) 10mA XDN (THWO) Body earth 10mA (E22) ZD6 (E3)
Page 289 ENGINE (J05E)/TROUBLESHOOTING 2–253 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 290 2–254 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P011A Inspect the engine coolant temperature sensor 1 connector Check the connection of the engine coolant temperature sensor 1 connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 291 ENGINE (J05E)/TROUBLESHOOTING 2–255 Inspect the engine coolant temperature sensor 1 unit Set the starter key to the "LOCK" position. Disconnect the engine coolant temperature sensor 1 connector. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor 1. Measurement Tester Standard values...
Page 292 2–256 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the engine coolant temperature sensor 1 harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. (Do not con- nect harness to the engine ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU and ground.
Page 293 ENGINE (J05E)/TROUBLESHOOTING 2–257 Inspect the engine coolant temperature sensor 2 connector Check the connection of the engine coolant temperature sensor 2 connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 8. Perform "After-inspection work" of INFOR- MATION section.
Page 294 2–258 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine coolant temperature sensor 2 unit Set the starter key to the "LOCK" position. THW2 Disconnect the engine coolant temperature sensor 2 connector. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor 2. Measurement Tester Standard values...
Page 295 ENGINE (J05E)/TROUBLESHOOTING 2–259 Inspect for short-circuit of the engine coolant temperature sensor 2 harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. (Do not con- nect harness to the engine ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU and ground.
Page 296 2–260 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 297 ENGINE (J05E)/TROUBLESHOOTING 2–261 DTC: P011C EN01H02127030602016047 P011C: Intake air temperature sensor (air flow sensor built-in) - rationality INFORMATION Engine ECU Coolant temperature sensor (THW) 10mA X28 (THW) Body earth 10mA (E5) 10mA X4K (VG) (FC) (EVG) 200mA Intake air (E2G) (VAF) temperature sensor 200mA...
Page 298 2–262 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 299 ENGINE (J05E)/TROUBLESHOOTING 2–263 INSPECTION PROCEDURE: P011C Inspect the intake air temperature sensor connector Check the connection of the intake air temperature sensor (air flow sensor) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 300 2–264 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (air flow sensor) con- nector. Measure the resistance between the terminals of the sensor using the electrical tester. Measurement Tester Standard values...
Page 301 ENGINE (J05E)/TROUBLESHOOTING 2–265 Inspect for short-circuits in wire harness of intake air temperature sensor Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between each terminal in the engine ECU (signal check harness) and ground.
Page 302 2–266 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform an engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 303 ENGINE (J05E)/TROUBLESHOOTING 2–267 DTC: P0122 and P0123 EN01H02127030602016048 P0122: Intake throttle valve position sensor 1 - out of range (Out of range low) INFORMATION Engine ECU TYP 0.2A XQT (M-) (E2R) TYP 1A (M+) (VCR) TYP 1A (E3) (E2) Diesel throttle TYP 0.2A (VTA2) (VTA2)
Page 304 2–268 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Abnormal resistance of sensor • Engine ECU sensor power supply failure or internal circuit failure • Disconnection or short-circuit in sensor harness •...
Page 305 ENGINE (J05E)/TROUBLESHOOTING 2–269 P0123: Intake throttle valve position sensor 1 - out of range (Out of range high) INFORMATION Engine ECU TYP 0.2A XQT (M-) (E2R) TYP 1A (M+) (VCR) TYP 1A (E3) (E2) Diesel throttle TYP 0.2A (VTA2) (VTA2) TYP 0.2A (VC2) (VC)
Page 306 2–270 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0122 and P0123 Inspect the intake throttle valve position sensor 1 connector Check the connection of the intake throttle valve position sensor 1 connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 307 ENGINE (J05E)/TROUBLESHOOTING 2–271 Inspect the intake throttle valve position sensor 1 unit Set the starter key to the "LOCK" position. Disconnect the connector of the intake throttle valve position sen- sor 1 connector. Use the electrical tester to measure the resistance between the terminals of the intake throttle valve position sensor 1 connector.
Page 308 2–272 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake throttle valve position sensor 1 power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the intake throttle valve position sensor 1 vehicle side con- nector.
Page 309 ENGINE (J05E)/TROUBLESHOOTING 2–273 Inspect for short-circuits in the wire harness of the diesel throttle (intake throttle valve) posi- tion sensor 1 Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 310 2–274 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnection in the wire harness of the diesel throttle (intake throttle valve) posi- tion sensor 1 Connect the intake throttle valve position sensor 1 connector. Use the electrical tester to measure the resistance between the terminal of the engine ECU (signal check harness).
Page 311 ENGINE (J05E)/TROUBLESHOOTING 2–275 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 312 2–276 ENGINE (J05E)/TROUBLESHOOTING DTC: P0128 EN01H02127030602016049 P0128: Thermostat - The coolant temperature does not reach a warmed-up temperature INFORMATION Engine coolant temperature sensor Thermostat 10mA (THW) X28 (THW) Body earth 10mA ZJQ (E5) Coolant temperature sensor Engine ECU SHTS021270300255 Technical description •...
Page 313 ENGINE (J05E)/TROUBLESHOOTING 2–277 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 314 2–278 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0128 Inspect the engine coolant temperature sensor connector Check the connection of the engine coolant temperature sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 315 ENGINE (J05E)/TROUBLESHOOTING 2–279 Inspect the engine coolant temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the engine coolant temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor. Measurement Tester Standard values...
Page 316 2–280 ENGINE (J05E)/TROUBLESHOOTING Inspect the thermostat valve-opening temperature Check valve opening temperature. Submerge in hot water (90 C {194 F}) and check if the valve lift is 10 mm {0.3937 in.} or greater. Was any failure found? Replace the thermostat. Go to step 6.
Page 317 ENGINE (J05E)/TROUBLESHOOTING 2–281 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 318 2–282 ENGINE (J05E)/TROUBLESHOOTING DTC: P0148 EN01H02127030602016050 P0148: Abnormality in post injection INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe Supply pump Overflow valve Fuel tank Pre fuel filter Fuel filter Engine ECU (#4)
Page 319 ENGINE (J05E)/TROUBLESHOOTING 2–283 DTC set condition DTC detection condition • The vehicle speed is 0 km/h. • A change in the engine revolution is 312 r/min/sec or less. • A change in the fuel injection quantity is 312 mm /st/sec or less. •...
Page 320 2–284 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0148 Check the DTC detected 1 [HINO DX Ⅱ ] Perform the engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ...
Page 321 ENGINE (J05E)/TROUBLESHOOTING 2–285 Inspect the fuel line Check that the fuel line has no leaks or clogging. <Main inspection locations> - Entry of foreign matter into the fuel tank - Fuel hose breakage, collapsing, looseness - High-pressure pipe breakage, collapsing, looseness A return line from the fuel filter Fuel filter Common rail...
Page 322 2–286 ENGINE (J05E)/TROUBLESHOOTING Inspect the pre fuel filter Check that the pre fuel filter is not dirty or clogged or damaged. Was any failure found? Replace the pre fuel filter. Go to step 5. Go to step 5 after replacement Check the DTC detected 3 [HINO DX Ⅱ...
Page 323 ENGINE (J05E)/TROUBLESHOOTING 2–287 Perform the cylinder cut-off test (HINO DX Ⅱ ) Start the engine and maintain the engine revolution at 1,500 r/min using the cruise function. Check the engine sound before the test (during normal operation). On the screen of the diagnostic system, select [Engine], and per- form [Cut off test] in [Data monitor and Active test].
Page 324 2–288 ENGINE (J05E)/TROUBLESHOOTING Replace the common rail assembly [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Replace common rail assembly. Perform the engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON"...
Page 325 ENGINE (J05E)/TROUBLESHOOTING 2–289 Check the valve clearance Check that the valve clearance of each cylinder is within the stan- dard values. (Check all the valves.) Rocker arm Feeler gauge Measurement conditions Standard values Cold engine Intake valve: 0.30 mm (0.0118 in.) Cross head Exhaust valve: 0.45 mm (0.0177 in.)
Page 326 2–290 ENGINE (J05E)/TROUBLESHOOTING Check the engine compression pressure Perform an engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Remove the all injectors. Set the special service tool (SST) and measure the compression. engine Measurement Standard values conditions...
Page 327 ENGINE (J05E)/TROUBLESHOOTING 2–291 Check the DTC detected 5 [HINO DX Ⅱ ] Perform an engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine Set the starter key to the "ON" position. On the screen of the diagnostic system, check DTC P0148. SHTS021270300270 Has DTC (P0148) been detected? Inspect the crankshaft, connecting rods, fly-...
Page 328 2–292 ENGINE (J05E)/TROUBLESHOOTING Flow-Cut off test <Cylinder cut-off test> Test to determine cylinder combustion abnormality of the engine usually operated by four cylinders, according to the sound difference when the fuel injection from any one of the cylinders is stopped <Purpose>...
Page 329 ENGINE (J05E)/TROUBLESHOOTING 2–293 Stop the fuel injection of the cylinder #1 to check the engine sound. (Assume A as the sound.) -> After checking, stop the test. HINT Because the engine maintains the rotation condition by three-cyl- inder fuel injection instead of four-cylinder fuel injection during the test, the sound A becomes larger than α.
Page 330 2–294 ENGINE (J05E)/TROUBLESHOOTING DTC: P016E and P016F EN01H02127030602016051 P016E: Fuel system pressure control - high INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe Supply pump Overflow valve Fuel tank Pre fuel filter Fuel filter SHTS021270300273...
Page 331 ENGINE (J05E)/TROUBLESHOOTING 2–295 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 332 2–296 ENGINE (J05E)/TROUBLESHOOTING P016F: Fuel system pressure control - low INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe Supply pump Overflow valve Fuel tank Pre fuel filter Fuel filter SHTS021270300274 Technical description •...
Page 333 ENGINE (J05E)/TROUBLESHOOTING 2–297 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 334 2–298 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P016E and P016F Inspect the start of the engine Inspect the start of the engine. Does the engine start? Go to step 4. Go to step 2. Inspect the supply pump Check if fuel is leaking or seeping out of the supply pump. Was any failure found? Replace the supply pump, and go to step 4.
Page 335 ENGINE (J05E)/TROUBLESHOOTING 2–299 Inspect the pre fuel filter Inspect the pre fuel filter. • Has the replacement period expired? • Is it dirty, damaged, or clogged? • Is it a genuine Hino part? Was any failure found? Replace the pre fuel filter element, and go to Go to step 10.
Page 336 2–300 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel tank feed pipe Make sure the fuel tank feed pipe is not clogged. Was any failure found? Repair or replace the faulty part, and go to Go to step 8. step 8. Inspect the fuel tank Drain fuel out of the fuel tank and check if there are foreign objects inside the tank.
Page 337 ENGINE (J05E)/TROUBLESHOOTING 2–301 Inspect the fuel high-pressure pipe. Make sure the fuel high-pressure pipe is not leaking fuel. Was any failure found? Repair or replace the faulty part, and go to Go to step 11. step 11. Inspect the fuel filter Make sure the fuel filter is not clogged.
Page 338 2–302 ENGINE (J05E)/TROUBLESHOOTING Inspect the common rail pressure sensor power supply Disconnect the common rail pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the common rail pressure sensor vehicle side connector. Measurement Tester Standard values...
Page 339 ENGINE (J05E)/TROUBLESHOOTING 2–303 Inspect the fuel return pipe and hose Check if the fuel return pipe and hose are clogged. Was any failure found? Repair or replace the faulty part. Contact the Hino national service manager.
Page 340 2–304 ENGINE (J05E)/TROUBLESHOOTING DTC: P0182 and P0183 EN01H02127030602016052 P0182: Fuel temperature sensor Low INFORMATION Engine ECU (THF) J5R (THF) 10mA Fuel temperature sensor (E2) (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail pressure sensor 15mA (E2) (E2) (PCR2) (PCR2) 15mA...
Page 341 ENGINE (J05E)/TROUBLESHOOTING 2–305 Estimated failure factors • Irregular contact (wet of connector) • Abnormal resistance of sensor • Harness disconnection or short-circuit • Engine ECU sensor power supply failure or internal circuit failure • Faulty connector contact or fit...
Page 342 2–306 ENGINE (J05E)/TROUBLESHOOTING P0183: Fuel temperature sensor High INFORMATION Engine ECU (THF) J5R (THF) 10mA Fuel temperature sensor (E2) (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC1) (VC) Common rail pressure sensor 15mA (E2) (E2) (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S) SHTS021270300279 Technical description...
Page 343 ENGINE (J05E)/TROUBLESHOOTING 2–307 Estimated failure factors • Irregular contact (disconnection or poor fit) • Abnormal resistance of sensor • Harness disconnection or short-circuit • Engine ECU sensor power supply failure or internal circuit failure • Faulty connector contact or fit...
Page 344 2–308 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0182 and P0183 Inspect the fuel temperature sensor connector Check the connection of the fuel temperature sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 345 ENGINE (J05E)/TROUBLESHOOTING 2–309 Inspect the fuel temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the connector of the fuel temperature sensor connec- tor. Use the electrical tester to measure the resistance between the terminals of the fuel temperature sensor connector. Measurement Tester Standard values...
Page 346 2–310 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuits in wire harness of fuel temperature sensor Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminal of the engine ECU (signal check harness) and ground.
Page 347 ENGINE (J05E)/TROUBLESHOOTING 2–311 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 348 2–312 ENGINE (J05E)/TROUBLESHOOTING DTC: P0191 EN01H02127030602016053 P0191: Fuel rail pressure sensor (main and sub) - out of range INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S)
Page 349 ENGINE (J05E)/TROUBLESHOOTING 2–313 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. • Cruise control does not work. • Idling stop system does not work. •...
Page 350 2–314 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0191 Inspect the start of the engine Inspect the start of the engine. Does the engine start? Go to step 4. Go to step 2. Inspect the supply pump Check if fuel is leaking or seeping out of the supply pump. Was any failure found? Replace the supply pump, and go to step 4.
Page 351 ENGINE (J05E)/TROUBLESHOOTING 2–315 Inspect the pre fuel filter Inspect the pre fuel filter. • Has the replacement period expired? • Is it dirty, damaged, or clogged? • Is it a genuine Hino part? Check if the fuel inside the pre fuel filter is within the standard value.
Page 352 2–316 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel tank breather Check if the breather hose is clogged, punctured, or bent. Make sure the check valve is functioning normally. Was any failure found? Repair or replace the faulty part, and go to Go to step 7. step 7.
Page 353 ENGINE (J05E)/TROUBLESHOOTING 2–317 Inspect the supply pump gauze filter Make sure the gauze filter (built into the supply pump) is not clogged. Was any failure found? Clean the gauze filter, and go to step 10. Go to step 10. Inspect the fuel high-pressure pipe. Make sure the fuel high-pressure pipe is not leaking fuel.
Page 354 2–318 ENGINE (J05E)/TROUBLESHOOTING Inspect the SCV connector Check the connection of the SCV connector (looseness and poor contact). Was any failure found? Repair or replace the faulty part, and go to Go to step 13. step 13. Inspect the common rail pressure sensor connector Check the connection of the common rail pressure sensor connec- tor (looseness and poor contact).
Page 355 ENGINE (J05E)/TROUBLESHOOTING 2–319 Inspect the common rail pressure sensor power supply Disconnect the common rail pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the common rail pressure sensor vehicle side connector. Measurement Tester Standard values...
Page 356 2–320 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel return pipe and hose Check if the fuel return pipe and hose are clogged. Was any failure found? Repair or replace the faulty part. Contact the Hino national service manager.
Page 357 ENGINE (J05E)/TROUBLESHOOTING 2–321 DTC: P0192 and P0193 EN01H02127030602016054 P0192: Fuel rail pressure sensor (main) - out of range (Out of range low) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA...
Page 358 2–322 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Abnormality in resistance of sensor • Failure in engine ECU sensor power supply • Disconnection or short-circuit in sensor harness • Sensor internal short.
Page 359 ENGINE (J05E)/TROUBLESHOOTING 2–323 P0193: Fuel rail pressure sensor (main) - out of range (Out of range high) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC1) (VC) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S) SHTS021270300290...
Page 360 2–324 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Abnormality in resistance of sensor • Disconnection or short-circuit in sensor harness • Engine ECU sensor power supply failure or internal circuit failure • Irregular contact...
Page 361 ENGINE (J05E)/TROUBLESHOOTING 2–325 INSPECTION PROCEDURE: P0192 and P0193 Inspect the common rail pressure sensor connector Check the connection of the common rail pressure sensor connec- tor (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 362 2–326 ENGINE (J05E)/TROUBLESHOOTING Inspect the common rail pressure sensor unit Set the starter key to the "LOCK" position. Disconnect the connector of the common rail pressure sensor con- PCR2 PCR2 nector. (main) (main) (main) PCR1 Use the electrical tester to measure the resistance between the (sub) (sub) (sub)
Page 363 ENGINE (J05E)/TROUBLESHOOTING 2–327 Inspect the common rail pressure sensor power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the common rail pressure sensor vehicle side connector. Measurement Tester Standard values...
Page 364 2–328 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuits in wire harness of the common rail pressure sensor Set the starter key to the "LOCK" position. Disconnect the connector of the engine ECU. GROUND Use the electrical tester to measure the resistance between the common rail pressure sensor vehicle side connector terminals and ground.
Page 365 ENGINE (J05E)/TROUBLESHOOTING 2–329 Inspect disconnection of the common rail pressure sensor harness Connect the connector of the common rail pressure sensor. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness).
Page 366 2–330 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 367 ENGINE (J05E)/TROUBLESHOOTING 2–331 DTC: P01A5 EN01H02127030602016055 P01A5: Fuel rail pressure sensor (sub) - out of range (Out of range low) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2)
Page 368 2–332 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Abnormal sensor resistance • Harness disconnection or short-circuit • looseness or poor contact of connector • Engine ECU sensor power supply or internal circuit failure...
Page 369 ENGINE (J05E)/TROUBLESHOOTING 2–333 INSPECTION PROCEDURE: P01A5 Inspect the common rail pressure sensor connector Check the connection of the common rail pressure sensor connec- tor (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 370 2–334 ENGINE (J05E)/TROUBLESHOOTING Inspect the common rail pressure sensor unit Set the starter key to the "LOCK" position. Disconnect the common rail pressure sensor connector. PCR1 PCR2 (main) (main) (main) Measure the resistance between the terminals of the sensor using PCR1 the electrical tester.
Page 371 ENGINE (J05E)/TROUBLESHOOTING 2–335 Inspect the common rail pressure sensor power supply Set the starter key to the "ON" position. Measure the voltage between the terminals of the common rail pressure sensor vehicle side connector using the electrical tester. Measurement Tester Standard values conditions connections...
Page 372 2–336 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuits in wire harness of the common rail pressure sensor Set the starter key to the "LOCK" position. Disconnect the engine ECU connector. GROUND Use the electrical tester to measure the resistance between the common rail pressure sensor vehicle side connector terminals and ground.
Page 373 ENGINE (J05E)/TROUBLESHOOTING 2–337 Inspect disconnection of the common rail pressure sensor harness Connect the common rail pressure sensor connector. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between the terminals in the engine ECU (signal check harness).
Page 374 2–338 ENGINE (J05E)/TROUBLESHOOTING DTC: P01A6 EN01H02127030602016056 P01A6: Fuel rail pressure sensor (sub) - out of range (Out of range high) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2)
Page 375 ENGINE (J05E)/TROUBLESHOOTING 2–339 Estimated failure factors • Abnormal resistance of sensor • Disconnection or short-circuit in sensor harness • Irregular contact (disconnection or poor fit of connector) • Engine ECU sensor power supply or internal circuit failure...
Page 376 2–340 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P01A6 Inspect the common rail pressure sensor connector Check the connection of the common rail pressure sensor connec- tor (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 377 ENGINE (J05E)/TROUBLESHOOTING 2–341 Inspect the common rail pressure sensor unit Set the starter key to the "LOCK" position. Disconnect the common rail pressure sensor connector. PCR1 PCR2 (main) (main) (main) Measure the resistance between the terminals of the sensor using PCR1 the electrical tester.
Page 378 2–342 ENGINE (J05E)/TROUBLESHOOTING Inspect the common rail pressure sensor power supply Set the starter key to the "ON" position. Measure the voltage between the terminals of the common rail pressure sensor vehicle side connector using the electrical tester. Measurement Tester Standard values conditions connections...
Page 379 ENGINE (J05E)/TROUBLESHOOTING 2–343 Inspect for short-circuits in wire harness of the common rail pressure sensor Set the starter key to the "LOCK" position. Disconnect the engine ECU connector. GROUND Use the electrical tester to measure the resistance between the common rail pressure sensor vehicle side connector terminals and ground.
Page 380 2–344 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the common rail pressure sensor harness Connect the common rail pressure sensor connector. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between the terminals in the engine ECU (signal check harness).
Page 381 ENGINE (J05E)/TROUBLESHOOTING 2–345 DTC: P0200 EN01H02127030602016057 P0200: Fuel injector driver charge circuit (circuit high) INFORMATION Monitor location of Fuel injector driver charge circuit ENGINE ECU Monitor location of Fuel injector driver circuit 2 circuit high Fuel injector driver Monitor location of Fuel injector driver circuit 1 circuit high charge circuit Fuel Fuel injector driver...
Page 382 2–346 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. • Cruise control does not work. • Idling stop system does not work. •...
Page 383 ENGINE (J05E)/TROUBLESHOOTING 2–347 INSPECTION PROCEDURE: P0200 Check the engine ECU internal circuit [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check the communication between HINO DX Ⅱ and the engine ECU.
Page 384 2–348 ENGINE (J05E)/TROUBLESHOOTING DTC: P0201, P0202, P0203 and P0204 EN01H02127030602016058 P0201: Fuel injector - disconnection (#1cyl) P0202: Fuel injector - disconnection (#2cyl) P0203: Fuel injector - disconnection (#3cyl) P0204: Fuel injector - disconnection (#4cyl) INFORMATION Engine ECU Injector sub (#10) (#1) Injector1 (IJ1+)
Page 385 ENGINE (J05E)/TROUBLESHOOTING 2–349 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Cruise control does not work. • Idling stop system does not work. • Vehicle start control does not work. <Symptoms on the vehicle due to malfunction>...
Page 386 2–350 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0201, P0202, P0203 and P0204 Inspect the engine ECU connector, injector connector Inspect the connection of the engine ECU connector and the tar- get's injector connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 387 ENGINE (J05E)/TROUBLESHOOTING 2–351 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 388 2–352 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the injector harness Disconnect the target's injector harness connector. Use the electrical tester to measure the resistance between the terminals in the target's injector harness connector (injector side). Measurement Tester Standard values conditions connections Injector harness 20 C {68 F}: Starter key: LOCK...
Page 389 ENGINE (J05E)/TROUBLESHOOTING 2–353 DTC: P0217 EN01H02127030602016059 P0217: Engine coolant over temperature condition INFORMATION Coolant temperature sensor Engine ECU (THW) 10mA X28 (THW) Body earth 10mA ZJQ (E5) SHTS021270300319 Technical description • Measure the engine coolant temperature with the coolant temperature sensor. <Description of malfunction>...
Page 390 2–354 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors Check for the relevant symptom by referring to the Workshop Manual, Engine Introduction, and Troubleshooting Overheating. • Faulty coolant-related component • Faulty cooling system • Faulty injection system • Faulty lubricating system Malfunction of cooling fan, malfunction of fan clutch Malfunction of coolant temperature sensor...
Page 391 ENGINE (J05E)/TROUBLESHOOTING 2–355 INSPECTION PROCEDURE: P0217 Inspect the engine Refer to "Engine Overheating" in the "Engine Introduction/Trouble- shooting" Workshop Manual and check the related problem areas. Was any failure found? Repair or replace the faulty part. Go to step 2. Perform "After-inspection work"...
Page 392 2–356 ENGINE (J05E)/TROUBLESHOOTING Inspect the coolant temperature sensor connector Check the connection of the engine coolant temperature sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 5. Perform "After-inspection work" of INFOR- MATION section.
Page 393 ENGINE (J05E)/TROUBLESHOOTING 2–357 Inspect the engine coolant temperature sensor unit Set the starter key to the "LOCK" position. Disconnect the engine coolant temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine coolant temperature sensor. Measurement Tester Standard values...
Page 394 2–358 ENGINE (J05E)/TROUBLESHOOTING DTC: P0219 EN01H02127030602016060 P0219: Engine overspeed condition INFORMATION Engine ECU (SNE) Engine speed main sensor (NE-) (NE-) (NE+) (NE+) SHTS021270300322 Technical description • The engine ECU detects the engine speed using the engine speed main sensor (crankshaft position sensor) mounted on the flywheel housing.
Page 395 ENGINE (J05E)/TROUBLESHOOTING 2–359 Estimated failure factors Miss-shift (MT vehicle) Operated with excessive engine oil running around to the air intake system Irregular contact of connector and harness Malfunction of engine speed main sensor (crankshaft position sensor)
Page 396 2–360 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0219 Inspect the engine oil level. Check the oil level gauge and make sure the engine oil quantity is within the standard value. Engine damage will occur. Oil level gauge Rivet FULL Preferred level Gauge end SHTS021270300323 Is the engine oil quantity within the standard value? Go to step 2.
Page 397 ENGINE (J05E)/TROUBLESHOOTING 2–361 Check the engine speed main sensor Check the installation of the engine speed main sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the engine speed main sensor. Was any failure found? Clean the sensing unit and install it properly.
Page 398 2–362 ENGINE (J05E)/TROUBLESHOOTING Check for disconnection in wire harness of engine speed main sensor Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the engine ECU (signal check harness) and each terminal in the engine speed main sensor vehicle side connector.
Page 399 ENGINE (J05E)/TROUBLESHOOTING 2–363 Check for short-circuit in wire harness of engine speed main sensor Use the electrical tester to measure the resistance between each terminal in the engine ECU (signal check harness) and ground. Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har- ness)
Page 400 2–364 ENGINE (J05E)/TROUBLESHOOTING Check the engine speed main sensor signal Connect the signal check harness to the engine ECU. Connect the engine speed main sensor connector. Start the engine. Use the oscilloscope to measure the voltage between the termi- nals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 401 ENGINE (J05E)/TROUBLESHOOTING 2–365 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 402 2–366 ENGINE (J05E)/TROUBLESHOOTING DTC: P0222 and P0223 EN01H02127030602016061 P0222: Intake throttle valve position sensor 2 - out of range (Out of range low) INFORMATION Engine ECU TYP 0.2A XQT (M-) (E2R) TYP 1A (M+) (VCR) TYP 1A (E3) (E2) Diesel throttle TYP 0.2A (VTA2) (VTA2)
Page 403 ENGINE (J05E)/TROUBLESHOOTING 2–367 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Abnormal resistance of sensor • Disconnection or short-circuit in sensor harness • Failure in engine ECU sensor power supply or internal circuit •...
Page 404 2–368 ENGINE (J05E)/TROUBLESHOOTING P0223: Intake throttle valve position sensor 2 - out of range (Out of range high) INFORMATION Engine ECU TYP 0.2A XQT (M-) (E2R) TYP 1A (M+) (VCR) TYP 1A (E3) (E2) Diesel throttle TYP 0.2A (VTA2) (VTA2) TYP 0.2A (VC2) (VC)
Page 405 ENGINE (J05E)/TROUBLESHOOTING 2–369 Estimated failure factors • Abnormal resistance of sensor • Disconnection or short-circuit in sensor harness • Sensor internal short-circuit • Engine ECU internal circuit failure...
Page 406 2–370 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0222 and P0223 Inspect the intake throttle valve position sensor 2 connector Check the connection of the intake throttle valve position sensor 2 connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 407 ENGINE (J05E)/TROUBLESHOOTING 2–371 Inspect the intake throttle valve position sensor 2 unit Set the starter key to the "LOCK" position. Disconnect the intake throttle valve position sensor 2 connector. VTA2 Use the electrical tester to measure the resistance between the terminals of the intake throttle valve position sensor 2.
Page 408 2–372 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake throttle valve position sensor 2 power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the intake throttle valve position sensor 2 vehicle side con- nector.
Page 409 ENGINE (J05E)/TROUBLESHOOTING 2–373 Inspect for short-circuits in wire harness of intake throttle valve position sensor 2 Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 410 2–374 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnections in wire harness of intake throttle valve Connect the intake throttle valve position sensor 2 connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 411 ENGINE (J05E)/TROUBLESHOOTING 2–375 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 412 2–376 ENGINE (J05E)/TROUBLESHOOTING DTC: P0234 EN01H02127030602016062 P0234: Overboost INFORMATION Engine ECU Resistor Actuator power relay controller actuator Boost pressure sensor Common rail Intake air pressure sensor temperature sensor Body earth (air flow sensor built in) SHTS021270300338 Technical description • The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and boost pressure.
Page 413 ENGINE (J05E)/TROUBLESHOOTING 2–377 Judgement criteria • Deviation between the target boost pressure and the actual boost pressure: the condition that the deviation exceeds the range of 40 to 50 kPa remains 30 seconds or more. • If target boost pressure is 140 to 220 kPa, the deviation of boost pressure detected is 40 kPa or more. •...
Page 414 2–378 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0234 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0234 (for exam- ple, P0045, P0401) has been detected.
Page 415 ENGINE (J05E)/TROUBLESHOOTING 2–379 Inspect the boost pressure sensor power supply system Set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor vehicle side connector.
Page 416 2–380 ENGINE (J05E)/TROUBLESHOOTING Inspect the response delay of the VNT controller Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position and select [Engine]. Select [Inspection Menu], then inspect the response delay at the Target VNT position and Actual VNT position.
Page 417 ENGINE (J05E)/TROUBLESHOOTING 2–381 Inspect the response delay of the EGR valve Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 418 2–382 ENGINE (J05E)/TROUBLESHOOTING DTC: P0237 EN01H02127030602016063 P0237: Boost pressure sensor - out of range (Out of range low) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S)
Page 419 ENGINE (J05E)/TROUBLESHOOTING 2–383 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Abnormal resistance of sensor • Disconnection or short-circuit in sensor harness • Failure in engine ECU sensor power supply or internal circuit •...
Page 420 2–384 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0237 Inspect the boost pressure sensor connector Check the connection of the boost pressure sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 421 ENGINE (J05E)/TROUBLESHOOTING 2–385 Inspect for short-circuit of the boost pressure sensor harness Set the starter key to the “LOCK” position. Disconnect the boost pressure sensor connect. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 422 2–386 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the boost pressure sensor harness Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and the boost pressure sensor vehicle side connector. Measurement Tester Standard values conditions connections Engine ECU (sig-...
Page 423 ENGINE (J05E)/TROUBLESHOOTING 2–387 Inspect the boost pressure sensor power supply Connect the engine ECU vehicle side harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor vehicle side connector.
Page 424 2–388 ENGINE (J05E)/TROUBLESHOOTING DTC: P0263, P0266, P0269 and P0272 EN01H02127030602016064 P0263: #1 Injection quantity and timing P0266: #2 Injection quantity and timing P0269: #3 Injection quantity and timing P0272: #4 Injection quantity and timing INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe...
Page 425 ENGINE (J05E)/TROUBLESHOOTING 2–389 Technical description • The engine speed main sensor (crankshaft position sensor) monitors the speed of each cylinder. • For control, it increases or reduces the compensation of the injection quantity of each cylinder to make constant the speed of each cylinder.
Page 426 2–390 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • Excessive vibration while engine is idling. Pre-inspection work •...
Page 427 ENGINE (J05E)/TROUBLESHOOTING 2–391 INSPECTION PROCEDURE: P0263, P0266, P0269 and P0272 Check the DTC detected 1 (Engine ECU) Perform the engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ...
Page 428 2–392 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel line Check that the fuel line has no leaks or clogging. <Main inspection locations> - Entry of foreign matter into the fuel tank - Fuel hose breakage, collapsing, looseness - High-pressure pipe breakage, collapsing, looseness A return line from the fuel filter Fuel filter Common rail...
Page 429 ENGINE (J05E)/TROUBLESHOOTING 2–393 Check the DTC detected 3 (engine ECU) Perform an engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if any followings DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected.
Page 430 2–394 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected 4 (engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if any followings DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected.
Page 431 ENGINE (J05E)/TROUBLESHOOTING 2–395 Check the injector clamp Check that the injector clamp is not loose. Check that there is no "insufficient engagement" of the injector BOLT clamp claw. INJECTOR INJECTION PIPE INJECTOR CLAMP INJECTION PIPE OIL SEAL O-RING SHTS021270300356 Was any failure found? Repair or replace the faulty parts.
Page 432 2–396 ENGINE (J05E)/TROUBLESHOOTING Check the valve clearance Check that the valve clearance of each cylinder is within the stan- dard values. (Check all the valves.) Rocker arm Feeler gauge Measurement conditions Standard values Cold engine Intake valve: 0.3 mm (0.0118 in.) Cross head Exhaust valve: 0.45 mm (0.0177 in.)
Page 433 ENGINE (J05E)/TROUBLESHOOTING 2–397 Check the engine compression pressure Perform the engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Remove the air cleaner. Remove the all injectors. engine Set the special service tool (SST) and measure the compression on each cylinder one at a time on all 6 cylinders.
Page 434 2–398 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine speed main sensor (Crankshaft position sensor) Inspect the condition of engine speed main sensor (crankshaft position sensor) connector (looseness or poor contact). Engine speed main sensor (Crankshaft position sensor) Check the installation of the engine speed main sensor. (Crank- shaft position sensor) Connector Flywheel housing...
Page 435 ENGINE (J05E)/TROUBLESHOOTING 2–399 DTC: P026C and P026D EN01H02127030602016065 P026C: All injector (#1 - #4) Injection quantity and timing P026D: All injector (#1 - #4) Injection quantity and timing INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe...
Page 436 2–400 ENGINE (J05E)/TROUBLESHOOTING DTC set condition DTC detection condition 1. The #1 – #4 injection quantity and timing diagnosis is detecting normally. 2. All the following conditions continue for at least 10 seconds. • Engine speed is in the range of 725-775 r/min. •...
Page 437 ENGINE (J05E)/TROUBLESHOOTING 2–401 INSPECTION PROCEDURE: P026C and P026D Check the DTC detected 1 (Engine ECU) Perform the engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ...
Page 438 2–402 ENGINE (J05E)/TROUBLESHOOTING Inspect the fuel line Check that the fuel line has no leaks or clogging. <Main inspection locations> - Entry of foreign matter into the fuel tank - Fuel hose breakage, collapsing, looseness - High-pressure pipe breakage, collapsing, looseness A return line from the fuel filter Fuel filter Common rail...
Page 439 ENGINE (J05E)/TROUBLESHOOTING 2–403 Inspect the pre fuel filter Check that the pre fuel filter is not dirty or clogged or damaged. Was any failure found? Replace the pre fuel filter. Go to step 5. Go to step 5 after replacement. Check the DTC detected (Engine ECU) Perform the engine warm up.
Page 440 2–404 ENGINE (J05E)/TROUBLESHOOTING Perform the cylinder cut-off test (HINO DX Ⅱ ) Use the cruise function to run the engine at 1,500 r/min. Check the engine sound during normal operation. (before Cut-off test) Use HINO DX Ⅱ [Data monitor and Active test] to perform a cut-off test.(For details, refer to the cut-off test procedure on the following pages.) <Cylinder cut-off test>...
Page 441 ENGINE (J05E)/TROUBLESHOOTING 2–405 Replace the common rail assembly Set the starter key to the "LOCK" position. Replace common rail assembly. Perform the engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if the DTC (P026C or P026D) has been SHTS021270300368 detected.
Page 442 2–406 ENGINE (J05E)/TROUBLESHOOTING Check the injector clamp Check that the injector clamp is not loose. Check that there is no "insufficient engagement" of the injector BOLT clamp claw. INJECTOR INJECTION PIPE INJECTOR CLAMP INJECTION PIPE OIL SEAL O-RING SHTS021270300369 Was any failure found? Repair or replace the faulty parts.
Page 443 ENGINE (J05E)/TROUBLESHOOTING 2–407 Check the valve clearance Check that the valve clearance of each cylinder is within the stan- dard values. (Check all the valves.) Rocker arm Feeler gauge Measurement conditions Standard values Cold engine Intake valve: 0.30 mm (0.0118 in.) Cross head Exhaust valve: 0.45 mm (0.0177 in.)
Page 444 2–408 ENGINE (J05E)/TROUBLESHOOTING Check the engine compression pressure Perform an engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Remove the all injectors. Set the special service tool (SST) and measure the compression. engine Measurement Standard values conditions...
Page 445 ENGINE (J05E)/TROUBLESHOOTING 2–409 Inspect the engine speed main sensor (Crankshaft position sensor) Inspect the condition of engine speed main sensor (crankshaft position sensor) connector (looseness or poor contact). Engine speed main sensor (Crankshaft position sensor) Check the installation of the engine speed main sensor. (Crank- shaft position sensor) Connector Flywheel housing...
Page 446 2–410 ENGINE (J05E)/TROUBLESHOOTING Flow-Cut off test <Cylinder cut-off test> By stopping fuel injection for one of the cylinders of an engine normally running with four, this test detects combustion abnormalities of each cylinder. <Purpose> Evaluation of combustion abnormalities in the cylinders by using sound differences. <Know-how &...
Page 447 ENGINE (J05E)/TROUBLESHOOTING 2–411 Stop injection for cylinder No. 1 and check the engine sound. (The sound at this time shall be A.) Stop the test after checking. HINT During the test, the engine tries to maintain the original four-cylin- der speed, but using only three cylinders, so that the sound A becomes larger in comparison with the sound α.
Page 448 2–412 ENGINE (J05E)/TROUBLESHOOTING DTC: P0299 EN01H02127030602016066 P0299: Underboost INFORMATION Coolant temperature sensor Engine ECU (THW) 10mA X28 (THW) Body earth 10mA ZJQ (E5) (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2)
Page 449 ENGINE (J05E)/TROUBLESHOOTING 2–413 Reset condition • After normal operation is restored and the starter key is turned "LOCK". Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)>...
Page 450 2–414 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0299 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0299 (for exam- ple, P0045, P0401) has been detected.
Page 451 ENGINE (J05E)/TROUBLESHOOTING 2–415 Inspect the boost pressure sensor power supply system Set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor vehicle side connector.
Page 452 2–416 ENGINE (J05E)/TROUBLESHOOTING Inspect the response delay of the VNT controller Select [Inspection Menu] from the menu, then inspect the response delay at the Target VNT position and Actual VNT posi- tion. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 453 ENGINE (J05E)/TROUBLESHOOTING 2–417 Inspect the response delay of the EGR valve Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 454 2–418 ENGINE (J05E)/TROUBLESHOOTING DTC: P0300 EN01H02127030602016067 P0300: All injector (#1 - #4) Misfire INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe Supply pump Overflow valve Fuel tank Pre fuel filter Fuel filter SHTS021270300381 Technical description...
Page 455 ENGINE (J05E)/TROUBLESHOOTING 2–419 DTC set condition DTC detection condition 1. All the following conditions continue for at least 30 seconds: • Engine speed is between 250 – 900 r/min. • Fuel injection quantity is within 0 – 50 mm /st. cyl. •...
Page 456 2–420 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0300 Inspect the fuel pipes Check the fuel pipe (high-pressure pipe between the common rail and injector) and verify that there are no bends, ruptures, or loose connections in it. A return line from the fuel filter Fuel filter Common rail Injector...
Page 457 ENGINE (J05E)/TROUBLESHOOTING 2–421 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "ON" position. Select [Engine] and check if P0300 has been detected. SHTS021270300383 Has DTC P0300 been detected? Go to step 3.
Page 458 2–422 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) 2 Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "ON" position. Select [Engine] and check if P0300 has been detected. SHTS021270300385 Has DTC P0300 been detected? Go to step 5.
Page 459 ENGINE (J05E)/TROUBLESHOOTING 2–423 Check the compression ratio Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Remove injectors from all cylinders. Install the special tool (SST) and measure the compression ratio of each cylinder. ENGINE Measurement conditions Standard values...
Page 460 2–424 ENGINE (J05E)/TROUBLESHOOTING Flow-Cut off test <Cylinder cut-off test> By stopping fuel injection for one of the cylinders of an engine normally running with six, this test detects combustion abnormalities of each cylinder. <Purpose> Evaluation of combustion abnormalities of each cylinder by sound difference. <Know-how &...
Page 461 ENGINE (J05E)/TROUBLESHOOTING 2–425 Stop injection for cylinder No. 1 and check the engine sound. (The sound at this time shall be A.) Stop the test after checking. HINT During the test, the engine tries to maintain the original four-cylin- der speed, but using only three cylinders, so that the sound A becomes larger in comparison with the sound.
Page 462 2–426 ENGINE (J05E)/TROUBLESHOOTING DTC: P0301, P0302, P0303 and P0304 EN01H02127030602016068 P0301: #1 Misfire P0302: #2 Misfire P0303: #3 Misfire P0304: #4 Misfire INFORMATION Injection Flow damper pipe Injector Common rail Pressure feeding pipe Leakage pipe Pressure limiter Overflow pipe Through feed pipe Supply pump Overflow valve...
Page 463 ENGINE (J05E)/TROUBLESHOOTING 2–427 DTC set condition DTC detection condition 1. All the following conditions continue for more than 30 seconds. • The engine speed is in the range of 250 to 900 r/min. • The fuel injection quantity is within 0 to 50 mm /st.
Page 464 2–428 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0301, P0302, P0303 and P0304 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ...
Page 465 ENGINE (J05E)/TROUBLESHOOTING 2–429 Inspect the fuel injection pipe between common rail and injector Check the fuel pipe (high-pressure pipe between the common rail and injector) and verify that there are no bends, ruptures, or loose connections in it. A return line from the fuel filter Fuel filter Common rail Injector...
Page 466 2–430 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and the starter key to the "ON" position. Select [Engine] and check if the DTC (P0301, P0302, P0303 or P0304) has been detected.
Page 467 ENGINE (J05E)/TROUBLESHOOTING 2–431 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and the starter key to the "ON" position. Select [Engine] and check if the DTC (P0301, P0302, P0303 or P0304) has been detected.
Page 468 2–432 ENGINE (J05E)/TROUBLESHOOTING Check the engine compression pressure Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Remove the all injectors Set the special service tool (SST) and measure the compression. ENGINE Measurement conditions Standard values 3.2 –...
Page 469 ENGINE (J05E)/TROUBLESHOOTING 2–433 Flow-Cut off test <Cylinder cut-off test> By stopping fuel injection for one of the cylinders of an engine normally running with four, this test detects combustion abnormalities of any cylinder. <Purpose> Evaluation of combustion abnormalities of each cylinder by sound difference. <Know-how &...
Page 470 2–434 ENGINE (J05E)/TROUBLESHOOTING Stop injection for cylinder No. 1 and check the engine sound. (The sound at this time shall be A.) Stop the test after checking. HINT During the test, the engine tries to maintain the original four-cylin- der speed, but using only three cylinders, so that the sound A becomes larger in comparison with the sound.
Page 471 ENGINE (J05E)/TROUBLESHOOTING 2–435 DTC: P0335 EN01H02127030602016069 P0335: Engine speed main sensor (Crankshaft position sensor) - disconnection INFORMATION Engine ECU (SNE) Engine speed main sensor (NE-) (NE-) (NE+) (NE+) SHTS021270300402 Technical description • The engine speed main sensor (crankshaft position sensor) consistently measures pulses from the engine speed main sensor (crankshaft position sensor).
Page 472 2–436 ENGINE (J05E)/TROUBLESHOOTING Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Abnormal resistance of sensor •...
Page 473 ENGINE (J05E)/TROUBLESHOOTING 2–437 INSPECTION PROCEDURE: P0335 Inspect the engine speed main sensor (crankshaft position sensor) connector Check the connection of the engine speed main sensor (crank- shaft position sensor) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 474 2–438 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine speed main sensor (crankshaft position sensor) unit Set the starter key to the "LOCK" position. Disconnect the engine speed main sensor (crankshaft position sensor) connector. Use the electrical tester to measure the resistance between the terminals of the engine speed main sensor (crankshaft position sensor).
Page 475 ENGINE (J05E)/TROUBLESHOOTING 2–439 Inspect the engine speed main sensor (crankshaft position sensor) power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine speed main sensor (crankshaft position sensor) vehicle side connector.
Page 476 2–440 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the engine speed main sensor (crankshaft position sensor) har- ness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. (Do not con- nect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 477 ENGINE (J05E)/TROUBLESHOOTING 2–441 Inspect disconnection of the engine speed main sensor (crankshaft position sensor) harness Connect the engine speed main sensor (crankshaft position sen- sor) connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 478 2–442 ENGINE (J05E)/TROUBLESHOOTING DTC: P0336 EN01H02127030602016070 P0336: Engine speed main sensor (Crankshaft position sensor) - rationality INFORMATION Engine ECU (SNE) Engine speed main sensor (NE-) (NE-) (NE+) (NE+) SHTS021270300408 Technical description • The engine speed main sensor (crankshaft position sensor) consistently measures pulses from the engine speed main sensor (crankshaft position sensor).
Page 479 ENGINE (J05E)/TROUBLESHOOTING 2–443 INSPECTION PROCEDURE: P0336 Inspect the engine speed main sensor (crankshaft position sensor) connector Check the connection of the engine speed main sensor (crank- shaft position sensor) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 480 2–444 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine speed main sensor (crankshaft position sensor) power supply Set the starter key to the "LOCK" position. Disconnect the engine speed main sensor (crankshaft position sensor) connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine speed main sensor (crankshaft position sensor) vehicle side connector.
Page 481 ENGINE (J05E)/TROUBLESHOOTING 2–445 Inspect disconnection of the engine speed main sensor (crankshaft position sensor) harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU engine speed main sensor (crankshaft position sensor to the ECU) Use the electrical tester to measure the resistance between the terminals of the engine ECU and engine speed main sensor (crankshaft position sensor) vehicle side connector.
Page 482 2–446 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the engine speed main sensor (crankshaft position sensor) har- ness Use the electrical tester to measure the resistance between the terminals of the engine ECU and ground. Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har- ness)
Page 483 ENGINE (J05E)/TROUBLESHOOTING 2–447 Check the engine speed main sensor (crankshaft position sensor) signal Connect the signal check harness to the engine ECU. Connect the engine speed main sensor (crankshaft position sen- sor) connector. Start the engine. Use the oscilloscope to measure the signal voltage between the terminals in the engine ECU (signal check harness).
Page 484 2–448 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 485 ENGINE (J05E)/TROUBLESHOOTING 2–449 DTC: P0340 EN01H02127030602016071 P0340: Engine speed sub sensor (Camshaft position sensor) - disconnection INFORMATION Engine ECU 15mA (G-) (G-) (G1) Engine speed sub sensor (G+) 15mA (VG) (VCG) SHTS021270300415 Technical description • The engine speed sub sensor (camshaft position sensor) consistently measures pulses from the engine speed sub sensor (camshaft position sensor).
Page 486 2–450 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0340 Inspect the engine speed sub sensor (camshaft position sensor) connector Check the connection of the engine speed sub sensor (camshaft position sensor) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 487 ENGINE (J05E)/TROUBLESHOOTING 2–451 Inspect the sensor power supply 1 Disconnect the engine speed sub sensor (camshaft position sen- sor) connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine speed sub sensor (camshaft position sensor) vehicle side connector.
Page 488 2–452 ENGINE (J05E)/TROUBLESHOOTING Inspect the sensor power supply 2 Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Connect the engine speed sub sensor (camshaft position sensor) connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness).
Page 489 ENGINE (J05E)/TROUBLESHOOTING 2–453 DTC: P0341 EN01H02127030602016072 P0341: Engine speed sub sensor (Camshaft position sensor) - rationality INFORMATION Engine ECU 15mA (G-) (G-) (G1) (G+) Engine speed sub sensor 15mA (VG) (VCG) SHTS021270300419 Technical description • The engine speed sub sensor (camshaft position sensor) consistently measures pulses from the engine speed sub sensor (camshaft position sensor).
Page 490 2–454 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Abnormal resistance of sensor • Improper pulses • Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to adhesion of dirt, damage, etc.) • Irregular contact (disconnection or poor fit of connector) •...
Page 491 ENGINE (J05E)/TROUBLESHOOTING 2–455 INSPECTION PROCEDURE: P0341 Inspect the engine speed sub sensor (camshaft position sensor) connector Check the connection of the engine speed sub sensor (camshaft position sensor) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 492 2–456 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the engine speed sub sensor (camshaft position sensor) harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Disconnect the engine speed sub sensor (camshaft position sen- sor) connector.
Page 493 ENGINE (J05E)/TROUBLESHOOTING 2–457 Inspect disconnection of the engine speed sub sensor (camshaft position sensor) harness Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and engine speed sub sensor (camshaft position sensor) vehicle side connec- tor.
Page 494 2–458 ENGINE (J05E)/TROUBLESHOOTING Inspect the engine speed sub sensor (camshaft position sensor) power supply Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine speed sub sensor (camshaft position sensor) vehicle side connector.
Page 495 ENGINE (J05E)/TROUBLESHOOTING 2–459 Inspect the engine speed sub sensor (camshaft position sensor) signal Connect the engine speed sub sensor (camshaft position sensor) connector. Start the engine. Use the oscilloscope to measure the signal voltage between the terminals in the engine ECU (signal check harness). Measurement Tester Standard values...
Page 496 2–460 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 497 ENGINE (J05E)/TROUBLESHOOTING 2–461 DTC: P0381 EN01H02127030602016073 P0381: Glow lamp (wait-to-start lamp) - circuit INFORMATION Engine ECU Combination meter 20mA (GIND) (GLW-) Glow indicator light SHTS021270300426 Technical description • The light will light up when the glow lamp is in drive status or light out when it is in non-drive status. <Description of malfunction>...
Page 498 2–462 ENGINE (J05E)/TROUBLESHOOTING Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Failure of glow light (in combination meter) •...
Page 499 ENGINE (J05E)/TROUBLESHOOTING 2–463 INSPECTION PROCEDURE: P0381 Inspect the combination meter connector Check the connection of the combination meter connector (loose- ness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 500 2–464 ENGINE (J05E)/TROUBLESHOOTING Check the glow light circuit Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 501 ENGINE (J05E)/TROUBLESHOOTING 2–465 Check for short-circuit in wire harness of glow light Set the starter key to the "LOCK" position. Disconnect the signal check harness from the engine ECU. (Leave the vehicle side engine ECU connector connected.) Disconnect the combination meter 40P connector. Use the electrical tester to measure the resistance between the GIND (V7) terminal in the engine ECU (signal check harness) and ground.
Page 502 2–466 ENGINE (J05E)/TROUBLESHOOTING Check for disconnection in glow light wire harness Use the electrical tester to measure the resistance between the engine ECU (signal check harness) and the combination meter 40P vehicle side connector terminals. Measurement Tester Standard values conditions connections GLW- Engine ECU (sig-...
Page 503 ENGINE (J05E)/TROUBLESHOOTING 2–467 DTC: P0401 EN01H02127030602016074 P0401: EGR low flow INFORMATION Coolant temperature sensor Reference Engine ECU (THW) 10mA X28 (THW) Body earth 10mA ZJQ (E5) (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC1) (VC) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2)
Page 504 2–468 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • Turbocharger noise or damage •...
Page 505 ENGINE (J05E)/TROUBLESHOOTING 2–469 INSPECTION PROCEDURE: P0401 Inspect the air cleaner element Check the air cleaner element for dirt, clogging, or damage. Make sure the element is a Hino genuine part. Was any failure found? Clean or replace the air cleaner element. Go to step 2.
Page 506 2–470 ENGINE (J05E)/TROUBLESHOOTING Check the boost pressure sensor output signal Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Start the engine. Select [Engine]. Select [Actual boost pressure] from the [Data monitor and Active test].
Page 507 ENGINE (J05E)/TROUBLESHOOTING 2–471 Inspect the intake air temperature sensor (intake manifold) unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (intake manifold) connector. Use the electrical tester to measure the resistance between the terminals of the intake air temperature sensor (intake manifold). Measurement Tester Standard values...
Page 508 2–472 ENGINE (J05E)/TROUBLESHOOTING Inspect the response delay of the EGR valve Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 509 ENGINE (J05E)/TROUBLESHOOTING 2–473 Inspect the EGR cooler Check if soot is obstructing the inlet/outlet of the EGR cooler gas passageway. Check if there are foreign substances stuck to the EGR cooler coolant passageway. Check the EGR cooler coolant passageway for obstruction due to deformation or other damage.
Page 510 2–474 ENGINE (J05E)/TROUBLESHOOTING Inspect the SCV Perform an SCV test and a malfunction reproduction test. • For a detailed procedure, refer to the separate "SCV free accelera- tion test". Was any failure found? Repair or replace the faulty part. Go to step 11. Perform "After-inspection work"...
Page 511 ENGINE (J05E)/TROUBLESHOOTING 2–475 Inspect the injector Check the injection quantity and the rotational fluctuation. Start the engine. Select [Injection quantity] from [Data monitor and Active test] on HINO DX Ⅱ and measure the fuel injection quantity. SHTS021270300435 Select [Engine revolution] from [Data monitor and Active test] on NE Rotational fluctuation HINO DX Ⅱ...
Page 512 2–476 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if P0401 has been detected. SHTS021270300438 Has DTC P0401 been detected? Replace the engine ECU.
Page 513 ENGINE (J05E)/TROUBLESHOOTING 2–477 SCV FREE ACCELERATION TEST Test method <Engine speed pattern> 1. After engine has reached operating temperature (more than 82 C {179.6 F}). 2. After air compressor completed building pressure. 3. A/C, Head lights off. 4. All devices off. (PTO, Refrigeration compressor. etc) 5.
Page 514 2–478 ENGINE (J05E)/TROUBLESHOOTING Types of HINO DX Ⅱ data to be measured SHTS021270300441 If the following symptoms occur, FAIL. If not, OK. a. Pressure is reduced by 5 MPa or more continually for 5 seconds or more.  Replace the supply pump. Engine speed pattern Actual common rail pressure a: Pressure is reduced by 5...
Page 515 ENGINE (J05E)/TROUBLESHOOTING 2–479 b. Pressure is increased by 5 MPa or more continually for 5 seconds or more.  Replace the SCV. Engine speed pattern Actual common rail pressure Pressure is increased by 5 MPa or more continually for Target common rail pressure 5 seconds or more.
Page 516 2–480 ENGINE (J05E)/TROUBLESHOOTING e. Before the maximum common rail pressure exceeds 222 MPa during pressure increase, the actual rail pressure falls below the target rail pressure rapidly.  Replace the common rail. Accelerator pattern 222 MPa Actual common rail pressure Target common rail pressure Time SHTS021270300446...
Page 517 ENGINE (J05E)/TROUBLESHOOTING 2–481 h. Hunting remains within 10 MPa or more for more than 5 seconds.  Replace the SCV. Engine speed pattern Actual common rail pressure 10 MPa or more Target common rail pressure Remains for 5 seconds or longer. Time SHTS021270300449 i.
Page 518 2–482 ENGINE (J05E)/TROUBLESHOOTING j. Target common rail pressure during idling deviates from the standard value.  Replace the SCV. <FINAL VALUE OF PUMP CURRENT TARGET test> 1. After engine has reached operating temperature. (more than 82 C {179.6 F}) 2. After air compressor has completed building pressure. 3.
Page 519 ENGINE (J05E)/TROUBLESHOOTING 2–483 DTC: P0402 EN01H02127030602016075 P0402: EGR high flow INFORMATION Engine ECU Resistor Actuator power relay controller actuator Boost pressure sensor Intake manifold Common rail Intake air temperature pressure sensor temperature sensor Body earth sensor (air flow sensor built in) SHTS021270300452 Technical description •...
Page 520 2–484 ENGINE (J05E)/TROUBLESHOOTING DTC set condition DTC detection condition The following conditions continue for at least 30 seconds. • Starter key "ON". • DPR auto-regeneration is inactive. • Engine coolant temperature is 30 C {86 F} or less. • Engine speed of 1,000 r/min or less. •...
Page 521 ENGINE (J05E)/TROUBLESHOOTING 2–485 Estimated failure factors • Intake manifold temperature sensor failure • Air flow sensor failure • Boost pressure sensor failure • Injector failure • EGR valve failure • Clogged intake system • VNT controller failure...
Page 522 2–486 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0402 Check the response delay of the EGR valve Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position.
Page 523 ENGINE (J05E)/TROUBLESHOOTING 2–487 Check the response delay of the VNT controller Select [Inspection Menu] from the menu, then inspect the response delay at the Target VNT position and Actual VNT posi- tion. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 524 2–488 ENGINE (J05E)/TROUBLESHOOTING Inspect the air flow sensor Check the installation of the air flow sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the air flow sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 5.
Page 525 ENGINE (J05E)/TROUBLESHOOTING 2–489 Inspect the boost pressure sensor Check the installation of the boost pressure sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the boost pressure sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 8.
Page 526 2–490 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor (intake manifold) Check the installation of the intake air temperature sensor (intake manifold). Make sure there is no dirt, damage or clogging in the sensing unit of the intake air temperature sensor (intake manifold). Was any failure found? Clean the sensing unit and install it properly.
Page 527 ENGINE (J05E)/TROUBLESHOOTING 2–491 Inspect the EGR valve Check the EGR valve for damage due to foreign substances. Check if there is soot obstructing the exhaust gas passageway inlet or outlet. Was any failure found? Remove foreign substances and clean the Go to step 12.
Page 528 2–492 ENGINE (J05E)/TROUBLESHOOTING Inspect the injector Check the injection quantity and the rotational fluctuation. Start the engine SHTS021270300456 Select [Injection quantity] from the [Data monitor and Active test] and measure the amount of fuel injection. NE Rotational fluctuation @1,500 r/min (measurement by HINO-DX II) Select [Engine revolution] from the [Data monitor and Active test] and measure the rotational fluctuation.
Page 529 ENGINE (J05E)/TROUBLESHOOTING 2–493 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if P0402 has been detected. SHTS021270300459 Has DTC P0402 been detected? Replace the engine ECU.
Page 530 2–494 ENGINE (J05E)/TROUBLESHOOTING DTC: P0404 EN01H02127030602016076 P0404: Valve position control failure - DC motor out of range, functional (EGR valve stick failure) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300460 Technical description • EGR valve is a butterfly type. •...
Page 531 ENGINE (J05E)/TROUBLESHOOTING 2–495 Reset condition • After normal status is resumed and accelerator opening is fully closed. Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Fuel injection limit Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)>...
Page 532 2–496 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0404 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if P0404 has been detected. SHTS021270300461 Has a DTC other than P0404 been detected? Go to diagnosis procedure of a related DTC.
Page 533 ENGINE (J05E)/TROUBLESHOOTING 2–497 Inspect the EGR valve connector Check the connection of the EGR valve connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the EGR valve power supply Set the starter key to the "LOCK"...
Page 534 2–498 ENGINE (J05E)/TROUBLESHOOTING Check the response delay of the EGR valve Select [Inspection Menu] and check the time lag (following charac- teristics) of the target EGR valve opening and actual EGR valve opening. ! CAUTION Perform the inspection while the engine is stopped to avoid engine damages.
Page 535 ENGINE (J05E)/TROUBLESHOOTING 2–499 DTC: P0405 and P0406 EN01H02127030602016077 P0405: EGR valve controller position sensor signal too low (EGR actuator position sensor signal too low) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300464 Technical description • EGR valve is a butterfly type. •...
Page 536 2–500 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 537 ENGINE (J05E)/TROUBLESHOOTING 2–501 P0406: Valve position sensor magnet lost (EGR actuator position sensor signal too high) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300465 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 538 2–502 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 539 ENGINE (J05E)/TROUBLESHOOTING 2–503 INSPECTION PROCEDURE: P0405 and P0406 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than (P0405 or P0406) has been detected.
Page 540 2–504 ENGINE (J05E)/TROUBLESHOOTING Inspect the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 541 ENGINE (J05E)/TROUBLESHOOTING 2–505 DTC: P041B EN01H02127030602016078 P041B: EGR gas temperature sensor - rationality INFORMATION [at engine start] Engine ECU Resistor Actuator power relay controller actuator EGR cooler outlet Intercooler outlet Common rail temperature sensor temperature sensor pressure sensor Boost pressure Intake manifold sensor temperature sensor...
Page 542 2–506 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 543 ENGINE (J05E)/TROUBLESHOOTING 2–507 P041B: EGR gas temperature sensor - rationality INFORMATION [at engine running 1] Engine ECU Resistor Actuator power relay controller actuator Intercooler outlet EGR cooler outlet Common rail temperature sensor temperature sensor pressure sensor Boost pressure Intake manifold sensor temperature sensor SHTS021270300470...
Page 544 2–508 ENGINE (J05E)/TROUBLESHOOTING Reset condition • After restoration to normal condition and starter key "LOCK" Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)>...
Page 545 ENGINE (J05E)/TROUBLESHOOTING 2–509 P041B: EGR gas temperature sensor - rationality INFORMATION [at engine running 2] Engine ECU Resistor Actuator power relay controller actuator Intercooler outlet EGR cooler outlet Common rail temperature sensor temperature sensor pressure sensor Boost pressure Intake manifold sensor temperature sensor SHTS021270300471...
Page 546 2–510 ENGINE (J05E)/TROUBLESHOOTING Judgement criteria • Judged when the calculated EGR cooler efficiency is less than 80%; • If the values of difference between the calculated intake manifold air intake temperature and the actual intake manifold air intake temperature) are as follows: If the EGR rate is 0%: the difference is 10 C {50 F} or more. If the EGR rate is 20%: the difference is 17 C {62.6 F} or more.
Page 547 ENGINE (J05E)/TROUBLESHOOTING 2–511 INSPECTION PROCEDURE: P041B Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if P041B (for example, P0401, P0402, P0404, P0234, P0299, P22D3, turbocharger, EGR system DTC) has been detected.
Page 548 2–512 ENGINE (J05E)/TROUBLESHOOTING Inspect the EGR cooler outlet temperature sensor Check the installation of the EGR cooler outlet temperature sen- sor. Make sure there is no dirt, damage or clogging in the sensing unit of the EGR cooler outlet temperature sensor. Was any failure found? Clean the sensing unit and install it properly.
Page 549 ENGINE (J05E)/TROUBLESHOOTING 2–513 Inspect the EGR cooler outlet temperature sensor power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR cooler outlet temperature sensor vehicle side con- nector.
Page 550 2–514 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the EGR cooler outlet temperature sensor harness Connect the EGR cooler outlet temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values conditions...
Page 551 ENGINE (J05E)/TROUBLESHOOTING 2–515 Inspect the intake air temperature sensor (intake manifold) unit Set the starter key to the "LOCK" position. Disconnect the intake air temperature sensor (intake manifold) connector. Use the electrical tester to measure the resistance between the terminals of the intake air temperature sensor (intake manifold). Measurement Tester Standard values...
Page 552 2–516 ENGINE (J05E)/TROUBLESHOOTING Inspect the intake air temperature sensor (intercooler outlet) unit Disconnect the intake air temperature sensor (intercooler outlet) connector. Use the electrical tester to measure the resistance between the terminals of the intake air temperature sensor (intercooler outlet). Measurement Tester Standard values...
Page 553 ENGINE (J05E)/TROUBLESHOOTING 2–517 Inspect the boost pressure sensor power supply system Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor vehicle side connector. Measurement Tester Standard values...
Page 554 2–518 ENGINE (J05E)/TROUBLESHOOTING DTC: P041C and P041D EN01H02127030602016079 P041C: EGR gas temperature sensor - out of range (Out of range low) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC1) (VC) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA...
Page 555 ENGINE (J05E)/TROUBLESHOOTING 2–519 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 556 2–520 ENGINE (J05E)/TROUBLESHOOTING P041D: EGR gas temperature sensor - out of range (Out of range high) INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S) 10mA (THG)
Page 557 ENGINE (J05E)/TROUBLESHOOTING 2–521 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 558 2–522 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P041C and P041D Inspect the EGR cooler outlet temperature sensor connector Check the connection of the EGR cooler outlet temperature sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 559 ENGINE (J05E)/TROUBLESHOOTING 2–523 Inspect the EGR cooler outlet temperature sensor Set the starter key to the "LOCK" position. Disconnect the EGR cooler outlet temperature sensor connector. Use the electrical tester to measure the resistance between the terminals of the EGR cooler outlet temperature sensor. Measurement Tester Standard values...
Page 560 2–524 ENGINE (J05E)/TROUBLESHOOTING Check for short-circuit in wire harness of EGR cooler outlet temperature sensor Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the EGR cooler outlet temperature sensor terminals and ground.
Page 561 ENGINE (J05E)/TROUBLESHOOTING 2–525 Check the DTC detected (Engine ECU) Warm up the Engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 562 2–526 ENGINE (J05E)/TROUBLESHOOTING DTC: P0420 EN01H02127030602016080 P0420: Tentative determination of ATC deterioration INFORMATION Technical description <Description of malfunction> • If the ATC (oxidation catalyst) is not generating heat, the engine ECU tentatively determines abnormality as ATC deterioration (P0420). • When this DTC is detected, perform troubleshooting for P0148 (abnormality in post injection) and P0421 (determi- nation of ATC deterioration).
Page 563 ENGINE (J05E)/TROUBLESHOOTING 2–527 INSPECTION PROCEDURE: P0420 Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle. Set the starter key to the "ON" position. On the screen of the diagnostic system, select [Engine] and check DTC P0420.
Page 564 2–528 ENGINE (J05E)/TROUBLESHOOTING DTC: P0421 EN01H02127030602016081 P0421: Determination of ATC deterioration INFORMATION Technical description <Description of malfunction> • If post injection is performed normally but the ATC (oxidation catalyst) is not generating heat, the engine ECU detects abnormality as ATC functional deterioration. DTC set condition DTC detection condition •...
Page 565 ENGINE (J05E)/TROUBLESHOOTING 2–529 INSPECTION PROCEDURE: P0421 Inspect fuel Open the fuel cap and check fuel for abnormality (in color and smell). Was any failure found? Replace the fuel with good quality fuel and Go to step 3. then go to Step 2. Check the DTC detected [HINO DX Ⅱ...
Page 566 2–530 ENGINE (J05E)/TROUBLESHOOTING Inspect the exhaust gas temperature sensor (DPF inlet) Inspect the exhaust gas temperature sensor (DPF inlet) for improper installation. Check the sensing area of the exhaust gas temperature sensor (DPF inlet) for dirt, clogging, and damage. Was any failure found? Clean the sensing area and install the sensor Replace the ATC.
Page 567 ENGINE (J05E)/TROUBLESHOOTING 2–531 DTC: P0422 EN01H02127030602016082 P0422: DOC deterioration INFORMATION Technical description <Description of malfunction> • If the DOC is not generating heat or if the DOC is generating heat but temperature does not increase at the DOC outlet, the engine ECU detects DOC deterioration. DTC set condition DTC detection condition •...
Page 568 2–532 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0422 Inspect fuel Open the fuel cap and check fuel for abnormality (in color and smell). Was any failure found? Replace the fuel with good quality fuel and Go to step 3. then go to Step 2. Check the DTC detected [HINO DX Ⅱ...
Page 569 ENGINE (J05E)/TROUBLESHOOTING 2–533 Inspect the exhaust gas temperature sensor (DPF inlet) Inspect the exhaust gas temperature sensor (DPF inlet) for improper installation. Check the sensing area of the exhaust gas temperature sensor (DPF inlet) for dirt, clogging, and damage. Was any failure found? Clean the sensing area and install the sensor Replace the DPR.
Page 570 2–534 ENGINE (J05E)/TROUBLESHOOTING DTC: P0489 and P0490 EN01H02127030602016083 P0489: EGR valve controller motor (open circuit) (EGR actuator motor open circuit) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300491 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 571 ENGINE (J05E)/TROUBLESHOOTING 2–535 Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Fuel injection limit Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> •...
Page 572 2–536 ENGINE (J05E)/TROUBLESHOOTING P0490: EGR valve controller motor (short circuit) (EGR actuator motor short circuit) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300492 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 573 ENGINE (J05E)/TROUBLESHOOTING 2–537 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 574 2–538 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0489 and P0490 Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than DTC of this inspection has been detected.
Page 575 ENGINE (J05E)/TROUBLESHOOTING 2–539 Inspect the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 576 2–540 ENGINE (J05E)/TROUBLESHOOTING DTC: P049D EN01H02127030602016084 P049D: Position failure (EGR actuator wiping fault) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300496 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 577 ENGINE (J05E)/TROUBLESHOOTING 2–541 Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Fuel injection quantity is limited. Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> •...
Page 578 2–542 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P049D Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P049D has been detected SHTS021270300497 Has a DTC other than P049D been detected?
Page 579 ENGINE (J05E)/TROUBLESHOOTING 2–543 Inspect the EGR valve connector Check the connection of the EGR valve connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the EGR valve power supply Set the starter key to the "LOCK"...
Page 580 2–544 ENGINE (J05E)/TROUBLESHOOTING Check the response delay of the EGR controller Select [Inspection Menu] [EGR inspection] from the menu, and inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid engine damages.
Page 581 ENGINE (J05E)/TROUBLESHOOTING 2–545 DTC: P04D5 and P04D6 EN01H02127030602016085 P04D5: Exhaust brake - circuit (Circuit low) INFORMATION Max : 61.1A Rating : 14.5A F ENG-2 30A U2-ACT (L ) (+ ) (L ) (-S) (+S) Actuator power relay Exhasut brake magnetic valve Engine ECU SHTS021270300500 Technical description...
Page 582 2–546 ENGINE (J05E)/TROUBLESHOOTING Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is detected after test drive. Estimated failure factors • GND short-circuit in exhaust brake drive signal line •...
Page 583 ENGINE (J05E)/TROUBLESHOOTING 2–547 P04D6: Exhaust brake - circuit (Circuit high) INFORMATION Max : 61.1A Rating : 14.5A F ENG-2 30A U2-ACT (L ) (+ ) (L ) (-S) (+S) Actuator power relay Exhasut brake magnetic valve Engine ECU SHTS021270300501 Technical description •...
Page 584 2–548 ENGINE (J05E)/TROUBLESHOOTING After-inspection work • Clear all past DTCs. • Check that no DTC is detected after test drive. Estimated failure factors • +B short-circuit or disconnection in exhaust brake drive signal line. • Malfunction of exhaust brake magnetic valve. •...
Page 585 ENGINE (J05E)/TROUBLESHOOTING 2–549 INSPECTION PROCEDURE: P04D5 and P04D6 Inspect the exhaust brake magnetic valve connector Check the connection of the exhaust brake magnetic valve con- nector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 586 2–550 ENGINE (J05E)/TROUBLESHOOTING Inspect the exhaust brake magnetic valve unit Set the starter key to the "LOCK" position. SOL- SOL+ Disconnect the exhaust brake magnetic valve connector. Use the electrical tester to measure the resistance between the terminals of the exhaust brake magnetic valve. Measurement Tester Standard values...
Page 587 ENGINE (J05E)/TROUBLESHOOTING 2–551 Inspect for short-circuit of the exhaust brake magnetic valve harness Disconnect the engine ECU connector. SOL- Use the electrical tester to measure the resistance between the terminals of the exhaust brake magnetic valve vehicle side con- nector and ground. Measurement Tester Standard values...
Page 588 2–552 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if the DTC (P04D5 or P04D6) has been detected.
Page 589 ENGINE (J05E)/TROUBLESHOOTING 2–553 DTC: P04DA EN01H02127030602016086 P04DA: EGR feedback failure INFORMATION Engine ECU Resistor Actuator power relay controller actuator Boost pressure sensor Intake manifold Common rail Intake air temperature pressure sensor temperature sensor Body earth sensor (air flow sensor built in) SHTS021270300507 Technical description •...
Page 590 2–554 ENGINE (J05E)/TROUBLESHOOTING Reset condition • After normal operation is restored and the starter key is turned "LOCK". Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Engine output is restricted. Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)>...
Page 591 ENGINE (J05E)/TROUBLESHOOTING 2–555 INSPECTION PROCEDURE: P04DA Check the response delay of the EGR valve Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position.
Page 592 2–556 ENGINE (J05E)/TROUBLESHOOTING Check the response delay of the VNT controller Select [Inspection Menu] from the menu, then inspect the response delay at the Target VNT position and Actual VNT posi- tion. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 593 ENGINE (J05E)/TROUBLESHOOTING 2–557 Inspect the air flow sensor Check the installation of the air flow sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the air flow sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 5.
Page 594 2–558 ENGINE (J05E)/TROUBLESHOOTING Inspect the boost pressure sensor Check the installation of the boost pressure sensor. Make sure there is no dirt, damage or clogging in the sensing unit of the boost pressure sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 8.
Page 595 ENGINE (J05E)/TROUBLESHOOTING 2–559 Inspect the intake air temperature sensor (intake manifold) Check the installation of the intake air temperature sensor (intake manifold). Make sure there is no dirt, damage or clogging in the sensing unit of the intake air temperature sensor (intake manifold). Was any failure found? Clean the sensing unit and install it properly.
Page 596 2–560 ENGINE (J05E)/TROUBLESHOOTING Inspect the EGR valve Check the EGR valve for damage due to foreign substances. Check if there is soot obstructing the exhaust gas passageway inlet or outlet. Was any failure found? Remove foreign substances and clean the Go to step 12.
Page 597 ENGINE (J05E)/TROUBLESHOOTING 2–561 Inspect the injector Check the injection quantity and the rotational fluctuation. Start the engine SHTS021270300511 Select [Injection quantity] from the [Data monitor and Active test] NE Rotational fluctuation and measure the amount of fuel injection. @1,500 r/min (measurement by HINO DX II) Select [Engine revolution] from the [Data monitor and Active test] and measure the rotational fluctuation.
Page 598 2–562 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if P04DA has been detected. SHTS021270300514 Has DTC P04DA been detected? Replace the engine ECU.
Page 599 ENGINE (J05E)/TROUBLESHOOTING 2–563 DTC: P0500 and P0501 EN01H02127030602016087 P0500: Vehicle speed sensor - low INFORMATION Engine ECU Combination meter 0.1A (SP1) (SP02) Vehicle speed signal SHTS021270300515 Technical description • The engine ECU consistently measures pulses from the vehicle speed sensor through combination meter. <Description of malfunction>...
Page 600 2–564 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Vehicle speed sensor failure • Malfunction of pulse modulator (in combination meter) • Harness disconnection or short-circuit • Irregular contact (disconnection or poor fit of connector)
Page 601 ENGINE (J05E)/TROUBLESHOOTING 2–565 P0501: Vehicle speed sensor - high INFORMATION Engine ECU Combination meter 0.1A (SP1) (SP02) Vehicle speed signal SHTS021270300516 Technical description • The Engine ECU consistently measures pulses from the vehicle speed sensor. <Description of malfunction> • Pulses from the vehicle speed sensor are improper. DTC set condition DTC detection condition •...
Page 602 2–566 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0500 and P0501 Inspect the combination meter Drive the vehicle and confirm that the combination meter (speed- ometer) is working properly. Was any failure found? Check the combination meter (vehicle speed Go to step 2. signal system).
Page 603 ENGINE (J05E)/TROUBLESHOOTING 2–567 Inspect for short-circuits in wire harness of vehicle speed signal circuit Set the starter key to the "LOCK" position. Disconnect the combination meter connector. GROUND Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the engine ECU (signal check harness) and ground.
Page 604 2–568 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnection in wire harness of vehicle speed signal circuit Use the electrical tester to measure the resistance between the combination meter vehicle side connector terminal and engine ECU (signal check harness) terminal. Measurement Tester Standard values conditions connections SPD2...
Page 605 ENGINE (J05E)/TROUBLESHOOTING 2–569 Inspect for disconnection in wire harness of vehicle speed signal circuit Set the starter key to the "LOCK" position. Disconnect the combination meter connector. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) SPD2 Use the electrical tester to measure the resistance between the combination meter vehicle side connector terminal and engine...
Page 606 2–570 ENGINE (J05E)/TROUBLESHOOTING DTC: P0504 EN01H02127030602016088 P0504: Brake Switch Correlation INFORMATION Engine ECU Brake switch 12.7mA (ST1-) (NC-) Stop light switch signal SHTS021270300521 Technical description • The brake switch detects brake input during deceleration. <Description of malfunction> • Malfunction of the brake switch caused by disconnection has been detected. DTC set condition DTC detection condition •...
Page 607 ENGINE (J05E)/TROUBLESHOOTING 2–571 INSPECTION PROCEDURE: P0504 Inspect the brake switch connector Check the connection of the brake switch connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 608 2–572 ENGINE (J05E)/TROUBLESHOOTING Inspect the brake switch unit Set the starter key to the "LOCK" position. Disconnect the brake switch connector. Use the electrical tester to measure the resistance between the terminals of the brake switch. Measurement Tester Standard values conditions connections •...
Page 609 ENGINE (J05E)/TROUBLESHOOTING 2–573 Check the brake switch signal Set the starter key to the "LOCK" position. Connect the brake switch connector. Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness).
Page 610 2–574 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if P0504 have been detected. SHTS021270300525 Has DTC P0504 been detected? Replace the engine ECU.
Page 611 ENGINE (J05E)/TROUBLESHOOTING 2–575 DTC: P0506 EN01H02127030602016089 P0506: Idle speed control system INFORMATION Technical description • A difference between a target speed and an actual speed is detected during idling in the engine ECU. <Description of malfunction> • A difference between a target speed and an actual speed has been detected during idling. DTC set condition DTC detection condition •...
Page 612 2–576 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0506 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0506 has been detected.
Page 613 ENGINE (J05E)/TROUBLESHOOTING 2–577 Check the injector fuel injection quantity [HINO DX Ⅱ ] Start the engine. Select [Injection quantity] from [Data monitor and Active test] in HINO DX Ⅱ and measure the fuel injection quantity. Select [Engine revolution] from [Data monitor and Active test] on HINO DX Ⅱ...
Page 614 2–578 ENGINE (J05E)/TROUBLESHOOTING Inspect the air compressor Check the air compressor for failure. Was any failure found? Repair or replace the faulty part. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the power steering pump Check the power steering pump for failure. Was any failure found? Repair or replace the faulty part.
Page 615 ENGINE (J05E)/TROUBLESHOOTING 2–579 DTC: P0507 EN01H02127030602016090 P0507: Idle speed control system INFORMATION Technical description • A difference between a target speed and an actual speed is detected during idling in the engine ECU. <Description of malfunction> • A difference between a target speed and an actual speed has been detected during idling. DTC set condition DTC detection condition •...
Page 616 2–580 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0507 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0507 has been detected.
Page 617 ENGINE (J05E)/TROUBLESHOOTING 2–581 Check the injector fuel injection quantity [HINO DX Ⅱ ] Start the engine. Select [Injection quantity] from [Data monitor and Active test] in HINO DX Ⅱ and measure the fuel injection quantity. Select [Engine revolution] from [Data monitor and Active test] on HINO DX Ⅱ...
Page 618 2–582 ENGINE (J05E)/TROUBLESHOOTING Inspect the air compressor Check the air compressor for failure. Was any failure found? Repair or replace the faulty part. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the power steering pump Check the power steering pump for failure. Was any failure found? Repair or replace the faulty part.
Page 619 ENGINE (J05E)/TROUBLESHOOTING 2–583 DTC: P0521 EN01H02127030602016091 P0521: Malfunction of oil pressure switch (High) INFORMATION Engine ECU Oil pressure switch 6.1mA (OSW) Body earth 12.3mA (DM) SHTS021270300534 Technical description • A rise in engine oil pressure is sensed by the oil pressure switch. <Description of malfunction>...
Page 620 2–584 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0521 Check the engine oil level Check the oil level gauge and make sure the engine oil quantity is within the stipulated value. Engine damage will occur. Check the engine oil condition (dirt, viscosity). Oil level gauge Rivet FULL Preferred level...
Page 621 ENGINE (J05E)/TROUBLESHOOTING 2–585 Inspect the oil pressure switch connector Check the connection of the oil pressure switch connector (loose- ness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section.
Page 622 2–586 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the oil pressure switch harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Disconnect the oil pressure switch connector.
Page 623 ENGINE (J05E)/TROUBLESHOOTING 2–587 DTC: P0524 EN01H02127030602016092 P0524: Engine oil pressure Too Low INFORMATION Engine ECU Oil pressure switch 6.1mA (OSW) Body earth 12.3mA (DM) SHTS021270300538 Technical description • A drop in engine oil pressure is sensed by the oil pressure switch. <Description of malfunction>...
Page 624 2–588 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0524 Check the engine oil level Check the oil level gauge and make sure the engine oil quantity is within the stipulated value. Engine damage will occur. Check the engine oil condition (dirt, viscosity). Oil level gauge Rivet FULL Preferred level...
Page 625 ENGINE (J05E)/TROUBLESHOOTING 2–589 Inspect the oil pressure switch connector Check the connection of the oil pressure switch connector (loose- ness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section.
Page 626 2–590 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the oil pressure switch harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Disconnect the oil pressure switch connector.
Page 627 ENGINE (J05E)/TROUBLESHOOTING 2–591 Inspect disconnection of the oil pressure switch harness Use the electrical tester to measure the resistance between the terminals of the engine ECU and oil pressure switch vehicle side connector. Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har- ness) –...
Page 628 2–592 ENGINE (J05E)/TROUBLESHOOTING DTC: P0545 and P0546 EN01H02127030602016093 P0545: Exhaust gas temperature sensor (DOC1 inlet) - out of range (Out of range low) INFORMATION Engine ECU TYP 0.001A XYD (THO1) Exhaust gas (TOIL) temperature sensor TYP 0.004A (E5) (GND) (DOC1 inlet) SHTS021270300543 Technical description •...
Page 629 ENGINE (J05E)/TROUBLESHOOTING 2–593 Estimated failure factors Exhaust gas temperature sensor (DOC1 inlet): • Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage) • Abnormal resistance of sensor • Failure in engine ECU sensor power supply • Disconnection or short-circuit in sensor harness •...
Page 630 2–594 ENGINE (J05E)/TROUBLESHOOTING P0546: Exhaust gas temperature sensor (DOC1 inlet) - out of range (Out of range high) INFORMATION Engine ECU TYP 0.001A XYD (THO1) Exhaust gas (TOIL) temperature sensor TYP 0.004A (E5) (GND) (DOC1 inlet) SHTS021270300544 Technical description • The exhaust gas temperature sensor (DOC1 inlet) consistently detects exhaust gas temperature. •...
Page 631 ENGINE (J05E)/TROUBLESHOOTING 2–595 Estimated failure factors Exhaust gas temperature sensor (DOC1 inlet): • Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage) • Abnormal resistance of sensor • Failure in engine ECU sensor power supply • Disconnection or short-circuit in sensor harness •...
Page 632 2–596 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0545 and P0546 Inspect the exhaust gas temperature sensor (DOC1 inlet) connector Check the connection of the exhaust gas temperature sensor (DOC1 inlet) connector (looseness or poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2.
Page 633 ENGINE (J05E)/TROUBLESHOOTING 2–597 Inspect the exhaust gas temperature sensor (DOC1 inlet) unit Set the starter key to the "LOCK" position. TOIL Disconnect the exhaust gas temperature sensor (DOC1 inlet) con- nector. Use the electrical tester to measure the resistance between the terminals of the exhaust gas temperature sensor (DOC1 inlet).
Page 634 2–598 ENGINE (J05E)/TROUBLESHOOTING Inspect the sensor power supply Set the starter key to the "ON" position. TOIL Use the electrical tester to measure the voltage between the termi- nals of the exhaust gas temperature sensor (DOC1 inlet). Measurement Tester Standard values conditions connections Exhaust gas tem-...
Page 635 ENGINE (J05E)/TROUBLESHOOTING 2–599 Check disconnection in wire harness of exhaust gas temperature sensor (DOC1 inlet) Connect the exhaust gas temperature sensor (DOC1 inlet) con- nector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values...
Page 636 2–600 ENGINE (J05E)/TROUBLESHOOTING DTC: P054E EN01H02127030602016094 P054E: Idling injection rate abnormality (Low) INFORMATION Technical description • The engine ECU detects that engine injection rate is abnormally low during idling. <Description of malfunction> • Abnormally low engine injection rate is detected during idling. DTC set condition DTC detection condition •...
Page 637 ENGINE (J05E)/TROUBLESHOOTING 2–601 INSPECTION PROCEDURE: P054E Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P054E has been detected.
Page 638 2–602 ENGINE (J05E)/TROUBLESHOOTING Check the injector fuel injection quantity [HINO DX Ⅱ ] Start the engine. Select [Injection quantity] from [Data monitor and Active test] in HINO DX Ⅱ and measure the fuel injection quantity. Select [Engine revolution] from [Data monitor and Active test] on HINO DX Ⅱ...
Page 639 ENGINE (J05E)/TROUBLESHOOTING 2–603 Inspect the air compressor Check the air compressor for failure. Was any failure found? Repair or replace the faulty part. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the power steering pump Check the power steering pump for failure. Was any failure found? Repair or replace the faulty part.
Page 640 2–604 ENGINE (J05E)/TROUBLESHOOTING DTC: P054F EN01H02127030602016095 P054F: Idling injection rate abnormality (High) INFORMATION Technical description • The engine ECU detects that engine injection rate is abnormally high during idling. <Description of malfunction> • Abnormally high engine injection rate is detected during idling. DTC set condition DTC detection condition •...
Page 641 ENGINE (J05E)/TROUBLESHOOTING 2–605 INSPECTION PROCEDURE: P054F Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P054F has been detected.
Page 642 2–606 ENGINE (J05E)/TROUBLESHOOTING Check the injector fuel injection quantity [HINO DX Ⅱ ] Start the engine. Select [Injection quantity] from [Data monitor and Active test] in HINO DX Ⅱ and measure the fuel injection quantity. Select [Engine revolution] from [Data monitor and Active test] on HINO DX Ⅱ...
Page 643 ENGINE (J05E)/TROUBLESHOOTING 2–607 Inspect the air compressor Check the air compressor for failure. Was any failure found? Repair or replace the faulty part. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the power steering pump Check the power steering pump for failure. Was any failure found? Repair or replace the faulty part.
Page 644 2–608 ENGINE (J05E)/TROUBLESHOOTING DTC: P0562 and P0563 EN01H02127030602016096 P0562: Battery voltage - out of range (Out of range low) INFORMATION Engine ECU 3.2 (Inrush : 6.87A) (+BM) 3.2 (Inrush : 6.87A) (+B2) 3.2 (Inrush : 6.87A) (+B1) 3.2 (Inrush : 6.87A) (+B) To EDU relay SHTS021270300558...
Page 645 ENGINE (J05E)/TROUBLESHOOTING 2–609 P0563: Battery voltage - out of range (Out of range high) INFORMATION Engine ECU 3.2 (Inrush : 6.87A) (+BM) 3.2 (Inrush : 6.87A) (+B2) 3.2 (Inrush : 6.87A) (+B1) 3.2 (Inrush : 6.87A) (+B) To EDU relay SHTS021270300559 Technical description •...
Page 646 2–610 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0562 and P0563 Inspect the fuse or fusible link Check for fusing or improper fit. Was any failure found? Connect the fusible link properly or replace. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 647 ENGINE (J05E)/TROUBLESHOOTING 2–611 Inspect the engine ECU power supply Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Start the engine. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness).
Page 648 2–612 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if the DTC (P0562 or P0563) has been detected. SHTS021270300561 Has DTC (P0562 or P0563) been detected? Replace the engine ECU.
Page 649 ENGINE (J05E)/TROUBLESHOOTING 2–613 DTC: P05F1 EN01H02127030602016097 P05F1: Crankcase ventilation system - disconnection between the CV valve and the intake manifold INFORMATION Coolant temperature sensor Engine ECU (THW) 10mA X28 (THW) Body earth 10mA ZJQ (E5) 10mA (VG) (FC) 200mA (EVG) (E2G) 200mA (VAF)
Page 650 2–614 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 651 ENGINE (J05E)/TROUBLESHOOTING 2–615 INSPECTION PROCEDURE: P05F1 Inspect the air cleaner element Check the air cleaner element for dirt, clogging, or damage. Make sure the element is a Hino genuine part. Was any failure found? Clean or replace the air cleaner element. Go to step 2.
Page 652 2–616 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the air flow sensor harness Set the starter key to the "LOCK" position. Disconnect the air flow sensor connector. Connect the signal check harness to the engine ECU. (Do not con- nect harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU and ground.
Page 653 ENGINE (J05E)/TROUBLESHOOTING 2–617 Inspect disconnection of the air flow sensor harness Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and air flow sensor vehicle side connector. Measurement Tester Standard values conditions connections Engine ECU (sig-...
Page 654 2–618 ENGINE (J05E)/TROUBLESHOOTING Check the response delay of the EGR valve [HINO DX Ⅱ ] Set the starter key to the "ON" position. Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position.
Page 655 ENGINE (J05E)/TROUBLESHOOTING 2–619 Inspect the intake throttle valve Stop the engine. Check the operating status of the intake throttle valve (for incorrect opening or sticky valve). Was any failure found? Replace the intake throttle valve. Go to step 9. Perform "After-inspection work" of INFOR- MATION section.
Page 656 2–620 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine. Set the starter key to the "ON" position. Select [Engine] and check if P05F1 has been detected. SHTS021270300566 Has DTC P05F1 been detected? Replace the engine ECU.
Page 657 ENGINE (J05E)/TROUBLESHOOTING 2–621 DTC: P0605 EN01H02127030602016098 P0605: Flash ROM error INFORMATION Technical description • Engine ECU flash ROM failure is detected. <Description of malfunction> • – DTC set condition DTC detection condition • Starter key "ON". Judgement criteria • Flash ROM check sum error •...
Page 658 2–622 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0605 Inspect the engine ECU circuit [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check the communication between HINO DX Ⅱ and the engine ECU.
Page 659 ENGINE (J05E)/TROUBLESHOOTING 2–623 DTC: P0606 EN01H02127030602016099 P0606: Control module processor INFORMATION Technical description • Engine ECU internal failure is detected. <Description of malfunction> • – DTC set condition DTC detection condition • Starter key "ON" Judgement criteria • IC for monitoring microcomputer failure inside ECU is detected. •...
Page 660 2–624 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0606 Inspect the engine ECU circuit [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] in HINO DX Ⅱ and check the communication between HINO DX Ⅱ...
Page 661 ENGINE (J05E)/TROUBLESHOOTING 2–625 DTC: P0607 EN01H02127030602016100 P0607: Control module performance INFORMATION Technical description • Engine ECU internal failure is detected. <Description of malfunction> • – DTC set condition DTC detection condition • Starter key "ON". Judgement criteria • Failure of IC for monitoring inside engine ECU is detected. •...
Page 662 2–626 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0607 Inspect the engine ECU circuit [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] in HINO DX Ⅱ and check the communication between HINO DX Ⅱ...
Page 663 ENGINE (J05E)/TROUBLESHOOTING 2–627 DTC: P0610 EN01H02127030602016101 P0610: VIN data error INFORMATION <Vehicle control ECU> <Engine ECU> CAN communication SHTS021270300570 Technical description • Receipt of vehicle information (VIN) is detected. <Description of malfunction> • Vehicle information is not received or the wrong vehicle information is received. DTC set condition DTC detection condition •...
Page 664 2–628 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0610 Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0610 (for exam- ple, U1001, U110A) has been detected.
Page 665 ENGINE (J05E)/TROUBLESHOOTING 2–629 Reprogram the vehicle control ECU [HINO DX Ⅱ ] Use HINO DX Ⅱ , and perform [Reprograming] from vehicle control ECU. Select [Engine] from the HINO DX Ⅱ and read the DTC that has been detected. SHTS021270300573 Has DTC P0610 been detected? Replace the vehicle control ECU.
Page 666 2–630 ENGINE (J05E)/TROUBLESHOOTING DTC: P0611 EN01H02127030602016102 P0611: Fuel injector driver charge circuit - circuit (circuit low) INFORMATION Technical description • – <Description of malfunction> • Low voltage failure of injector actuation charging circuit is detected. DTC set condition DTC detection condition •...
Page 667 ENGINE (J05E)/TROUBLESHOOTING 2–631 INSPECTION PROCEDURE: P0611 Inspect the engine ECU circuit [HINO DX Ⅱ ] Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] in HINO DX Ⅱ and check the communication between HINO DX Ⅱ...
Page 668 2–632 ENGINE (J05E)/TROUBLESHOOTING DTC: P0617 EN01H02127030602016103 P0617: Starter key - rationality INFORMATION Starter relay Fuse To starter STCR Engine Starter cut relay Ignition switch Neutral start switch SHTS021270300576 Technical description - Engine ECU detects the starter signal while the engine is running (START position signal). <Description of malfunction>...
Page 669 ENGINE (J05E)/TROUBLESHOOTING 2–633 INSPECTION PROCEDURE: P0617 Inspect the starter key connector Check the connection of the starter key connector (looseness and poor contact). Was any failure found? Connect securely, repair replace Go to step 2. needed. Inspect the starter key "Start" signal Set the shift lever to the "N"...
Page 670 2–634 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the wire harness of the starter key "Start" signal Set the starter key to the "LOCK" position. Disconnect the neutral start switch. Use the electrical tester to measure the resistance between the engine ECU (signal check harness) and ground. Measurement Tester Standard values...
Page 671 ENGINE (J05E)/TROUBLESHOOTING 2–635 Inspect disconnection of the wire harness of the starter key "Start" signal Set the starter key to the "LOCK" position. Use the electrical tester to measure the resistance between the engine ECU (signal check harness) and the #6 terminals in neutral start switch vehicle side connector.
Page 672 2–636 ENGINE (J05E)/TROUBLESHOOTING DTC: P0628 and P0629 EN01H02127030602016104 P0628: Suction control valve for fuel supply pump - circuit (Circuit low) INFORMATION Engine ECU (PCV+) 1.5A (PV+S) (SCV+) Suction control valve 1.5A (SCV-) (PV-S) XZD (PCV-) SHTS021270300580 Technical description • The supply pump controls a fuel delivery rate to control common rail pressure. <Description of malfunction>...
Page 673 ENGINE (J05E)/TROUBLESHOOTING 2–637 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Harness disconnection or short-circuit • Looseness or poor contact of connector • Supply pump (SCV) unit failure •...
Page 674 2–638 ENGINE (J05E)/TROUBLESHOOTING P0629: Suction control valve for fuel supply pump - circuit (Circuit high) INFORMATION Engine ECU (PCV+) 1.5A (SCV+) (PV+S) Suction control valve 1.5A (SCV-) (PV-S) XZD (PCV-) SHTS021270300581 Technical description • The supply pump controls a fuel delivery rate to control common rail pressure. <Description of malfunction>...
Page 675 ENGINE (J05E)/TROUBLESHOOTING 2–639 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Harness disconnection or short-circuit • Looseness or poor contact of connector • Supply pump (SCV) unit failure •...
Page 676 2–640 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0628 and P0629 Inspect the suction control valve (SCV) connector Check the connection of the suction control valve (SCV) connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 677 ENGINE (J05E)/TROUBLESHOOTING 2–641 Inspect for short-circuit in wire harness of suction control valve Set the starter key to the "LOCK" position. SCV+ Disconnect the engine ECU connector. SCV- Use the electrical tester to measure the resistance between the suction control valve vehicle side connector terminals and ground. Measurement Tester Standard values...
Page 678 2–642 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnection in wire harness of suction control valve Connect the SCV connector. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) terminals.
Page 679 ENGINE (J05E)/TROUBLESHOOTING 2–643 Check the DTC detected (Engine ECU) Warm up the engine. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 680 2–644 ENGINE (J05E)/TROUBLESHOOTING DTC: P062F EN01H02127030602016105 P062F: Controller store data error (VNT actuator EEPROM error) INFORMATION POWER (12V) Power supply block Moter driver I/F block DC Brushless motor High side MOTOR (U) Low side FET MOTOR (V) CAN-H Micro CAN I/F MOTOR (W) computer CAN-L...
Page 681 ENGINE (J05E)/TROUBLESHOOTING 2–645 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 682 2–646 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P062F Check the DTC detected 1 (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P062F (for exam- ple, U010C) has been detected.
Page 683 ENGINE (J05E)/TROUBLESHOOTING 2–647 Check operation of VNT controller [HINO DX Ⅱ ] Set the starter key to the "ON" position. Erase the trouble history using HINO DX Ⅱ . Set the starter key to the "OFF" position. Set the starter key to the "ON" position again. Select [Engine] and check if P062F has been detected.
Page 684 2–648 ENGINE (J05E)/TROUBLESHOOTING DTC: P0630 EN01H02127030602016106 P0630: VIN Not Programmed or Mismatch INFORMATION <Engine ECU> <Vehicle control ECU> CAN communication SHTS021270300590 Technical description • Reception of vehicle information (VIN) is detected. <Description of malfunction> • Vehicle information is not received or may be faulty. DTC set condition DTC detection condition •...
Page 685 ENGINE (J05E)/TROUBLESHOOTING 2–649 Estimated failure factors • Vehicle control ECU failure • Engine ECU failure • Vehicle power supply failure (noise) • CAN circuit failure (noise)
Page 686 2–650 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0630 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P0630 (for exam- ple U1001, U110A) has been detected.
Page 687 ENGINE (J05E)/TROUBLESHOOTING 2–651 Check the vehicle control ECU [HINO DX Ⅱ ] After replacing the vehicle control ECU, check if it was previously used in another vehicle. Was the vehicle control ECU used in another vehicle? Replace the vehicle control ECU. Go to step 4.
Page 688 2–652 ENGINE (J05E)/TROUBLESHOOTING DTC: P0642 EN01H02127030602016107 P0642: ECU sensor power supply 1 failure (Out of range low) INFORMATION Engine ECU (PC1S) (VPA) (VPA1) 20mA 15mA (EPA) (E1) (E1) (E1) 20mA (PCR1) (PCR1) (VCPA) (VCP1) Accelerator 15mA (VC) (VC1) (VPA2) (VPA2) sensor Common rail 20mA...
Page 689 ENGINE (J05E)/TROUBLESHOOTING 2–653 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 690 2–654 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0642 Check the DTC detected 1 (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Erase the trouble history and set the starter key to the "LOCK" position. Disconnect the common rail pressure sensor1 (main) connector. Set the starter key to the "ON"...
Page 691 ENGINE (J05E)/TROUBLESHOOTING 2–655 Check the DTC detected 3 (Engine ECU) Erase the trouble history and set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Select [Engine] and check if P0642 has been detected. SHTS021270300597 Has DTC P0642 been detected? Connect the connector, and go to step 4.
Page 692 2–656 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected 5 (Engine ECU) Erase the trouble history and set the starter key to the "LOCK" position. Disconnect the engine speed sub sensor (camshaft position sen- sor) connector. Set the starter key to the "ON" position. Select [Engine] and check if P0642 has been detected.
Page 693 ENGINE (J05E)/TROUBLESHOOTING 2–657 Check the wire harness of the sensor power supply Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness).
Page 694 2–658 ENGINE (J05E)/TROUBLESHOOTING DTC: P0643 EN01H02127030602016108 P0643: ECU sensor power supply 1 failure (Out of range high) INFORMATION Engine ECU (PC1S) (VPA) (VPA1) 20mA 15mA (EPA) (E1) (E1) (E1) 20mA (PCR1) (PCR1) (VCPA) (VCP1) Accelerator 15mA (VC) (VC1) (VPA2) (VPA2) sensor Common rail 20mA...
Page 695 ENGINE (J05E)/TROUBLESHOOTING 2–659 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 696 2–660 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0643 Check the power supply of common rail pressure sensor 1 Set the starter key to the "LOCK" position. Disconnect the common rail pressure sensor 1 connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the common rail pressure sensor 1 connector.
Page 697 ENGINE (J05E)/TROUBLESHOOTING 2–661 Check the power supply of accelerator sensor 2 Set the starter key to the "LOCK" position. VCP2 Disconnect the accelerator sensor 2 connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the accelerator sensor 2 connector.
Page 698 2–662 ENGINE (J05E)/TROUBLESHOOTING Check the power supply of boost pressure sensor Set the starter key to the "LOCK" position. Disconnect the boost pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the boost pressure sensor connector.
Page 699 ENGINE (J05E)/TROUBLESHOOTING 2–663 Check the power supply of intake throttle valve position sensor Set the starter key to the "LOCK" position. Disconnect the intake throttle valve position sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the intake throttle valve position sensor connector.
Page 700 2–664 ENGINE (J05E)/TROUBLESHOOTING Check the power supply of engine speed sub sensor (camshaft position sensor) Set the starter key to the "LOCK" position. Disconnect the engine speed sub sensor (camshaft position sen- sor) connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine speed sub sensor (camshaft position sensor) connector.
Page 701 ENGINE (J05E)/TROUBLESHOOTING 2–665 Check the power supply of all sensors Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness).
Page 702 2–666 ENGINE (J05E)/TROUBLESHOOTING DTC: P064C EN01H02127030602016109 P064C: Glow controller - Battery for glow plug open, GND short Glow controller - Over temperature INFORMATION ENG3 Glow BATT GLW1 Glow Plug 1 #1cyl GLW2 Glow Plug 2 #2cyl Control signal GLW3 Glow Plug 3 #3cyl GLW4 Glow Plug 4...
Page 703 ENGINE (J05E)/TROUBLESHOOTING 2–667 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • Vehicle is difficult to start. Pre-inspection work •...
Page 704 2–668 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P064C Inspect the fuse (GCU (M)), fusible link (GLOW) Check if the fuse (GCU (M)) and fusible link (GLOW) are blown and if they are properly installed. Was any failure found? Replace or correctly connect the fuse and Go to step 2.
Page 705 ENGINE (J05E)/TROUBLESHOOTING 2–669 Inspect the glow control unit power supply circuit Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the GCU vehicle side connector. Measurement Tester Standard values conditions connections BATT...
Page 706 2–670 ENGINE (J05E)/TROUBLESHOOTING Inspect the ground circuit voltage Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between each ter- minal in the engine ECU (signal check harness) and ground. Measure the voltage between the GND terminal in the glow control unit vehicle side connector and ground.
Page 707 ENGINE (J05E)/TROUBLESHOOTING 2–671 DTC: P0652 EN01H02127030602016110 P0652: ECU sensor power supply 2 failure (Out of range low) INFORMATION Engine ECU Common rail pressure sensor (PC1S) (VPA) (VPA1) 15mA 20mA (EPA) (E1) (E1) (E1) 20mA (VCPA) (PCR1) (PCR1) (VCP1) Accelerator 15mA (VC1) (VC) (VPA2)
Page 708 2–672 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 709 ENGINE (J05E)/TROUBLESHOOTING 2–673 INSPECTION PROCEDURE: P0652 Check the DTC detected 1 (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Erase the trouble history and set the starter key to the "LOCK" position. Disconnect the common rail pressure sensor 2 (sub) connector. Set the starter key to the "ON"...
Page 710 2–674 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected 3 (Engine ECU) Erase the trouble history and set the starter key to the "LOCK" position. Disconnect the differential pressure sensor connector. Set the starter key to the "ON" position. Select [Engine] and check if P0652 has been detected. SHTS021270300616 Has DTC P0652 been detected? After connecting the connector, go to step 4.
Page 711 ENGINE (J05E)/TROUBLESHOOTING 2–675 Check the DTC detected 5 (Engine ECU) Erase the trouble history and set the starter key to the "LOCK" position. Disconnect the aftertreatment fuel injection line pressure sensor. Set the starter key to the "ON" position. Select [Engine] and check if P0652 has been detected. SHTS021270300618 Has DTC P0652 been detected? After connecting the connector, go to step 6.
Page 712 2–676 ENGINE (J05E)/TROUBLESHOOTING Inspect the wire harness of the sensor power supply Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness).
Page 713 ENGINE (J05E)/TROUBLESHOOTING 2–677 DTC: P0653 EN01H02127030602016111 P0653: ECU sensor power supply 2 failure (Out of range high) INFORMATION Engine ECU Common rail pressure sensor (PC1S) (VPA) (VPA1) 15mA 20mA (EPA) (E1) (E1) (E1) 20mA (VCPA) (PCR1) (PCR1) (VCP1) Accelerator 15mA (VC1) (VC) (VPA2)
Page 714 2–678 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 715 ENGINE (J05E)/TROUBLESHOOTING 2–679 INSPECTION PROCEDURE: P0653 Inspect the power supply of common rail pressure sensor 2 Set the starter key to the "LOCK" position. Disconnect the common rail pressure sensor 2 connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the common rail pressure sensor 2 vehicle side connector.
Page 716 2–680 ENGINE (J05E)/TROUBLESHOOTING Inspect the power supply of accelerator sensor 1 Set the starter key to the "LOCK" position. VCP1 Disconnect the accelerator sensor 1 connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the accelerator sensor 1 vehicle side connector.
Page 717 ENGINE (J05E)/TROUBLESHOOTING 2–681 Inspect the power supply of the PTO accelerator sensor Set the starter key to the "LOCK" position. Disconnect the PTO accelerator sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the PTO accelerator sensor vehicle side connector.
Page 718 2–682 ENGINE (J05E)/TROUBLESHOOTING Inspect the power supply of aftertreatment fuel injection line pressure sensor Set the starter key to the "LOCK" position. Disconnect the aftertreatment fuel injection line pressure sensor. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the after- treatment fuel injection line pressure sensor.
Page 719 ENGINE (J05E)/TROUBLESHOOTING 2–683 Inspect the power supply of all sensors Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness).
Page 720 2–684 ENGINE (J05E)/TROUBLESHOOTING DTC: P0671 and P0672 EN01H02127030602016112 P0671: Glow plug (Circuit low) (#1cyl), Glow plug (Circuit high) (#1cyl) INFORMATION ENG3 Glow BATT GLW1 Glow Plug 1 #1cyl GLW2 Glow Plug 2 #2cyl Control signal GLW3 Glow Plug 3 #3cyl GLW4 Glow Plug 4 #4cyl...
Page 721 ENGINE (J05E)/TROUBLESHOOTING 2–685 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • Vehicle is difficult to start. Pre-inspection work •...
Page 722 2–686 ENGINE (J05E)/TROUBLESHOOTING P0672: Glow plug (Circuit low) (#2cyl), Glow plug (Circuit high) (#2cyl) INFORMATION ENG3 Glow BATT GLW1 Glow Plug 1 #1cyl GLW2 Glow Plug 2 #2cyl Control signal GLW3 Glow Plug 3 #3cyl GLW4 Glow Plug 4 #4cyl Diagnosis signal SHTS021270300628 Technical description...
Page 723 ENGINE (J05E)/TROUBLESHOOTING 2–687 Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Harness disconnection or short-circuit between GCU and glow plug #2 •...
Page 724 2–688 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0671 and P0672 Inspect the fusible link (GLOW) Check for fusing and improper fit. Was any failure found? Connect the fusible link correctly or replace Go to step 2. Perform "After-inspection work" of INFOR- MATION section. Inspect the power supply wire harness of the glow control unit (GCU) Set the starter key to the "LOCK"...
Page 725 ENGINE (J05E)/TROUBLESHOOTING 2–689 Inspect the wire harness of the glow plug Disconnect the target's glow plug terminal. Use the electrical tester to measure the resistance between the GLW1 glow control unit vehicle side connector and the target's glow plug GLW2 terminal.
Page 726 2–690 ENGINE (J05E)/TROUBLESHOOTING DTC: P0673 and P0674 EN01H02127030602016113 P0673: Glow plug (Circuit low) (#3cyl), Glow plug (Circuit high) (#3cyl) INFORMATION ENG3 Glow BATT GLW1 Glow Plug 1 #1cyl GLW2 Glow Plug 2 #2cyl Control signal GLW3 Glow Plug 3 #3cyl GLW4 Glow Plug 4 #4cyl...
Page 727 ENGINE (J05E)/TROUBLESHOOTING 2–691 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • Vehicle is difficult to start. Pre-inspection work •...
Page 728 2–692 ENGINE (J05E)/TROUBLESHOOTING P0674: Glow plug (Circuit low) (#4cyl), Glow plug (Circuit high) (#4cyl) INFORMATION ENG3 Glow BATT GLW1 Glow Plug 1 #1cyl GLW2 Glow Plug 2 #2cyl Control signal GLW3 Glow Plug 3 #3cyl GLW4 Glow Plug 4 #4cyl Diagnosis signal SHTS021270300633 Technical description...
Page 729 ENGINE (J05E)/TROUBLESHOOTING 2–693 Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Harness disconnection or short-circuit between GCU and glow plug #4 •...
Page 730 2–694 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0673 and P0674 Inspect the fusible link (GLOW) Check for fusing and improper fit. Was any failure found? Connect the fusible link correctly or replace Go to step 2. Perform "After-inspection work" of INFOR- MATION section. Inspect the power supply wire harness of the glow control unit (GCU) Set the starter key to the "LOCK"...
Page 731 ENGINE (J05E)/TROUBLESHOOTING 2–695 Inspect the wire harness of the glow plug Disconnect the target's glow plug terminal. Use the electrical tester to measure the resistance between the GLW3 glow control unit vehicle side connector and the target's glow plug GLW4 terminal.
Page 732 2–696 ENGINE (J05E)/TROUBLESHOOTING DTC: P0683 EN01H02127030602016114 P0683: Glow controller - Battery for glow controller open, GND short Glow controller - Glow control signal Glow controller - Diagnosis signal INFORMATION ENG3 Glow BATT GLW1 Glow Plug 1 #1cyl GLW2 Glow Plug 2 #2cyl Control signal GLW3...
Page 733 ENGINE (J05E)/TROUBLESHOOTING 2–697 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • Vehicle is hard to start. Pre-inspection work •...
Page 734 2–698 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0683 Inspect the fuse and fusible link Check the fuse (GCU (M)) and fusible link (GLOW) for fusing or improper fit. Was any failure found? Connect the fuse and fusible link properly or Go to step 2. replace.
Page 735 ENGINE (J05E)/TROUBLESHOOTING 2–699 Inspect the GCU power supply circuit Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the GCU vehicle side connector. Measurement Tester Standard values conditions connections BATT GCU vehicle side...
Page 736 2–700 ENGINE (J05E)/TROUBLESHOOTING Inspect the harness of the GCU Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the GCU vehicle side connector terminals and engine ECU (signal check harness) terminals.
Page 737 ENGINE (J05E)/TROUBLESHOOTING 2–701 Check the ground circuit voltage Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between each ter- minal in the engine ECU (signal check harness) and ground. Measure the voltage between the GCU vehicle side connector GND terminal and ground.
Page 738 2–702 ENGINE (J05E)/TROUBLESHOOTING DTC: P0686 EN01H02127030602016115 P0686: ECM/PCM Power Relay Control Circuit high INFORMATION (INJ) (L ) (IREL) (B2) EDU relay Engine ECU SHTS021270300642 Technical description • The main relay (EDU relay) supplies power from the battery to the ECU. <Description of malfunction>...
Page 739 ENGINE (J05E)/TROUBLESHOOTING 2–703 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • Battery is depleted. Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 740 2–704 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P0686 Inspect the main (EDU) relay Check the connection of the main relay (EDU relay) (inside chassis relay block B) (looseness or poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work"...
Page 741 ENGINE (J05E)/TROUBLESHOOTING 2–705 Inspect the main relay power supply circuit Set the starter key to the "ON" position. EDU RELAY Use the electrical tester to measure the voltage between each ter- minal in the main relay vehicle side connector (inside chassis relay block B) and ground.
Page 742 2–706 ENGINE (J05E)/TROUBLESHOOTING Inspect the main relay power supply Set the starter key to the "LOCK" position. Connect the main relay. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Set the starter key to the "ON"...
Page 743 ENGINE (J05E)/TROUBLESHOOTING 2–707 DTC: P06D3 and P06D4 EN01H02127030602016116 P06D3: Air flow sensor power supply failure Short to GND INFORMATION Coolant temperature sensor Engine ECU 10mA (THW) X28 (THW) Body earth 10mA ZJQ (E5) 10mA (VG) (FC) 200mA (EVG) (E2G) 200mA (VAF) (+B) 10mA...
Page 744 2–708 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Harness disconnection or short-circuit • Air flow sensor failure • Engine ECU failure...
Page 745 ENGINE (J05E)/TROUBLESHOOTING 2–709 P06D4: Air flow sensor power supply failure (High) INFORMATION Coolant temperature sensor Engine ECU (THW) 10mA X28 (THW) Body earth 10mA ZJQ (E5) 10mA (VG) (FC) 200mA (EVG) (E2G) 200mA (VAF) (+B) 10mA (E2) 10mA (THA) (THA) Intake air temperature sensor (built in the air flow sensor) SHTS021270300647...
Page 746 2–710 ENGINE (J05E)/TROUBLESHOOTING Estimated failure factors • Harness disconnection or short-circuit • Air flow sensor failure • Engine ECU failure...
Page 747 ENGINE (J05E)/TROUBLESHOOTING 2–711 INSPECTION PROCEDURE: P06D3 and P06D4 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than (P06D3 or P06D4) (for example P0642, P0643, P0652, P0653) have been detected.
Page 748 2–712 ENGINE (J05E)/TROUBLESHOOTING Inspect the air flow sensor Check the installation of the air flow sensor. Make sure there is no dirt, damage or clogging in the sensing unit of air flow sensor. Was any failure found? Clean the sensing unit and install it properly. Go to step 4.
Page 749 ENGINE (J05E)/TROUBLESHOOTING 2–713 Inspect for disconnection in wire harness or air flow sensor Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and the air flow sensor vehicle side connector terminals. Measurement Tester Standard values...
Page 750 2–714 ENGINE (J05E)/TROUBLESHOOTING Inspect the air flow sensor power supply Connect the signal check harness to engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the air flow sensor vehicle side connector. Measurement Tester Standard values...
Page 751 ENGINE (J05E)/TROUBLESHOOTING 2–715 Check the DTC detected (Engine ECU) Warm up the engine (engine coolant temperature: 80 C {176 F} or more) Set the starter key to the "ON" position. Select [Engine] and check if the DTC (P06D3 or P06D4) has been detected.
Page 752 2–716 ENGINE (J05E)/TROUBLESHOOTING DTC: P073D EN01H02127030602016117 P073D: Transmission information - rationality INFORMATION Engine ECU Neutral switch 6.4mA (NSW) (L ) Neutral signal SHTS021270300654 Technical description • Transmission information is transferred through CAN communication. <Description of malfunction> • Information sent from the transmission ECU (AT) is incorrect. •...
Page 753 ENGINE (J05E)/TROUBLESHOOTING 2–717 After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Neutral switch failure (stuck ON or faulty contact) • Harness disconnection or short-circuit • Harness/connector faulty contact or improper fit •...
Page 754 2–718 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P073D Check the DTC detected (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if no DTC other than P073D (CAN com- munication failure, etc.) is detected.
Page 755 ENGINE (J05E)/TROUBLESHOOTING 2–719 Check the neutral switch signal Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the NSW (V11) terminal in the engine ECU (signal check harness) and ground.
Page 756 2–720 ENGINE (J05E)/TROUBLESHOOTING DTC: P081A EN01H02127030602016118 P081A: Starter Disable Circuit Low INFORMATION Starter relay Fuse To starter STCR Engine Starter cut relay Ignition switch Neutral start switch SHTS021270300658 Technical description • The starter cut relay prevents further rotations of the starter when the starter key is turned after start of the engine. <Description of malfunction>...
Page 757 ENGINE (J05E)/TROUBLESHOOTING 2–721 Estimated failure factors • Harness disconnection or short-circuit • Looseness or poor contact of connector • starter cut relay failure • Engine ECU failure...
Page 758 2–722 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P081A Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Disconnect the starter cut relay. Set the starter key to the "ON" position. Select [Engine] and check if P081A has been detected. SHTS021270300659 Has DTC P081A been detected? Go to step 2.
Page 759 ENGINE (J05E)/TROUBLESHOOTING 2–723 Inspect for short-circuit in wire harness of starter cut relay signal circuit Set the starter key to the "LOCK" position. Remove the starter cut relay. Connect the signal check harness to the engine ECU. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the STCR (V2) terminals of the engine ECU (signal check harness) and ground.
Page 760 2–724 ENGINE (J05E)/TROUBLESHOOTING Inspect for disconnection in wire harness of starter cut relay signal circuit Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and starter cut Starter cut relay relay vehicle side connector terminals. (Vehicle side connector) Measurement Tester...
Page 761 ENGINE (J05E)/TROUBLESHOOTING 2–725 Check the DTC detected (Engine ECU) Set the starter key to the "ON" position. Select [Engine] and check if P081A has been detected. SHTS021270300663 Has DTC P081A been detected? Replace the engine ECU. Procedure completed. Perform "After-inspection work" of INFOR- Perform "After-inspection work"...
Page 762 2–726 ENGINE (J05E)/TROUBLESHOOTING DTC: P081B EN01H02127030602016119 P081B: Starter Disable Circuit High INFORMATION Starter relay Fuse To starter STCR Engine Starter cut relay Ignition switch Neutral start switch SHTS021270300664 Technical description • The starter block relay prevents further rotations of the starter when the starter key is turned after start of the engine.
Page 763 ENGINE (J05E)/TROUBLESHOOTING 2–727 Estimated failure factors • Harness disconnection or short-circuit • Looseness or poor contact of connector • starter block relay failure • Engine ECU failure...
Page 764 2–728 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P081B Inspect the starter block relay connector Check the connection of the starter block relay connector (loose- ness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 765 ENGINE (J05E)/TROUBLESHOOTING 2–729 Check the DTC detected (Engine ECU) Set the starter key to the "ON" position. Select [Engine] and check if P081B has been detected. SHTS021270300666 Has DTC P081B been detected? Replace the engine ECU. Procedure completed. Perform "After-inspection work" of INFOR- Perform "After-inspection work"...
Page 766 2–730 ENGINE (J05E)/TROUBLESHOOTING DTC: P0A7B EN01H02127030602016120 P0A7B: HV BATTERY system failure INFORMATION Technical description <Description of malfunction> • The engine ECU detected malfunction in the HV battery system. DTC set condition DTC detection condition • – Judgement criteria • – Reset condition •...
Page 767 ENGINE (J05E)/TROUBLESHOOTING 2–731 INSPECTION PROCEDURE: P0A7B Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle. Set the starter key to the "ON" position. On the screen of the diagnostic system, select [Engine], and read the detected DTC.
Page 768 2–732 ENGINE (J05E)/TROUBLESHOOTING DTC: P0AC4 EN01H02127030602016121 P0AC4: HV system failure INFORMATION Technical description <Description of malfunction> • The engine ECU detected malfunction in the hybrid system. DTC set condition DTC detection condition • – Judgement criteria • – Reset condition •...
Page 769 ENGINE (J05E)/TROUBLESHOOTING 2–733 INSPECTION PROCEDURE: P0AC4 Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle. Set the starter key to the "ON" position. On the screen of the diagnostic system, select [Engine], and read the detected DTC.
Page 770 2–734 ENGINE (J05E)/TROUBLESHOOTING DTC: P0CA1 EN01H02127030602016122 P0CA1: HV MOTOR system failure INFORMATION Technical description <Description of malfunction> • The engine ECU detected malfunction in the hybrid motor. DTC set condition DTC detection condition • – Judgement criteria • – Reset condition •...
Page 771 ENGINE (J05E)/TROUBLESHOOTING 2–735 INSPECTION PROCEDURE: P0CA1 Check the DTC detected [HINO DX Ⅱ ] Set the starter key to the "LOCK" position. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle. Set the starter key to the "ON" position. On the screen of the diagnostic system, select [Engine], and read the detected DTC.
Page 772 2–736 ENGINE (J05E)/TROUBLESHOOTING DTC: P1133 EN01H02127030602016123 P1133: PTO accelerator sensor (Hi) INFORMATION Engine ECU 20mA (EPA) (GND) 20mA PTO accelerator sensor (VPA1) (SIG) 20mA (VCP1) (VCC) SHTS021270300670 Technical description • The operational accelerator sensor measures accelerator opening if PTO (power take off) is used. (This applies only to PTO-equipped vehicles.) <Description of malfunction>...
Page 773 ENGINE (J05E)/TROUBLESHOOTING 2–737 INSPECTION PROCEDURE: P1133 Inspect the PTO accelerator sensor connector Check the connection of the PTO accelerator sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 774 2–738 ENGINE (J05E)/TROUBLESHOOTING Inspect the PTO accelerator sensor unit Set the starter key to the "LOCK" position. Disconnect the PTO accelerator sensor connector. Use the electrical tester to measure the resistance between the terminals of the PTO accelerator sensor. Measurement Tester Standard values conditions...
Page 775 ENGINE (J05E)/TROUBLESHOOTING 2–739 Inspect for short-circuit of the PTO accelerator sensor harness Connect the signal check harness to the engine ECU. (Do not con- nect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 776 2–740 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the PTO accelerator sensor harness Connect the PTO accelerator sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har-...
Page 777 ENGINE (J05E)/TROUBLESHOOTING 2–741 Check the DTC detected (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if P1133 has been detected. SHTS021270300674 Has DTC P1133 been detected? Replace the engine ECU.
Page 778 2–742 ENGINE (J05E)/TROUBLESHOOTING DTC: P119F EN01H02127030602016124 P119F: Fuel rail pressure sensor - rationality INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S) SHTS021270300675 Technical description •...
Page 779 ENGINE (J05E)/TROUBLESHOOTING 2–743 Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Sensor disconnected from measuring site •...
Page 780 2–744 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P119F Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P119F (for exam- ple, P0192, P0193, P01A5, P01A6) have been detected.
Page 781 ENGINE (J05E)/TROUBLESHOOTING 2–745 Inspect the sensor power supply Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU. Disconnect the common rail pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness).
Page 782 2–746 ENGINE (J05E)/TROUBLESHOOTING Inspect the signal of the common rail pressure sensor Set the starter key to the "LOCK" position. Connect the common rail pressure sensor connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the engine ECU (signal check harness).
Page 783 ENGINE (J05E)/TROUBLESHOOTING 2–747 Check the DTC detected 2(Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "ON" position. Select [Engine] and check if P119F has been detected. SHTS021270300679 Has DTC P119F been detected? Replace the engine ECU.
Page 784 2–748 ENGINE (J05E)/TROUBLESHOOTING DTC: P1426 EN01H02127030602016125 P1426: Differential pressure sensor - rationality INFORMATION TYP 0.018A (VC) TYP 0.001A (PEX) TYP 0.018A (E2) DPR differential pressure sensor Engine ECU SHTS021270300680 Technical description • It detects a difference between pressure at the inlet of the muffler and atmospheric pressure and monitors any fail- ure or malfunction of the DPR.
Page 785 ENGINE (J05E)/TROUBLESHOOTING 2–749 Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work • Clear all past DTCs. • Check that no DTC is stored after test drive. Estimated failure factors • Loose/disconnected sensor and failure in sensing area (contamination or clogging) •...
Page 786 2–750 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P1426 Check the differential pressure hose and pipe Check if the differential pressure hose and pipe are cracked, bent, ruptured, or clogged. Was any failure found? Clean or replace the differential pressure Go to step 2. hose and pipe.
Page 787 ENGINE (J05E)/TROUBLESHOOTING 2–751 Inspect the differential pressure sensor unit Set the starter key to the "LOCK" position. Disconnect the DPR differential pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the differential pressure sensor. Measurement Tester Standard values...
Page 788 2–752 ENGINE (J05E)/TROUBLESHOOTING Inspect for short-circuit of the differential pressure sensor harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 789 ENGINE (J05E)/TROUBLESHOOTING 2–753 Inspect disconnection of the differential pressure sensor harness Connect the differential pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har-...
Page 790 2–754 ENGINE (J05E)/TROUBLESHOOTING Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 791 ENGINE (J05E)/TROUBLESHOOTING 2–755 DTC: P1427 EN01H02127030602016126 P1427: Differential pressure sensor - out of range (Out of range low) INFORMATION TYP 0.018A (VC) TYP 0.001A (PEX) TYP 0.018A (E2) DPR differential pressure sensor Engine ECU SHTS021270300685 Technical description • It detects a difference between pressure at the inlet of the muffler and atmospheric pressure and monitors any fail- ure or malfunction of the DPR.
Page 792 2–756 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 793 ENGINE (J05E)/TROUBLESHOOTING 2–757 INSPECTION PROCEDURE: P1427 Inspect the differential pressure sensor connector Check the connection of the differential pressure sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 794 2–758 ENGINE (J05E)/TROUBLESHOOTING Inspect the differential pressure sensor unit Set the starter key to the "LOCK" position. Disconnect the DPR differential pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the differential pressure sensor. Measurement Tester Standard values...
Page 795 ENGINE (J05E)/TROUBLESHOOTING 2–759 Inspect the power supply of the sensor Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the differential pressure sensor vehicle side connector. Measurement Tester Standard values conditions connections...
Page 796 2–760 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the differential pressure sensor harness Connect the differential pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har-...
Page 797 ENGINE (J05E)/TROUBLESHOOTING 2–761 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 798 2–762 ENGINE (J05E)/TROUBLESHOOTING DTC: P1428 EN01H02127030602016127 P1428: Differential pressure sensor - out of range (Out of range high) INFORMATION TYP 0.018A (VC) TYP 0.001A (PEX) TYP 0.018A (E2) DPR differential pressure sensor Engine ECU SHTS021270300691 Technical description • It detects a difference between pressure at the inlet of the muffler and atmospheric pressure and monitors any fail- ure or malfunction of the DPR.
Page 799 ENGINE (J05E)/TROUBLESHOOTING 2–763 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 800 2–764 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P1428 Inspect the differential pressure sensor connector Check the connection of the differential pressure sensor connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 2. Perform "After-inspection work" of INFOR- MATION section.
Page 801 ENGINE (J05E)/TROUBLESHOOTING 2–765 Inspect the sensor power supply Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the differential pressure sensor vehicle side connector. Measurement Tester Standard values conditions connections Differential pres-...
Page 802 2–766 ENGINE (J05E)/TROUBLESHOOTING Inspect the differential pressure sensor unit Set the starter key to the "LOCK" position. Disconnect the differential pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the differential pressure sensor. Measurement Tester Standard values conditions...
Page 803 ENGINE (J05E)/TROUBLESHOOTING 2–767 Inspect for short-circuit of the differential pressure sensor harness Set the starter key to the "LOCK" position. Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness) and ground.
Page 804 2–768 ENGINE (J05E)/TROUBLESHOOTING Inspect disconnection of the differential pressure sensor harness Connect the differential pressure sensor connector. Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness). Measurement Tester Standard values conditions connections Engine ECU (sig- nal check har-...
Page 805 ENGINE (J05E)/TROUBLESHOOTING 2–769 Check the DTC detected (Engine ECU) Perform engine warm up. (engine coolant temperature: 80 C {176 F} or more) Stop the engine and set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON"...
Page 806 2–770 ENGINE (J05E)/TROUBLESHOOTING DTC: P1458 EN01H02127030602016128 P1458: Valve position control failure - DC motor out of range, functional (EGR actuator over temp warning level) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300697 Technical description • EGR valve is a butterfly type. •...
Page 807 ENGINE (J05E)/TROUBLESHOOTING 2–771 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 808 2–772 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P1458 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P1458 have been detected.
Page 809 ENGINE (J05E)/TROUBLESHOOTING 2–773 Inspect the EGR valve connector Check the connection of the EGR valve connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the EGR power supply Set the starter key to the "LOCK"...
Page 810 2–774 ENGINE (J05E)/TROUBLESHOOTING Inspect the response delay of the EGR valve Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 811 ENGINE (J05E)/TROUBLESHOOTING 2–775 DTC: P1459 EN01H02127030602016129 P1459: Controller high temperature (EGR actuator over temp severe level) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300701 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 812 2–776 ENGINE (J05E)/TROUBLESHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 813 ENGINE (J05E)/TROUBLESHOOTING 2–777 INSPECTION PROCEDURE: P1459 Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P1459 has been detected.
Page 814 2–778 ENGINE (J05E)/TROUBLESHOOTING Inspect the EGR valve connector Check the connection of the EGR valve connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Check the EGR valve power supply Set the starter key to the "LOCK"...
Page 815 ENGINE (J05E)/TROUBLESHOOTING 2–779 Inspect the response delay of the EGR valve Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 816 2–780 ENGINE (J05E)/TROUBLESHOOTING DTC: P14B0 EN01H02127030602016130 P14B0: Controller store data error (EGR actuator abnormal information reading) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300705 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 817 ENGINE (J05E)/TROUBLESHOOTING 2–781 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 818 2–782 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P14B0 Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P14B0 have been detected.
Page 819 ENGINE (J05E)/TROUBLESHOOTING 2–783 Inspect the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 820 2–784 ENGINE (J05E)/TROUBLESHOOTING DTC: P14B2 EN01H02127030602016131 P14B2: EGR controller power supply open circuit (EGR actuator power supply open circuit) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300709 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 821 ENGINE (J05E)/TROUBLESHOOTING 2–785 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 822 2–786 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P14B2 Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P14B2 has been detected.
Page 823 ENGINE (J05E)/TROUBLESHOOTING 2–787 Inspect the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 824 2–788 ENGINE (J05E)/TROUBLESHOOTING DTC: P14B3 and P14B4 EN01H02127030602016132 P14B3: Battery voltage (high) (EGR actuator power supply too high) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300713 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 825 ENGINE (J05E)/TROUBLESHOOTING 2–789 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 826 2–790 ENGINE (J05E)/TROUBLESHOOTING P14B4: Battery voltage (low) (EGR actuator power supply too low) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300714 Technical description • EGR valve is a butterfly type. • EGR valve opening is controlled by engine speed and amount of intake air. •...
Page 827 ENGINE (J05E)/TROUBLESHOOTING 2–791 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 828 2–792 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P14B3 and P14B4 Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than DTC (P14B3 or P14B4) has been detected.
Page 829 ENGINE (J05E)/TROUBLESHOOTING 2–793 Inspect the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 830 2–794 ENGINE (J05E)/TROUBLESHOOTING DTC: P14B7 and P14B8 EN01H02127030602016133 P14B7: EGR valve controller temperature sensor 1 (Signal too low) (EGR actuator temp. sensor 1 signal too low) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300718 Technical description • EGR valve is a butterfly type. •...
Page 831 ENGINE (J05E)/TROUBLESHOOTING 2–795 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 832 2–796 ENGINE (J05E)/TROUBLESHOOTING P14B8: EGR valve controller temperature sensor 1 (Signal too high) (EGR actuator temp. sensor 1 signal too high) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300719 Technical description • EGR valve is a butterfly type. •...
Page 833 ENGINE (J05E)/TROUBLESHOOTING 2–797 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 834 2–798 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P14B7 and P14B8 Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than DTC (P14B7 or P14B8) has been detected.
Page 835 ENGINE (J05E)/TROUBLESHOOTING 2–799 Check the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 836 2–800 ENGINE (J05E)/TROUBLESHOOTING DTC: P14BC and P14BD EN01H02127030602016134 P14BC: EGR valve controller temperature sensor 2 (Signal too low) (EGR actuator temp. sensor 2 signal too low) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300723 Technical description • EGR valve is a butterfly type. •...
Page 837 ENGINE (J05E)/TROUBLESHOOTING 2–801 Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Engine output is restricted. Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> •...
Page 838 2–802 ENGINE (J05E)/TROUBLESHOOTING P14BD: EGR valve controller temperature sensor 2 (Signal too high) (EGR actuator temp. sensor 2 signal too high) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300724 Technical description • EGR valve is a butterfly type. •...
Page 839 ENGINE (J05E)/TROUBLESHOOTING 2–803 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • Engine output is insufficient. <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 840 2–804 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P14BC and P14BD Check the DTC detected 1 (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than DTC (P14BC or P14BD) has been detected.
Page 841 ENGINE (J05E)/TROUBLESHOOTING 2–805 Inspect the EGR valve power supply Set the starter key to the "LOCK" position. Disconnect the EGR valve connector. Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the termi- nals of the EGR valve vehicle side connector.
Page 842 2–806 ENGINE (J05E)/TROUBLESHOOTING DTC: P14BF EN01H02127030602016135 P14BF: EGR valve controller temperature sensor 1, 2 - rationality (EGR actuator temp. sensor 1 performance invalid) INFORMATION Engine ECU Resistor Actuator power relay controller actuator SHTS021270300728 Technical description • EGR valve is a butterfly type. •...
Page 843 ENGINE (J05E)/TROUBLESHOOTING 2–807 Indication, warning or system control regulation when the DTC is set. • MIL: ON • SVS light: OFF • Engine output is restricted. Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> •...
Page 844 2–808 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P14BF Check the DTC detected (Engine ECU) Set the starter key to the "LOCK" position. Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P14BF has been detected.
Page 845 ENGINE (J05E)/TROUBLESHOOTING 2–809 Inspect the EGR valve connector Check the connection of the EGR valve connector (looseness and poor contact). Was any failure found? Connect securely, repair if needed. Go to step 4. Perform "After-inspection work" of INFOR- MATION section. Inspect the EGR valve power supply Set the starter key to the "LOCK"...
Page 846 2–810 ENGINE (J05E)/TROUBLESHOOTING Check the response delay of the EGR valve Select [Inspection Menu] and then [EGR inspection] from the menu, then inspect the response delay at the Target EGR position and Actual EGR position. ! CAUTION Perform the inspection while the engine is stopped to avoid dam- ages.
Page 847 ENGINE (J05E)/TROUBLESHOOTING 2–811 DTC: P1515 EN01H02127030602016136 P1515: Charge air undercooling INFORMATION Engine ECU (PC1S) 15mA (E1) (E1) (PCR1) (PCR1) 15mA (VC) (VC1) Common rail 15mA (E2) (E2) pressure sensor (PCR2) (PCR2) 15mA (VC2) (VC2) $XW (PC2S) 15mA (VC) X0G (PIM) (PIM) Boost pressure sensor 15mA...
Page 848 2–812 ENGINE (J05E)/TROUBLESHOOTING Judgement criteria The following conditions are detected. • The detected intake manifold intake air temperature minus the actual intake manifold intake air temperature is less than 10 C {50 F} if the EGR activation rate is 0%; less than 17 C {62.6 F} if the EGR activation rate is less than 20%;...
Page 849 ENGINE (J05E)/TROUBLESHOOTING 2–813 INSPECTION PROCEDURE: P1515 Check the DTC detected (Engine ECU) Connect the vehicle to HINO DX Ⅱ . Set the starter key to the "ON" position. Select [Engine] and check if any DTC other than P1515 (for exam- ple P0096, P0101, P0106, P011C, P2227, P2457) have been detected.
Page 850 2–814 ENGINE (J05E)/TROUBLESHOOTING Inspect the radiator fan Check that the radiator fan (fan blades) was damaged Was any failure found? Replace the radiator fan. Go to step 5. Perform "After-inspection work" of INFOR- MATION section. Inspect the fan clutch Check if silicone oil is leaking from the fan clutch. Was any failure found? Replace the fan clutch.
Page 851 ENGINE (J05E)/TROUBLESHOOTING 2–815 Inspect the intercooler tube Check if the intercooler tubes are abnormally swollen or cracked. Was any failure found? Replace the intercooler tube. Go to step 8. Perform "After-inspection work" of INFOR- MATION section. Inspect the radiator Check if the radiator outer fins are clogged or damaged. Was any failure found? Replace the radiator.
Page 852 2–816 ENGINE (J05E)/TROUBLESHOOTING DTC: P1530 EN01H02127030602016137 P1530: Engine stop switch malfunction INFORMATION Engine ECU Engine stop switch 6.5mA (PTO) (PSW1) 6.5mA (PTO2) (PSW2) 0.1A (ESTP) (ESSW) 6.4mA (PTOC) (PCRL) SHTS021270300734 Technical description • Through the engine stop switch, the ECU senses engine stop signals. <Description of malfunction>...
Page 853 ENGINE (J05E)/TROUBLESHOOTING 2–817 INSPECTION PROCEDURE: P1530 Inspect the engine stop switch Check the installation of the engine stop switch. Was any failure found? Install the engine stop switch correctly. Go to step 2. Perform "After-inspection work" of INFOR- MATION section. Inspect the engine stop switch connector Check the connection of the engine stop switch connector (loose- ness and poor contact).
Page 854 2–818 ENGINE (J05E)/TROUBLESHOOTING Inspect for power supply short-circuit in the wire harness of the engine stop switch Connect the signal check harness to the engine ECU vehicle side harness. (Do not connect the harness to the ECU.) Set the starter key to the "ON" position. Use the electrical tester to measure the voltage between the ESTP (V32) terminals of the engine ECU (signal check harness) and E04 (V80)
Page 855 ENGINE (J05E)/TROUBLESHOOTING 2–819 Inspect for disconnection in the wire harness of the engine stop switch Set the starter key to the "LOCK" position. Use the electrical tester to measure the resistance between the ESTP (V32) terminal in the engine ECU (signal check harness) and terminals in the engine stop switch vehicle side connector.
Page 856 2–820 ENGINE (J05E)/TROUBLESHOOTING DTC: P1601 EN01H02127030602016138 P1601: Fuel injector adjustment data error INFORMATION QR CODE Computer QR CODE reader Injector DST-i Engine type code QR CODE New injector Connector Engine ECU SHTS021270300736 Technical description • The fuel injection rate is controlled by operation of the injector magnetic valve according to the injector valve-open- ing interval instructions from the engine ECU.
Page 857 ENGINE (J05E)/TROUBLESHOOTING 2–821 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe function)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check that the battery voltage is in the normal range. After-inspection work •...
Page 858 2–822 ENGINE (J05E)/TROUBLESHOOTING INSPECTION PROCEDURE: P1601 Check the injector replaced record Check the injector replaced record. Has the injector been replaced in the past? (Replacement history exists or is unclear.) (No replacement history) Go to step 3. Go to step 2. Check the QR CODE 1 [HINO DX Ⅱ...
Page 859 ENGINE (J05E)/TROUBLESHOOTING 2–823 Check the QR CODE 2 [HINO DX Ⅱ ] Read the QR code date of the injectors using HINO DX Ⅱ , re-input QR code date. Erase the DTC memory, and check again DTC code. Check that DTC code P1601 is not displayed.
Page 860 Hino Motors Sales U.S.A., Inc. 41180 Bridge Street, Novi, MI 48375 Telephone: (248) 699-9300 PRINTED IN JAPAN Pub.No. S7-LXJE05A 1/5 '13. 11...

This manual is also suitable for:

Hino 195h series Hino 155h series Hino 195 series

Hino Motors HINO 155 series Workshop Manual

How to Identify Vehicle Type

Appearance of Vehicle

Safety Instructions and Readiness to Work

Warning

Safety Instructions for Work

Introduction to Workshop Manual

Troubleshooting with Diagnosis Monitor

Trouble Diagnosis Using the Computer (Hino DX Ⅱ )

Glossary

Definition of Abbreviation

Quick Links

Troubleshooting

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Questions and answers

Summary of Contents for Hino Motors HINO 155 series

Page 3: Heater And Air Conditioner

Page 5: Table Of Contents

Page 6: How To Identify Vehicle Type

Page 7: Structure

Page 8: Appearance Of Vehicle

Page 9: General Precautions

Page 14: Identification Information

Page 17: Safety Instructions For Work

Page 21: Introduction To Workshop Manual

Page 22: Introduction To Descriptions

Page 25: Definition Of Term

Page 26: Trouble Shooting

Page 28: Apparatus For Trouble Shooting

Page 29: Step Of Trouble Diagnosis

Page 30: Apparatus For Trouble Diagnosis

Page 31: Glossary

Page 34: Glossary Of Sae And Hino Terms

Page 40: Troubleshooting

This manual is also suitable for:

Hino Motors HINO 155 series Workshop Manual

How to Identify Vehicle Type

Appearance of Vehicle

Safety Instructions and Readiness to Work

Warning

Safety Instructions for Work

Introduction to Workshop Manual

Troubleshooting with Diagnosis Monitor

Trouble Diagnosis Using the Computer (Hino DX Ⅱ )

Glossary

Definition of Abbreviation

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for Hino Motors HINO 155 series

Summary of Contents for Hino Motors HINO 155 series

This manual is also suitable for:

Table of Contents