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Isuzu 4HK1-TC Manual
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Isuzu 4HK1-TC Manual

Mechanical features, control system & diagnosis
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FOR SERVICE TRAINING
4HK1-TC ENGINE
-Engine Mechanical Features-
-Engine Control System & Diagnosis-
Applicable Model
Model Year
Vehicle Model
Main Market
General Export (Euro 3 Regulation)
2005
NPR & NQR
Europe, Australia, Thailand, South Africa & etc.
ISUZU MOTORS LIMITED

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Summary of Contents for Isuzu 4HK1-TC

  • Page 1 FOR SERVICE TRAINING 4HK1-TC ENGINE -Engine Mechanical Features- -Engine Control System & Diagnosis- Applicable Model Model Year Vehicle Model Main Market General Export (Euro 3 Regulation) 2005 NPR & NQR Europe, Australia, Thailand, South Africa & etc. ISUZU MOTORS LIMITED...
  • Page 2 N*R 4HK1-TC Engine-1 INTRODUCTION & ENGINE MECHANICAL FEATURES The 2005 model year NPR/NQR truck, the 4HK1-TC inline 4 cylinder engine replaces the 4HE1-TC engine for advanced exhaust emission countries. The 4HK1-TC engine has been newly developed on the basis of...
  • Page 3 N*R 4HK1-TC Engine-2 Major mechanical changed items are listed below. Part Status Description or Reason in Comparison with 4HE1-TC Engine Cylinder Block Change Bore size is upped (110mm to 115mm / 4.33in to 4.53in) Crankshaft Carry-over Cylinder Head Change Four valve type with camshaft position sensor hole...
  • Page 4 N*R 4HK1-TC Engine-3 ENGINE MAIN DATA & SPECIFICATIONS Engine Model 4HE1-TC 4HK1-TC Engine Type Diesel, Four Cycle Cylinder Layout - Number of Cylinders Inline-Four Cylinders Fuel Injection Order 1-3-4-2 Bore x Stroke (mm/in) 110.0 x 125.0 / 4.33 x 4.92 115.0 x 125.0 / 4.53 x 4.92...
  • Page 5 N*R 4HK1-TC Engine-4 Oil Pump Type Gear Oil Capacity (litter/gal) 13 (3.4) Oil Filter Type Cartridge Paper Element Air Cleaner Type Dry Paper Element W/O Cooler & Vacuum Control W/Cooler & Electrical Control EGR System EGR Valve EGR Valve PCV System...

  • Page 6: Gear Train

    Valve Train To improve exhaust emission and engine output performance, four valve mechanism is newly adopted for 4HK1-TC engine. Note that the adjustment method of valve clearance has been changed from 4HK1-TC engine as following steps. 1. Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC).
  • Page 7 N*R 4HK1-TC Engine-6 2. Loosen fully each adjusting screw (8) & (2) of the bridge and the rocker arm. 3. Insert a 0.4mm (0.016in) thickness gauge between the tip of the rocker arm and bridge cap (5), and adjust the clearance with the adjusting screw (3) on the rocker arm, and then fix it with a lock nut (4).
  • Page 8 N*R 4HK1-TC Engine-7 Fuel Supply Pump Installation 1. Apply white paint to the top of the fuel supply pump gear tooth directly above the stamped “O” mark. 2. Rotate the crankshaft to the compression top dead center (TDC). There are 2 marks stamped on the crank pulley.
  • Page 9 N*R 4HK1-TC Engine-8 5. Check through the hole (1) that a white paint (2) on the gear is in the position shown on the left. Fixing nut tightening torque: 50Nm (37lb ft) Fixing bolt tightening torque: 76Nm (56lb ft) CYLINDER HEAD COVER & HEAD COVER...

  • Page 10: Engine Control Module (Ecm)

    N*R 4HK1-TC Engine-9 ENGINE CONTROL MODULE (ECM) The engine control module (ECM) is located at inside of engine-side cover on the left via mounting bracket and is beside the engine. The ECM is made by Transtron. The ECM mainly controls the following.
  • Page 11 N*R 4HK1-TC Engine-10...
  • Page 12 N*R 4HK1-TC Engine-11 ECM Connector Pin Assignment Pin No. Pin Function Pin Function Pin Function ECM Power Ground Not Used Not Used Main Relay Voltage Not Used Not Used ECM Power Ground Not Used Not Used ECM Power Ground Not Used...
  • Page 13 N*R 4HK1-TC Engine-12 Not Used Not Used ECM Case Ground Pin No. Pin Function Pin Function Pin Function FRP Sensor Input Signal Not Used Not Used FT Sensor Input Signal SCV Low Control EGR Valve DC Motor Control ECT Sensor Input Signal...
  • Page 14 N*R 4HK1-TC Engine-13 ECM Inputs & Outputs Sensor Input Fuel Injection Control Output • Crankshaft position (CKP) sensor • Suction control valve (SCV) • Camshaft position (CMP) sensor • Fuel injector #1 • Intake air temperature (IAT) sensor • Fuel injector #2 •...
  • Page 15 N*R 4HK1-TC Engine-14 The ECM monitors the battery voltage through the ECM main relay load supply voltage terminals “2” and “5”, and the ignition voltage on the ignition voltage feed terminal “24” to make sure that the voltage stays within the proper range.
  • Page 16 N*R 4HK1-TC Engine-15 The engine control module (ECM) provides 5volts reference voltage through the reference circuit 1, 2, 3, 4 and 5 to the following sensors. 5volts reference circuit 1 Accelerator pedal position (APP) sensor 1 Idle up volume sensor...
  • Page 17 N*R 4HK1-TC Engine-16 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1631 5 Volt Reference DTC P1630 is not set. The ECM detects that the 5 volts APP sensor 1 5V reference circuit is short to...
  • Page 18 N*R 4HK1-TC Engine-17 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1633 5 Volt Reference DTC P1630 is not set. The ECM detects that the 5 volts Circuit 3...
  • Page 19 N*R 4HK1-TC Engine-18 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1635 5 Volt Reference DTC P1630 is not set. The ECM detects that the 5 volts FRP sensor 5V reference circuit is short to...
  • Page 20 N*R 4HK1-TC Engine-19 The engine control module (ECM), the smoother control module, ABS control module (EHCU) and the DMU, interchange of data among each controller performed via a controller area network (CAN) communication bus. Following signals are communicated via a CAN bus.
  • Page 21 N*R 4HK1-TC Engine-20 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool U2104 CAN Bus Reset The ignition switch is ON. The ECM detects that the CAN CAN high circuit is short to ground, short to Counter Overrun Bus OFF is detected.

  • Page 22: Intake Air Temperature (Iat) Sensor

    N*R 4HK1-TC Engine-21 ELECTRICAL COMPONENTS INTAKE AIR TEMPERATURE (IAT) SENSOR The intake air temperature (IAT) sensor is fitted between the air cleaner and turbocharger. The IAT sensor is a variable resistor. The IAT sensor measures the temperature of the air entering the engine. The...
  • Page 23 N*R 4HK1-TC Engine-22 IAT Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0112 Intake Air Temperature DTCs P1630 and P1632 are not The ECM detects that the IAT...
  • Page 24 N*R 4HK1-TC Engine-23 ENGINE COOLTANT TEMPERATURE (ECT) SENSOR The engine coolant temperature (ECT) sensor is installed to the coolant stream on the thermostat housing. It is a variable resistor. The ECT sensor measures the temperature of the engine coolant. The...
  • Page 25 N*R 4HK1-TC Engine-24 ECT Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0117 Engine Coolant DTCs P1630 and P1634 are not The ECM detects that the ECT...
  • Page 26 N*R 4HK1-TC Engine-25 FUEL TEMPERATURE (FT) SENSOR The fuel temperature (FT) sensor is installed to the supply pump. It is a variable resistor. The FT sensor measures the temperature of the fuel. The engine control module (ECM) supplies 5volts to the FT sensor signal circuit and a ground for the FT sensor low reference circuit.
  • Page 27 N*R 4HK1-TC Engine-26 FT Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0182 Fuel Temperature DTCs P1630 and P1634 are not The ECM detects that the FT...
  • Page 28 N*R 4HK1-TC Engine-27 CRANKSHAFT POSITION (CKP) SENSOR & CAMSHAFT POSITION (CMP) SENSOR The crankshaft position (CKP) sensor is located on top of the flywheel housing. There are 56 notches spaced 6deg. apart and a 30deg. section that is uncut. This uncut portion allows for the detection of top dead center (TDC).
  • Page 29 N*R 4HK1-TC Engine-28 The camshaft position (CMP) sensor is installed on the cylinder head at the rear of the camshaft. The CMP sensor detects a total five through holes, four reference holes arranged equally every 90deg. space and one reference hole on the camshaft gear flange surface, and sends signals to the engine control module (ECM).
  • Page 30 N*R 4HK1-TC Engine-29 No.1 TDC No.3 TDC 6deg.CA 30deg.CA 30deg.CA 90deg.CA No.1 TDC 90deg.CA 90deg.CA The relationship of CKP sensor and CMP sensor is displayed on the above picture. The ECM detects 112 CKP sensor pulses (56 x 2) and 5 CMP sensor pulses per 2 crankshaft rotations (720 deg.CA).
  • Page 31 N*R 4HK1-TC Engine-30 CKP Sensor Connector Face CMP Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0219 Engine Overspeed Engine speed is higher than 4300 Engine over-running.
  • Page 32 N*R 4HK1-TC Engine-31 P0340 Camshaft Position DTCs P0335, P0336, P0341 and The ECM detects that the CMP Sensor 12V reference circuit is open circuit, short (CMP) Sensor No P1345 are not set. sensor pulses are not generated. to ground circuit.

  • Page 33: Vehicle Speed Sensor (Vss)

    N*R 4HK1-TC Engine-32 VEHICLE SPEED SENSOR (VSS) The vehicle speed sensor (VSS) is a magnet rotated by the transmission output shaft. The VS sensor uses a hall effect element. It interacts with the magnetic field created by the rotating magnet and outputs square wave pulse signal.
  • Page 34 N*R 4HK1-TC Engine-33 VS Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0500 Vehicle Speed Sensor The ignition switch is ON. The ECM detects that the VSS Sensor +12V circuit is open circuit.

  • Page 35: Barometric Pressure Sensor

    N*R 4HK1-TC Engine-34 BAROMETRIC PRESSURE (BARO) SENSOR The barometric pressure (BARO) sensor is located under the instrument panel cluster near the clutch pedal bracket. But, it is not installed into the manifold. Just placed on via a bracket. The BARO sensor is a transducer that varies voltage according to changes surrounding barometric pressure.
  • Page 36 N*R 4HK1-TC Engine-35 BARO Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0107 Barometric Pressure DTCs P1630 and P1635 are not The ECM detects that the BARO...

  • Page 37: Boost Pressure Sensor

    N*R 4HK1-TC Engine-36 BOOST PRESSURE SENSOR The boost pressure sensor is located in the air induction tubing. The boost pressure sensor is a transducer that varies voltage according to changes in the air pressure inside the air tubing. The boost pressure sensor...
  • Page 38 N*R 4HK1-TC Engine-37 Boost Pressure Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0234 Turbocharger Engine DTCs P0237, P0238, P1630 and The ECM detects that the boost...
  • Page 39 N*R 4HK1-TC Engine-38 P0237 Turbocharger Boost DTCs P1630 and P1634 are not The ECM detects that the boost Sensor 5V reference circuit is open circuit, high Sensor Circuit Low set. pressure sensor signal voltage is resistance. Voltage The ignition switch is ON.
  • Page 40 N*R 4HK1-TC Engine-39 ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal position (APP) sensor is mounted on the accelerator pedal assembly. The sensor is made up of two individual sensors within one housing. The engine control module (ECM) uses the APP sensors to...
  • Page 41 N*R 4HK1-TC Engine-40 APP Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1271 Accelerator Pedal DTCs P1630, P1631 and P1632 The ECM detects that the APP...
  • Page 42 N*R 4HK1-TC Engine-41 P1278 Accelerator Pedal DTCs P1630 and P1631 are not The ECM detects that the APP Sensor 5V reference circuit is short to battery, Position (APP) Sensor set. sensor 1 signal voltage is more ignition voltage circuit or short to any 12V 1 Circuit High Voltage The ignition switch is ON.
  • Page 43 N*R 4HK1-TC Engine-42 ENGINE IDLE UP CONTROL VOLUME The idle up volume controls the idle speed during warm- up and it is installed in the driver’s side instrument panel. This volume is active only when the gear position is neutral position. When the shift lever is moved to another position, the volume is canceled.
  • Page 44 N*R 4HK1-TC Engine-43 Idle Up Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1225 Engine Idle Speed DTCs P1630 and P1631 are not The ECM detects that the idle up...

  • Page 45: Fuel System

    N*R 4HK1-TC Engine-44 FUEL SYSTEM FEATURE OF THE COMMON RAIL SYSTEM 1. Fuel Tank 2. Fuel Filter 3. Fuel Supply Pump 4. Fuel Rail 5. Pressure Limiter 6. Flow Damper 7. Fuel Rail Pressure Sensor 8. Injector 9. Engine Control Module (ECM) 10.

  • Page 46: Fuel Supply Pump

    N*R 4HK1-TC Engine-45 FUEL SUPPLY PUMP Along with the employment of the common rail type electronic control fuel injection system, the injection pump was disused and a plunger type supply pump is provided to supply high pressure fuel to the fuel rail. The...
  • Page 47 N*R 4HK1-TC Engine-46 1. Fuel Tank 2. Fuel Filter 3. Suction 4. Fuel Inlet 5. Feed Pump 6. Regulating Valve 7. Suction Control Valve (SCV) 8. Return Spring 9. Plunger 10. Suction Valve 11. Delivery Valve 12. Fuel Overflow 13. Return 14.
  • Page 48 N*R 4HK1-TC Engine-47 Operation of the Fuel Feed Pump 1. From Fuel Tank 2. Intake Port 3. To Pump Chamber 4. Discharge Port 5. Inner Rotor 6. Outer Rotor 7. Fuel Quantity Decrease 8. Fuel Quantity Increase 9. Fuel Quantity Decrease (Fuel Discharge) 10.
  • Page 49 N*R 4HK1-TC Engine-48 Operation of the Fuel Supply Pump 1. Suction Control Valve (SCV) 2. Suction Valve 3. Delivery Valve 4. Eccentric Cam 5. Ring Cam 6. Plunger A Top Dead Center (TDC) at Compression Stroke 7. Plunger B Bottom Dead Center (BDC) at Intake Stroke 8.
  • Page 50 N*R 4HK1-TC Engine-49 Operation of Suction Control Valve (SCV) A linear solenoid type valve has been adopted. The ECM controls the 250Hz duty ratio (the length of time that the current is applied to the SCV), in order to control the quantity of fuel that is supplied to the high- pressure plunger.
  • Page 51 N*R 4HK1-TC Engine-50 1. Feed Pump 2. Suction Control Valve (SCV) 3. Cylinder 4. Large Valve Opening (Maximum Intake Quantity) 5. Small Valve Opening (Minimum Intake Quantity)
  • Page 52 N*R 4HK1-TC Engine-51 Suction Control Valve (SCV) Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0090 Fuel Pressure DTCs P1630 is not set. The ECM detects that the SCV...
  • Page 53 N*R 4HK1-TC Engine-52 FUEL RAIL (COMMON RAIL) Along with the employment of a common rail type electronic control fuel injection system, the fuel rail is provided to store high pressure fuel between supply pump and injectors. A pressure sensor and a pressure limiter are installed on the fuel rail.
  • Page 54 N*R 4HK1-TC Engine-53 Operation of the Flow Damper The flow dampers are installed at the outlet of fuel rail to damp a pulsation of fuel pressure inside the fuel rail or to cut off the fuel supply when the fuel leaks in the downstream of flow damper.
  • Page 55 N*R 4HK1-TC Engine-54 FUEL RAIL PRESSURE (FRP) SENSOR The fuel rail pressure (FRP) sensor is installed to the fuel rail and it detects the fuel pressure in the fuel rail, converts the pressure into a voltage signal, and sends the signal to the engine control module (ECM). The ECM supplies 5-volts to the FRP sensor on the 5-volts reference circuit.
  • Page 56 N*R 4HK1-TC Engine-55 Fuel Rail Pressure (FRP) Sensor Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0192 Fuel Rail Pressure DTCs P1630 and P1635 are not The ECM detects that the FRP...

  • Page 57: Fuel Injector

    N*R 4HK1-TC Engine-56 FUEL INJECTOR Electronic control type injectors controlled by the engine control module (ECM) are used. Compared with conventional injection nozzles, a command piston, solenoid valve, etc. are added. Two dimensional barcode displaying various injector characteristics are laser marked on the fuel injector...

  • Page 58: Table Of Contents

    N*R 4HK1-TC Engine-57 The each fuel injector’s ID code can also be found on the factory affixed label located on the cylinder head cover. Notice! When programming ID code, recording from this label only perform if the fuel injector(s) is (are) NOT being replaced in the past.
  • Page 59 N*R 4HK1-TC Engine-58 Operation of Fuel Injector 1. Return Port 2. Solenoid 3. Tow Way Valve (TWV) 4. Outlet Orifice 5. Control Chamber 6. Inlet Orifice 7. Command Piston 8. Nozzle 9. High Pressure Fuel 10. Driving Current 11. Pressure in Control Chamber 12.
  • Page 60 N*R 4HK1-TC Engine-59 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0201 Injector 1 Control The ignition switch is ON. The ECM detects that the cylinder Cylinder #1 fuel injector solenoid coil control circuit...
  • Page 61 N*R 4HK1-TC Engine-60 P1261 Injector Positive The ignition switch is ON. The ECM detects that the cylinder Voltage Circuit Group The battery voltage is more than #1 or #4 fuel injector solenoid coil 1 Load Short 18 volts. control circuit is short to ground or Engine is running.

  • Page 62: Fuel Filter & Water Separator

    N*R 4HK1-TC Engine-61 FEATURE OF THE FUEL LINE & FUEL FILTER Low-pressure side fuel line consists following components. Fuel Tank Fuel Feed Pipe/Hose Fuel Return Pipe/Hose Fuel Filter & Water Separator FUEL FILTER & WATER SEPARATOR As the inside of the fuel supply pump is lubricated by the fuel which it is pumping and common rail system is needed perfectly clean.
  • Page 63 N*R 4HK1-TC Engine-62 1. Gasket 2. Cartridge 3. Water Level Sensor 4. Heater Harness Air Bleeding Procedure: Insufficient air bleeding may cause the DTC store or driveability concern. 1. Before starting the engine a. Fit a tray below the fuel filter (below the air bleed plug).

  • Page 64: Fuel Injection Quantity Control

    N*R 4HK1-TC Engine-63 FUEL INJECTION QUANTITY CONTROL • Accelerator pedal position Basic fuel rate • Boost pressure • Engine speed • Engine coolant temperature • Intake air temperature • Fuel temperature • Barometric pressure Compensation • Starter switch input • Fuel rail pressure •...
  • Page 65 N*R 4HK1-TC Engine-64 Idle Speed Control A control is made so as to achieve stable idling speed at all time regardless of engine secular changes or engine condition variations. The ECM sets target idling speed and controls the fuel injection quantity according...
  • Page 66 N*R 4HK1-TC Engine-65 Fuel System DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0087 Fuel Rail Pressure DTCs P1095, P1630 and P1635 The ECM detects that the fuel rail Fuel leaking at high pressure side.
  • Page 67 N*R 4HK1-TC Engine-66 DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0088 Fuel Rail Pressure DTCs P1092, P1093, P1630 and The ECM detects that the fuel rail SCV is sticking. (FRP) Too High P1635 are not set.
  • Page 68 N*R 4HK1-TC Engine-67 DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0089 Fuel Pressure DTCs P0090, P0192, P0193 The ECM detects that the actual SCV is sticking. Regulator P1092, P0201, P0202, P0203, fuel rail pressure is higher than Faulty FRP sensor.
  • Page 69 N*R 4HK1-TC Engine-68 DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1093 Fuel Rail Pressure DTCs P1095, P1630 and P1635 The ECM detects that the actual Fuel leaking at high pressure side.
  • Page 70 N*R 4HK1-TC Engine-69 DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1094 Fuel Rail Pressure DTCs P0117, P0118, P0500, The engine speed is between 600 Loss fuel or less fuel in the fuel tank.
  • Page 71 N*R 4HK1-TC Engine-70 DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1094 Fuel Rail Pressure DTCs P1095, P1630 and P1635 The ECM detects that the actual Loss fuel or less fuel in the fuel tank.
  • Page 72 N*R 4HK1-TC Engine-71 DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P1095 Fuel Rail Pressure DTCs P0192, P0193, P1630 and The ECM detects that the fuel rail Loss fuel or less fuel in the fuel tank.

  • Page 73: Egr (Exhaust Gas Re-Circulation) System

    N*R 4HK1-TC Engine-72 EGR (EXHAUST GAS RE-CIRCULATION) SYSTEM exhaust re-circulation (EGR) system combination with EGR cooler reduces the temperature of the combustion temperature. This results in reducing nitrogen oxide (NOx) emissions. The EGR control system uses an electronic control system to ensure both driveability and emission.

  • Page 74: Egr Valve

    N*R 4HK1-TC Engine-73 The system is started from engine idle speed and enabled based on following inputs are met. Active Coolant temperature Barometric pressure Inactive Fuel injection quantity 149/65 203/95 Engine Coolant Temp.(deg.F/deg.C) Active Inactive 13/90 (Approx. 1000m) Barometric Pressure (psi/KPa) EGR VALVE The EGR valve is mounted on the intake manifold.
  • Page 75 N*R 4HK1-TC Engine-74 The characteristic of the EGR valve position sensor is EGR Valve Characteristic -Reference- displayed in the graph and table. The output voltage can be found on the Tech 2. Desired position and actual position are compared and ECM adjusts EGR valve motor driven by duty cycle signal.
  • Page 76 N*R 4HK1-TC Engine-75 EGR Valve Connector Face Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0485 Exhaust Gas DTCs P1630 and P1635 are not The ECM detects that the EGR...
  • Page 77 N*R 4HK1-TC Engine-76 P0488 Exhaust Gas DTCs P1630 and P1634 are not The ECM detects that the EGR Sensor 5V reference circuit is short to battery, Recirculation (EGR) set. valve position sensor signal ignition voltage circuit or short to any 12V reference Position Sensor The ignition switch is ON.

  • Page 78: Preheating System

    N*R 4HK1-TC Engine-77 PREHEATING SYSTEM The preheating system consists the engine control module (ECM), glow relay and glow plugs. The ECM switches glow relay depends on engine coolant temperature to energize the glow plugs. In the after glow phase, the glow indicator lamp is not illuminated but glow plugs remain active for a certain period.
  • Page 79 N*R 4HK1-TC Engine-78 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool P0380 Glow Plug Relay The battery voltage is between 16 The ECM detects a high voltage Glow relay battery feed circuit is open circuit or high Control Circuit - 32 volts.
  • Page 80 N*R 4HK1-TC Engine-79 EXHAUST BRAKE SYSTEM & ENGINE WARM UP SYSTEM The exhaust brake system consists the exhaust brake valve, exhaust brake magnetic valve, exhaust brake switch and engine control module (ECM). In addition to this, intake throttle valve is used to reduce engine noise during exhaust brake operation.
  • Page 81 N*R 4HK1-TC Engine-80 In order to warm up the engine more quickly and reduce white smoke at low temperature, engine warm up system is adopted. The engine load is increased by the exhaust pressure and energy in the engine is transmitted to cooling water through the cylinder block, and warm up has been improved.
  • Page 82 N*R 4HK1-TC Engine-81 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool Exhaust Brake Control The battery voltage is between 16 The ECM detects a low voltage Exhaust throttle solenoid valve voltage feed...
  • Page 83 N*R 4HK1-TC Engine-82 POWER TAKE OFF (PTO) SYSTEM The engine control module (ECM) has the functionality R e m o te P T O A c c e l. S e n s o r C h a ra c te ris tic -R e fe re n c e - 5 .0...
  • Page 84 N*R 4HK1-TC Engine-83 Related DTC DTC Name On Scan Condition for Running the DTC Condition for Setting the DTC Suspected Cause Tool PTO Engine Speed DTCs P1630 and P1631 are not The ECM detects that the PTO Sensor 5V reference circuit is short to battery,...
  • Page 85 N*R 4HK1-TC Engine-84 ANTI SLIP REGULATOR (ASR) SYSTEM Anti Slip Regulator (ASR) system controls the engine torque to prevent the drive wheels slip when the vehicle with heavy accelerated or slippery road. The ABS/ASR control unit (EHCU) calculates the engine...
  • Page 86 N*R 4HK1-TC Engine-85 Load Sensing Proportioning Valve (LSPV) Wheel Speed Sensor (Rear) Electronic Hydraulic Control Unit (EHCU) (ABS Module) Battery Wheel Speed Sensor (Front) ASR OFF Switch Engine Control Module (ECM) ASR Indicator Lamp ABS Indicator Lamp 10. Data Link Connector...

  • Page 87: Malfunction Indicator Lamp (Mil)

    N*R 4HK1-TC Engine-86 DIAGNOSTIC MALFUNCTION INDICATOR LAMP (MIL) The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display the engine symbol when commanded ON: The MIL indicates that an emission related fault has occurred and vehicle service is required.

  • Page 88: Data Link Connector (Dlc)

    N*R 4HK1-TC Engine-87 DATA LINK CONNECTOR (DLC) Data link connector (DLC) is fixed to the driver’s side dash panel on the. The communication between the Tech 2 and ECM is established using Keyword 2000 serial data communication. Data Link Connector Face...
  • Page 89 N*R 4HK1-TC Engine-88 Clearing Diagnostic Trouble Codes (DTCs) with The Tech 2 or without Tech2 Do not clear DTCs unless directed to do so by the service information provided for each diagnostic procedure. To clear DTCs, use the Tech 2 “Clear DTC Information”. If there is no Tech 2, history DTCs cannot be cleared by driving cycles.

  • Page 90: Tech 2 Scan Tool

    N*R 4HK1-TC Engine-89 Operating Procedure TECH 2 SCAN TOOL 1. Press Enter at start screen.           2. Select “F0: Diagnostic” then press Enter.   F0: Diagnostic Trouble Codes 3. Select the appropriate vehicle identification.    ...
  • Page 91 N*R 4HK1-TC Engine-90 Injector Balancing The purpose of this test is for checking whether the fuel injector is operated when it commanded ON/OFF. Faulty injector(s) could be considered that does not change the engine speed when commanded OFF. Injection Timing The purpose of this test is for checking whether the main injection timing is changed within -5 - 10°CA as...
  • Page 92 N*R 4HK1-TC Engine-91 F4: Programming The purpose of “Programming” is to program the fuel injector ID code into the ECM if the fuel injector or ECM is to be replaced. Fuel Injector ID Code Data Programming Procedure 1. Install the Tech 2.

  • Page 93: Cylinder Number 1 Fuel Injector Id Code

    N*R 4HK1-TC Engine-92 Retrieving the Fuel Injector ID Code Data with a Non-communicating ECM Important: Only perform following procedure if the ECM being replaced Tech does communicate. The current fuel injector ID code data can not be determined with the Tech 2, the fuel injector numbers must be recorded from the factory affixed label on the cylinder head cover or each fuel injector ID plate.
  • Page 94 N*R 4HK1-TC Engine-93 5. Turn ON the ignition. 6. Select Injector ID Code then press Enter. At this point, all downloaded fuel injector ID code data can be verified. Compare the ID code values downloaded into the ECM and each fuel injector.
  • Page 95 N*R 4HK1-TC Engine-94 TECH 2 DATA & DEFINITIONS Tech 2 Parameter Units Displayed Definitions Ignition Voltage Volts This parameter displays the ignition voltage measured by the ECM at the ignition feed circuit. Voltage is applied to the ECM when the ignition switch is ON position.
  • Page 96 N*R 4HK1-TC Engine-95 Tech 2 Parameter Units Displayed Definitions SCV Duty Cycle This parameter displays the suction control valve (SCV) control duty signal from the ECM terminals. When the small duty signal, the SCV is controlled to open (fuel supply to the fuel rail is increased). When the large duty signal, the SCV is controlled to close (fuel supply to the fuel rail is reduced).
  • Page 97 N*R 4HK1-TC Engine-96 Tech 2 Parameter Units Displayed Definitions EGR Position (DC This parameter displays the difference of actual and desired EGR Motor) valve position (actual – desired) as calculated by the ECM using the signal from the EGR position sensor. The negative value is indicating a lower actual valve position.
  • Page 98 N*R 4HK1-TC Engine-97 Tech 2 Parameter Units Displayed Definitions Cylinder 4 This parameter displays the adjustment of fuel volume for cylinder 4 Compensation at low engine speed area (from idle to around 1000RPM) as calculated by the ECM. When the compensation volume is negative, the fuel volume is reducing.
  • Page 99 N*R 4HK1-TC Engine-98 Tech 2 Parameter Units Displayed Definitions remote accelerator pedal position sensors. This parameter displays the voltage signal sent to the ECM from the PTO Accelerator Volts PTO throttle sensor. The PTO throttle sensor is a range of values...
  • Page 100 N*R 4HK1-TC Engine-99 ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name Customer’s Name Model & Model Year Driver’s Name Chassis No. Date Vehicle Brought In Engine No. License No. Odometer Reading Km/miles Engine Does □ □ Engine does not crank □ No initial combustion □...
  • Page 101 N*R 4HK1-TC Engine-100 Engine Cranks but Does Not Run Description Test Description The Engine Cranks but Does Not Run diagnostic table The numbers below refers to the step number on the is an organized approach to identifying a condition that diagnostic table.
  • Page 102 N*R 4HK1-TC Engine-101 Step Action Value(s) Observe the SCV (suction control valve) Feedback parameter on the Tech 2 while Go to Fuel cranking over the engine for 5 seconds. 800 mA System Check - Fuel System Does the SCV Feedback parameter more than...
  • Page 103 N*R 4HK1-TC Engine-102 Step Action Value(s) 1. Other possible causes for the no-start condition: • Engine mechanical timing • Flywheel installed incorrectly causing the crankshaft position (CKP) sensor to be incorrectly timed to the engine. Disconnect sensor and attempt to start engine to verify.
  • Page 104 N*R 4HK1-TC Engine-103 Fuel System Check Description Diagnostic Aids The common rail fuel system is comprised of two fuel The fuel system from the fuel tank(s) to the fuel pressure sections: a suction side between the fuel tank supply pump is under a slight vacuum with the and the fuel supply pump and a high-pressure side engine running.
  • Page 105 N*R 4HK1-TC Engine-104 Step Action Value(s) 1. Inspect the high pressure side between the fuel supply pump and the fuel injectors for fuel leakage. The following components may contain an external leak: Fuel supply pump Fuel rail Pressure limiter valve...
  • Page 106 N*R 4HK1-TC Engine-105 Step Action Value(s) 1. Make sure the fuel tank(s) have adequate fuel and the fuel quality is good (take a sample). 2. Bleed the air from the fuel system as necessary. Refer to Fuel System Air Bleeding in this section.
  • Page 107 N*R 4HK1-TC Engine-106 Step Action Value(s) 1. Inspect the fuel system line connections between the fuel tank and the fuel supply pump for tightness and all fuel hoses for cuts, cracks and for the use of proper clamps. 2. Draw fuel from the fuel tank at the fuel line going to the fuel pickup tube to verify a - ...
  • Page 108 N*R 4HK1-TC Engine-107 Step Action Value(s) 1. Turn OFF the ignition. 2. Make sure the in-line harness connector (H- 125) is disconnected from the cylinder head cover case. 3. Remove the eyebolt from the cylinder head that connects to the leak-off pipe.
  • Page 109 N*R 4HK1-TC Engine-108 Step Action Value(s) Replace the pressure limiter valve. Refer to Fuel Rail Replacement is this section. Go to Step 18 Did you complete the replacement? Important: Replacement injector must be programmed. Replace the appropriate injector(s) that was leaking fuel found at Step.
  • Page 110 N*R 4HK1-TC Engine-109 Diagnostic Trouble Code (DTC) List Flash (Symptom MIL Status DTC Name on Tech 2 Condition for Running the DTC Condition for Setting the DTC Suspected Cause Code Code) P0087 Fuel Rail Pressure (FRP) DTCs P1095, P1630 and P1635 are not The ECM detects that the fuel rail pressure Fuel leaking at high pressure side.
  • Page 111 N*R 4HK1-TC Engine-110 Flash (Symptom MIL Status DTC Name on Tech 2 Condition for Running the DTC Condition for Setting the DTC Suspected Cause Code Code) P0183 Fuel Temperature Sensor DTCs P1630 and P1634 are not set. The ECM detects that the FT sensor signal...
  • Page 112 N*R 4HK1-TC Engine-111 Flash (Symptom MIL Status DTC Name on Tech 2 Condition for Running the DTC Condition for Setting the DTC Suspected Cause Code Code) P0340 Camshaft Position (CMP) DTCs P0335, P0336, P0341 and P1345 The ECM detects that the CMP sensor Sensor 12V reference circuit is open circuit, short to ground circuit.
  • Page 113 N*R 4HK1-TC Engine-112 Flash (Symptom MIL Status DTC Name on Tech 2 Condition for Running the DTC Condition for Setting the DTC Suspected Cause Code Code) P0650 Malfunction Indicator The ignition voltage is more than 18 volts. The ECM detects a high voltage condition MIL battery feed circuit is open circuit or high resistance.
  • Page 114 N*R 4HK1-TC Engine-113 Flash (Symptom MIL Status DTC Name on Tech 2 Condition for Running the DTC Condition for Setting the DTC Suspected Cause Code Code) P1277 Accelerator Pedal DTCs P1630 and P1631 are not set. The ECM detects that the APP sensor 1 Sensor 5V reference circuit is open circuit, high resistance.
  • Page 115 N*R 4HK1-TC Engine-114 Flash (Symptom MIL Status DTC Name on Tech 2 Condition for Running the DTC Condition for Setting the DTC Suspected Cause Code Code) U2104 CAN Bus Reset Counter The ignition switch is ON. The ECM detects that the CAN Bus OFF is CAN high circuit is short to ground, short to battery or ignition voltage.
  • Page 116 N*R 4HK1-TC Engine-115 SERVICE SPECIAL TOOL (SST) SST Illustration SST Usage SST Name SST Parts Number J-26999-12 / 5-8840-2675-0 Compression Gage EN-46722 / Gage Adapter 5-8840-2815-0 EN-47680 / Crankshaft Stopper 5-8840-2230-0 J-43263 / Valve Spring Replacer 5-8840-2621-0 EN-46721 / Pivot Assembly...
  • Page 117 N*R 4HK1-TC Engine-116 SST Illustration SST Usage SST Name SST Parts Number J-23907 / Sliding Hammer 5-8840-0019-0 EN-46720 / Fuel Injector Remover 5-8840-2826-0 J-43265 / Nozzle Sleeve Remover 5-8840-2623-0 J-43266 / Nozzle Sleeve Installer 5-8840-2624-0 J-43268 / 5-8840-2626-0 Bridge Installer...
  • Page 118 N*R 4HK1-TC Engine-117 SST Illustration SST Usage SST Name SST Parts Number J-43269 / 5-8840-2627-0 Oil Seal Installer EN-47682 / Connecting Rod Bush Replacer 5-8840-2340-0 J-8037 / Piston Ring Compressor 5-8840-9018-0 J-43285 / Slinger Puller 5-8840-26300-0...
  • Page 119 N*R 4HK1-TC Engine-118 SST Illustration SST Usage SST Name SST Parts Number J-43282 / Oil Seal Installer Kit 5-8840-2703-0 EN-47684 / Crankshaft Gear Puller 8-9439-618-0 J-41222 / Crankshaft Gear Installer 8-9439-6189-0 Scissors Gear Spring Wrench 5-8840-2674-0 EN-47683 / Oil Filter Wrench...
  • Page 120 N*R 4HK1-TC Engine-119 SST Illustration SST Usage SST Name SST Parts Number J-22700 / Fuel Filter Wrench 5-8840-0253-0 J-43620-20 / Oil Pressure Gauge J-43630 / Hose J-43630-14 / Connector J-46333 / Oil Pressure Testing Adapter EN-47667 / Fuel Pressure Gauge...
  • Page 121 N*R 4HK1-TC Engine-120 SST Illustration SST Usage SST Name SST Parts Number J-35616-C / Connector Test Adapter Kit with Test Lamp 5-8840-2835-0 J-39200 / Digital Multimeter 5-8840-0285-0 Tech 2 Kit...

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