Isuzu 2008MY N Series Instruction manual

WORKSHOP MANUAL
ENGINE CONTROL SYSTEM
(4HK1 model)
No.LG4HKED-WE-0871
WORKSHOP MANUAL
ENGINE CONTROL SYSTEM (4HK1 model)

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
51085Maegaki07.11.26 9:32AM ページ1

Engine Control System (4HK1) 1A-1
ENGINE
Engine Control System
(4HK1)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Temperature vs Resistance . . . . . . . . . . . . . . . . 1A-3
Altitude vs Barometric Pressure. . . . . . . . . . . . . 1A-4
Diagnostic Trouble Code (DTC) Type
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Diagnostic Trouble Code (DTC) List . . . . . . . . . 1A-6
Schematic and Rounting Diagrams. . . . . . . . . . . . 1A-9
Fuel System Routing Diagram . . . . . . . . . . . . . . 1A-9
Engine Controls Schematics . . . . . . . . . . . . . . 1A-10
Component Locator. . . . . . . . . . . . . . . . . . . . . . . 1A-12
Engine Controls Component Views . . . . . . . . . 1A-12
Engine Control Module (ECM)
Connector End Views . . . . . . . . . . . . . . . . . . . 1A-18
Engine Control Connector End Views . . . . . . . 1A-20
Diagnostic Information and Procedures . . . . . . . 1A-33
Engine Control System Check Sheet. . . . . . . . 1A-33
Diagnostic Starting Point - Engine Controls . . . 1A-34
Diagnostic System Check - Engine Controls . . 1A-35
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 1A-39
Scan Tool Data Definitions . . . . . . . . . . . . . . . . 1A-43
Scan Tool Output Controls . . . . . . . . . . . . . . . . 1A-49
Scan Tool Does Not Power Up. . . . . . . . . . . . . 1A-50
Scan Tool Does Not Communicate with
CAN Device (Euro 4 Specification) . . . . . . . . . 1A-51
Scan Tool Does Not Communicate with
Keyword Device (Except Euro 4 Specification)1A-55
Lost Communication with
The Engine Control Module (ECM)
(Except Euro 4 Specification) . . . . . . . . . . . . . 1A-59
Engine Cranks but Does Not Run . . . . . . . . . . 1A-62
DTC P0016 (Flash Code 16) . . . . . . . . . . . . . . 1A-65
DTC P0045 (Flash Code 33) . . . . . . . . . . . . . . 1A-67
DTC P0079 or P0080 (Flash Code 38) . . . . . . 1A-71
DTC P0087 (Flash Code 225) . . . . . . . . . . . . . 1A-74
DTC P0088 (Flash Code 118) . . . . . . . . . . . . . 1A-79
DTC P0089 (Flash Code 151) . . . . . . . . . . . . . 1A-84
DTC P0091 or P0092 (Flash Code 247) . . . . . 1A-87
DTC P0093 (Flash Code 227) . . . . . . . . . . . . . 1A-90
DTC P0101 (Flash Code 92) . . . . . . . . . . . . . . 1A-96
DTC P0102 or P0103 (Flash Code 91) . . . . . . 1A-99
DTC P0107 or P0108 (Flash Code 32) . . . . . 1A-103
DTC P0112 or P0113 (Flash Code 22) . . . . .1A-108
DTC P0116 (Flash Code 23) . . . . . . . . . . . . . 1A-113
DTC P0117 or P0118 (Flash Code 23) . . . . . 1A-115
DTC P0122 or P0123 (Flash Code 43) . . . . . 1A-119
DTC P0182 or P0183 (Flash Code 211) . . . . 1A-124
DTC P0192 or P0193 (Flash Code 245) . . . .1A-128
DTC P0201, P0202, P0203 or P0204
(Flash Code 271, 272, 273 or 274) . . . . . . . .1A-132
DTC P0217 (Flash Code 542) . . . . . . . . . . . . 1A-142
DTC P0219 (Flash Code 543) . . . . . . . . . . . . 1A-144
DTC P0234 (Flash Code 42) . . . . . . . . . . . . . 1A-146
DTC P0299 (Flash Code 65) . . . . . . . . . . . . . 1A-149
DTC P0335 (Flash Code 15) . . . . . . . . . . . . . 1A-152
DTC P0336 (Flash Code 15) . . . . . . . . . . . . . 1A-156
DTC P0340 (Flash Code 14) . . . . . . . . . . . . . 1A-158
DTC P0341 (Flash Code 14) . . . . . . . . . . . . . 1A-162
DTC P0380 (Flash Code 66) . . . . . . . . . . . . . 1A-164
DTC P0381 (Flash Code 67) . . . . . . . . . . . . . 1A-167
DTC P0401 (Flash Code 93) . . . . . . . . . . . . . 1A-170
DTC P0404 (Flash Code 45) . . . . . . . . . . . . . 1A-173
DTC P0409 (Flash Code 44) . . . . . . . . . . . . . 1A-176
DTC P0426 (Flash Code 143) . . . . . . . . . . . . 1A-180
DTC P0427 or P0428 (Flash Code 48) . . . . .1A-182
DTC P042B (Flash Code 145) . . . . . . . . . . . .1A-187
DTC P042C or P042D (Flash Code 49). . . . .1A-189
DTC P0477 or P0478 (Flash Code 46) . . . . .1A-194
DTC P0500 (Flash Code 25) . . . . . . . . . . . . . 1A-197
DTC P0502 or P0503 (Flash Code 25) . . . . .1A-200
DTC P0560 (Flash Code 155) . . . . . . . . . . . . 1A-207
DTC P0563 (Flash Code 35) . . . . . . . . . . . . . 1A-210
DTC P0601 (Flash Code 53) . . . . . . . . . . . . . 1A-212
DTC P0602 (Flash Code 154) . . . . . . . . . . . . 1A-213
DTC P0604, P0606 or P060B
(Flash Code 153, 51 or 36) . . . . . . . . . . . . . .1A-215
DTC P0633 (Flash Code 176) . . . . . . . . . . . . 1A-216
DTC P0638 (Flash Code 61) . . . . . . . . . . . . . 1A-217
DTC P0641 (Flash Code 55) . . . . . . . . . . . . . 1A-220
DTC P0650 (Flash Code 77) . . . . . . . . . . . . . 1A-223
DTC P0651 (Flash Code 56) . . . . . . . . . . . . . 1A-226
DTC P0685 or P0687 (Flash Code 416) . . . .1A-229
DTC P0697 (Flash Code 57) . . . . . . . . . . . . . 1A-232
DTC P1093 (Flash Code 227) . . . . . . . . . . . . 1A-235
DTC P1261 or P1262 (Flash Code 34) . . . . .1A-240
DTC P1404 (Flash Code 45) . . . . . . . . . . . . . 1A-241
DTC P1455 (Flash Code 132) . . . . . . . . . . . . 1A-243
DTC P1471 (Flash Code 149) . . . . . . . . . . . . 1A-245
DTC P161B (Flash Code 179) . . . . . . . . . . . .1A-248
DTC P1621 (Flash Code 54) . . . . . . . . . . . . . 1A-250
DTC P1664 (Flash Code 76) . . . . . . . . . . . . . 1A-251
DTC P1669 (Flash Code 75) . . . . . . . . . . . . . 1A-254
DTC P2122 or P2123 (Flash Code 121) . . . .1A-257
DTC P2127 or P2128 (Flash Code 122) . . . .1A-262
DTC P2138 (Flash Code 124) . . . . . . . . . . . . 1A-267
DTC P2146 or P2149
(Flash Code 158 or 159) . . . . . . . . . . . . . . . .1A-269
DTC P2227 (Flash Code 71) . . . . . . . . . . . . . 1A-275
DTC P2228 or P2229 (Flash Code 71) . . . . .1A-278
DTC P242F (Flash Code 131) . . . . . . . . . . . .1A-283
DTC P2452 (Flash Code 142) . . . . . . . . . . . . 1A-285
LG4HKED-WE-0871.book 1 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-2 Engine Control System (4HK1)
DTC P2453 (Flash Code 141) . . . . . . . . . . . . 1A-288
DTC P2454 or P2455 (Flash Code 47) . . . . . 1A-291
DTC P2456 (Flash Code 47) . . . . . . . . . . . . . 1A-296
DTC P2458 (Flash Code 139) . . . . . . . . . . . . 1A-298
DTC P253A (Flash Code 28) . . . . . . . . . . . . . 1A-301
DTC P256A (Flash Code 31) . . . . . . . . . . . . . 1A-304
DTC U0073 (Flash Code 84) . . . . . . . . . . . . . 1A-308
DTC U0101 (Flash Code 85) . . . . . . . . . . . . . 1A-312
DTC U0110 (Flash Code 87) . . . . . . . . . . . . . 1A-315
DTC U0167 (Flash Code 177) . . . . . . . . . . . . 1A-318
EGR Control System Check. . . . . . . . . . . . . . 1A-319
Glow Control System Check . . . . . . . . . . . . .1A-323
Engine Warm Up Control System Check . . . .1A-326
Exhaust Brake Control System Check . . . . . . 1A-329
Diesel Particulate Defuser (DPD)
Control System Check . . . . . . . . . . . . . . . . .1A-336
Symptoms - Engine Controls . . . . . . . . . . . . . . 1A-342
Symptoms - Engine Controls . . . . . . . . . . . . . 1A-342
Intermittent Conditions . . . . . . . . . . . . . . . . . .1A-344
Hard Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-347
Rough, Unstable, or
Incorrect Idle and Stalling . . . . . . . . . . . . . . . 1A-349
High Idle Speed . . . . . . . . . . . . . . . . . . . . . . .1A-352
Cuts Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-353
Surges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-355
Lack of Power, Sluggishness or Sponginess .1A-357
Hesitation, Sag or Stumble. . . . . . . . . . . . . . . 1A-359
Abnormal Combustion Noise . . . . . . . . . . . . . 1A-361
Poor Fuel Economy . . . . . . . . . . . . . . . . . . . .1A-362
Excessive Smoke (Black Smoke) . . . . . . . . . 1A-364
Excessive Smoke (White Smoke) . . . . . . . . . 1A-366
DPD System Manual Regeneration
Frequently . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-368
DPD System Regeneration Long Time . . . . . 1A-370
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 1A-372
Engine Control Module (ECM) Replacement . 1A-372
Service Programming System (SPS)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-374
Service Programming System (SPS)
(Remote Procedure) . . . . . . . . . . . . . . . . . . . 1A-375
Service Programming System (SPS)
(Pass-Thru Procedure) . . . . . . . . . . . . . . . . . 1A-376
Description and Operation . . . . . . . . . . . . . . . . 1A-378
Engine Control Module (ECM) Description . .1A-378
Engine Control Component Description. . . . . 1A-381
Fuel System Description . . . . . . . . . . . . . . . .1A-385
Fuel System Component Description. . . . . . .1A-386
Fuel Injection System Description . . . . . . . . . 1A-390
Exhaust Gas Recirculation (EGR)
System Description . . . . . . . . . . . . . . . . . . . .1A-390
Turbocharger Description. . . . . . . . . . . . . . . . 1A-392
Diesel Particulate Defuser (DPD)
System Description . . . . . . . . . . . . . . . . . . . .1A-394
Special Tools and Equipment . . . . . . . . . . . . . .1A-397
Special Tools and Equipment . . . . . . . . . . . . . 1A-397
LG4HKED-WE-0871.book 2 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-3
Specifications
Temperature vs Resistance
Engine Coolant Temperature vs. Resistance
Intake Air Temperature vs. Resistance (Euro 4
Specification)
Intake Air Temperature vs. Resistance (Except Euro
4 Specification)
Fuel Temperature vs. Resistance
°C°FOhms
Temperature vs. Resistance Value (Approximately)
110 230 160
100 212 200
90 194 260
80 176 350
70 158 470
60 140 640
50 122 880
40 104 1250
30 86 1800
20 68 2650
10 50 4000
0326180
-10 14 9810
-20 -4 16000
-30 -22 27000
°C°FOhms
Temperature vs. Resistance Value (Approximately)
90 194 240
80 176 320
70 158 430
60 140 590
50 122 810
40 104 1150
30 86 1650
20 68 2430
10 50 3660
0 32 5650
-10 14 8970
-20 -4 14700
°C°FOhms
Temperature vs. Resistance Value (Approximately)
90 194 240
80 176 320
70 158 450
60 140 660
50 122 960
40 104 1440
30 86 2300
20 68 3430
10 50 5410
0 32 9770
-10 14 16410
-20 -4 28560
°C°FOhms
Temperature vs. Resistance Value (Approximately)
110 230 140
100 212 180
90 194 240
80 176 310
70 158 420
60 140 580
50 122 810
40 104 1150
30 86 1660
20 68 2450
10 50 3700
0 32 5740
-10 14 9160
-20 -4 15000
-30 -22 25400
LG4HKED-WE-0871.book 3 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-4 Engine Control System (4HK1)
Exhaust Temperature vs. Resistance
Altitude vs Barometric Pressure
°C°FOhms
Temperature vs. Resistance Value (Approximately)
1000 1832 115 - 127
950 1742 130 - 143
900 1652 147 - 163
850 1562 167 - 187
800 1472 192 - 219
750 1382 226 - 258
700 1292 267 - 309
650 1202 333 - 360
600 1112 406 - 442
550 1022 504 - 552
500 932 640 - 709
450 842 835 - 937
400 752 1130 - 1280
350 662 1590 - 1850
300 572 2360 - 2830
200 392 6230 - 7830
150 302 11900 - 16300
100 212 27600 - 41200
50 122 82000 - 137000
Altitude
Measured in
Meters (m)
Altitude
Measured in
Feet (ft)
Barometric
Pressure
Measured in
Kilopascals
(kPa)
Determine your altitude by contacting a local weather
station or by using another reference source.
4267 14000 56-64
3962 13000 58-66
3658 12000 61-69
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
0 0 Sea Level 96-104
-305 -1000 101-105
LG4HKED-WE-0871.book 4 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-5
Diagnostic Trouble Code (DTC) Type Definitions
Emission Related DTC
Action Taken When the DTC Sets - Type A
• The ECM illuminates the malfunction indicator
lamp (MIL) when the diagnostic runs and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The ECM stores this
information in the Freeze Frame/ Failure Records.
(Euro 4 specification)
Action Taken When the DTC Sets - Type B
• The ECM illuminates the MIL on the second
consecutive driving cycle when the diagnostic runs
and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the ECM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive driving cycle, the
ECM records the operating conditions at the time
of failure and stores this information in the Freeze
Frame and updates the Failure Records.
Conditions for Clearing the MIL/DTC - Type A or
Type B
• The ECM turns OFF the MIL after 3 consecutive
driving cycles when the diagnostic runs and does
not fail. (Euro 4 specification)
• The ECM turns OFF the MIL after 1 ignition cycle
when the diagnostic runs and does not fail. (Except
Euro 4 specification)
• A current DTC clears when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported. (Euro 4
specification)
• A history DTC clears after 20 consecutive driving
cycles, if no failures are reported. (Except Euro 4
specification)
• Use a scan tool to clear the MIL and the DTC.
Non-Emissions Related DTCs
Action Taken When the DTC Sets - Type C
• The ECM illuminates the Service Vehicle Soon
(SVS) lamp when the diagnostic runs and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The ECM stores this
information in the Failure Records.
Conditions for Clearing the SVS Lamp/DTC - Type C
• The ECM turns OFF the SVS lamp after 1 driving
cycle when the diagnostic runs and does not fail.
• A current DTC clears when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported.
• Use a scan tool to clear the SVS lamp and the
DTC.
Action Taken When the DTC Sets - Type D
• The ECM will not illuminate the MIL or SVS lamp.
• The ECM records the operating conditions at the
time the diagnostic fails. The ECM stores this
information in the Failure Records. (Euro 4
specification)
Conditions for Clearing the DTC - Type D
• A current DTC clears when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported. (Euro 4
specification)
• A history DTC clears after 20 consecutive driving
cycles, if no failures are reported. (Except Euro 4
specification)
• Use a scan tool to clear the DTC.
LG4HKED-WE-0871.book 5 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-6 Engine Control System (4HK1)
Diagnostic Trouble Code (DTC) List
DTC Flash
Code
DTC Type
DTC Descriptor
Euro 4
Specifi
cation
Euro 3
Specifi
cation
Euro 2
Specifi
cation
P0016 16 A A A Crankshaft Position - Camshaft Position Correlation
P0045 33 A – – Turbocharger Boost Control Solenoid Circuit
P0079 38 A – – Exhaust Valve Control Solenoid Circuit Low
P0080 38 A – – Exhaust Valve Control Solenoid Circuit High
P0087 225 A A A Fuel Rail/ System Pressure Too Low
P0088 118 D A A Fuel Rail/ System Pressure Too High (First Stage)
P0088 118 A A A Fuel Rail/ System Pressure Too High (Second Stage)
P0089 151 A A A Fuel Pressure Regulator Performance
P0091 247 A A A Fuel Pressure Regulator Control Circuit Low
P0092 247 A A A Fuel Pressure Regulator Control Circuit High
P0093 227 A A A Fuel System Leak Detected
P0101 92 B – – Mass Air Flow Sensor Circuit Range/ Performance
P0102 91 A – – Mass Air Flow Sensor Circuit Low Input
P0103 91 A – – Mass Air Flow Sensor Circuit High Input
P0107 32 A A A Manifold Absolute Pressure Sensor Circuit Low Input
P0108 32 A A A Manifold Absolute Pressure Sensor Circuit High Input
P0112 22 A A A Intake Air Temperature Sensor Circuit Low
P0113 22 A A A Intake Air Temperature Sensor Circuit High
P0116 23 B – – Engine Coolant Temperature Sensor Circuit Range/ Performance
P0117 23 A A A Engine Coolant Temperature Sensor Circuit Low
P0118 23 A A A Engine Coolant Temperature Sensor Circuit High
P0122 43 A A A Throttle Position Sensor Circuit Low
P0123 43 A A A Throttle Position Sensor Circuit High
P0182 211 A A A Fuel Temperature Sensor Circuit Low
P0183 211 A A A Fuel Temperature Sensor Circuit High
P0192 245 A A A Fuel Rail Pressure Sensor Circuit Low
P0193 245 A A A Fuel Rail Pressure Sensor Circuit High
P0201 271 A A A Injector Circuit Open - Cylinder 1
P0202 272 A A A Injector Circuit Open - Cylinder 2
P0203 273 A A A Injector Circuit Open - Cylinder 3
P0204 274 A A A Injector Circuit Open - Cylinder 4
P0217 542 D A A Engine Coolant Over Temperature Condition
P0219 543 D D D Engine Overspeed Condition
P0234 42 A A A Turbocharger Overboost Condition
P0299 65 B A A Turbocharger Underboost
LG4HKED-WE-0871.book 6 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-7
P0335 15 A A A Crankshaft Position Sensor Circuit
P0336 15 A A A Crankshaft Position Sensor Circuit Range/ Performance
P0340 14 A A A Camshaft Position Sensor Circuit
P0341 14 A A A Camshaft Position Sensor Circuit Range/ Performance
P0380 66 C A A Glow Plug Circuit
P0381 67 C A A Glow Plug Indicator Circuit
P0401 93 A – – EGR Flow Insufficient Detected
P0404 45 A A – EGR Control Circuit Range/ Performance
P0409 44 A A – EGR Sensor Circuit
P0426 143 C – – Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1
P0427 48 A – – Catalyst Temperature Sensor Circuit Low Sensor 1
P0428 48 A – – Catalyst Temperature Sensor Circuit High Sensor 1
P042B 145 C – – Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2
P042C 49 C – – Catalyst Temperature Sensor Circuit Low Sensor 2
P042D 49 C – – Catalyst Temperature Sensor Circuit High Sensor 2
P0477 46 – A A Exhaust Pressure Control Valve Low
P0478 46 – A A Exhaust Pressure Control Valve High
P0500 25 B A A Vehicle Speed Sensor
P0502 25 A A A Vehicle Speed Sensor Circuit Low Input
P0503 25 A A A Vehicle Speed Sensor Circuit High Input
P0560 155 A – – System Voltage
P0563 35 C A A System Voltage High
P0601 53 A A A Internal Control Module Memory Check Sum Error
P0602 154 C A A Control Module Programming Error
P0604 153 A A A Internal Control Module RAM Error
P0606 51 A A A ECM Processor
P060B 36 A A A Internal Control Module A/D Processing Performance
P0633 176 C – A Immobilizer Not Programmed
P0638 61 B A A Throttle Actuator Control Range/ Performance
P0641 55 A A A Sensor Reference Voltage 1 Circuit
P0650 77 A D D Malfunction Indicator Lamp (MIL) Control Circuit
P0651 56 A A A Sensor Reference Voltage 2 Circuit
P0685 416 C A A ECM Power Relay Control Circuit Open
P0687 416 C A A ECM Power Relay Control Circuit High
P0697 57 A A A Sensor Reference Voltage 3 Circuit
P1093 227 A A A Fuel Rail Pressure Too Low
DTC Flash
Code
DTC Type
DTC Descriptor
Euro 4
Specifi
cation
Euro 3
Specifi
cation
Euro 2
Specifi
cation
LG4HKED-WE-0871.book 7 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-8 Engine Control System (4HK1)
P1261 34 A A A Injector Positive Voltage Control Circuit Group 1
P1262 34 A A A Injector Positive Voltage Control Circuit Group 2
P1404 45 A – – EGR Position Fault (Closed Position Error)
P1404 45 A A – EGR Position Fault (Learned Position Error)
P1455 132 A – – PM Over Accumulation
P1471 149 A – – DPD Insufficient Regeneration
P161B 179 C – A Immobilizer Wrong Response
P1621 54 A A A Control Module Long Term Memory Performance
P1664 76 C – – Service Vehicle Soon Lamp Control Circuit
P1669 75 C – – DPD Lamp Control Circuit
P2122 121 B A A Pedal Position Sensor 1 Circuit Low Input
P2123 121 B A A Pedal Position Sensor 1 Circuit High Input
P2127 122 B A A Pedal Position Sensor 2 Circuit Low Input
P2128 122 B A A Pedal Position Sensor 2 Circuit High Input
P2138 124 B A A Pedal Position Sensor 1-2 Voltage Correlation
P2146 158 A A A Fuel Injector Group 1 Supply Voltage Circuit
P2149 159 A A A Fuel Injector Group 2 Supply Voltage Circuit
P2227 71 B – – Barometric Pressure Sensor Circuit Range/ Performance
P2228 71 A A A Barometric Pressure Sensor Circuit Low
P2229 71 A A A Barometric Pressure Sensor Circuit High
P242F 131 A – – DPD Restriction
P2452 142 A – – DPD Differential Pressure Sensor Circuit
P2453 141 A – – DPD Differential Pressure Sensor Circuit Range/ Performance
P2454 47 A – – DPD Differential Pressure Sensor Circuit Low
P2455 47 A – – DPD Differential Pressure Sensor Circuit High
P2456 47 A – – DPD Differential Pressure Sensor Learned Position
P2458 139 A – – DPD Regeneration Duration
P253A 28 C A A PTO Sensor Circuit
P256A 31 C A A Engine Idle Speed Selector Sensor
U0073 84 B A A Control Module Communication Bus Off
U0101 85 C – – Lost Communication with TCM
U0110 87 A A A Lost Communication with VNT System
U0167 177 C – A Lost Communication With Vehicle Immobilizer Control
DTC Flash
Code
DTC Type
DTC Descriptor
Euro 4
Specifi
cation
Euro 3
Specifi
cation
Euro 2
Specifi
cation
LG4HKED-WE-0871.book 8 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-9
Schematic and Rounting Diagrams
Fuel System Routing Diagram
Legend
1. Fuel rail
2. Pressure limiter valve
3. Leak off pipe
4. Fuel injector
5. Fuel return pipe
6. Fuel feed pipe
7. Fuel tank
8. Vent valve
9. Priming pump
10. Fuel filter with water separator
11. Return fuel flow back valve
12. Fuel supply pump
LNW71BSF000501
11 10 9
8
5
6
7
12
1 2 34
LG4HKED-WE-0871.book 9 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-10 Engine Control System (4HK1)
Engine Controls Schematics
LNW71AXF001601
PTO throttle sensor
Accel pedal position sensor 1
Accel pedal position sensor 2
BARO sensor
Mass air flow sensor
Intake air temperature sensor
Exhaust differential pressure sensor
Vehicle speed sensor or EHCU
Exhaust temperature sensor 2
Exhaust temperature sensor 1
Intake air temperature sensor
Clutch switch
Exhaust brake switch
DPD switch
A/C switch
Engine warm up switch
Condenser
fan relay
Heater & A/C
relay Refrigerant
pressure switch
A/C unit
Neutral switch
Parking brake switch
PTO switch
Oil level switch
Ignition switch (on)
Ignition switch (start)
Main relay
Dropping
resistor
Case ground
Signal ground
Signal ground
Power ground
Power ground
Power ground
Key position
Battery 24V
MIL
Glow lamp
DPD lamp
Oil pressure lamp
Glow relay
Glow plug
Starter cut relay
Exhaust brake
solenoid valve
Starter relay
Exhaust brake solenoid valve
Exhaust brake relay
Intake throttle solenoid valve
Tacho meter
ECM
70
41
Idle up sensor 66
20
63
42
24
46
21
40
2
5
35
81
43
62
1
3
4
6
11
16
Exhaust brake lamp
7
SVS lamp
17
9
10
14
15
8
18
37
64
60
71
23
69
22
72
39
73
79
67
80
59
74
19
47
Cruise main switch 25
Refrigerator switch 33
26
45
51
34
50
48
44
53
61
BCM or DRM VNT C/UIP clusterTCMEHCU
EURO 4
EURO 4
EURO 4
EURO 4
EURO 4
EURO 4
EURO 2
EURO 3
Cruise resume switch
Cruise set switch
Cruise cancel switch
Cruise switch
(Combination switch)
65
13245768
9 10111213141516
38
52
EURO 2
EURO 3
EURO 4
EURO 2
EURO 3
A
C
A
C
B
A
C
B
LG4HKED-WE-0871.book 10 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-11
LNW71AXF001701
EURO 4
EURO 4
EURO 4
EURO 4
Crank shaft position sensor
Boost pressure sensor
Intake throttle position sensor
Engine coolant temperature sensor
Fuel temperature sensor
EGR motor
U
V
W
U
V
W
EGR position sensor
Fuel rail pressure sensor
Camshaft position sensor
Fuel injector 1
Intake throttle solenoid
Fuel injector 3
Fuel injector 2
Fuel injector 4
Fuel rail pressure regulator
Exhaust throttle solenoid valve
ECM
121
119
118
112
104
116
120
117
105
113
89
97
102
68
95
107
109
108
91
85
87
98
101
100
82
90
84
83
111
103
110
94
93
99
MM+
M-
M
Immobilizer
control unit
(ICU)
CAN Registor
58
78
Cylinder #1
Cylinder #4
Cylinder #3
Cylinder #2
Ground
13245768
9 10111213141516
B
LG4HKED-WE-0871.book 11 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-12 Engine Control System (4HK1)
Component Locator
Engine Controls Component Views
Legend
1. Barometric pressure (BARO) sensor 2. Accelerator pedal position (APP) sensor
Legend
1. Boost pressure sensor
LNW81ASF000901
1
2
LNW76ESF001201
1
LG4HKED-WE-0871.book 12 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-13
Legend
1. Crankshaft position (CKP) sensor
2. Camshaft position (CMP) sensor
3. Variable nozzle turbocharger (VNT) actuator &
sensor
Legend
1. Engine coolant temperature (ECT) sensor
2. Exhaust gas recirculation (EGR) valve
3. Intake throttle valve
LNW76ESF001301
1
2
3
LNW76ESF001401
12
3
LG4HKED-WE-0871.book 13 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-14 Engine Control System (4HK1)
Legend
1. Pressure limiter valve
2. Fuel rail pressure (FRP) sensor
3. Fuel temperature (FT) sensor
4. Fuel rail pressure (FRP) regulator
Legend
1. Fuel injector No.1 cylinder
2. Fuel injector No.2 cylinder
3. Fuel injector No.3 cylinder
4. Fuel injector No.4 cylinder
LNW76EMF002201
12
3
4
LNW76ESF001601
1
2
3
4
LG4HKED-WE-0871.book 14 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-15
Legend
1. Exhaust brake valve
2. Exhaust temperature sensor 2 (in front of oxygen
catalyst)
3. Exhaust temperature sensor 1 (in front of filter)
4. Exhaust differential pressure sensor
5. Exhaust throttle valve
6. DPD assembly
Legend
1. Mass air flow (MAF) sensor/ intake air
temperature (IAT) sensor
LNW76ESF000901
1
2
3
4
5
6
LNW76ESF001001
1
LG4HKED-WE-0871.book 15 ページ ２００７年１１月２９日 木曜日 午後６時２９分

1A-16 Engine Control System (4HK1)
Legend
1. Vehicle speed sensor (VSS) (without ABS)
Legend
1. CAN resistor (RHD)
LNW76ESF001101
1
LNW81ASF001101
1
LG4HKED-WE-0871.book 16 ページ ２００７年１１月２９日 木曜日 午後６時２９分

Engine Control System (4HK1) 1A-17
Legend
1. ECM 2. Dropping resistor
Legend
1. VNT control module
LNW81ASF000101
12
LNW81ASF000201
1
LG4HKED-WE-0871.book 17 ページ ２００７年１１月２９日 木曜日 午後６時２９分